Abstract: The information of the impact cutting behavior of plants stalk plays an important role in the design and fabrication of plants cutting equipment. It is difficult to investigate a theoretical method for defining cutting properties of plants stalks because the cutting process is complex. Thus, it is necessary to set up an experimental approach to determine cutting parameters for a single stalk. To measure the shear force, shear energy and shear strength of plant stalk, a special impact cutting tester was fabricated. It was similar to an Izod impact cutting tester for metals but a cutting blade and data acquisition system were attached to the end of pendulum's arm. The apparatus was included four strain gages and a digital indicator to show the real-time cutting force of plant stalk. To measure the shear force and also testing the apparatus, two plants’ stalks, like buxus and privet, were selected. The samples (buxus and privet stalks) were cut under impact cutting process at four loading rates 1, 2, 3 and 4 m.s-1 and three internodes fifth, tenth and fifteenth by the apparatus. At buxus cutting analysis: the minimum value of cutting energy was obtained at fifth internode and loading rate 4 m.s-1 and the maximum value of shear energy was obtained at fifteenth internode and loading rate 1 m.s-1. At privet cutting analysis: the minimum value of shear consumption energy was obtained at fifth internode and loading rate: 4 m.s-1 and the maximum value of shear energy was obtained at fifteenth internode and loading rate: 1 m.s-1. The statistical analysis at both plants showed that the increase of impact cutting speed would decrease the shear consumption energy and shear strength. In two scenarios, the results showed that with increase the cutting speed, shear force would decrease.
Abstract: Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.
Abstract: Chatter vibrations, occurring during cutting process,
cause vibration between the cutting tool and workpiece, which
deteriorates surface roughness and reduces tool life. The purpose of
this study is to investigate the influence of cutting parameters and
tool construction on surface roughness and vibration in turning of
aluminum alloy AA2024. A new design of cutting tool is proposed,
which is filled up with epoxy granite in order to improve damping
capacity of the tool. Experiments were performed at the lathe using
carbide cutting insert coated with TiC and two different cutting tools
made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to
design of experiment and to optimize cutting conditions. By the help
of signal-to-noise ratio and analysis of variance the optimal cutting
condition and the effect of the cutting parameters on surface
roughness and vibration were determined. Effectiveness of Taguchi
method was verified by confirmation test. It was revealed that new
cutting tool with epoxy granite has reduced vibration and surface
roughness due to high damping properties of epoxy granite in
toolholder.
Abstract: The effects of the contact ball-lens on the soda lime
glass in laser thermal cleavage with a cw Nd-YAG laser were
investigated in this study. A contact ball-lens was adopted to generate
a bending force on the crack formation of the soda-lime glass in the
laser cutting process. The Nd-YAG laser beam (wavelength of 1064
nm) was focused through the ball-lens and transmitted to the soda-lime
glass, which was coated with a carbon film on the surface with a
bending force from a ball-lens to generate a tensile stress state on the
surface cracking. The fracture was controlled by the contact ball-lens
and a straight cutting was tested to demonstrate the feasibility.
Experimental observations on the crack propagation from the leading
edge, main section and trailing edge of the glass sheet were compared
with various mechanical and thermal loadings. Further analyses on the
stress under various laser powers and contact ball loadings were made
to characterize the innovative technology. The results show that the distributions of the side crack at the
leading and trailing edges are mainly dependent on the boundary
condition, contact force, cutting speed and laser power. With the
increase of the mechanical and thermal loadings, the region of the side
cracks might be dramatically reduced with proper selection of the
geometrical constrains. Therefore the application of the contact
ball-lens is a possible way to control the fracture in laser cleavage with
improved cutting qualities.
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: Present study is aimed on the cutting process of circular
cross-section rods where the fracture is used to separate one rod
into two pieces. Incorporating the phenomenological ductile fracture
model into the explicit formulation of finite element method, the
process can be analyzed without the necessity of realizing too many
real experiments which could be expensive in case of repetitive
testing in different conditions. In the present paper, the steel AISI
1045 was examined and the tensile tests of smooth and notched
cylindrical bars were conducted together with biaxial testing of the
notched tube specimens to calibrate material constants of selected
phenomenological ductile fracture models. These were implemented
into the Abaqus/Explicit through user subroutine VUMAT and used
for cutting process simulation. As the calibration process is based
on variables which cannot be obtained directly from experiments,
numerical simulations of fracture tests are inevitable part of the
calibration. Finally, experiments regarding the cutting process were
carried out and predictive capability of selected fracture models is
discussed. Concluding remarks then make the summary of gained
experience both with the calibration and application of particular
ductile fracture criteria.
Abstract: Several researches have been conducted to study
consumption of energy in cutting process. Most of these researches
are focusing to measure the consumption and propose consumption
reduction methods. In this work, the relation between the cutting
parameters and the consumption is investigated in order to establish a
generalized energy consumption model that can be used for process
and production planning in real production lines. Using the
generalized model, the process planning will be carried out by taking
into account the energy as a function of the selected process
parameters. Similarly, the generalized model can be used in
production planning to select the right operational parameters like
batch sizes, routing, buffer size, etc. in a production line. The
description and derivation of the model as well as a case study are
given in this paper to illustrate the applicability and validity of the
model.
Abstract: The quality of machined surfaces is an important characteristic of cutting processes and surface roughness has strong effects on the performance of sliding, moving components. The ability to forecast these values for a given process has been of great interests among researchers for a long time. Different modeling procedures and algorithms have been worked-out, and each has its own advantages and drawbacks. A new method will be introduced in this paper which will make it possible to calculate both the profile (2D) and surface (3D) parameters of theoretical roughness in the face milling of plain surfaces. This new method is based on an expediently developed CAD model, and uses a professional program for the roughness evaluation. Cutting experiments were performed on 42CrMo4 specimens in order to validate the accuracy of the model. The results have revealed that the method is able to predict surface roughness with good accuracy.
Abstract: This paper is intended to develop an artificial neural network (ANN) based model of material removal rate (MRR) in the turning of ferrous and nonferrous material in a Indian small-scale industry. MRR of the formulated model was proved with the testing data and artificial neural network (ANN) model was developed for the analysis and prediction of the relationship between inputs and output parameters during the turning of ferrous and nonferrous materials. The input parameters of this model are operator, work-piece, cutting process, cutting tool, machine and the environment.
The ANN model consists of a three layered feedforward back propagation neural network. The network is trained with pairs of independent/dependent datasets generated when machining ferrous and nonferrous material. A very good performance of the neural network, in terms of contract with experimental data, was achieved. The model may be used for the testing and forecast of the complex relationship between dependent and the independent parameters in turning operations.
Abstract: This paper introduces a novel design for boring bar with enhanced damping capability. The principle followed in the design phase was to enhance the damping capability minimizing the loss in static stiffness through implementation of composite material interfaces. The newly designed tool has been compared to a conventional tool. The evaluation criteria were the dynamic characteristics, frequency and damping ratio, of the machining system, as well as the surface roughness of the machined workpieces. The use of composite material in the design of damped tool has been demonstrated effective. Furthermore, the autoregressive moving average (ARMA) models presented in this paper take into consideration the interaction between the elastic structure of the machine tool and the cutting process and can therefore be used to characterize the machining system in operational conditions.
Abstract: Optimization of cutting parameters important in precision machining in regards to efficiency and surface integrity of the machined part. Usually productivity and precision in machining is limited by the forces emanating from the cutting process. Due to the inherent varying nature of the workpiece in terms of geometry and material composition, the peak cutting forces vary from point to point during machining process. In order to increase productivity without compromising on machining accuracy, it is important to control these cutting forces. In this paper a fuzzy logic control algorithm is developed that can be applied in the control of peak cutting forces in milling of spherical surfaces using ball end mills. The controller can adaptively vary the feedrate to maintain allowable cutting force on the tool. This control algorithm is implemented in a computer numerical control (CNC) machine. It has been demonstrated that the controller can provide stable machining and improve the performance of the CNC milling process by varying feedrate.
Abstract: The machining performance is determined by the
frequency characteristics of the machine-tool structure and the
dynamics of the cutting process. Therefore, the prediction of dynamic
vibration behavior of spindle tool system is of great importance for the
design of a machine tool capable of high-precision and high-speed
machining. The aim of this study is to develop a finite element model
to predict the dynamic characteristics of milling machine tool and
hence evaluate the influence of the preload of the spindle bearings. To
this purpose, a three dimensional spindle bearing model of a high
speed engraving spindle tool was created. In this model, the rolling
interfaces with contact stiffness defined by Harris model were used to
simulate the spindle bearing components. Then a full finite element
model of a vertical milling machine was established by coupling the
spindle tool unit with the machine frame structure. Using this model,
the vibration mode that had a dominant influence on the dynamic
stiffness was determined. The results of the finite element simulations
reveal that spindle bearing with different preloads greatly affect the
dynamic behavior of the spindle tool unit and hence the dynamic
responses of the vertical column milling system. These results were
validated by performing vibration on the individual spindle tool unit
and the milling machine prototype, respectively. We conclude that
preload of the spindle bearings is an important component affecting
the dynamic characteristics and machining performance of the entire
vertical column structure of the milling machine.
Abstract: In present work, prediction the effect of nose radius, rz (mm) on the equivalent strain (PEEQ) and surface finish during the machining of titanium alloy (Ti-6Al-4V) through orthogonal cutting process. The results were performed at several of the nose radiuses, rz (mm) while the cutting speed, vc (m/min), feed rate, f (mm/tooth) and depth of cut, d (mm) were remained constant. The equivalent plastic strain (PEEQ) was estimated by using finite element modeling (FEM) and applied through ABAQUS/EXPLICIT software. The simulation results led to conclude that the equivalent plastic strain (PEEQ) was increased and surface roughness (Ra) decreased when increasing nose radius, rz (mm) during the machining of titanium alloy (Ti–6Al–4V) in dry cutting conditions.
Abstract: One of the main research directions in CAD/CAM
machining area is the reducing of machining time.
The feedrate scheduling is one of the advanced techniques that
allows keeping constant the uncut chip area and as sequel to keep
constant the main cutting force. They are two main ways for feedrate
optimization. The first consists in the cutting force monitoring, which
presumes to use complex equipment for the force measurement and
after this, to set the feedrate regarding the cutting force variation. The
second way is to optimize the feedrate by keeping constant the
material removal rate regarding the cutting conditions.
In this paper there is proposed a new approach using an extended
database that replaces the system model.
The feedrate scheduling is determined based on the identification
of the reconfigurable machine tool, and the feed value determination
regarding the uncut chip section area, the contact length between tool
and blank and also regarding the geometrical roughness.
The first stage consists in the blank and tool monitoring for the
determination of actual profiles. The next stage is the determination
of programmed tool path that allows obtaining the piece target
profile.
The graphic representation environment models the tool and blank
regions and, after this, the tool model is positioned regarding the
blank model according to the programmed tool path. For each of
these positions the geometrical roughness value, the uncut chip area
and the contact length between tool and blank are calculated. Each of
these parameters are compared with the admissible values and
according to the result the feed value is established.
We can consider that this approach has the following advantages:
in case of complex cutting processes the prediction of cutting force is
possible; there is considered the real cutting profile which has
deviations from the theoretical profile; the blank-tool contact length
limitation is possible; it is possible to correct the programmed tool
path so that the target profile can be obtained.
Applying this method, there are obtained data sets which allow the
feedrate scheduling so that the uncut chip area is constant and, as a
result, the cutting force is constant, which allows to use more
efficiently the machine tool and to obtain the reduction of machining
time.
Abstract: Industrial surveys shows that manufacturing
companies define the qualities of thermal removing process based on
the dimension and physical appearance of the cutting material
surface. Therefore, the roughness of the surface area of the material
cut by the plasma arc cutting process and the rate of the removed
material by the manual plasma arc cutting machine was importantly
considered. Plasma arc cutter Selco Genesis 90 was used to cut
Standard AISI 1017 Steel of 200 mm x100 mm x 6 mm manually
based on the selected parameters setting. The material removal rate
(MRR) was measured by determining the weight of the specimens
before and after the cutting process. The surface roughness (SR)
analysis was conducted using Mitutoyo CS-3100 to determine the
average roughness value (Ra). Taguchi method was utilized to
achieve optimum condition for both outputs studied. The
microstructure analysis in the region of the cutting surface is
performed using SEM. The results reveal that the SR values are
inversely proportional to the MRR values. The quality of the surface
roughness depends on the dross peak that occurred after the cutting
process.
Abstract: This paper proposes a method to vibration analysis in
order to on-line monitoring and predictive maintenance during the
milling process. Adapting envelope method to diagnostics and the
analysis for milling tool materials is an important contribution to the
qualitative and quantitative characterization of milling capacity and a
step by modeling the three-dimensional cutting process. An
experimental protocol was designed and developed for the
acquisition, processing and analyzing three-dimensional signal. The
vibration envelope analysis is proposed to detect the cutting capacity
of the tool with the optimization application of cutting parameters.
The research is focused on Hilbert transform optimization to evaluate
the dynamic behavior of the machine/ tool/workpiece.
Abstract: The objective of this research is to study plant layout
of iron manufacturing based on the systematic layout planning
pattern theory (SLP) for increased productivity. In this case study,
amount of equipments and tools in iron production are studied. The
detailed study of the plant layout such as operation process chart,
flow of material and activity relationship chart has been investigated.
The new plant layout has been designed and compared with the
present plant layout. The SLP method showed that new plant layout
significantly decrease the distance of material flow from billet
cutting process until keeping in ware house.
Abstract: The analysis of Acoustic Emission (AE) signal
generated from metal cutting processes has often approached
statistically. This is due to the stochastic nature of the emission
signal as a result of factors effecting the signal from its generation
through transmission and sensing. Different techniques are applied in
this manner, each of which is suitable for certain processes. In metal
cutting where the emission generated by the deformation process is
rather continuous, an appropriate method for analysing the AE signal
based on the root mean square (RMS) of the signal is often used and
is suitable for use with the conventional signal processing systems.
The aim of this paper is to set a strategy in tool failure detection in
turning processes via the statistic analysis of the AE generated from
the cutting zone. The strategy is based on the investigation of the
distribution moments of the AE signal at predetermined sampling.
The skews and kurtosis of these distributions are the key elements in
the detection. A normal (Gaussian) distribution has first been
suggested then this was eliminated due to insufficiency. The so
called Beta distribution was then considered, this has been used with
an assumed β density function and has given promising results with
regard to chipping and tool breakage detection.
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: We present the development of a new underwater laser
cutting process in which a water-jet has been used along with the
laser beam to remove the molten material through kerf. The
conventional underwater laser cutting usually utilizes a high pressure
gas jet along with laser beam to create a dry condition in the cutting
zone and also to eject out the molten material. This causes a lot of gas
bubbles and turbulence in water, and produces aerosols and waste
gas. This may cause contamination in the surrounding atmosphere
while cutting radioactive components like burnt nuclear fuel. The
water-jet assisted underwater laser cutting process produces much
less turbulence and aerosols in the atmosphere. Some amount of
water vapor bubbles is formed at the laser-metal-water interface;
however, they tend to condense as they rise up through the
surrounding water. We present the design and development of a
water-jet assisted underwater laser cutting head and the parametric
study of the cutting of AISI 304 stainless steel sheets with a 2 kW
CW fiber laser. The cutting performance is similar to that of the gas
assist laser cutting; however, the process efficiency is reduced due to
heat convection by water-jet and laser beam scattering by vapor. This
process may be attractive for underwater cutting of nuclear reactor
components.