Abstract: Considering complexity of products, new geometrical
design and investment tolerances that are necessary, measuring and
dimensional controlling involve modern and more precise methods.
Photo digitizing method using two cameras to record pictures and
utilization of conventional method named “cloud points" and data
analysis by the use of ATOUS software, is known as modern and
efficient in mentioned context. In this paper, benefits of photo
digitizing method in evaluating sampling of machining processes
have been put forward. For example, assessment of geometrical
integrity surface in 5-axis milling process and measurement of
carbide tool wear in turning process, can be can be brought forward.
Advantages of this method comparing to conventional methods have
been expressed.
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: 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: 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: Sharing the manufacturing facility through remote
operation and monitoring of a machining process is challenge for
effective use the production facility. Several automation tools in term
of hardware and software are necessary for successfully remote
operation of a machine. This paper presents a prototype of workpiece
holding attachment for remote operation of milling process by self
configuration the workpiece setup. The prototype is designed with
mechanism to reorient the work surface into machining spindle
direction with high positioning accuracy. Variety of parts geometry
is hold by attachment to perform single setup machining. Pin type
with array pattern additionally clamps the workpiece surface from
two opposite directions for increasing the machining rigidity.
Optimum pins configuration for conforming the workpiece geometry
with minimum deformation is determined through hybrid algorithms,
Genetic Algorithms (GA) and Particle Swarm Optimization (PSO).
Prototype with intelligent optimization technique enables to hold
several variety of workpiece geometry which is suitable for
machining low of repetitive production in remote operation.
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: Yam starch obtained from the water yam (munlued)
by the wet milling process was studied for some physicochemical
properties. Yam starch film was prepared by casting using glycerol as
a plasticizer. The effect of different glycerol (1.30, 1.65 and
2.00g/100g of filmogenic solution) and starch concentrations (3.30,
3.65 and 4.00g /100g of filmogenic solution) were evaluated on some
characteristics of the film. The temperature for obtaining the
gelatinized starch solution was 70-80°C and then dried at 45°C for 4
hours. The resulting starch from munlued granular morphology was
triangular and the average size of the granule was 26.68 μm. The
amylose content by colorimetric method was 26 % and the gelatinize
temperature was 70-80°C. The appearance of the film was smooth,
transparent, and glossy with average moisture content of 25.96% and
thickness of 0.01mm. Puncture deformation and flexibility increased
with glycerol content. The starch and glycerol concentration were a
significant factor of the yam starch film characteristics. Yam starch
film can be described as a biofilm providing many applications and
developments with the advantage of biodegradability.
Abstract: In this study the effect of incorporation of recycled
glass-fibre reinforced polymer (GFRP) waste materials, obtained by
means of milling processes, on mechanical behaviour of polyester
polymer mortars was assessed. For this purpose, different contents of
recycled GFRP waste powder and fibres, with distinct size gradings,
were incorporated into polyester based mortars as sand aggregates
and filler replacements. Flexural and compressive loading capacities
were evaluated and found better than unmodified polymer mortars.
GFRP modified polyester based mortars also show a less brittle
behaviour, with retention of some loading capacity after peak load.
Obtained results highlight the high potential of recycled GFRP waste
materials as efficient and sustainable reinforcement and admixture for
polymer concrete and mortars composites, constituting an emergent
waste management solution.
Abstract: Thermochemcial characteristics of powder fabricated
using oxidation treatment of spent PWR fuel and SIMFUEL were
evaluated for recycling of spent fuel such as DUPIC process.
Especially, the influence of spent fuel burn-ups on the powder
fabrication characteristics was experimentally evaluated, ranging from
27,300 to 65,000 MWd/tU. Densities of powder manufactured from an
oxidation, OREOX and the milling processes at the same process
conditions were compared as a function of the fuel burn-ups
respectively. Also, based on chemical analysis results, homogeneity of
fissile elements in oxidized powder was confirmed.