Abstract: Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al2O3 particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.
Abstract: In this paper, a robust fault detection and isolation
(FDI) scheme is developed to monitor a multivariable nonlinear
chemical process called the Chylla-Haase polymerization reactor,
when it is under the cascade PI control. The scheme employs a radial
basis function neural network (RBFNN) in an independent mode to
model the process dynamics, and using the weighted sum-squared
prediction error as the residual. The Recursive Orthogonal Least
Squares algorithm (ROLS) is employed to train the model to
overcome the training difficulty of the independent mode of the
network. Then, another RBFNN is used as a fault classifier to isolate
faults from different features involved in the residual vector. Several
actuator and sensor faults are simulated in a nonlinear simulation of
the reactor in Simulink. The scheme is used to detect and isolate the
faults on-line. The simulation results show the effectiveness of the
scheme even the process is subjected to disturbances and
uncertainties including significant changes in the monomer feed rate,
fouling factor, impurity factor, ambient temperature, and
measurement noise. The simulation results are presented to illustrate
the effectiveness and robustness of the proposed method.
Abstract: Carbon Fiber Reinforced Plastics (CFRPs) are widely
used for advanced applications, in particular in aerospace, automotive
and wind energy industries. Once cured to near net shape, CFRP
parts need several finishing operations such as trimming, milling or
drilling in order to accommodate fastening hardware and meeting the
final dimensions. The present research aims to study the effect of the
cutting temperature in trimming on the mechanical strength of high
performance CFRP laminates used for aeronautics applications. The
cutting temperature is of great importance when dealing with
trimming of CFRP. Temperatures higher than the glass-transition
temperature (Tg) of the resin matrix are highly undesirable: they
cause degradation of the matrix in the trimmed edges area, which can
severely affect the mechanical performance of the entire component.
In this study, a 9.50mm diameter CVD diamond coated carbide tool
with six flutes was used to trim 24-plies CFRP laminates. A
300m/min cutting speed and 1140mm/min feed rate were used in the
experiments. The tool was heated prior to trimming using a
blowtorch, for temperatures ranging from 20°C to 300°C. The
temperature at the cutting edge was measured using embedded KType
thermocouples. Samples trimmed for different cutting
temperatures, below and above Tg, were mechanically tested using
three-points bending short-beam loading configurations. New cutting
tools as well as worn cutting tools were utilized for the experiments.
The experiments with the new tools could not prove any correlation
between the length of cut, the cutting temperature and the mechanical
performance. Thus mechanical strength was constant, regardless of
the cutting temperature. However, for worn tools, producing a cutting
temperature rising up to 450°C, thermal damage of the resin was
observed. The mechanical tests showed a reduced mean resistance in
short beam configuration, while the resistance in three point bending
decreases with increase of the cutting temperature.
Abstract: This study investigates the effects of the lead angle
and chip thickness variation on surface roughness during the
machining of compacted graphite iron using ceramic cutting tools
under dry cutting conditions. Analytical models were developed for
predicting the surface roughness values of the specimens after the
face milling process. Experimental data was collected and imported
to the artificial neural network model. A multilayer perceptron model
was used with the back propagation algorithm employing the input
parameters of lead angle, cutting speed and feed rate in connection
with chip thickness. Furthermore, analysis of variance was employed
to determine the effects of the cutting parameters on surface
roughness. Artificial neural network and regression analysis were
used to predict surface roughness. The values thus predicted were
compared with the collected experimental data, and the
corresponding percentage error was computed. Analysis results
revealed that the lead angle is the dominant factor affecting surface
roughness. Experimental results indicated an improvement in the
surface roughness value with decreasing lead angle value from 88° to
45°.
Abstract: Haynes 25 alloy (also known as L-605 alloy) is cobalt
based super alloy which has widely applications such as aerospace
industry, turbine and furnace parts, power generators and heat
exchangers and petroleum refining components due to its excellent
characteristics. However, the workability of this alloy is more
difficult compared to normal steels or even stainless. In present work,
an experimental investigation was performed under cryogenic
cooling to determine cutting tool wear patterns and obtain optimal
cutting parameters in turning of cobalt based superalloy Haynes 25.
In experiments, uncoated carbide tool was used and cutting speed (V)
and feed rate (f) were considered as test parameters. Tool wear
(VBmax) were measured for process performance indicators.
Analysis of variance (ANOVA) was performed to determine the
importance of machining parameters.
Abstract: In this study, ultrasonic assisted machining (UAM) technique is applied in side-surface milling experiment for glass-ceramic workpiece material. The tungsten carbide cutting-tool with diamond coating is used in conjunction with two kinds of cooling/lubrication mediums such as water-soluble (WS) cutting fluid and minimum quantity lubricant (MQL). Full factorial process parameter combinations on the milling experiments are planned to investigate the effect of process parameters on cutting performance. From the experimental results, it tries to search for the better process parameter combination which the edge-indentation and the surface roughness are acceptable. In the machining experiments, ultrasonic oscillator was used to excite a cutting-tool along the radial direction producing a very small amplitude of vibration frequency of 20KHz to assist the machining process. After processing, toolmaker microscope was used to detect the side-surface morphology, edge-indentation and cutting tool wear under different combination of cutting parameters, and analysis and discussion were also conducted for experimental results. The results show that the main leading parameters to edge-indentation of glass ceramic are cutting depth and feed rate. In order to reduce edge-indentation, it needs to use lower cutting depth and feed rate. Water-soluble cutting fluid provides a better cooling effect in the primary cutting area; it may effectively reduce the edge-indentation and improve the surface morphology of the glass ceramic. The use of ultrasonic assisted technique can effectively enhance the surface finish cleanness and reduce cutting tool wear and edge-indentation.
Abstract: This paper presents a study the effect of nose radius
(Rz-mm) on cutting force components and temperatures during the
machining simulation in an orthogonal cutting process for titanium
alloy (Ti-6Al-4V). The cutting process was performed at various
nose radiuses (Rz-mm) while the depth of cut (d-mm), feed rate (fmm/
tooth) and cutting speed (vc-m/ min) were remained constant.
The main cutting force (Fc), feed cutting force (Ft) and temperatures
were estimated by using finite element modeling (FEM) through
ABAQUS/EXPLICIT software and the simulation was developed the
two-dimension via an orthogonal cutting process during machining
titanium alloy (Ti-6Al-4V). The results led to the conclusion that the
nose radius (Rz-mm) has affected directly on the cutting force
components. However, temperature gave no indication or has no
significant relation with nose radius during machining titanium alloy
(Ti-6Al-4V). Hence, any increase or decrease in the nose radius (Rzmm)
during machining operation led to effect on the cutting forces
and thus it will be effective on surface finish, quality, and quantity of
products.
Abstract: Machining of hard materials is a recent technology for
direct production of work-pieces. The primary challenge in
machining these materials is selection of cutting tool inserts which
facilitates an extended tool life and high-precision machining of the
component. These materials are widely for making precision parts for
the aerospace industry. Nickel-based alloys are typically used in
extreme environment applications where a combination of strength,
corrosion resistance and oxidation resistance material characteristics
are required. The present paper reports the theoretical and
experimental investigations carried out to understand the influence of
machining parameters on the response parameters. Considering the
basic machining parameters (speed, feed and depth of cut) a study has
been conducted to observe their influence on material removal rate,
surface roughness, cutting forces and corresponding tool wear.
Experiments are designed and conducted with the help of Central
Composite Rotatable Design technique. The results reveals that for a
given range of process parameters, material removal rate is favorable
for higher depths of cut and low feed rate for cutting forces. Low feed
rates and high values of rotational speeds are suitable for better finish
and higher tool life.
Abstract: Burnishing is increasingly used as a finishing operation to improve surface roughness and surface hardness. This can be achieved by applying a hard ball or roller onto metallic surfaces under pressure, in order to achieve many advantages in the metallic surface. In the present work, the feed rate, speed and force have been considered as the basic burnishing parameters to study the surface roughness and surface hardness of metallic matrix composites. The considered metal matrix composites were made from Aluminum-Magnesium-Graphite with five different weight percentage of graphite. Both effects of burnishing parameters mentioned above and the graphite percentage on the surface hardness and surface roughness of the metallic matrix composites were studied. The results of this investigation showed that the surface hardness of the metallic composites increases with the increase of the burnishing force and decreases with the increase in the burnishing feed rate and burnishing speed. The surface roughness of the metallic composites decreases with the increasing of the burnishing force, feed rate, and speed to certain values, then it starts to increase. On the other hand, the increase in the weight percentage of the graphite in the considered composites causes a decrease in the surface hardness and an increase in the surface roughness.
Abstract: Metal matrix composites (MMCs) attract considerable
attention as a result from its ability in providing a high strength, high
modulus, high toughness, high impact properties, improving wear
resistance and providing good corrosion resistance compared to
unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been
widely used in various industrial sectors such as in transportation,
domestic equipment, aerospace, military, construction, etc.
Aluminium silicon alloy is an MMC that had been reinforced with
aluminium nitrate (AlN) particle and become a new generation
material use in automotive and aerospace sector. The AlN is one of
the advance material that have a bright prospect in future since it has
features such as lightweight, high strength, high hardness and
stiffness quality. However, the high degree of ceramic particle
reinforcement and the irregular nature of the particles along the
matrix material that contribute to its low density is the main problem
which leads to difficulties in machining process. This paper examined
the tool wear when milling AlSi/AlN Metal Matrix Composite using
a TiB2 (Titanium diboride) coated carbide cutting tool. The volume
of the AlN reinforced particle was 10% and milling process was
carried out under dry cutting condition. The TiB2 coated carbide
insert parameters used were at the cutting speed of (230, 300 and
370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The
Sometech SV-35 video microscope system used to quantify of the
tool wear. The result shown that tool life span increasing with the
cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at
0.4mm) which constituted an optimum condition for longer tool life
lasted until 123.2 mins. Meanwhile, at medium cutting speed which
at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we
found that tool life span lasted until 119.86 mins while at low cutting
speed it lasted in 119.66 mins. High cutting speed will give the best
parameter in cutting AlSi/AlN MMCs material. The result will help
manufacturers in machining process of AlSi/AlN MMCs materials.
Abstract: Flow forming is widely used in many industries, especially in defence technology industries. Pressure vessels requirements are high precision, light weight, seamless and optimum strength. For large pressure vessels, flow forming by 3 rollers machine were used. In case of long range rocket motor case flow forming and welding of pressure vessels have been used for manufacturing. Due to complication of welding process, researchers had developed 4 meters length pressure vessels without weldment by 4 rollers flow forming machine. Design and preparation of preform work pieces are performed. The optimization of flow forming parameter such as feed rate, spindle speed and depth of cut will be discussed. The experimental result shown relation of flow forming parameters to quality of flow formed tube and prototype pressure vessels have been made.
Abstract: This paper presents the findings of an experimental investigation of important machining parameters for the horizontal boring tool modified to mouth with a horizontal lathe machine to bore an overlength workpiece. In order to verify a usability of a modified tool, design of experiment based on Taguchi method is performed. The parameters investigated are spindle speed, feed rate, depth of cut and length of workpiece. Taguchi L9 orthogonal array is selected for four factors three level parameters in order to minimize surface roughness (Ra and Rz) of S45C steel tubes. Signal to noise ratio analysis and analysis of variance (ANOVA) is performed to study an effect of said parameters and to optimize the machine setting for best surface finish. The controlled factors with most effect are depth of cut, spindle speed, length of workpiece, and feed rate in order. The confirmation test is performed to test the optimal setting obtained from Taguchi method and the result is satisfactory.
Abstract: Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.
Abstract: This investigation proposes a grey-based Taguchi method to solve the multi-response problems. The grey-based Taguchi method is based on the Taguchi’s design of experimental method, and adopts grey relational analysis (GRA) to transfer multi-response problems into single-response problems. In this investigation, an attempt has been made to optimize the drilling process parameters considering weighted output response characteristics using grey relational analysis. The output response characteristics considered are surface roughness, burr height and hole diameter error under the experimental conditions of cutting speed, feed rate, step angle, and cutting environment. The drilling experiments were conducted using L27 orthogonal array. A combination of orthogonal array, design of experiments and grey relational analysis was used to ascertain best possible drilling process parameters that give minimum surface roughness, burr height and hole diameter error. The results reveal that combination of Taguchi design of experiment and grey relational analysis improves surface quality of drilled hole.
Abstract: Shear spinning is closely related to the asymmetric incremental sheet forming (AISF) that could significantly reduce costs incurred by the fabrication of complex aeronautical components with a minimal environmental impact. The spinning experiments were carried out on commercially pure titanium (Ti-Gr2) and Ti-6Al-4V (Ti-Gr5) alloy. Three forming modes were used to characterize the titanium alloys properties from the point of view of different spinning parameters. The structure and properties of the materials were assessed by means of metallographic analyses and microhardness measurements. The highest value wall angle failure limit was achieved using spinning parameters mode for both materials. The feed rate effect was observed only in the samples from the Ti-Gr2 material, when a refinement of the grain microstructure with lower feed rate and higher tangential speed occurred. Ti-Gr5 alloy exhibited a decrease of the microhardness at higher straining due to recovery processes.
Abstract: Determination of optimal conditions of machining parameters is important to reduce the production cost and achieve the desired surface quality. This paper investigates the influence of cutting parameters on surface roughness and natural frequency in turning of aluminum alloy AA2024. The experiments were performed at the lathe machine using two different cutting tools made of AISI 5140 and carbide cutting insert coated with TiC. Turning experiments were planned by Taguchi method L9 orthogonal array.Three levels for spindle speed, feed rate, depth of cut and tool overhang were chosen as cutting variables. The obtained experimental data has been analyzed using signal to noise ratio and analysis of variance. The main effects have been discussed and percentage contributions of various parameters affecting surface roughness and natural frequency, and optimal cutting conditions have been determined. Finally, optimization of the cutting parameters using Taguchi method was verified by confirmation experiments.
Abstract: An attempt has been made to investigate the
machinability of zirconia toughened alumina (ZTA) inserts while
turning AISI 4340 steel. The insert was prepared by powder
metallurgy process route and the machining experiments were
performed based on Response Surface Methodology (RSM) design
called Central Composite Design (CCD). The mathematical model of
flank wear, cutting force and surface roughness have been developed
using second order regression analysis. The adequacy of model has
been carried out based on Analysis of variance (ANOVA) techniques.
It can be concluded that cutting speed and feed rate are the two most
influential factor for flank wear and cutting force prediction. For
surface roughness determination, the cutting speed & depth of cut
both have significant contribution. Key parameters effect on each
response has also been presented in graphical contours for choosing
the operating parameter preciously. 83% desirability level has been
achieved using this optimized condition.
Abstract: Monitoring the tool flank wear without affecting the
throughput is considered as the prudent method in production
technology. The examination has to be done without affecting the
machining process. In this paper we proposed a novel work that is
used to determine tool flank wear by observing the sound signals
emitted during the turning process. The work-piece material we used
here is steel and aluminum and the cutting insert was carbide
material. Two different cutting speeds were used in this work. The
feed rate and the cutting depth were constant whereas the flank wear
was a variable. The emitted sound signal of a fresh tool (0 mm flank
wear) a slightly worn tool (0.2 -0.25 mm flank wear) and a severely
worn tool (0.4mm and above flank wear) during turning process were
recorded separately using a high sensitive microphone. Analysis
using Singular Value Decomposition was done on these sound
signals to extract the feature sound components. Observation of the
results showed that an increase in tool flank wear correlates with an
increase in the values of SVD features produced out of the sound
signals for both the materials. Hence it can be concluded that wear
monitoring of tool flank during turning process using SVD features
with the Fuzzy C means classification on the emitted sound signal is
a potential and relatively simple method.
Abstract: Metal matrix composites have been increasingly used
as materials for components in automotive and aerospace industries
because of their improved properties compared with non-reinforced
alloys. During machining the selection of appropriate machining
parameters to produce job for desired surface roughness is of great
concern considering the economy of manufacturing process. In this
study, a surface roughness prediction model using fuzzy logic is
developed for end milling of Al-SiCp metal matrix composite
component using carbide end mill cutter. The surface roughness is
modeled as a function of spindle speed (N), feed rate (f), depth of cut
(d) and the SiCp percentage (S). The predicted values surface
roughness is compared with experimental result. The model predicts
average percentage error as 4.56% and mean square error as 0.0729.
It is observed that surface roughness is most influenced by feed rate,
spindle speed and SiC percentage. Depth of cut has least influence.
Abstract: Owning to the high-speed feed rate and ultra spindle
speed have been used in modern machine tools, the tool-path
generation plays a key role in the successful application of a
High-Speed Machining (HSM) system. Because of its importance in
both high-speed machining and tool-path generation, approximating a
contour by NURBS format is a potential function in CAD/CAM/CNC
systems. It is much more convenient to represent an ellipse by
parametric form than to connect points laboriously determined in a
CNC system. A new approximating method based on optimum
processes and NURBS curves of any degree to the ellipses is presented
in this study. Such operations can be the foundation of tool-radius
compensation interpolator of NURBS curves in CNC system. All
operating processes for a CAD tool is presented and demonstrated by
practical models.