Search results for: Abrasive Waterjet Milling

Authors: Jatinder Kumar

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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. There is a considerable lack of research on its application to the cost-effective machining of tough materials such as titanium. In this investigation, the application of USM process for machining of titanium (ASTM Grade-I) has been explored. Experiments have been conducted to assess the effect of different parameters of USM process on machining rate and tool wear rate as response characteristics. The process parameters that were included in this study are: abrasive grit size, tool material and power rating of the ultrasonic machine. It has been concluded that titanium is fairly machinable with USM process. Significant improvement in the machining rate can be realized by manipulating the process parameters and obtaining the optimum combination of these parameters.

Keywords: abrasive grit size, tool material, titanium, ultrasonic machining

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Authors: B. Voucko, M. Benkovic, N. Cukelj, S. Drakula, D. Novotni, S. Balbino, D. Curic

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Oxidative stress is considered as one of the causes leading to metabolic disorders in humans. Therefore, the ability of antioxidants to inhibit free radical production is their primary role in the human organism. Antioxidants originating from cereals, especially flavonoids and polyphenols, are mostly bound and indigestible. Micronization damages the cell wall which consecutively results in bioactive material to be more accessible in vivo. In order to ensure complete fragmentation, micronization is often combined with high temperatures (e.g., for bran 200°C) which can lead to degradation of bioactive compounds. The innovative non-thermal technology of cryo-milling is an ultra-fine micronization method that uses liquid nitrogen (LN2) at a temperature of 195°C to freeze and cool the sample during milling. Freezing at such low temperatures causes the material to become brittle which ensures the generation of fine particles while preserving the bioactive content of the material. The aim of this research was to determine if production of ultra-fine material with cryo-milling will result in the augmentation of available bioactive compounds of buckwheat and pumpkin seed cake. For that reason, buckwheat and pumpkin seed cake were ground in a ball mill (CryoMill, Retch, Germany) with and without the use of LN2 for 8 minutes, in a 50 mL stainless steel jar containing one grinding ball (Ø 25 mm) at an oscillation frequency of 30 Hz. The cryo-milled samples were cooled with LN2 for 2 minutes prior to milling, followed by the first cycle of milling (4 minutes), intermediary cooling (2 minutes), and finally the second cycle of milling (further 4 minutes). A continuous process of milling was applied to the samples ground without freezing with LN2. Particle size distribution was determined using the Scirocco 2000 dry dispersion unit (Malvern Instruments, UK). Antioxidant activity was determined by 2,2-Diphenyl-1-picrylhydrazyl (DPPH) test and ferric reducing antioxidant power (FRAP) assay, while the total phenol content was determined using the Folin Ciocalteu method, using the ultraviolet-visible spectrophotometer (Specord 50 Plus, Germany). The content of the free phenolic acids, rutin in buckwheat, tyrosol in pumpkin seed cake, was determined with an HPLC-PDA method (Agilent 1200 series, Germany). Cryo-milling resulted in 11 times smaller size of buckwheat particles, and 3 times smaller size of pumpkin seed particles than milling without the use of LN2, but also, a lower uniformity of the particle size distribution. Lack of freezing during milling of pumpkin seed cake caused a formation of agglomerates due to its high-fat content (21 %). Cryo-milling caused augmentation of buckwheat flour antioxidant activity measured by DPPH test (23,9%) and an increase in available rutin content (14,5%). Also, it resulted in an augmentation of the total phenol content (36,9%) and available tyrosol content (12,5%) of pumpkin seed cake. Antioxidant activity measured with the FRAP test, as well as the content of phenolic acids remained unchanged independent of the milling process. The results of this study showed the potential of cryo-milling for complete raw material utilization in the food industry, as well as a tool for extraction of aimed bioactive components.

Keywords: bioactive, ball-mill, buckwheat, cryo-milling, pumpkin seed cake

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Authors: Opeyemi Atiba-Oyewo, Maurice S. Onya, Christian Wolkersdorfer

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Nanostructure formation and characterization of eco-friendly banana peels nanosorbent are thoroughly described in this paper. The transformation of material during mechanical milling to enhance certain properties such as changes in microstructure and surface area to solve the current problems involving water pollution and water quality were studied. The mechanical milling was employed using planetary continuous milling machine and ethanol as process control agent, the sample were taken at time interval between 10 h to 30 h to examine the structural changes. The samples were characterised by X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infra-red (FTIR), Transmission electron microscopy (TEM) and Brunauer Emmett and teller (BET). Results revealed that the three typical structures with different grain-size, lattice strain and shapes were observed, and the deformation mechanisms in these structures were found to be different, further particles fracturing results to surface area increment which was confirmed by Brunauer Emmett and teller (BET) analysis. X-ray diffraction (XRD) shows high densities of dislocations in large crystallites, implying that dislocation slip is the dominant deformation mechanism. Scanning electron microscopy revealed the morphological properties of the materials at different milling time, nanostructure of the particles and fibres were confirmed by Transmission electron microscopy and FT-IR identified the functional groups responsible for its capacity to coordinate and remove metal ions, such as the carboxylic and amine groups at absorption bands of 1730 and 889 cm-1, respectively. However, the choice of this sorbent material for the sorption of any contaminants will depend on the composition of the effluent to be treated.

Keywords: banana peels, eco-friendly, mechanical milling, nanosorbent, nanostructure water quality

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Authors: Harshkumar K. Desai, Anuj K. Desai, Jay P. Patel, Snehal V. Trivedi, Yogendrasinh Parmar

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The need of continuous improvement in a product or process in this era of global competition leads to apply value engineering for functional and aesthetic improvement in consideration with economic aspect too. Solar industries located at G.I.D.C., Makarpura, Vadodara, Gujarat, India; a manufacturer of variety of CNC Machines had a challenge to analyze the structural design of column, base, carriage and table of CNC Milling Machine in the account of reduction of overall weight of a machine without affecting the rigidity and accuracy at the time of operation. The identified task is the first attempt to validate and optimize the proposed design of ribbed structure statically using advanced modeling and analysis tools in a systematic way. Results of stress and deformation obtained using analysis software are validated with theoretical analysis and found quite satisfactory. Such optimized results offer a weight reduction of the final assembly which is desired by manufacturers in favor of reduction of material cost, processing cost and handling cost finally.

Keywords: CNC milling machine, optimization, finite element analysis (FEA), weight reduction

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Authors: Md. Anayet U. Patwari, Mohammad Ahsan Habib, Md. Tanzib Ehsan, Md Golam Ahnaf, Md. S. I. Chowdhury

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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.

Keywords: aluminium, milling operation, peltier cooling effect, surface roughness

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Authors: Hatim Laalej, Salvador Sumohano-Verdeja, Thomas McLeay

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Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.

Keywords: machining, milling operation, tool condition monitoring, tool wear prediction

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Authors: Joseph Chen, N. Hundal

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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.

Keywords: surface roughness, Taguchi parameter design, turning center, turn-milling operations, vertical machining center

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Authors: Mohieddine Benghersallah, Lakhdar Boulanouar, Salim Belhadi

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Currently, higher production rate with required quality and low cost is the basic principle in the competitive manufacturing industry. This is mainly achieved by using high cutting speed and feed rates. Elevated temperatures in the cutting zone under these conditions shorten tool life and adversely affect the dimensional accuracy and surface integrity of component. Thus it is necessary to find optimum cutting conditions (cutting speed, feed rate, machining environment, tool material and geometry) that can produce components in accordance with the project and having a relatively high production rate. Response surface methodology is a collection of mathematical and statistical techniques that are useful for modelling and analysis of problems in which a response of interest is influenced by several variables and the objective is to optimize this response. The work presented in this paper examines the effects of cutting parameters (cutting speed, feed rate and depth of cut) on to the surface roughness through the mathematical model developed by using the data gathered from a series of milling experiments performed.

Keywords: Statistical analysis (RSM), Bearing steel, Coating inserts, Tool life, Surface Roughness, End milling.

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Authors: Bruno S. Soria, Mauricio R. Policena, Andre J. Souza

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The state of the cutting tool is an important factor to consider during machining to achieve a good surface quality. The vibration generated during material cutting can also directly affect the surface quality and life of the cutting tool. In this work, the effect of mechanical broken failure (MBF) on carbide insert tools during face milling of AISI 304 stainless steel was evaluated using three levels of feed rate and two spindle speeds for each tool condition: three carbide inserts have perfect geometry, and three other carbide inserts have MBF. The axial and radial depths remained constant. The cutting forces were determined through a sensory system that consists of a piezoelectric dynamometer and data acquisition system. Discrete Wavelet Transform was used to separate the static part of the signals of force and vibration. The roughness of the machined surface was analyzed for each machining condition. The MBF of the tool increased the intensity and force of vibration and worsened the roughness factors.

Keywords: face milling, stainless steel, tool condition monitoring, wavelet discrete transform

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Authors: W. A. Nalaka Wijesooriya

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The increasing paddy production, stabilization of domestic rice consumption and the increasing dynamism of rice processing and domestic markets call for a rethinking of the general direction of the rice milling industry in Sri Lanka. The main purpose of the study was to explore levels of concentration in rice milling industry in Polonnaruwa and Hambanthota which are the major hubs of the country for rice milling. Concentration indices reveal that the rice milling industry in Polonnaruwa operates weak oligopsony and is highly competitive in Hambanthota. According to the actual quantity of paddy milling per day, 47 % is less than 8Mt/Day, while 34 % is 8-20 Mt/day, and the rest (19%) is greater than 20 Mt/day. In Hambanthota, nearly 50% of the mills belong to the range of 8-20 Mt/day. Lack of experience of the milling industry, poor knowledge on milling technology, lack of capital and finding an output market are the major entry barriers to the industry. Major problems faced by all the rice millers are the lack of a uniform electricity supply and low quality paddy. Many of the millers emphasized that the rice ceiling price is a constraint to produce quality rice. More than 80% of the millers in Polonnaruwa which is the major parboiling rice producing area have mechanical dryers. Nearly 22% millers have modern machineries like color sorters, water jet polishers. Major paddy purchasing method of large scale millers in Polonnaruwa is through brokers. In Hambanthota major channel is miller purchasing from paddy farmers. Millers in both districts have major rice selling markets in Colombo and suburbs. Huge variation can be observed in the amount of pledge (for paddy storage) loans. There is a strong relationship among the storage ability, credit affordability and the scale of operation of rice millers. The inter annual price fluctuation ranged 30%-35%. Analysis of market margins by using series of secondary data shows that farmers’ share on rice consumer price is stable or slightly increases in both districts. In Hambanthota a greater share goes to the farmer. Only four mills which have obtained the Good Manufacturing Practices (GMP) certification from Sri Lanka Standards Institution can be found. All those millers are small quantity rice exporters. Priority should be given for the Small and medium scale millers in distribution of storage paddy of PMB during the off season. The industry needs a proper rice grading system, and it is recommended to introduce a ceiling price based on graded rice according to the standards. Both husk and rice bran were underutilized. Encouraging investment for establishing rice oil manufacturing plant in Polonnaruwa area is highly recommended. The current taxation procedure needs to be restructured in order to ensure the sustainability of the industry.

Keywords: conduct, performance, structure (SCP), rice millers

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Authors: A. B. Moldes, X. Vecino, L. Rodriguez-López, J. M. Dominguez, J. M. Cruz

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The concept of the circular economy is focus on the importance of providing goods and services sustainably. Thus, in a future it will be necessary to respond to the environmental contamination and to the use of renewables substrates by moving to a more restorative economic system that drives towards the utilization and revalorization of residues to obtain valuable products. During its evolution our industrial economy has hardly moved through one major characteristic, established in the early days of industrialization, based on a linear model of resource consumption. However, this industrial consumption system will not be maintained during long time. On the other hand, there are many industries, like the corn milling industry, that although does not consume high amount of non renewable substrates, they produce valuable streams that treated accurately, they could provide additional, economical and environmental, benefits by the extraction of interesting commercial renewable products, that can replace some of the substances obtained by chemical synthesis, using non renewable substrates. From this point of view, the use of streams from corn milling industry to obtain surface-active compounds will decrease the utilization of non-renewables sources for obtaining this kind of compounds, contributing to a circular and global economy. However, the success of the circular economy depends on the interest of the industrial sectors in the revalorization of their streams by developing relevant and new business models. Thus, it is necessary to invest in the research of new alternatives that reduce the consumption of non-renewable substrates. In this study is proposed the utilization of a corn milling industry stream to obtain an extract with surfactant capacity. Once the biosurfactant is extracted, the corn milling stream can be commercialized as nutritional media in biotechnological process or as animal feed supplement. Usually this stream is combined with other ingredients obtaining a product namely corn gluten feed or may be sold separately as a liquid protein source for beef and dairy feeding, or as a nutritional pellet binder. Following the productive scheme proposed in this work, the corn milling industry will obtain a biosurfactant extract that could be incorporated in its productive process replacing those chemical detergents, used in some point of its productive chain, or it could be commercialized as a new product of the corn manufacture. The biosurfactants obtained from corn milling industry could replace the chemical surfactants in many formulations, and uses, and it supposes an example of the potential that many industrial streams could offer for obtaining valuable products when they are manage properly.

Keywords: biosurfactantes, circular economy, corn, sustainability

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Authors: Khaled M. Youssef, Sara I. Ahmed

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In this study, artifacts-free bulk nanocrystalline pure aluminum alloy samples were prepared through mechanical milling under ultra-high purity argon and at both liquid nitrogen and room temperatures. The nanostructure evolution during milling was examined using X-ray diffraction and transmission electron microscope techniques. The in-situ consolidated samples after milling exhibited an average grain size of 18 nm. The tensile properties of this novel material are reported in comparison with coarse-grained aluminum alloys. The 0.2% offset yield strength of the nanocrystalline aluminum was found to be 340 MPa. This value is at least one order of magnitude higher than that of the coarse-grained aluminum alloy. In addition to this extraordinarily high strength, the nanocrystalline aluminum showed a significant tensile ductility, with 6% uniform elongation and 11% elongation-to-failure. The transmission electron microscope observations in this study provide evidence of deformation twinning in the plastically deformed nanocrystalline aluminum. These results highlight a change of the deformation mechanism from a typical dislocation slip to twinning deformation induced by partial dislocation activities.

Keywords: nanocrystalline, aluminum, strength, ductility

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Authors: Catherine Kuforiji, Michel Nganbe

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The abrasive wear of composite materials is a major challenge in highly demanding wear applications. Therefore, this study focuses on fabricating, testing and assessing the properties of 50wt% SS316L stainless steel–50wt% Al2O3 particle composites. Composite samples were fabricated using the powder metallurgy route. The effects of the powder metallurgy processing parameters and hard particle reinforcement were studied. The microstructure, density, hardness and toughness were characterized. The wear behaviour was studied using pin-on-disc testing under dry sliding conditions. The highest hardness of 1085.2 HV, the highest theoretical density of 94.7% and the lowest wear rate of 0.00397 mm3/m were obtained at a milling speed of 720 rpm, a compaction pressure of 794.4 MPa and sintering at 1400 °C in an argon atmosphere. Compared to commercial SS316 and fabricated SS316L, the composites had 7.4 times and 11 times lower wear rate, respectively. However, the commercial 90WC-10Co showed 2.2 times lower wear rate compared to the fabricated SS316L-Al2O3 composites primarily due to the higher ceramic content of 90 wt.% in the reference WC-Co. However, eliminating the relatively high porosity of about 5 vol% using processes such as HIP and hot pressing can be expected to lead to further substantial improvements of the composites wear resistance.

Keywords: SS316L, Al2O3, powder metallurgy, wear characterization

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Authors: Chularat Leewuttanakul, Khanitta Ruttarattanamongkol, Sasivimon Chittrakorn

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Rice during grain development stage is a rich source of many bioactive compounds. Dough stage rice contains high amounts of photochemical and can be used for rice milling industries. However, rice grain at dough stage had low milling quality due to high moisture content. Thermal processing can be applied to rice grain for improving milled rice yield. This experiment was conducted to study the chemical and physic properties of dough stage rice grain after roasting treatment. Rice were roasted with two different methods including traditional pan roasting at 140 °C for 60 minutes and using the electrical roasting machine at 140 °C for 30, 40, and 50 minutes. The chemical, physical properties, and bioactive compounds of brown rice and milled rice were evaluated. The result of this experiment showed that moisture content of brown and milled rice was less than 10 % and amylose contents were in the range of 26-28 %. Rice grains roasting for 30 min using electrical roasting machine had high head rice yield and length and breadth of grain after milling were close to traditional pan roasting (p > 0.05). The lightness (L*) of rice did not affect by roasting treatment (p > 0.05) and the a* indicated the yellowness of milled rice was lower than brown rice. The bioactive compounds of brown and milled rice significantly decreased with increasing of drying time. Brown rice roasted for 30 minutes had the highest of total phenolic content, antioxidant activity, α-tocopherol, and ɤ-oryzanol content. Volume expansion and elongation of cooked rice decreased as roasting time increased and quality of cooked rice roasted for 30 min was comparable to traditional pan roasting. Hardness of cooked rice as measured by texture analyzer increased with increasing roasting time. The results indicated that rice grains at dough stage, containing a high amount of bioactive compounds, have a great potential for rice milling industries and the electrical roasting machine can be used as an alternative to pan roasting which decreases processing time and labor costs.

Keywords: bioactive compounds, cooked rice, dough stage rice grain, grain development, roasting

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Authors: N. Boudinar, A. Djekoun, A. Otmani, B. Bouzabata, J. M. Greneche

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High-energy ball milling is a solid-state powder processing technique that allows synthesizing a variety of equilibrium and non-equilibrium alloy phases starting from elemental powders. The advantage of this process technology is that the powder can be produced in large quantities and the processing parameters can be easily controlled, thus it is a suitable method for commercial applications. It can also be used to produce amorphous and nanocrystalline materials in commercially relevant amounts and is also amenable to the production of a variety of alloy compositions. Mechanical alloying (high-energy ball milling) provides an inter-dispersion of elements through a repeated cold welding and fracture of free powder particles; the grain size decreases to nano metric scale and the element mix together. Progressively, the concentration gradients disappear and eventually the elements are mixed at the atomic scale. The end products depend on many parameters such as the milling conditions and the thermodynamic properties of the milled system. Here, the mechanical alloying technique has been used to prepare nano crystalline Fe_50 and Fe_64 wt.% Ni alloys from powder mixtures. Scanning electron microscopy (SEM) with energy-dispersive, X-ray analyses and Mössbauer spectroscopy were used to study the mixing at nanometric scale. The Mössbauer Spectroscopy confirmed the ferromagnetic ordering and was use to calculate the distribution of hyperfin field. The Mössbauer spectrum for both alloys shows the existence of a ferromagnetic phase attributed to γ-Fe-Ni solid solution.

Keywords: nanocrystalline, mechanical alloying, X-ray diffraction, Mössbauer spectroscopy, phase transformations

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Authors: Ş. Karabulut, A. Güllü, A. Güldaş, R. Gürbüz

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This study investigates the effects of the lead angle and chip thickness variation on surface roughness during the machining of compacted graphite iron using ceramic cutting tools under dry cutting conditions. Analytical models were developed for predicting the surface roughness values of the specimens after the face milling process. Experimental data was collected and imported to the artificial neural network model. A multilayer perceptron model was used with the back propagation algorithm employing the input parameters of lead angle, cutting speed and feed rate in connection with chip thickness. Furthermore, analysis of variance was employed to determine the effects of the cutting parameters on surface roughness. Artificial neural network and regression analysis were used to predict surface roughness. The values thus predicted were compared with the collected experimental data, and the corresponding percentage error was computed. Analysis results revealed that the lead angle is the dominant factor affecting surface roughness. Experimental results indicated an improvement in the surface roughness value with decreasing lead angle value from 88° to 45°.

Keywords: CGI, milling, surface roughness, ANN, regression, modeling, analysis

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Authors: Mahmoud Rabh

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Garnet has been used for decades as an abrasive in water jet cutting and sand blasting because of its superior physical properties. When added to use in water-cutting process of marble. A standard commercial sample of the mineral was tested in terms of the hardness and abrasiveness properties. The sample was sized to 4 fractions having the size of < 60 um, > 60 < 100 um, > 100 < 180 um > 1280 < 250 and 250 um designated the symbols, FF, MF, MC and C respectively. Each sample was separately heated in controlled conditions at temperatures up to 1000 °C at a heating rate of 10°C/min in an electrically heated chamber furnace. Soaking time at the maximum temperature was up to 6 h. Hardness and abrasiveness properties of the heat treated samples were tested to cut marble having a thickness of 25 mm. Results revealed that H/A of the natural garnet mineral increased by heating at temperatures up to 600°C and exhibited pronounced decrease with higher temperatures up to 1000 °C. Results were explained in the light of a structural irreversible dislocation (SD) of the crystals of garnet almandine Fe2+3Al2Si3O12 and pyrope Mg3Al2Si3O12. Characterization of the mineral was carried out with the help of XRD, SEM and FT-IR measurements.

Keywords: garnet abrasive, heat treatment, water jet cutting, hardness abrasiveness

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Authors: Chalakorn Chitsaart, Suchada Rianmora, Mann Rattana-Areeyagon, Wutichai Namjaiprasert

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G-code is the main factor in computer numerical control (CNC) machine for controlling the tool-paths 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.

Keywords: geometric shapes, milling operation, minor changes, CNC Machine, G-code, cutting parameters

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Authors: A. A. Selaimia, H. Bensouilah, M. A. Yallese, I. Meddour, S. Belhadi, T. Mabrouki

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The objective of this work is to model the output responses namely; surface roughness (Ra), cutting force (Fc), during the face milling of the austenitic stainless steel X2CrNi18-9 with coated carbide tools (GC4040). For raison, response surface methodology (RMS) is used to determine the influence of each technological parameter. A full factorial design (L27) is chosen for the experiments, and the ANOVA is used in order to evaluate the influence of the technological cutting parameters namely; cutting speed (Vc), feed per tooth, and depth of cut (ap) on the out-put responses. The results reveal that (Ra) is mostly influenced by (fz) and (Fc) is found considerably affected by (ap).

Keywords: austenitic stainless steel, ANOVA, coated carbide, response surface methodology (RSM)

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Authors: Amir Mahyar Khorasani, Ian Gibson, Moshe Goldberg, Mohammad Masoud Movahedi, Guy Littlefair

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One of the important factors in manufacturing processes especially machining operations is surface quality. Improving this parameter results in improving fatigue strength, corrosion resistance, creep life and surface friction. The reliability and clearance of removable joints such as thread and nuts are highly related to the surface roughness. In this work, the effect of different cutting parameters such as cutting fluid pressure, feed rate and cutting speed on the surface quality of the crest of thread in the high-speed milling of Brass C3600 have been determined. Two popular neural networks containing MLP and RBF coupling with Taguchi L32 have been used to model surface roughness which was shown to be highly adept for such tasks. The contribution of this work is modelling surface roughness on the crest of the thread by using precise profilometer with nanoscale resolution. Experimental tests have been carried out for validation and approved suitable accuracy of the proposed model. Also analysing the interaction of parameters two by two showed that the most effective cutting parameter on the surface value is feed rate followed by cutting speed and cutting fluid pressure.

Keywords: artificial neural networks, cutting conditions, high-speed machining, surface roughness, thread milling

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Authors: Ergin Kosa, Ali Göksenli

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Erosion and abrasion are wear mechanisms reducing the lifetime of machine elements like valves, pump and pipe systems. Both wear mechanisms are acting at the same time, causing a “Synergy” effect, which leads to a rapid damage of the surface. Different parameters are effective on erosive abrasive wear rate. In this study effect of particle impact angle on wear rate and wear mechanism of ductile and brittle materials was investigated. A new slurry pot was designed for experimental investigation. As abrasive particle, silica sand was used. Particle size was ranking between 200-500 µm. All tests were carried out in a sand-water mixture of 20% concentration for four hours. Impact velocities of the particles were 4,76 m/s. As ductile material steel St 37 with Brinell Hardness Number (BHN) of 245 and quenched St 37 with 510 BHN was used as brittle material. After wear tests, morphology of the eroded surfaces were investigated for better understanding of the wear mechanisms acting at different impact angles by using optical microscopy and Scanning Electron Microscope. The results indicated that wear rate of ductile material was higher than brittle material. Maximum wear was observed by ductile material at a particle impact angle of 300. On the contrary wear rate increased by brittle materials by an increase in impact angle and reached maximum value at 450. High amount of craters were detected after observation on ductile material surface Also plastic deformation zones were detected, which are typical failure modes for ductile materials. Craters formed by particles were deeper according to brittle material worn surface. Amount of craters decreased on brittle material surface. Microcracks around craters were detected which are typical failure modes of brittle materials. Deformation wear was the dominant wear mechanism on brittle material. At the end it is concluded that wear rate could not be directly related to impact angle of the hard particle due to the different responses of ductile and brittle materials.

Keywords: erosive wear, particle impact angle, silica sand, wear rate, ductile-brittle material

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Authors: Kious Mecheri, Hadjadj Abdechafik, Ameur Aissa

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The wear of cutting tool degrades the quality of the product in the manufacturing processes. The online 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 online. 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.

Keywords: flank wear, cutting forces, high speed milling, signal processing, neural network

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Authors: Jerzy F. Janik, Mariusz Drygas, Miroslaw M. Bucko

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A simple precursor system has been recently developed in our laboratory for the conversion of affordable microcrystalline gallium antimonide GaSb to a range of nanocrystalline powders of gallium nitride GaN – a wide bandgap semiconductor indispensable in modern optoelectronics. The process relies on high temperature nitridation reactions of GaSb with ammonia. Topochemical relationships set up by the cubic lattice of GaSb result in some metastable cubic GaN formed in addition to the stable hexagonal GaN. A prior application of high energy ball milling to the initially microcrystalline GaSb precursor is shown to alter the nitridation output.

Keywords: nanocrystalline, gallium nitride, GaN, gallium antimonide, GaSb, nitridation, ball milling

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Authors: M. S. Said, J. A. Ghani, Izzati Osman, Z. A. Latiff, S. A .F. Syed Mohd

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Metal matrix composites have demand for light-weight structural and functional materials. MMCs have been shown to offer improvements in strength, rigidity, temperature stability, wear resistance, reliability and control of physical properties such as density and coefficient of thermal expansion, thereby providing improved engineering performance in comparison to the un-reinforced matrix. Experiment were conducted at various cutting speed, feed rate and difference cutting tools according to Taguchi method using a standard orthogonal array L9. The volume of AlN reinforced particle was 10% in MMC. The milling process was carried out under dry cutting condition using uncoated carbide, TiN and TiCN tool insert. The parameters used were the cutting speed of (230,300,370 m/min) the federate used were (0.4, 0.6, 0.8 mm/tooth) while the depth of cut is constant (0.3 mm). The tool diameter is 20mm. From the project, the surface roughness mechanism was investigated in detail using Mitutoyo portable surface roughness measurements surftest SJ-310. This machining will be fabricated on MMC with 150mm length, 100mm width and 30mm thick. The results showed using S/N ratio, concluded that a combination of low cutting speed, medium feed rate and uncoated insert give a remarkable surface finish. From the ANOVA result showed the feed rate was major contributing factor (43.76%) following type of insert (40.89%).

Keywords: MMC, milling operation and surface roughness, Taguchi method

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Authors: Pankaj Chandna, Dinesh Kumar

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The present work analyses different parameters of end milling to minimize the surface roughness for AISI D2 steel. D2 Steel is generally used for stamping or forming dies, punches, forming rolls, knives, slitters, shear blades, tools, scrap choppers, tyre shredders etc. Surface roughness is one of the main indices that determines the quality of machined products and is influenced by various cutting parameters. In machining operations, achieving desired surface quality by optimization of machining parameters, is a challenging job. In case of mating components the surface roughness become more essential and is influenced by the cutting parameters, because, these quality structures are highly correlated and are expected to be influenced directly or indirectly by the direct effect of process parameters or their interactive effects (i.e. on process environment). In this work, the effects of selected process parameters on surface roughness and subsequent setting of parameters with the levels have been accomplished by Taguchi’s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L9 orthogonal array. Experimental investigation of the end milling of AISI D2 steel with carbide tool by varying feed, speed and depth of cut and the surface roughness has been measured using surface roughness tester. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the contribution of the different process parameters on the process.

Keywords: D2 steel, orthogonal array, optimization, surface roughness, Taguchi methodology

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Authors: Dolly Gadhiya, Jayvadan Patel, Mihir Raval

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Lercanidipine hydrochloride is a calcium channel blockers used for treating angina pectoris and hypertension. Lercanidipine is a BCS Class II drug having poor aqueous solubility. Absolute bioavailability of Lercanidipine is very low and the main reason ascribed for this is poor aqueous solubility of the drug. Design and formulatation of nanocrystals by media milling method was main focus of this study. In this present study preliminary optimization was carried out with one factor at a time (OFAT) approach. For this different parameters like size of milling beads, amount of zirconium beads, types of stabilizer, concentrations of stabilizer, concentrations of drug, stirring speeds and milling time were optimized on the basis of particle size, polydispersity index and zeta potential. From the OFAT model different levels for above parameters selected for Plackett - Burman Design (PBD). Plackett-Burman design having 13 runs involving 6 independent variables was carried out at higher and lower level. Based on statistical analysis of PBD it was found that concentration of stabilizer, concentration of drug and stirring speed have significant impact on particle size, PDI, zeta potential value and saturation solubility. These experimental designs for preparation of nanocrystals were applied successfully which shows increase in aqueous solubility and dissolution rate of Lercanidipine hydrochloride.

Keywords: Lercanidipine hydrochloride, nanocrystals, OFAT, Plackett Burman

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Authors: Nikolai Bertelsen, Robert A. Alphinas, Klaus B. Orskov

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The shortest possible tool stickout has been the traditional go-to approach with expectations of increased stability and productivity. However, experimental studies at Danish Advanced Manufacturing Research Center (DAMRC) have proven that for some tool stickout lengths, there exist local productivity optimums when utilizing the Stability Lobe Diagrams for chatter avoidance. This contradicts with traditional logic and the best practices taught to machinists. This paper explores the vibrational characteristics and behaviour of a milling system over the tool stickout length. The experimental investigation has been conducted by tap testing multiple endmills where the tool stickout length has been varied. For each length, the modal parameters have been recorded and mapped to visualize behavioural tendencies. Furthermore, the paper explores the correlation between the modal parameters and the Stability Lobe Diagram to outline the influence and importance of each parameter in a multi-mode system. The insights are conceptualized into a tool tuning approximation solution. It builds on an almost linear change in the natural frequencies when amending tool stickout, which results in changed positions of the Chatter-free Stability Lobes. Furthermore, if the natural frequency of two modes become too close, it will onset of the dynamic absorber effect phenomenon. This phenomenon increases the critical stable depth of cut, allowing for a more stable milling process. Validation tests on the tool tuning approximation solution have shown varying success of the solution. This outlines the need for further research on the boundary conditions of the solution to understand at which conditions the tool tuning approximation solution is applicable. If the conditions get defined, the conceptualized tool tuning approximation solution outlines an approach for quick and roughly approximating tool stickouts with the potential for increased stiffness and optimized productivity.

Keywords: milling, modal parameters, stability lobes, tap testing, tool tuning

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Authors: Saad Nawaz, Yu Gang, Miao Haibin

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Titanium alloys are attractive materials for aerospace industry due to their exceptional strength to weight ratio that is maintained at elevated temperatures and their good corrosion resistance. Major applications of titanium alloys were military aerospace industry, but since last decade the trend has now shifted towards commercial industry. On the other hand, titanium alloys are notorious for being poor thermal conductor that leads to them being difficult materials for machining. In this experimental study, Stellram Indexable milling cutter XDLT09-D41 is used for rough down milling of Ti6Al4V for small depth of cut under different combinations of parameters and application of high-pressure coolant. The machining performance was evaluated in terms of tool wear, tool life, and thermal crack. The tool wear was mostly observed at the tool tip and at bottom part of tool thermal deformations were observed which propagated with respect to time. Flank wear due to scratching of the cutting chips and diffusion wear because of high thermal stresses were observed specially at the bottom of the cutting tool. It was found that maximum tool life was obtained at the speed of 40m/min, feed rate of 358mm/min and depth of cut of 0.8mm. In the end, it was concluded that machining of Ti6Al4V is a thermally dominant process which leads to high thermal stresses in machining zone that results in increasing tool wear rate and deformation propagation.

Keywords: tool wear, cutting speed, flank wear , tool life

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Authors: Daniel Karthik, Vijay Baheti, Jiri Militky, Sundaramurthy Palanisamy

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Fibre based nano particles are presently considered as one of the potential filler materials for the improvement of mechanical and physical properties of polymer composites. Due to high matrix-filler interfacial area there will be uniform and homogeneous dispersion of nanoparticles. In micro/nano filler reinforced composites, resin material is usually tailored by organic or inorganic nanoparticles to have improved matrix properties. The objective of this study was to compare the potential of reinforcement of different organic and inorganic micro/nano fillers in epoxy composites. Industrial and agricultural waste of fibres like Agave Americana, cornhusk, jute, basalt, carbon, glass and fly ash was utilized to prepare micro/nano particles. Micro/nano particles were obtained using high energy planetary ball milling process in dry condition. Milling time and ball size were kept constant throughout the ball milling process. Composites were fabricated by hand lay method. Particle loading was kept constant to 3% wt. for all composites. In present study, loading of fillers was selected as 3 wt. % for all composites. Dynamic mechanical properties of the nanocomposite films were performed in three-point bending mode with gauge length and sample width of 50 mm and 10 mm respectively. The samples were subjected to an oscillating frequency of 1 Hz, 5 Hz and 10 Hz and 100 % oscillating amplitude in the temperature ranges of 30°C to 150°C at the heating rate of 3°C/min. Damping was found to be higher with the jute composites. Amongst organic fillers lowest damping factor was observed with Agave Americana particles, this means that Agave americana fibre particles have betters interface adhesion with epoxy resin. Basalt, fly ash and glass particles have almost similar damping factors confirming better interface adhesion with epoxy.

Keywords: ball milling, damping factor, matrix-filler interface, particle reinforcements

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Authors: Hoai Nam Huynh, Edouard Rivière-Lorphèvre, Olivier Verlinden

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.

Keywords: control, milling, multibody, robotic, simulation

Procedia PDF Downloads 226