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: 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: In this paper a simple terrain evaluation method for
hexapod robot is introduced. This method is based on feet coordinate
evaluation when all are on the ground. Depending on the feet
coordinate differences the local terrain evaluation is possible. Terrain
evaluation is necessary for right gait selection and/or body position
correction. For terrain roughness evaluation three planes are plotted:
two of them as definition points use opposite feet coordinates, third
coincides with the robot body plane. The leaning angle of body plane
is evaluated measuring gravity force using three-axis accelerometer.
Terrain roughness evaluation method is based on angle estimation
between normal vectors of these planes. Aim of this work is to
present a simple method for embedded robot controller, allowing to
find the best further movement settings.
Abstract: Today technological process makes possible surface
control of producing parts which is needful for product quality
guarantee. Geometrical structure of part surface includes form,
proportion, accuracy to shape, accuracy to size, alignment and
surface topography (roughness, waviness, etc.). All these parameters
are dependence at technology, production machine parameters,
material properties, but also at human, etc. Every parameters
approves at total part accuracy, it is means at accuracy to shape. One
of the most important accuracy to shape element is roundness. This
paper will be deals by comparison of roughness deviations at
coordination measuring machines and at special single purpose
machines. Will describing measuring by discreet method
(discontinuous) and scanning method (continuous) at coordination
measuring machines and confrontation with reference method using
at single purpose machines.
Abstract: Production of hard-to-cut materials with uncoated carbide cutting tools in turning, not only cause tool life reduction but also, impairs the product surface roughness. In this paper, influence of hot machining method were studied and presented in two cases. Case1-Workpiece surface roughness quality with constant cutting parameter and 300 ºC initial workpiece surface temperature. Case 2- Tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min). The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10(SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300 ºC, causing reduction of yield stress about 15%. Results obtained experimentally, show that the method used can considerably improved surface quality of the workpiece.
Abstract: This work deals with problems of tool axis inclination angles in ball-end milling. Tool axis inclination angle contributes to improvement of functional surface properties (surface integrity - surface roughness, residual stress, micro hardness, etc.), decreasing cutting forces and improving production. By milling with ball-end milling tool, using standard way of cutting, when work piece and cutting tool contain right angle, we have zero cutting speed on edge. At this point cutting tool only pushes material into the work piece. Here we can observe the following undesirable effects - chip contraction, increasing of cutting temperature, increasing vibrations or creation of built-up edge. These effects have negative results – low quality of surface and decreasing of tool life (in the worse case even it is pinching out). These effects can be eliminated with the tilt of cutting tool or tilt of work piece.
Abstract: Polymer-like organic thin films were deposited on both
aluminum alloy type 6061 and glass substrates at room temperature by
Plasma Enhanced Chemical Vapor Deposition (PECVD) methodusing
benzene and hexamethyldisiloxane (HMDSO) as precursor materials.
The surface and physical properties of plasma-polymerized organic
thin films were investigated at different r.f. powers. The effects of
benzene/argon ratio on the properties of plasma polymerized benzene
films were also investigated. It is found that using benzene alone
results in a non-coherent and non-adherent powdery deposited
material. The chemical structure and surface properties of the asgrown
plasma polymerized thin films were analyzed on glass
substrates with FTIR and contact angle measurements. FTIR spectra
of benzene deposited film indicated that the benzene rings are
preserved when increasing benzene ratio and/or decreasing r.f.
powers. FTIR spectra of HMDSO deposited films indicated an
increase of the hydrogen concentration and a decrease of the oxygen
concentration with the increase of r.f. power. The contact angle (θ) of
the films prepared from benzene was found to increase by about 43%
as benzene ratio increases from 10% to 20%. θ was then found to
decrease to the original value (51°) when the benzene ratio increases
to 100%. The contact angle, θ, for both benzene and HMDSO
deposited films were found to increase with r.f. power. This signifies
that the plasma polymerized organic films have substantially low
surface energy as the r.f power increases. The corrosion resistance of
aluminum alloy substrate both bare and covered with plasma
polymerized thin films was carried out by potentiodynamic
polarization measurements in standard 3.5 wt. % NaCl solution at
room temperature. The results indicate that the benzene and HMDSO
deposited films are suitable for protection of the aluminum substrate
against corrosion. The changes in the processing parameters seem to
have a strong influence on the film protective ability. Surface
roughness of films deposited on aluminum alloy substrate was
investigated using scanning electron microscopy (SEM). The SEM
images indicate that the surface roughness of benzene deposited films
increase with decreasing the benzene ratio. SEM images of benzene
and HMDSO deposited films indicate that the surface roughness
decreases with increasing r.f. power. Studying the above parameters
indicate that the films produced are suitable for specific practical
applications.
Abstract: Minimum Quantity Lubrication (MQL) technique
obtained a significant attention in machining processes to reduce
environmental loads caused by usage of conventional cutting fluids.
Recently nanofluids are finding an extensive application in the field
of mechanical engineering because of their superior lubrication and
heat dissipation characteristics. This paper investigates the use of a
nanofluid under MQL mode to improve grinding characteristics of
Ti-6Al-4V alloy. Taguchi-s experimental design technique has been
used in the present investigation and a second order model has been
established to predict grinding forces and surface roughness.
Different concentrations of water based Al2O3 nanofluids were
applied in the grinding operation through MQL setup developed in
house and the results have been compared with those of conventional
coolant and pure water. Experimental results showed that grinding
forces reduced significantly when nano cutting fluid was used even at
low concentration of the nano particles and surface finish has been
found to improve with higher concentration of the nano particles.
Abstract: Traditional wind tunnel models are meticulously machined from metal in a process that can take several months. While very precise, the manufacturing process is too slow to assess a new design's feasibility quickly. Rapid prototyping technology makes this concurrent study of air vehicle concepts via computer simulation and in the wind tunnel possible. This paper described the Affects layer thickness models product with rapid prototyping on Aerodynamic Coefficients for Constructed wind tunnel testing models. Three models were evaluated. The first model was a 0.05mm layer thickness and Horizontal plane 0.1μm (Ra) second model was a 0.125mm layer thickness and Horizontal plane 0.22μm (Ra) third model was a 0.15mm layer thickness and Horizontal plane 4.6μm (Ra). These models were fabricated from somos 18420 by a stereolithography (SLA). A wing-body-tail configuration was chosen for the actual study. Testing covered the Mach range of Mach 0.3 to Mach 0.9 at an angle-of-attack range of -2° to +12° at zero sideslip. Coefficients of normal force, axial force, pitching moment, and lift over drag are shown at each of these Mach numbers. Results from this study show that layer thickness does have an effect on the aerodynamic characteristics in general; the data differ between the three models by fewer than 5%. The layer thickness does have more effect on the aerodynamic characteristics when Mach number is decreased and had most effect on the aerodynamic characteristics of axial force and its derivative coefficients.
Abstract: The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the new three parameters are introduced from three dynamic cutting forces, which are calculated by taking the ratio of the average variances of dynamic cutting forces to the absolute variances of themselves. It had been proved that the chatter can be easier to detect during the in-process cutting by using the new parameters which are proposed in this research. The experimentally obtained results showed that the wavelet transform can provide the reliable results to detect the chatter under various cutting conditions.
Abstract: Electro Discharge Sawing is a hybrid process
combining the features of SEDM and ECM. Its major characteristic is
extremely fast erosion rate compare to either of the above processes.
This paper brings out its relative feature of SEDM and EDS about
their erosion rates, surface roughness, and morphology of machined
surfaces.
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: Machining is an important manufacturing process used to produce a wide variety of metallic parts. Among various machining processes, turning is one of the most important one which is employed to shape cylindrical parts. In turning, the quality of finished product is measured in terms of surface roughness. In turn, surface quality is determined by machining parameters and tool geometry specifications. The main objective of this study is to simultaneously model and optimize machining parameters and tool geometry in order to improve the surface roughness for AISI1045 steel. Several levels of machining parameters and tool geometry specifications are considered as input parameters. The surface roughness is selected as process output measure of performance. A Taguchi approach is employed to gather experimental data. Then, based on signal-to-noise (S/N) ratio, the best sets of cutting parameters and tool geometry specifications have been determined. Using these parameters values, the surface roughness of AISI1045 steel parts may be minimized. Experimental results are provided to illustrate the effectiveness of the proposed approach.
Abstract: This research was conducted in the Lower Ping River
Basin downstream of the Bhumibol Dam and the Lower Wang River
Basin in Tak Province, Thailand. Most of the tributary streams of the
Ping can be considered as ungauged catchments. There are 10-
pumping station installation at both river banks of the Ping in Tak
Province. Recently, most of them could not fully operate due to the
water amount in the river below the level that would be pumping,
even though included water from the natural river and released flow
from the Bhumibol Dam. The aim of this research was to increase the
performance of those pumping stations using weir projects in the
Ping. Therefore, the river analysis system model (HEC-RAS) was
applied to study the hydraulic behavior of water surface profiles in
the Ping River with both cases of existing conditions and proposed
weirs during the violent flood in 2011 and severe drought in 2013.
Moreover, the hydrologic modeling system (HMS) was applied to
simulate lateral streamflow hydrograph from ungauged catchments of
the Ping. The results of HEC-RAS model calibration with existing
conditions in 2011 showed best trial roughness coefficient for the
main channel of 0.026. The simulated water surface levels fitted to
observation data with R2 of 0.8175. The model was applied to 3
proposed cascade weirs with 2.35 m in height and found surcharge
water level only 0.27 m higher than the existing condition in 2011.
Moreover, those weirs could maintain river water levels and increase
of those pumping performances during less river flow in 2013.
Abstract: Carriers scattering in the inversion channel of n-
MOSFET dominates the drain current. This paper presents an effective
electron mobility model for the pocket implanted nano scale
n-MOSFET. The model is developed by using two linear pocket
profiles at the source and drain edges. The channel is divided into
three regions at source, drain and central part of the channel region.
The total number of inversion layer charges is found for these three
regions by numerical integration from source to drain ends and the
number of depletion layer charges is found by using the effective
doping concentration including pocket doping effects. These two
charges are then used to find the effective normal electric field,
which is used to find the effective mobility model incorporating the
three scattering mechanisms, such as, Coulomb, phonon and surface
roughness scatterings as well as the ballistic phenomena for the
pocket implanted nano-scale n-MOSFET. The simulation results show
that the derived mobility model produces the same results as found
in the literatures.
Abstract: This study investigated the effect of cross sectional
geometry on sediment transport rate. The processes of sediment
transport are generally associated to environmental management,
such as pollution caused by the forming of suspended sediment in the
channel network of a watershed and preserving physical habitats and
native vegetations, and engineering applications, such as the
influence of sediment transport on hydraulic structures and flood
control design. Many equations have been proposed for computing
the sediment transport, the influence of many variables on sediment
transport has been understood; however, the effect of other variables
still requires further research. For open channel flow, sediment
transport capacity is recognized to be a function of friction slope,
flow velocity, grain size, grain roughness and form roughness, the
hydraulic radius of the bed section and the type and quantity of
vegetation cover. The effect of cross sectional geometry of the
channel on sediment transport is one of the variables that need
additional investigation. The width-depth ratio (W/d) is a
comparative indicator of the channel shape. The width is the total
distance across the channel and the depth is the mean depth of the
channel. The mean depth is best calculated as total cross-sectional
area divided by the top width. Channels with high W/d ratios tend to
be shallow and wide, while channels with low (W/d) ratios tend to be
narrow and deep. In this study, the effects of the width-depth ratio on
sediment transport was demonstrated theoretically by inserting the
shape factor in sediment continuity equation and analytically by
utilizing the field data sets for Yalobusha River. It was found by
utilizing the two approaches as a width-depth ratio increases the
sediment transport decreases.
Abstract: The present paper is an experimental investigation of
roughness effects on nucleate pool boiling of refrigerant R113 on
horizontal circular copper surfaces. The copper samples were treated
by different sand paper grit sizes to achieve different surface
roughness. The average surface roughness of the four samples was
0.901, 0.735, 0.65, and 0.09, respectively. The experiments were
performed in the heat flux range of 8 to 200kW/m2. The heat transfer
coefficient was calculated by measuring wall superheat of the
samples and the input heat flux. The results show significant
improvement of heat transfer coefficient as the surface roughness is
increased. It is found that the heat transfer coefficient of the sample
with Ra=0.901 is 3.4, 10.5, and 38.5% higher in comparison with
surfaces with Ra of 0.735, 0.65, and 0.09 at heat flux of 170 kW/m2.
Moreover, the results are compared with literature data and the well
known Cooper correlation.
Abstract: Aspheric optical components are an alternative to the use of conventional lenses in the implementation of imaging systems for the visible range. Spherical lenses are capable of producing aberrations. Therefore, they are not able to focus all the light into a single point. Instead, aspherical lenses correct aberrations and provide better resolution even with compact lenses incorporating a small number of lenses.
Metrology of these components is very difficult especially when the resolution requirements increase and insufficient or complexity of conventional tools requires the development of specific approaches to characterization.
This work is part of the problem existed because the objectives are the study and comparison of different methods used to measure surface rays hybrid aspherical lenses.
Abstract: The stilling basins are commonly used to dissipate the
energy and protect the downstream floor from erosion. The aim of
the present experimental work is to improve the roughened stilling
basin using T-shape roughness instead of the regular cubic one and
design this new shape. As a result of the present work the best
intensity and the best roughness length are identified. Also, it is
found that the T-shape roughness save materials and reduce the jump
length compared to the cubic one. Sensitivity analysis was performed
and it was noticed that the change in the length of jump is more
sensitive to the change in roughness length than the change in
intensity.
Abstract: Titanium oxide films with different morphologies have for the first time been fabricated through hydrothermal reactions between a titanium substrate and iodine powder in water or ethanol. SEM revealed that iodine supported titanium (Ti-I2) surface shows different morphologies with variable treatment conditions. The mean surface roughness (Ra) was increased in the different groups. Use of surfactant has a role to increase the roughness of the film. The surface roughness was in the range of 0.15 μm-0.42 μm. Furthermore, the electrochemical examinations showed that the Ti-I2 surface fabricated in alcoholic medium has high corrosion resistance than in aqueous medium.