Abstract: Machining instability, or chatter, can impose an important limitation to discrete part machining. In this work, a networked implementation of milling stability optimization with Bayesian learning is presented. The milling process was monitored with a wireless sensory tool holder instrumented with an accelerometer at the TU Wien, Vienna, Austria. The recorded data from a milling test cut were used to classify the cut as stable or unstable based on a frequency analysis. The test cut result was used in a Bayesian stability learning algorithm at the University of Tennessee, Knoxville, Tennessee, USA. The algorithm calculated the probability of stability as a function of axial depth of cut and spindle speed based on the test result and recommended parameters for the next test cut. The iterative process between two transatlantic locations was repeated until convergence to a stable optimal process parameter set was achieved.
Abstract: Abrasive jet machining is one of the promising non-traditional machining processes which uses mechanical energy (pressure and velocity) for machining various materials. The process parameters that influence the metal removal rate are kerfs, surface finish, depth of cut, air pressure, and distance between nozzle and work piece, nozzle diameter, abrasive type, abrasive shape, and mass flow rate of abrasive particles. The abrasive particles coming out with high pressure not only hits work surface but also passes through the nozzle resulting in erosion. This paper focuses mainly on the effect of different parameters on the erosion of nozzle in Abrasive jet machining. Three different types of nozzles made of sapphire, tungsten carbide, and high carbon high chromium steel (HCHCS) are used for machining glass and the erosion of these nozzles are calculated. The results are shown in tabular form and graphical representation.
Abstract: For the required function of components with the thermal spray coating, it is necessary to perform additional machining of the coated surface. The paper deals with assessing the surface integrity of Metco 2042, a plasma sprayed coating, after its machining. The selected plasma sprayed coating serves as an abradable sealing coating in a jet engine. Therefore, the spray and its surface must meet high quality and functional requirements. Plasma sprayed coatings are characterized by lamellar structure, which requires a special approach to their machining. Therefore, the experimental part involves the set-up of special cutting tools and cutting parameters under which the applied coating was machined. For the assessment of suitably set machining parameters, selected parameters of surface integrity were measured and evaluated during the experiment. To determine the size of surface irregularities and the effect of the selected machining technology on the sprayed coating surface, the surface roughness parameters Ra and Rz were measured. Furthermore, the measurement of sprayed coating surface hardness by the HR 15 Y method before and after machining process was used to determine the surface strengthening. The changes of strengthening were detected after the machining. The impact of chosen cutting parameters on the surface roughness after the machining was not proven.
Abstract: The present research reports the investigation of fast etching of silicon for the fabrication of microelectromechanical systems (MEMS) structures using silicon wet bulk micromachining. Low concentration tetramethyl-ammonium hydroxide (TMAH) and hydroxylamine (NH2OH) are used as main etchant and additive, respectively. The concentration of NH2OH is varied to optimize the composition to achieve best etching characteristics such as high etch rate, significantly high undercutting at convex corner for the fast release of the microstructures from the substrate, and improved etched surface morphology. These etching characteristics are studied on Si{100} and Si{110} wafers as they are most widely used in the fabrication of MEMS structures as wells diode, transistors and integrated circuits.
Abstract: Selective laser melting (SLM), a promising additive manufacturing (AM) technology, has a huge potential in the fabrication of Ti-6Al-4V near-net shape components. However, poor surface finish of the components fabricated from this technology requires secondary machining to achieve the desired accuracy and tolerance. Therefore, a systematic understanding of the machinability of SLM fabricated Ti-6Al-4V components is paramount to improve the productivity and product quality. Considering the significance of machining in SLM fabricated Ti-6Al-4V components, this research aim is to study the influence of build orientation on machinability characteristics by performing low speed orthogonal cutting tests. In addition, the machinability of SLM fabricated Ti-6Al-4V is compared with conventionally produced wrought Ti-6Al-4V to understand the influence of SLM technology on machining. This paper is an attempt to provide evidence to the hypothesis associated that build orientation influences cutting forces, chip formation and surface integrity during orthogonal cutting of SLM Ti-6Al-4V samples. Results obtained from the low speed orthogonal cutting tests highlight the practical importance of microstructure and build orientation on machinability of SLM Ti-6Al-4V.
Abstract: Oil in water (O/W) emulsions are utilized extensively for cooling and lubricating cutting tools during parts machining. A robust Lattice Boltzmann (LBM) thermal-surfactants model, which provides a useful platform for exploring complex emulsions’ characteristics under variety of flow conditions, is used here for the study of the fluid behavior during conventional tools cooling. The transient thermal capabilities of the model are employed for simulating the effects of the flow conditions of O/W emulsions on the cooling of cutting tools. The model results show that the temperature outcome is slightly affected by reversing the direction of upper plate (workpiece). On the other hand, an important increase in effective viscosity is seen which supports better lubrication during the work.
Abstract: Surface roughness is one of the key quality parameters of the finished product. During any machining operation, high temperatures are generated at the tool-chip interface impairing surface quality and dimensional accuracy of products. Cutting fluids are generally applied during machining to reduce temperature at the tool-chip interface. However, usages of cutting fluids give rise to problems such as waste disposal, pollution, high cost, and human health hazard. Researchers, now-a-days, are opting towards dry machining and other cooling techniques to minimize use of coolants during machining while keeping surface roughness of products within desirable limits. In this paper, a concept of using peltier cooling effects during aluminium milling operation has been presented and adopted with an aim to improve surface roughness of the machined surface. Experimental evidence shows that peltier cooling effect provides better surface roughness of the machined surface compared to dry machining.
Abstract: Manufacturing technologies are becoming continuously
more diversified over the years. The increasing use of robots for
various applications such as assembling, painting, welding has also
affected the field of machining. Machining robots can deal with
larger workspaces than conventional machine-tools at a lower cost
and thus represent a very promising alternative for machining
applications. Furthermore, their inherent structure ensures them a
great flexibility of motion to reach any location on the workpiece with
the desired orientation. Nevertheless, machining robots suffer from
a lack of stiffness at their joints restricting their use to applications
involving low cutting forces especially finishing operations. Vibratory
instabilities may also happen while machining and deteriorate the
precision leading to scrap parts. Some researchers are therefore
concerned with the identification of optimal parameters in robotic
machining. This paper continues the development of a virtual robotic
machining simulator in order to find optimized cutting parameters in
terms of depth of cut or feed per tooth for example. The simulation
environment combines an in-house milling routine (DyStaMill)
achieving the computation of cutting forces and material removal
with an in-house multibody library (EasyDyn) which is used to
build a dynamic model of a 3-DOF planar robot with flexible links.
The position of the robot end-effector submitted to milling forces is
controlled through an inverse kinematics scheme while controlling
the position of its joints separately. Each joint is actuated through
a servomotor for which the transfer function has been computed
in order to tune the corresponding controller. The output results
feature the evolution of the cutting forces when the robot structure
is deformable or not and the tracking errors of the end-effector.
Illustrations of the resulting machined surfaces are also presented.
The consideration of the links flexibility has highlighted an increase
of the cutting forces magnitude. This proof of concept will aim
to enrich the database of results in robotic machining for potential
improvements in production.
Abstract: In the manufacturing sector, hard turning has emerged as vital machining process for cutting hardened steels. Besides many advantages of hard turning operation, one has to implement to achieve close tolerances in terms of surface finish, high product quality, reduced machining time, low operating cost and environmentally friendly characteristics. In the present study, three-dimensional CAE (Computer Aided Engineering) based simulation of hard turning by using commercial software DEFORM 3D has been compared to experimental results of stresses, temperatures and tool forces in machining of AISI D3 steel using mixed Ceramic inserts (CC6050). In the present analysis, orthogonal cutting models are proposed, considering several processing parameters such as cutting speed, feed, and depth of cut. An exhaustive friction modeling at the tool-work interfaces is carried out. Work material flow around the cutting edge is carefully modeled with adaptive re-meshing simulation capability. In process simulations, feed rate and cutting speed are constant (i.e.,. 0.075 mm/rev and 155 m/min), and analysis is focused on stresses, forces, and temperatures during machining. Close agreement is observed between CAE simulation and experimental values.
Abstract: Ultrasonic machining is one of the most widely used non-traditional machining processes for machining of materials that are relatively brittle, hard, and fragile such as advanced ceramics, refractories, crystals, quartz etc. Present article has been targeted at investigating the impact of different experimental conditions (power rating, cobalt content, tool material, thickness of work piece, tool geometry, and abrasive grit size) on over cut in ultrasonic drilling of WC-Co composite material. Taguchi’s L-36 orthogonal array has been employed for conducting the experiments. Significant factors have been identified using analysis of variance (ANOVA) test. The experimental results revealed that abrasive grit size and tool material are most significant factors for over cut.
Abstract: In this article, the radial displacement error correction
capability of a high precision spindle grinding caused by unbalance
force was investigated. The spindle shaft is considered as a flexible
rotor mounted on two sets of angular contact ball bearing. Finite
element methods (FEM) have been adopted for obtaining the
equation of motion of the spindle. In this paper, firstly, natural
frequencies, critical frequencies, and amplitude of the unbalance
response caused by residual unbalance are determined in order to
investigate the spindle behaviors. Furthermore, an optimization
design algorithm is employed to minimize radial displacement of the
spindle which considers dimension of the spindle shaft, the dynamic
characteristics of the bearings, critical frequencies and amplitude of
the unbalance response, and computes optimum spindle diameters
and stiffness and damping of the bearings. Numerical simulation
results show that by optimizing the spindle diameters, and stiffness
and damping in the bearings, radial displacement of the spindle can
be reduced. A spindle about 4 μm radial displacement error can be
compensated with 2 μm accuracy. This certainly can improve the
accuracy of the product of machining.
Abstract: Water miscible cutting fluids are conventionally used to lubricate and cool the machining zone. But issues related to health hazards, maintenance and disposal costs have limited their usage, leading to application of Minimum Quantity Lubrication (MQL). To increase the effectiveness of MQL, nanocutting fluids are proposed. In the present work, water miscible nanographite cutting fluids of varying concentration are applied at cutting zone by two systems A and B. System A utilizes high pressure air and supplies cutting fluid at a flow rate of 1ml/min. System B uses low pressure air and supplies cutting fluid at a flow rate of 5ml/min. Their performance in machining is evaluated by measuring cutting temperatures, tool wear, cutting forces and surface roughness and compared with dry machining and flood machining. Application of nanocutting fluid using both systems showed better performance than dry machining. Cutting temperatures and cutting forces obtained by both techniques are more than flood machining. But tool wear and surface roughness showed improvement compared to flood machining. Economic analysis has been carried out in all the cases to decide the applicability of the techniques.
Abstract: This paper proposes a new method to find the equations
of transformation matrix for the rotation angles of the two rotational
axes and the coordinates of the three linear axes of an orthogonal
multi-axis milling machine. This approach provides intuitive physical
meanings for rotation angles of multi-axis machines, which can be
used to evaluate the accuracy of the conversion from CL data to NC
data.
Abstract: In the product design and development process, the prototyping or model making is one of the important step to finalize a product which helps in conceptualization of a design. Rapid Prototyping (RP) is layer-by-layer material deposition started during early 1980s with the enormous growth in Computer Aided Design and Manufacturing (CAD/CAM) technologies. The edges and surfaces of a complex solid model and their information are used for defining a product which is further manufactured as a finished product by CNC machining. This paper provides a better platform for researchers, new learners and product manufacturers for various applications of RP models. Subsequently it creates awareness among the peoples of recently developing RP method of manufacturing in product design, developments and its applications.
Abstract: The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc…. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.
Abstract: The group of progressive cutting materials can include non-traditional, emerging and less-used materials that can be an efficient use of cutting their lead to a quantum leap in the field of machining. This is essentially a “superhard” materials (STM) based on polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) cutting performance ceramics and development is constantly "perfecting" fine coated cemented carbides. The latter cutting materials are broken down by two parameters, toughness and hardness. A variation of alloying elements is always possible to improve only one of each parameter. Reducing the size of the core on the other hand doing achieves "contradictory" properties, namely to increase both hardness and toughness.
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: 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, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.
Abstract: It is well known that the abrasive particles in the
abrasive water suspension has significant effect on the erosion
characteristics of the inside surface of the nozzle. Abrasive particles
moving with the flow cause severe skin friction effect, there by
altering the nozzle diameter due to wear which in turn reflects on the
life of the nozzle for effective machining. Various commercial
abrasives are available for abrasive water jet machining. The erosion
characteristic of each abrasive is different. In consideration of this
aspect, in the present work, the effect of abrasive materials namely
garnet, aluminum oxide and silicon carbide on skin friction
coefficient due to wall shear stress and jet kinetic energy has been
analyzed. It is found that the abrasive material of lower density
produces a relatively higher skin friction effect and higher jet exit
kinetic energy.
Abstract: This work presents a study on the abrasive water jet
(AWJ) machining. An explicit finite element analysis (FEA) of
single abrasive particle impact on stainless steel 1.4304 (AISI 304) is
conducted. The abrasive water jet machining is modeled by FEA
software ABAQUS/CAE. Shapes of craters in FEM simulation
results were used and compared with the previous experimental and
FEM works by means of crater sphericity. The influence of impact
angle and particle velocity was observed. Adaptive mesh domain is
used to model the impact zone. Results are in good agreement with
those obtained from the experimental and FEM simulation. The
crater-s depth is also obtained for different impact angle and abrasive
particle velocities.