Abstract: Experimental & numeral study of temperature
distribution during milling process, is important in milling quality
and tools life aspects. In the present study the milling cross-section
temperature is determined by using Artificial Neural Networks
(ANN) according to the temperature of certain points of the work
piece and the point specifications and the milling rotational speed of
the blade. In the present work, at first three-dimensional model of the
work piece is provided and then by using the Computational Heat
Transfer (CHT) simulations, temperature in different nods of the
work piece are specified in steady-state conditions. Results obtained
from CHT are used for training and testing the ANN approach. Using
reverse engineering and setting the desired x, y, z and the milling
rotational speed of the blade as input data to the network, the milling
surface temperature determined by neural network is presented as
output data. The desired points temperature for different milling
blade rotational speed are obtained experimentally and by
extrapolation method for the milling surface temperature is obtained
and a comparison is performed among the soft programming ANN,
CHT results and experimental data and it is observed that ANN soft
programming code can be used more efficiently to determine the
temperature in a milling process.
Abstract: The current study investigated the influence of milling
time and ball-to-powder (BPR) weight ratio on the microstructural
constituents and mechanical properties of bulk nanocrystalline Al;
Al-10%Cu; and Al-10%Cu-5%Ti alloys. Powder consolidation was
carried out using a high frequency induction heat sintering where the
processed metal powders were sintered into a dense and strong bulk
material. The powders and the bulk samples were characterized using
XRD and FEGSEM techniques. The mechanical properties were
evaluated at various temperatures of 25°C, 100°C, 200°C, 300°C and
400°C to study the thermal stability of the processed alloys. The
processed bulk nanocrystalline alloys displayed extremely high
hardness values even at elevated temperatures. The Al-10%Cu-5%Ti
alloy displayed the highest hardness values at room and elevated
temperatures which are related to the presence of Ti-containing
phases such as Al3Ti and AlCu2Ti. These phases are thermally stable
and retain the high hardness values at elevated temperatures up to
400ºC.
Abstract: Machining parameters are very important in
determining the surface quality of any material. In the past decade,
some new engineering materials were developed for the
manufacturing industry which created a need to conduct an
investigation on the impact of the said parameters on their surface
roughness. Polyurethane (PU) block is widely used in the automotive
industry to manufacture parts such as checking fixtures that are used
to verify the dimensional accuracy of automotive parts. In this paper,
the design of experiment (DOE) was used to investigate on the effect
of the milling parameters on the PU block. Furthermore, an analysis
of the machined surface chemical composition was done using
scanning electron microscope (SEM). It was found that the surface
roughness of the PU block is severely affected when PU undergoes a
flood machining process instead of a dry condition. In addition the
stepover and the silicon content were found to be the most significant
parameters that influence the surface quality of the PU block.
Abstract: Metal matrix composites (MMCs) attract considerable
attention as a result from its ability in providing a high strength, high
modulus, high toughness, high impact properties, improving wear
resistance and providing good corrosion resistance compared to
unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been
widely used in various industrial sectors such as in transportation,
domestic equipment, aerospace, military, construction, etc.
Aluminium silicon alloy is an MMC that had been reinforced with
aluminium nitrate (AlN) particle and become a new generation
material use in automotive and aerospace sector. The AlN is one of
the advance material that have a bright prospect in future since it has
features such as lightweight, high strength, high hardness and
stiffness quality. However, the high degree of ceramic particle
reinforcement and the irregular nature of the particles along the
matrix material that contribute to its low density is the main problem
which leads to difficulties in machining process. This paper examined
the tool wear when milling AlSi/AlN Metal Matrix Composite using
a TiB2 (Titanium diboride) coated carbide cutting tool. The volume
of the AlN reinforced particle was 10% and milling process was
carried out under dry cutting condition. The TiB2 coated carbide
insert parameters used were at the cutting speed of (230, 300 and
370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The
Sometech SV-35 video microscope system used to quantify of the
tool wear. The result shown that tool life span increasing with the
cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at
0.4mm) which constituted an optimum condition for longer tool life
lasted until 123.2 mins. Meanwhile, at medium cutting speed which
at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we
found that tool life span lasted until 119.86 mins while at low cutting
speed it lasted in 119.66 mins. High cutting speed will give the best
parameter in cutting AlSi/AlN MMCs material. The result will help
manufacturers in machining process of AlSi/AlN MMCs materials.
Abstract: Nanocrystalline powders of the lead-free piezoelectric
material, tantalum-substituted potassium sodium niobate
(K0.5Na0.5)(Nb0.9Ta0.1)O3 (KNNT), were produced using a Retsch
PM100 planetary ball mill by setting the milling time to 15h, 20h,
25h, 30h, 35h and 40h, at a fixed speed of 250rpm. The average
particle size of the milled powders was found to decrease from 12nm
to 3nm as the milling time increases from 15h to 25h, which is in
agreement with the existing theoretical model. An anomalous
increase to 98nm and then a drop to 3nm in the particle size were
observed as the milling time further increases to 30h and 40h
respectively. Various sizes of these starting KNNT powders were
used to investigate the effect of milling time on the microstructure,
dielectric properties, phase transitions and piezoelectric properties of
the resulting KNNT ceramics. The particle size of starting KNNT
was somewhat proportional to the grain size. As the milling time
increases from 15h to 25h, the resulting ceramics exhibit
enhancement in the values of relative density from 94.8% to 95.8%,
room temperature dielectric constant (εRT) from 878 to 1213, and
piezoelectric charge coefficient (d33) from 108pC/N to 128pC/N. For
this range of ceramic samples, grain size refinement suppresses the
maximum dielectric constant (εmax), shifts the Curie temperature (Tc)
to a lower temperature and the orthorhombic-tetragonal phase
transition (Tot) to a higher temperature. Further increase of milling
time from 25h to 40h produces a gradual degradation in the values of
relative density, εRT, and d33 of the resulting ceramics.
Abstract: Yttrium oxide (Y2O3) films have been successfully
deposited with yttrium-ethylenediamine tetraacetic acid (EDTA·Y·H)
complexes prepared by various milling techniques. The effects of the
properties of the EDTA·Y·H complex on the properties of the
deposited Y2O3 films have been analyzed. Seven different types of the
raw EDTA·Y·H complexes were prepared by various commercial
milling techniques such as ball milling, hammer milling, commercial
milling, and mortar milling. The milled EDTA·Y·H complexes
exhibited various particle sizes and distributions, depending on the
milling method. Furthermore, we analyzed the crystal structure,
morphology and elemental distribution profile of the metal oxide films
deposited on stainless steel substrate with the milled EDTA·Y·H
complexes. Depending on the milling technique, the flow properties of
the raw powders differed. The X-ray diffraction pattern of all the
samples revealed the formation of Y2O3 crystalline phase, irrespective
of the milling technique. Of all the different milling techniques, the
hammer milling technique is considered suitable for fabricating dense
Y2O3 films.
Abstract: The effects of varying air temperature (full, ¾ full, ½ full aircon adjustment, no aircon) in polishing component of Single-Pass Mill on the quality of Philippine inbred rice variety, was investigated. Parameters measured were milling recovery (MR), headrice recovery (HR), and percentage with bran streaks. Cooling method (with aircon) increased MR, HR, and percentage with bran streaks of milled rice. Highest MR and HR (67.62%; 47.33%) were obtained from ¾ full adjustment whereas no aircon were lowest (66.27%; 39.76%). Temperature in polishing component at ¾ full adjustment was 33oC whereas no aircon was 45oC. There was increase of 1.35% in MR and 7.57% in HR. Additional cost of milling per kg due to aircon cooling was P0.04 at 300 tons/yr volume, with 0.15 yr payback period. Net income was estimated at ₱98,100.00. Percentage of kernels with bran streaks increased from 5%–14%, indicating more nutrients of milled rice.
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: Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.
Abstract: In this work the concentration of steepwater from corn starch industry is monitored using ultrafiltration membrane. The aim was to examine the conditions of ultrafiltration of steepwater by applying the membrane of 2.5nm. The parameters that vary during the course of ultrafiltration, were the transmembrane pressure, flow rate, while the permeate flux and the dry matter content of permeate and retentate were the dependent parameter constantly monitored during the process. Experiments of ultrafiltration are conducted on the samples of steepwater, which were obtained from the starch wet milling plant „Jabuka“ Pancevo. The procedure of ultrafiltration on a single-channel 250mm lenght, with inner diameter of 6.8mm and outer diameter of 10mm membrane were carried on. The membrane is made of a-Al2O3 with TiO2 layer obtained from GEA (Germany). The experiments are carried out at a flow rate ranging from 100 to 200lh-1 and transmembrane pressure of 1-3 bars. During the experiments of steepwater ultrafiltration, the change of permeate flux, dry matter content of permeate and retentate, as well as the absorbance changes of the permeate and retentate were monitored. The experimental results showed that the maximum flux reaches about 40lm-2h-1. For responses obtained after experiments, a polynomial model of the second degree is established to evaluate and quantify the influence of the variables. The quadratic equitation fits with the experimental values, where the coefficient of determination for flux is 0.96. The dry matter content of the retentate is increased for about 6%, while the dry matter content of permeate was reduced for about 35-40%, respectively. During steepwater ultrafiltration in permeate stays 40% less dry matter compared to the feed.
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: 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: In this project three type of tools, straight cylindrical, taper cylindrical and triangular tool all made of High speed steel (Wc-Co) used for the friction stir welding (FSW) aluminum alloy H20–H20 and the mechanical properties of the welded joint tested by tensile test and vicker hardness test. Besides, mentioned mechanical properties compared with each other to make conclusion. The result helped design of welding parameter optimization for different types of friction stir process like rotational speed, depth of welding, travel speed, type of material, type of joint, work piece dimension, joint dimension, tool material and tool geometry. Previous investigations in different types of materials work pieces; joint type, machining parameter and preheating temperature take placed. In this investigation 3 mentioned tool types that are popular in FSW tested and the results completed other aspects of the process. Hope this paper can open a new horizon in experimental investigation of mechanical properties for friction stir welded joint with other different type of tools like oval shape probe, paddle shape probe, three flat sided probe, and three sided re-entrant probe and other materials and alloys like titanium or steel in near future.
Abstract: G-code is the main factor in computer numerical control (CNC) machine for controlling the toolpaths and generating the profile of the object’s features. For obtaining high surface accuracy of the surface finish, non-stop operation is required for CNC machine. Recently, to design a new product, the strategy that concerns about a change that has low impact on business and does not consume lot of resources has been introduced. Cost and time for designing minor changes can be reduced since the traditional geometric details of the existing models are applied. In order to support this strategy as the alternative channel for machining operation, this research proposes the automatic generating codes for CNC milling operation. Using this technique can assist the manufacturer to easily change the size and the geometric shape of the product during the operation where the time spent for setting up or processing the machine are reduced. The algorithm implemented on MATLAB platform is developed by analyzing and evaluating the geometric information of the part. Codes are created rapidly to control the operations of the machine. Comparing to the codes obtained from CAM, this developed algorithm can shortly generate and simulate the cutting profile of the part.
Abstract: The objective in this work is to generate and discuss the stability results of fully-immersed end-milling process with parameters; tool mass m=0.0431kg,tool natural frequency ωn = 5700 rads^-1, damping factor ξ=0.002 and workpiece cutting coefficient C=3.5x10^7 Nm^-7/4. Different no of teeth is considered for the end-milling. Both 1-DOF and 2-DOF chatter models of the system are generated on the basis of non-linear force law. Chatter stability analysis is carried out using a modified form (generalized for both 1-DOF and 2-DOF models) of recently developed method called Full-discretization. The full-immersion three tooth end-milling together with higher toothed end-milling processes has secondary Hopf bifurcation lobes (SHBL’s) that exhibit one turning (minimum) point each. Each of such SHBL is demarcated by its minimum point into two portions; (i) the Lower Spindle Speed Portion (LSSP) in which bifurcations occur in the right half portion of the unit circle centred at the origin of the complex plane and (ii) the Higher Spindle Speed Portion (HSSP) in which bifurcations occur in the left half portion of the unit circle. Comments are made regarding why bifurcation lobes should generally get bigger and more visible with increase in spindle speed and why flip bifurcation lobes (FBL’s) could be invisible in the low-speed stability chart but visible in the high-speed stability chart of the fully-immersed three-tooth miller.
Abstract: Present investigations involve a systematic study on the machinability of austempered ductile irons (ADI) developed from four commercially viable ductile irons alloyed with different contents of 0, 0.1, 0.3 and 0.6 wt.% of Ni. The influence of Ni content, amount of retained austenite and hardness of ADI on machining behavior has been conducted systematically. Austempering heat treatment was carried out for 120 minutes at four temperatures- 270oC, 320oC, 370oC or 420oC, after austenitization at 900oC for 120 min. Milling tests were performed and machinability index, cutting forces and surface roughness measurements were used to evaluate the machinability. Higher cutting forces, lower machinability index and the poorer surface roughness of the samples austempered at lower temperatures indicated that austempering at higher temperatures resulted in better machinability. The machinability of samples austempered at 420oC, which contained higher fractions of retained austenite, was superior to that of samples austempered at lower temperatures, indicating that hardness is an important factor in assessing machinability in addition to high carbon austenite content. The ADI with 0.6% Ni, austempered at 420°C for 120 minutes, demonstrated best machinability.
Abstract: Two types of crushing were applied to grains of red sorghum: manual crushing using a mortar and pestle of kitchen and mechanical crushing using a hammer mill. The flours obtained at the end of these various crushing were filtered and subdivided in different fractions according to the diameters of the mesh of the sieves (0.16mm; 0.25mm; 0.315mm; 0.4mm, and 0.63mm…). Some physical, chemical and nutritional traits of these flours were evaluated using Association of Official Analytical Chemists (AOAC). In vitro digestibility of these flours was also studied with freezing of flour 1% like substrate and α-amylase from B. licheniformis (E.C.3.2.1.1; Megazyme, Wicklow, Ireland). The results revealed that the batches of flours which have the finest diameters as 0.16mm; 0.25mm are the richest one in nutrients and are also the most digestible. Also mechanical crushing is the best mean to obtain significant amount of flours. In conclusion, the type of crushing and the size of the particles have an impact on the final concentration of some nutrients of the flours obtained. Indeed, the finest particles (0.16mm – 0.25mm 0.315mm) obtained after sifting of the flours are more nutritive and have a better digestibility than others size. So the finest particles could be advised for management of cereals namely the sorghum for the production of the infantile foods.
Abstract: The design of temperature measuring approach for a re-configured milling machine to produce friction stir welds is reported in this paper. The product design specifications for the redesigning of a milling machine were first outlined and the ranking criteria were determined. Three different concepts were generated for the temperature measurement on the reconfigured system and the preferred or the best concept was selected based on the set design ranking criteria. Further simulation and performance analysis was then conducted on the concept. The Infrared Thermography (IRT) concept was selected for the temperature measurement among other concepts generated because it is an ideal and most effective system of measurement in this regard.
Abstract: The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.
Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.
Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.
This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HRC=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,
Ra= 0.305-0.005X1 - 0.0175X2 + 0.0525X4 + 0.0125X1X4 -0.02X2X4 - 0.0375X3X4
Hv=160.625 -2.37 5X1 + 5.125X2 + 1.875X3 + 4.375X4 - 1.625X1X4 + 4.375X2X4 - 2.375X3X4
High surface microhardness (175HV) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.
Abstract: Abrasive Water Jet Machining is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application, i.e., abrasive size, flow rate, standoff distance and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.