Abstract: Conventionally the selection of parameters depends
intensely on the operator-s experience or conservative technological
data provided by the EDM equipment manufacturers that assign
inconsistent machining performance. The parameter settings given by
the manufacturers are only relevant with common steel grades. A
single parameter change influences the process in a complex way.
Hence, the present research proposes artificial neural network (ANN)
models for the prediction of surface roughness on first commenced
Ti-15-3 alloy in electrical discharge machining (EDM) process. The
proposed models use peak current, pulse on time, pulse off time and
servo voltage as input parameters. Multilayer perceptron (MLP) with
three hidden layer feedforward networks are applied. An assessment
is carried out with the models of distinct hidden layer. Training of the
models is performed with data from an extensive series of
experiments utilizing copper electrode as positive polarity. The
predictions based on the above developed models have been verified
with another set of experiments and are found to be in good
agreement with the experimental results. Beside this they can be
exercised as precious tools for the process planning for EDM.
Abstract: We address the balancing problem of transfer lines in
this paper to find the optimal line balancing that minimizes the nonproductive
time. We focus on the tool change time and face
orientation change time both of which influence the makespane. We
consider machine capacity limitations and technological constraints
associated with the manufacturing process of auto cylinder heads.
The problem is represented by a mixed integer programming model
that aims at distributing the design features to workstations and
sequencing the machining processes at a minimum non-productive
time. The proposed model is solved by an algorithm established using
linearization schemes and Benders- decomposition approach. The
experiments show the efficiency of the algorithm in reaching the
exact solution of small and medium problem instances at reasonable
time.
Abstract: As a part of the development of a numerical method of
close capture exhausts systems for machining devices, a test rig
recreating a situation similar to a grinding operation, but in a
perfectly controlled environment, is used. The properties of the
obtained spray of solid particles are initially characterized using
particle tracking velocimetry (PTV), in order to obtain input and
validation parameters for numerical simulations. The dispersion of a
tracer gas (SF6) emitted simultaneously with the particle jet is then
studied experimentally, as the dispersion of such a gas is
representative of that of finer particles, whose aerodynamic response
time is negligible. Finally, complete modeling of the test rig is
achieved to allow comparison with experimental results and thus to
progress towards validation of the models used to describe a twophase
flow generated by machining operation.
Abstract: Surface roughness (Ra) is one of the most important requirements in machining process. In order to obtain better surface roughness, the proper setting of cutting parameters is crucial before the process take place. This research presents the development of mathematical model for surface roughness prediction before milling process in order to evaluate the fitness of machining parameters; spindle speed, feed rate and depth of cut. 84 samples were run in this study by using FANUC CNC Milling α-Τ14ιE. Those samples were randomly divided into two data sets- the training sets (m=60) and testing sets(m=24). ANOVA analysis showed that at least one of the population regression coefficients was not zero. Multiple Regression Method was used to determine the correlation between a criterion variable and a combination of predictor variables. It was established that the surface roughness is most influenced by the feed rate. By using Multiple Regression Method equation, the average percentage deviation of the testing set was 9.8% and 9.7% for training data set. This showed that the statistical model could predict the surface roughness with about 90.2% accuracy of the testing data set and 90.3% accuracy of the training data set.
Abstract: Tool wear and surface roughness prediction plays a
significant role in machining industry for proper planning and control
of machining parameters and optimization of cutting conditions. This
paper deals with developing an artificial neural network (ANN)
model as a function of cutting parameters in turning steel under
minimum quantity lubrication (MQL). A feed-forward
backpropagation network with twenty five hidden neurons has been
selected as the optimum network. The co-efficient of determination
(R2) between model predictions and experimental values are 0.9915,
0.9906, 0.9761 and 0.9627 in terms of VB, VM, VS and Ra
respectively. The results imply that the model can be used easily to
forecast tool wear and surface roughness in response to cutting
parameters.
Abstract: Coated tool inserts can be considered as the backbone
of machining processes due to their wear and heat resistance.
However, defects of coating can degrade the integrity of these inserts
and the number of these defects should be minimized or eliminated if
possible. Recently, the advancement of coating processes and
analytical tools open a new era for optimizing the coating tools.
First, an overview is given regarding coating technology for cutting
tool inserts. Testing techniques for coating layers properties, as well
as the various coating defects and their assessment are also surveyed.
Second, it is introduced an experimental approach to examine the
possible coating defects and flaws of worn multicoated carbide
inserts using two important techniques namely scanning electron
microscopy and atomic force microscopy. Finally, it is
recommended a simple procedure for investigating manufacturing
defects and flaws of worn inserts.
Abstract: Nowadays, engineering ceramics have significant
applications in different industries such as; automotive, aerospace,
electrical, electronics and even martial industries due to their
attractive physical and mechanical properties like very high hardness
and strength at elevated temperatures, chemical stability, low friction
and high wear resistance. However, these interesting properties plus
low heat conductivity make their machining processes too hard,
costly and time consuming. Many attempts have been made in order
to make the grinding process of engineering ceramics easier and
many scientists have tried to find proper techniques to economize
ceramics' machining processes. This paper proposes a new diamond
plunge grinding technique using ultrasonic vibration for grinding
Alumina ceramic (Al2O3). For this purpose, a set of laboratory
equipments have been designed and simulated using Finite Element
Method (FEM) and constructed in order to be used in various
measurements. The results obtained have been compared with the
conventional plunge grinding process without ultrasonic vibration
and indicated that the surface roughness and fracture strength
improved and the grinding forces decreased.
Abstract: In the current research, neuro-fuzzy model and regression model was developed to predict Material Removal Rate in Electrical Discharge Machining process for AISI D2 tool steel with copper electrode. Extensive experiments were conducted with various levels of discharge current, pulse duration and duty cycle. The experimental data are split into two sets, one for training and the other for validation of the model. The training data were used to develop the above models and the test data, which was not used earlier to develop these models were used for validation the models. Subsequently, the models are compared. It was found that the predicted and experimental results were in good agreement and the coefficients of correlation were found to be 0.999 and 0.974 for neuro fuzzy and regression model respectively
Abstract: This paper presents a complete procedure for tool path
planning and blade machining in 5-axis manufacturing. The actual
cutting contact and cutter locations can be determined by lead and tilt
angles. The tool path generation is implemented by piecewise curved
approximation and chordal deviation detection. An application about
drive surface method promotes flexibility of tool control and stability
of machine motion. A real manufacturing process is proposed to
separate the operation into three regions with five stages and to modify
the local tool orientation with an interactive algorithm.
Abstract: The present work is concerned with the effect of turning process parameters (cutting speed, feed rate, and depth of cut) and distance from the center of work piece as input variables on the chip micro-hardness as response or output. Three experiments were conducted; they were used to investigate the chip micro-hardness behavior at diameter of work piece for 30[mm], 40[mm], and 50[mm]. Response surface methodology (R.S.M) is used to determine and present the cause and effect of the relationship between true mean response and input control variables influencing the response as a two or three dimensional hyper surface. R.S.M has been used for designing a three factor with five level central composite rotatable factors design in order to construct statistical models capable of accurate prediction of responses. The results obtained showed that the application of R.S.M can predict the effect of machining parameters on chip micro-hardness. The five level factorial designs can be employed easily for developing statistical models to predict chip micro-hardness by controllable machining parameters. Results obtained showed that the combined effect of cutting speed at it?s lower level, feed rate and depth of cut at their higher values, and larger work piece diameter can result increasing chi micro-hardness.
Abstract: The objective of present work is to stimulate the
machining of material by electrical discharge machining (EDM) to
give effect of input parameters like discharge current (Ip), pulse on
time (Ton), pulse off time (Toff) which can bring about changes in the
output parameter, i.e. material removal rate. Experimental data was
gathered from die sinking EDM process using copper electrode and
Medium Carbon Steel (AISI 1040) as work-piece. The rules of
membership function (MF) and the degree of closeness to the
optimum value of the MMR are within the upper and lower range of
the process parameters. It was found that proposed fuzzy model is in
close agreement with the experimental results. By Intelligent, model
based design and control of EDM process parameters in this study
will help to enable dramatically decreased product and process
development cycle times.
Abstract: Nowadays, the demand for high product quality
focuses extensive attention to the quality of machined surface. The
(CNC) milling machine facilities provides a wide variety of
parameters set-up, making the machining process on the glass
excellent in manufacturing complicated special products compared to
other machining processes. However, the application of grinding
process on the CNC milling machine could be an ideal solution to
improve the product quality, but adopting the right machining
parameters is required. In glass milling operation, several machining
parameters are considered to be significant in affecting surface
roughness. These parameters include the lubrication pressure, spindle
speed, feed rate and depth of cut. In this research work, a fuzzy logic
model is offered to predict the surface roughness of a machined
surface in glass milling operation using CBN grinding tool. Four
membership functions are allocated to be connected with each input
of the model. The predicted results achieved via fuzzy logic model
are compared to the experimental result. The result demonstrated
settlement between the fuzzy model and experimental results with the
93.103% accuracy.
Abstract: A novel nanofinishing process using improved ball
end magnetorheological (MR) finishing tool was developed for finishing of flat as well as 3D surfaces of ferromagnetic and non ferromagnetic workpieces. In this process a magnetically controlled
ball end of smart MR polishing fluid is generated at the tip surface of
the tool which is used as a finishing medium and it is guided to
follow the surface to be finished through computer controlled 3-axes
motion controller. The experiments were performed on ferromagnetic
workpiece surface in the developed MR finishing setup to study the effect of finishing time on final surface roughness. The performance
of present finishing process on final finished surface roughness was studied. The surface morphology was observed under scanning
electron microscopy and atomic force microscope. The final surface finish was obtained as low as 19.7 nm from the initial surface
roughness of 142.9 nm. The outcome of newly developed finishing process can be found useful in its applications in aerospace,
automotive, dies and molds manufacturing industries, semiconductor and optics machining etc.
Abstract: The paper is dealing by testing of ceramic cutting
tools with an interrupted machining. Tests will be provided on fixture
– interrupted cut simulator. This simulator has 4 mouldings on
circumference and cutting edge is put a shocks during 1 revolution.
Criteria of tool wear are destruction of cutting tool or 6000 shocks.
Like testing cutting tool material will be products of Sandvik
Coromant 6190, 620, 650 and 670. Machined materials was be steels
15 128 (13MoCrV6). Cutting speed (408 m.min-1 and 580 m.min-1)
and cutting feed (0,15 mm; 0,2 mm; 0,25 mm and 0,3 mm) were
variable parameters and cutting depth was constant parameter.
Abstract: This paper presents methodologies for developing an
intelligent CAD system assisting in analysis and design of
reconfigurable special machines. It describes a procedure for
determining feasibility of utilizing these machines for a given part
and presents a model for developing an intelligent CAD system. The
system analyzes geometrical and topological information of the given
part to determine possibility of the part being produced by
reconfigurable special machines from a technical point of view. Also
feasibility of the process from a economical point of view is
analyzed. Then the system determines proper positioning of the part
considering details of machining features and operations needed.
This involves determination of operation types, cutting tools and the
number of working stations needed. Upon completion of this stage
the overall layout of the machine and machining equipment required
are determined.
Abstract: Development of artificial neural network (ANN) for
prediction of aluminum workpieces' surface roughness in ultrasonicvibration
assisted turning (UAT) has been the subject of the present
study. Tool wear as the main cause of surface roughness was also
investigated. ANN was trained through experimental data obtained
on the basis of full factorial design of experiments. Various
influential machining parameters were taken into consideration. It
was illustrated that a multilayer perceptron neural network could
efficiently model the surface roughness as the response of the
network, with an error less than ten percent. The performance of the
trained network was verified by further experiments. The results of
UAT were compared with the results of conventional turning
experiments carried out with similar machining parameters except for
the vibration amplitude whence considerable reduction was observed
in the built-up edge and the surface roughness.
Abstract: As networking has become popular, Web-learning
tends to be a trend while designing a tool. Moreover, five-axis
machining has been widely used in industry recently; however, it has
potential axial table colliding problems. Thus this paper aims at
proposing an efficient web-learning collision detection tool on
five-axis machining. However, collision detection consumes heavy
resource that few devices can support, thus this research uses a
systematic approach based on web knowledge to detect collision. The
methodologies include the kinematics analyses for five-axis motions,
separating axis method for collision detection, and computer
simulation for verification. The machine structure is modeled as STL
format in CAD software. The input to the detection system is the
g-code part program, which describes the tool motions to produce the
part surface. This research produced a simulation program with C
programming language and demonstrated a five-axis machining
example with collision detection on web site. The system simulates the
five-axis CNC motion for tool trajectory and detects for any collisions
according to the input g-codes and also supports high-performance
web service benefiting from C. The result shows that our method
improves 4.5 time of computational efficiency, comparing to the
conventional detection method.
Abstract: Since straightness error of linear motor stage is hardly
dependent upon machining accuracy and assembling accuracy, there is
limit on maximum realizable accuracy. To cope with this limitation,
this paper proposed a servo system to compensate straightness error of
a linear motor stage. The servo system is mounted on the slider of the
linear motor stage and moves in the direction of the straightness error
so as to compensate the error. From position dependency and
repeatability of the straightness error of the slider, a feedforward
compensation control is applied to the platform servo control. In the
consideration of required fine positioning accuracy, a platform driven
by an electro-magnetic actuator is suggested and a sliding mode
control was applied. The effectiveness of the sliding mode control was
verified along with some experimental results.
Abstract: Integration of process planning and scheduling
functions is necessary to achieve superior overall system
performance. This paper proposes a methodology for integration of
process planning and scheduling for prismatic component that can be
implemented in a company with existing departments. The developed
model considers technological constraints whereas available time for
machining in shop floor is the limiting factor to produce multiple
process plan (MPP). It takes advantage of MPP while guarantied the
fulfillment of the due dates via using overtime. This study has been
proposed to determinate machining parameters, tools, machine and
amount of over time within the minimum cost objective while
overtime is considered for this. At last the illustration shows that the
system performance is improved by as measured by cost and
compatible with due date.
Abstract: In the present work, a study has been made on the combination of the electrical discharge machining (EDM) with ultrasonic vibrations to improve the machining efficiency. In experiments the graphite used as tool electrode and material of workpiece was AISIH13 tool steel. The parameters such as discharge peak current and pulse duration were changed to explore their effect on the material removal rate (MRR), relative tool wear ratio (TWR) and surface roughness. From the experimental result it can be seen that ultrasonic vibration of the workpiece can significantly reduces the inactive pulses and improves the stability of process. It was found that ultrasonic assisted EDM (US-EDM) is effective in attaining a high material removal rate (MRR) in finishing regime.