Abstract: In this paper the authors propose and verify an approach to control heat flow in machine tool components. Thermal deformations are a main aspect that affects the accuracy of machining. Due to goals of energy efficiency, thermal basic loads should be reduced. This leads to inhomogeneous and time variant temperature profiles. To counteract these negative consequences, material with high melting enthalpy is used as a method for thermal stabilization. The increased thermal capacity slows down the transient thermal behavior. To account for the delayed thermal equilibrium, a control mechanism for thermal flow is introduced. By varying a gap in a heat flow path the thermal resistance of an assembly can be controlled. This mechanism is evaluated in two experimental setups. First to validate the ability to control the thermal resistance and second to prove the possibility of a self-sufficient option based on the selfsensing abilities of thermal shape memory alloys.
Abstract: A filter is used to remove undesirable frequency information from a dynamic signal. This paper shows that the Znotch filter filtering technique can be applied to remove the noise nuisance from a machining signal. In machining, the noise components were identified from the sound produced by the operation of machine components itself such as hydraulic system, motor, machine environment and etc. By correlating the noise components with the measured machining signal, the interested components of the measured machining signal which was less interfered by the noise, can be extracted. Thus, the filtered signal is more reliable to be analysed in terms of noise content compared to the unfiltered signal. Significantly, the I-kaz method i.e. comprises of three dimensional graphical representation and I-kaz coefficient, Z∞ could differentiate between the filtered and the unfiltered signal. The bigger space of scattering and the higher value of Z∞ demonstrated that the signal was highly interrupted by noise. This method can be utilised as a proactive tool in evaluating the noise content in a signal. The evaluation of noise content is very important as well as the elimination especially for machining operation fault diagnosis purpose. The Z-notch filtering technique was reliable in extracting noise component from the measured machining signal with high efficiency. Even though the measured signal was exposed to high noise disruption, the signal generated from the interaction between cutting tool and work piece still can be acquired. Therefore, the interruption of noise that could change the original signal feature and consequently can deteriorate the useful sensory information can be eliminated.
Abstract: In this paper, a methodology of a model based on
predicting the tool forces oblique machining are introduced by
adopting the orthogonal technique. The applied analytical calculation
is mostly based on Devries model and some parts of the methodology
are employed from Amareggo-Brown model. Model validation is
performed by comparing experimental data with the prediction results
on machining titanium alloy (Ti-6Al-4V) based on micro-cutting tool
perspective. Good agreements with the experiments are observed. A
detailed friction form that affected the tool forces also been examined
with reasonable results obtained.
Abstract: This paper deals with a novel technique for the
fabrication of Spiral grooves in a dynamic thrust bearing. The main
scheme proposed in this paper is to fabricate the microgrooves using
desktop forming system. This process has advantages compared to the
conventional electro-chemical machining in the viewpoint of a higher
productivity. For this reason, a new testing apparatus is designed and
built for press forming microgrooves on a surface of the thrust bearing.
The material used in this study is sintered Cu-Fe alloy. The effects of
the forming load on the performance of micro press forming are
experimentally investigated. From the experimental results, formed
depths are closed to the target ones with increasing the forming load.
Abstract: Surface metrology with image processing is a challenging task having wide applications in industry. Surface roughness can be evaluated using texture classification approach. Important aspect here is appropriate selection of features that characterize the surface. We propose an effective combination of features for multi-scale and multi-directional analysis of engineering surfaces. The features include standard deviation, kurtosis and the Canny edge detector. We apply the method by analyzing the surfaces with Discrete Wavelet Transform (DWT) and Dual-Tree Complex Wavelet Transform (DT-CWT). We used Canberra distance metric for similarity comparison between the surface classes. Our database includes the surface textures manufactured by three machining processes namely Milling, Casting and Shaping. The comparative study shows that DT-CWT outperforms DWT giving correct classification performance of 91.27% with Canberra distance metric.
Abstract: A mathematical model of the surface roughness
has been developed by using response surface methodology
(RSM) in grinding of AISI D2 cold work tool steels. Analysis
of variance (ANOVA) was used to check the validity of the
model. Low and high value for work speed and feed rate are
decided from design of experiment. The influences of all
machining parameters on surface roughness have been
analyzed based on the developed mathematical model. The
developed prediction equation shows that both the feed rate
and work speed are the most important factor that influences
the surface roughness. The surface roughness was found to be
the lowers with the used of low feed rate and low work speed.
Accuracy of the best model was proved with the testing data.
Abstract: This paper was aimed at developing a computer aided
design and manufacturing system for spatial cylindrical cams. In the
proposed system, a milling tool with a diameter smaller than that of the
roller, instead of the standard cutter for traditional machining process,
was used to generate the tool path for spatial cams. To verify the
feasibility of the proposed method, a multi-axis machining simulation
software was further used to simulate the practical milling operation of
spatial cams. It was observed from computer simulation that the tool
path of small-sized cutter were within the motion range of a standard
cutter, no occurrence of overcutting. Examination of a finished cam
component clearly verifies the accuracy of the tool path generated for
small-sized milling tool. It is believed that the use of small-sized cutter
for the machining of the spatial cylindrical cams can generate a better
surface morphology with higher accuracy. The improvement in
efficiency and cost for the manufacturing of the spatial cylindrical cam
can be expected through the proposed method.
Abstract: The importance of machining process in today-s
industry requires the establishment of more practical approaches to
clearly represent the intimate and severe contact on the tool-chipworkpiece
interfaces. Mathematical models are developed using the
measured force signals to relate each of the tool-chip friction
components on the rake face to the operating cutting parameters in
rough turning operation using multilayers coated carbide inserts.
Nonlinear modeling proved to have high capability to detect the
nonlinear functional variability embedded in the experimental data.
While feedrate is found to be the most influential parameter on the
friction coefficient and its related force components, both cutting
speed and depth of cut are found to have slight influence. Greater
deformed chip thickness is found to lower the value of friction
coefficient as the sliding length on the tool-chip interface is reduced.
Abstract: In recent years, scanning probe atomic force
microscopy SPM AFM has gained acceptance over a wide spectrum
of research and science applications. Most fields focuses on physical,
chemical, biological while less attention is devoted to manufacturing
and machining aspects. The purpose of the current study is to assess
the possible implementation of the SPM AFM features and its
NanoScope software in general machining applications with special
attention to the tribological aspects of cutting tool. The surface
morphology of coated and uncoated as-received carbide inserts is
examined, analyzed, and characterized through the determination of
the appropriate scanning setting, the suitable data type imaging
techniques and the most representative data analysis parameters
using the MultiMode SPM AFM in contact mode. The NanoScope
operating software is used to capture realtime three data types
images: “Height", “Deflection" and “Friction". Three scan sizes are
independently performed: 2, 6, and 12 μm with a 2.5 μm vertical
range (Z). Offline mode analysis includes the determination of three
functional topographical parameters: surface “Roughness", power
spectral density “PSD" and “Section". The 12 μm scan size in
association with “Height" imaging is found efficient to capture every
tiny features and tribological aspects of the examined surface. Also,
“Friction" analysis is found to produce a comprehensive explanation
about the lateral characteristics of the scanned surface. Configuration
of many surface defects and drawbacks has been precisely detected
and analyzed.
Abstract: This paper presents a experiment to estimate the
influences of cutting conditions in microstructure changes of
machining austenitic 304 stainless steel, especially for wear insert. The
wear insert were prefabricated with a width of 0.5 mm. And the forces,
temperature distribution, RS, and microstructure changes were
measured by force dynamometer, infrared thermal camera, X-ray
diffraction, XRD, SEM, respectively. The results told that the different
combinations of machining condition have a significant influence on
machined surface microstructure changes. In addition to that, the
ANOVA and AOMwere used to tell the different influences of cutting
speed, feed rate, and wear insert.
Abstract: Chatter vibration has been a troublesome problem for a
machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process. Therefore the dynamic vibration behavior of spindle tool
system greatly determines the performance of machine tool. The
purpose of this study is to investigate the influences of the machine
frame structure on the dynamic frequency of spindle tool unit through
finite element modeling approach. To this end, a realistic finite
element model of the vertical milling system was created by
incorporated the spindle-bearing model into the spindle head stock of
the machine frame. Using this model, the dynamic characteristics of
the milling machines with different structural designs of spindle head
stock and identical spindle tool unit were demonstrated. The results of
the finite element modeling reveal that the spindle tool unit behaves
more compliant when the excited frequency approaches the natural
mode of the spindle tool; while the spindle tool show a higher dynamic
stiffness at lower frequency that may be initiated by the structural
mode of milling head. Under this condition, it is concluded that the
structural configuration of spindle head stock associated with the
vertical column of milling machine plays an important role in
determining the machining dynamics of the spindle unit.
Abstract: The paper provides a literature review of the STEPNC
compliant research around the world. The first part of this paper
focuses on projects based on STEP compliance followed by research
and development in this area based on machining operations. Review
the literature relating to relevant STEP standards and application in
the area of turning centers. This research will review the various
research work, carried out from the evolution of STEP-NC of the
CNC manufacturing activities. The paper concludes with discussion
of the applications in this particular area.
Abstract: The operating control parameters of injection
flushing type of electrical discharge machining process on stainless
steel 304 workpiece using copper tools are being optimized
according to its individual machining characteristic i.e. Electrode
Wear Ratio (EWR). Higher EWR would give bad dimensional
precision for the EDM machined workpiece because of high
electrode wear. Hence, the quality characteristic for EWR is set to
lower-the-better to achieve the optimum dimensional precision for
the machined workpiece. Taguchi method has been used for the
construction, layout and analysis of the experiment for EWR
machining characteristic. The use of Taguchi method in the
experiment saves a lot of time and cost of preparing and machining
the experiment samples. Therefore, an L18 Orthogonal array
which was the fundamental component in the statistical design of
experiments has been used to plan the experiments and Analysis of
Variance (ANOVA) is used to determine the optimum machining
parameters for this machining characteristic. The control
parameters selected for this optimization experiments are polarity,
pulse on duration, discharge current, discharge voltage, machining
depth, machining diameter and dielectric liquid pressure. The
result had shown that negative polarity machining parameter
setting will decreases EWR.
Abstract: Helical milling operations are used to generate or
enlarge boreholes by means of a milling tool. The bore diameter can be
adjusted through the diameter of the helical path. The kinematics of
helical milling on a three axis machine tool is analysed firstly. The
relationships between processing parameters, cutting tool geometry
characters with machined hole feature are formulated. The feed motion
of the cutting tool has been decomposed to plane circular feed and
axial linear motion. In this paper, the time varying cutting forces acted
on the side cutting edges and end cutting edges of the flat end cylinder
miller is analysed using a discrete method separately. These two
components then are combined to produce the cutting force model
considering the complicated interaction between the cutters and
workpiece. The time varying cutting force model describes the
instantaneous cutting force during processing. This model could be
used to predict cutting force, calculate statics deflection of cutter and
workpiece, and also could be the foundation of dynamics model and
predicting chatter limitation of the helical milling operations.
Abstract: The contribution is dealing with the influence of high speed parameters on the quality of machined surface. In general the principle of high speed cutting lies in achieving faster machine times with concurrent increase in accuracy and quality of the machined areas in largely irregular, mathematically hard to define shapes. High speed machining is a highly effective method of machining with the following goals: increasing of machining productivity, increasing of quality of the machined surface, improving of machining economy, improving of ecological aspects of machining. This article is based on an experiment performed by the Department of Machining and Assembly of the Faculty of Mechanical Engineering of VŠBTechnical University of Ostrava.
Abstract: The machining of Carbon Fiber Reinforced Plastics
has come to constitute a significant challenge for many fields of
industry. The resulting surface finish of machined parts is of primary
concern for several reasons, including contact quality and impact on
the assembly. Therefore, the characterization and prediction of
roughness based on machining parameters are crucial for costeffective
operations. In this study, a PCD tool comprised of two
straight flutes was used to trim 32-ply carbon fiber laminates in a bid
to analyze the effects of the feed rate and the cutting speed on the
surface roughness. The results show that while the speed has but a
slight impact on the surface finish, the feed rate for its part affects it
strongly. A detailed study was also conducted on the effect of fiber
orientation on surface roughness, for quasi-isotropic laminates used
in aerospace. The resulting roughness profiles for the four-ply
orientation lay-up were compared, and it was found that fiber angle is
a critical parameter relating to surface roughness. One of the four
orientations studied led to very poor surface finishes, and
characteristic roughness profiles were identified and found to only
relate to the ply orientations of multilayer carbon fiber laminates.
Abstract: In the modern manufacturing systems, the use of
thermal cutting techniques using oxyfuel, plasma and laser have
become indispensable for the shape forming of high quality complex
components; however, the conventional chip removal production
techniques still have its widespread space in the manufacturing
industry. Both these types of machining operations require the
positioning of end effector tool at the edge where the cutting process
commences. This repositioning of the cutting tool in every machining
operation is repeated several times and is termed as non-productive
time or airtime motion. Minimization of this non-productive
machining time plays an important role in mass production with high
speed machining. As, the tool moves from one region to the other by
rapid movement and visits a meticulous region once in the whole
operation, hence the non-productive time can be minimized by
synchronizing the tool movements. In this work, this problem is
being formulated as a general travelling salesman problem (TSP) and
a genetic algorithm approach has been applied to solve the same. For
improving the efficiency of the algorithm, the GA has been
hybridized with a noble special heuristic and simulating annealing
(SA). In the present work a novel heuristic in the combination of GA
has been developed for synchronization of toolpath movements
during repositioning of the tool. A comparative analysis of new Meta
heuristic techniques with simple genetic algorithm has been
performed. The proposed metaheuristic approach shows better
performance than simple genetic algorithm for minimization of nonproductive
toolpath length. Also, the results obtained with the help of
hybrid simulated annealing genetic algorithm (HSAGA) are also
found better than the results using simple genetic algorithm only.
Abstract: In this paper, a particle swarm optimization (PSO)
algorithm is proposed to solve machine loading problem in flexible
manufacturing system (FMS), with bicriterion objectives of
minimizing system unbalance and maximizing system throughput in
the occurrence of technological constraints such as available
machining time and tool slots. A mathematical model is used to
select machines, assign operations and the required tools. The
performance of the PSO is tested by using 10 sample dataset and the
results are compared with the heuristics reported in the literature. The
results support that the proposed PSO is comparable with the
algorithms reported in the literature.
Abstract: The stochastic nature of tool life using conventional discrete-wear data from experimental tests usually exists due to many individual and interacting parameters. It is a common practice in batch production to continually use the same tool to machine different parts, using disparate machining parameters. In such an environment, the optimal points at which tools have to be changed, while achieving minimum production cost and maximum production rate within the surface roughness specifications, have not been adequately studied. In the current study, two relevant aspects are investigated using coated and uncoated inserts in turning operations: (i) the accuracy of using machinability information, from fixed parameters testing procedures, when variable parameters situations are emerged, and (ii) the credibility of tool life machinability data from prior discrete testing procedures in a non-stop machining. A novel technique is proposed and verified to normalize the conventional fixed parameters machinability data to suit the cases when parameters have to be changed for the same tool. Also, an experimental investigation has been established to evaluate the error in the tool life assessment when machinability from discrete testing procedures is employed in uninterrupted practical machining.
Abstract: In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.