Abstract: The operation performance of a valveless micro-pump
is strongly dependent on the shape of connected nozzle/diffuser and
Reynolds number. The aims of present work are to compare the
performance curves of micropump with the original straight
nozzle/diffuser and contoured nozzle/diffuser under different back
pressure conditions. The tested valveless micropumps are assembled
of five pieces of patterned PMMA plates with hot-embracing
technique. The structures of central chamber, the inlet/outlet
reservoirs and the connected nozzle/diffuser are fabricated with laser
cutting machine. The micropump is actuated with circular-type PZT
film embraced on the bottom of central chamber. The deformation of
PZT membrane with various input voltages is measured with a
displacement laser probe. A simple testing facility is also constructed
to evaluate the performance curves for comparison.
In order to observe the evaluation of low Reynolds number
multiple vortex flow patterns within the micropump during suction
and pumping modes, the unsteady, incompressible laminar
three-dimensional Reynolds-averaged Navier-Stokes equations are
solved. The working fluid is DI water with constant thermo-physical
properties. The oscillating behavior of PZT film is modeled with the
moving boundary wall in way of UDF program. With the dynamic
mesh method, the instants pressure and velocity fields are obtained
and discussed.Results indicated that the volume flow rate is not
monotony increased with the oscillating frequency of PZT film,
regardless of the shapes of nozzle/diffuser. The present micropump
can generate the maximum volume flow rate of 13.53 ml/min when
the operation frequency is 64Hz and the input voltage is 140 volts.
The micropump with contoured nozzle/diffuser can provide 7ml/min
flow rate even when the back pressure is up to 400 mm-H2O. CFD
results revealed that the flow central chamber was occupied with
multiple pairs of counter-rotating vortices during suction and
pumping modes. The net volume flow rate over a complete
oscillating periodic of PZT
Abstract: This paper presents an advance in monitoring and
process control of surface roughness in CNC machine for the turning
and milling processes. An integration of the in-process monitoring
and process control of the surface roughness is proposed and
developed during the machining process by using the cutting force
ratio. The previously developed surface roughness models for turning
and milling processes of the author are adopted to predict the inprocess
surface roughness, which consist of the cutting speed, the
feed rate, the tool nose radius, the depth of cut, the rake angle, and
the cutting force ratio. The cutting force ratios obtained from the
turning and the milling are utilized to estimate the in-process surface
roughness. The dynamometers are installed on the tool turret of CNC
turning machine and the table of 5-axis machining center to monitor
the cutting forces. The in-process control of the surface roughness
has been developed and proposed to control the predicted surface
roughness. It has been proved by the cutting tests that the proposed
integration system of the in-process monitoring and the process
control can be used to check the surface roughness during the cutting
by utilizing the cutting force ratio.
Abstract: The objective of this research was to study factors,
which were affected on surface roughness in high speed milling of
hardened tool steel. Material used in the experiment was tool steel JIS
SKD 61 that hardened on 60 ±2 HRC. Full factorial experimental
design was conducted on 3 factors and 3 levels (3
3
designs) with 2
replications. Factors were consisted of cutting speed, feed rate, and
depth of cut. The results showed that influenced factor affected to
surface roughness was cutting speed, feed rate and depth of cut which
showed statistical significant. Higher cutting speed would cause on
better surface quality. On the other hand, higher feed rate would cause
on poorer surface quality. Interaction of factor was found that cutting
speed and depth of cut were significantly to surface quality. The
interaction of high cutting speed associated with low depth of cut
affected to better surface quality than low cutting speed and high depth
of cut.
Abstract: This research work is aimed at speech recognition
using scaly neural networks. A small vocabulary of 11 words were
established first, these words are “word, file, open, print, exit, edit,
cut, copy, paste, doc1, doc2". These chosen words involved with
executing some computer functions such as opening a file, print
certain text document, cutting, copying, pasting, editing and exit.
It introduced to the computer then subjected to feature extraction
process using LPC (linear prediction coefficients). These features are
used as input to an artificial neural network in speaker dependent
mode. Half of the words are used for training the artificial neural
network and the other half are used for testing the system; those are
used for information retrieval.
The system components are consist of three parts, speech
processing and feature extraction, training and testing by using neural
networks and information retrieval.
The retrieve process proved to be 79.5-88% successful, which is
quite acceptable, considering the variation to surrounding, state of
the person, and the microphone type.
Abstract: The use of hard and brittle material has become
increasingly more extensive in recent years. Therefore processing of
these materials for the parts fabrication has become a challenging
problem. However, it is time-consuming to machine the hard brittle
materials with the traditional metal-cutting technique that uses
abrasive wheels. In addition, the tool would suffer excessive wear as
well. However, if ultrasonic energy is applied to the machining
process and coupled with the use of hard abrasive grits, hard and
brittle materials can be effectively machined. Ultrasonic machining
process is mostly used for the brittle materials. The present research
work has developed models using finite element approach to predict
the mechanical stresses sand strains produced in the tool during
ultrasonic machining process. Also the flow behavior of abrasive
slurry coming out of the nozzle has been studied for simulation using
ANSYS CFX module. The different abrasives of different grit sizes
have been used for the experimentation work.
Abstract: Machining through turning was carried out in a lathe
to study the chip formation of Multiphase Ferrite
(F-B-M) microalloyed steel. Taguchi orthogonal array was employed
to perform the machining. Continuous and discontinuous chips were
formed for different cutting parameters like speed, feed and depth of
cut. Optical and scanning electron microscope was employed to
identify the chip morphology.
Abstract: This paper describes a method to measure and
compensate a 4 axes ultra-precision machine tool that generates micro
patterns on the large surfaces. The grooving machine is usually used
for making a micro mold for many electrical parts such as a light guide
plate for LCD and fuel cells. The ultra precision machine tool has three
linear axes and one rotational table. Shaping is usually used to
generate micro patterns. In the case of 50 μm pitch and 25 μm height
pyramid pattern machining with a 90° wedge angle bite, one of linear
axis is used for long stroke motion for high cutting speed and other
linear axis are used for feeding. The triangular patterns can be
generated with many times of long stroke of one axis. Then 90°
rotation of work piece is needed to make pyramid patterns with
superposition of machined two triangular patterns.
To make a two dimensional positioning error, straightness of two
axes in out of plane, squareness between the each axis are important.
Positioning errors, straightness and squarness were measured by laser
interferometer system. Those were compensated and confirmed by
ISO230-6. One of difficult problem to measure the error motions is
squareness or parallelism of axis between the rotational table and
linear axis. It was investigated by simultaneous moving of rotary table
and XY axes. This compensation method is introduced in this paper.
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: The aim of this research is to evaluate surface
roughness and develop a multiple regression model for surface roughness as a function of cutting parameters during the turning of
flame hardened medium carbon steel with TiN-Al2O3-TiCN coated inserts. An experimental plan of work and signal-to-noise ratio (S/N)
were used to relate the influence of turning parameters to the
workpiece surface finish utilizing Taguchi methodology. The effects
of turning parameters were studied by using the analysis of variance (ANOVA) method. Evaluated parameters were feed, cutting speed,
and depth of cut. It was found that the most significant interaction among the considered turning parameters was between depth of cut and feed. The average surface roughness (Ra) resulted by TiN-Al2O3-
TiCN coated inserts was about 2.44 μm and minimum value was 0.74 μm. In addition, the regression model was able to predict values for surface roughness in comparison with experimental values within
reasonable limit.
Abstract: End milling process is one of the common metal
cutting operations used for machining parts in manufacturing
industry. It is usually performed at the final stage in manufacturing a
product and surface roughness of the produced job plays an
important role. In general, the surface roughness affects wear
resistance, ductility, tensile, fatigue strength, etc., for machined parts
and cannot be neglected in design. In the present work an
experimental investigation of end milling of aluminium alloy with
carbide tool is carried out and the effect of different cutting
parameters on the response are studied with three-dimensional
surface plots. An artificial neural network (ANN) is used to establish
the relationship between the surface roughness and the input cutting
parameters (i.e., spindle speed, feed, and depth of cut). The Matlab
ANN toolbox works on feed forward back propagation algorithm is
used for modeling purpose. 3-12-1 network structure having
minimum average prediction error found as best network architecture
for predicting surface roughness value. The network predicts surface
roughness for unseen data and found that the result/prediction is
better. For desired surface finish of the component to be produced
there are many different combination of cutting parameters are
available. The optimum cutting parameter for obtaining desired
surface finish, to maximize tool life is predicted. The methodology is
demonstrated, number of problems are solved and algorithm is coded
in Matlab®.
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: The quality of a machined surface is becoming more and more important to justify the increasing demands of sophisticated component performance, longevity, and reliability. Usually, any machining operation leaves its own characteristic evidence on the machined surface in the form of finely spaced micro irregularities (surface roughness) left by the associated indeterministic characteristics of the different elements of the system: tool-machineworkpart- cutting parameters. However, one of the most influential sources in machining affecting surface roughness is the instantaneous state of tool edge. The main objective of the current work is to relate the in-process immeasurable cutting edge deformation and surface roughness to a more reliable easy-to-measure force signals using a robust non-linear time-dependent modeling regression techniques. Time-dependent modeling is beneficial when modern machining systems, such as adaptive control techniques are considered, where the state of the machined surface and the health of the cutting edge are monitored, assessed and controlled online using realtime information provided by the variability encountered in the measured force signals. Correlation between wear propagation and roughness variation is developed throughout the different edge lifetimes. The surface roughness is further evaluated in the light of the variation in both the static and the dynamic force signals. Consistent correlation is found between surface roughness variation and tool wear progress within its initial and constant regions. At the first few seconds of cutting, expected and well known trend of the effect of the cutting parameters is observed. Surface roughness is positively influenced by the level of the feed rate and negatively by the cutting speed. As cutting continues, roughness is affected, to different extents, by the rather localized wear modes either on the tool nose or on its flank areas. Moreover, it seems that roughness varies as wear attitude transfers from one mode to another and, in general, it is shown that it is improved as wear increases but with possible corresponding workpart dimensional inaccuracy. The dynamic force signals are found reasonably sensitive to simulate either the progressive or the random modes of tool edge deformation. While the frictional force components, feeding and radial, are found informative regarding progressive wear modes, the vertical (power) components is found more representative carrier to system instability resulting from the edge-s random deformation.
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: Titanium alloys like the modern alloy Ti 6Al 2Sn 4Zr 6Mo (Ti-6246) combine excellent specific mechanical properties and corrosion resistance. On the other hand,due to their material characteristics, machining of these alloys is difficult to perform. The aim of the current study is the analyses of wear mechanisms of coated cemented carbide tools applied in orthogonal cutting experiments of Ti-6246 alloy. Round bars were machined with standard coated tools in dry conditions on a CNC latheusing a wide range of cutting speeds and cutting depths. Tool wear mechanisms were afterwards investigated by means of stereo microscopy, optical microscopy, confocal microscopy and scanning electron microscopy. Wear mechanisms included fracture of the tool tip (total failure) and abrasion. Specific wear features like crater wear, micro cracks and built-up edgeformation appeared depending of the mechanical and thermal conditions generated in the workpiece surface by the cutting action.
Abstract: Novel Coconut oil nanofluids of various concentrations have been prepared through ultrasonically assisted sol-gel method. The structural and morphological properties of the copper oxide nanoparticle have been analyzed with respectively and it revealed the monoclinic end-centered structure of crystallite and shuttle like flake morphology of agglomerates. Ultrasonic studies have been made for the nanofluids at different temperatures. The molecular interactions responsible for the changes in acoustical parameter with respect to concentration and temperature are discussed.
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: Aspect Oriented Programming promises many
advantages at programming level by incorporating the cross cutting
concerns into separate units, called aspects. Join Points are
distinguishing features of Aspect Oriented Programming as they
define the points where core requirements and crosscutting concerns
are (inter)connected. Currently, there is a problem of multiple
aspects- composition at the same join point, which introduces the
issues like ordering and controlling of these superimposed aspects.
Dynamic strategies are required to handle these issues as early as
possible. State chart is an effective modeling tool to capture dynamic
behavior at high level design. This paper provides methodology to
formulate the strategies for multiple aspect composition at high level,
which helps to better implement these strategies at coding level. It
also highlights the need of designing shared join point at high level,
by providing the solutions of these issues using state chart diagrams
in UML 2.0. High level design representation of shared join points
also helps to implement the designed strategy in systematic way.
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: In this paper, we propose an algorithm to compute
initial cluster centers for K-means clustering. Data in a cell is
partitioned using a cutting plane that divides cell in two smaller cells.
The plane is perpendicular to the data axis with the highest variance
and is designed to reduce the sum squared errors of the two cells as
much as possible, while at the same time keep the two cells far apart
as possible. Cells are partitioned one at a time until the number of
cells equals to the predefined number of clusters, K. The centers of
the K cells become the initial cluster centers for K-means. The
experimental results suggest that the proposed algorithm is effective,
converge to better clustering results than those of the random
initialization method. The research also indicated the proposed
algorithm would greatly improve the likelihood of every cluster
containing some data in it.