Search results for: cutting performance

Authors: Riccardo Angiuli, Michele Giannuzzi, Rodolfo Franchi, Gabriele Papadia

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Temperature knowledge in machining is fundamental to improve the numerical and FEM models used for the study of some critical process aspects, such as the behavior of the worked material and tool. The extreme conditions in which they operate make it impossible to use traditional measuring instruments; infrared thermography can be used as a valid measuring instrument for temperature measurement during metal cutting. In the study, a large experimental program on superduplex steel (ASTM A995 gr. 5A) cutting was carried out, the relevant cutting temperatures were measured by infrared thermography when certain cutting parameters changed, from traditional values to extreme ones. The values identified were used to calibrate a FEM model for the prediction of residual life of the tools. During the study, the problems related to the detection of cutting temperatures by infrared thermography were analyzed, and a dedicated procedure was developed that could be used during similar processing.

Keywords: machining, infrared thermography, FEM, temperature measurement

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Authors: M. N. Osman Zahid, K. Case, D. Watts

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This paper reports an advanced approach in the application of CNC machining for rapid manufacturing processes (CNC-RM). The aim of this study is to improve the quality of machined parts by introducing different cutting tools during finishing operations. As the cutting is performed in different directions, the surfaces presented on part can be classified into several categories. Therefore, suitable cutting tools are assigned to machine particular surfaces and to improve the quality. Experimental studies have been carried out by fabricating several parts based on the suggested approach. The results provide further support for implementing this approach in rapid machining processes.

Keywords: CNC machining, end mill tool, finishing operation, rapid manufacturing

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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: M A. Habit, S. A. Syed-Sahil, A. Bahari

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Abstract—Laser cutting is a method of manufacturing process that uses laser in order to cut materials. It provides and ensures extreme accuracy which has a clean cut effect, CO2 laser dominate this application due to their good- quality beam combined with high output power. It comes with a small scale and it has a limitation in cutting sizes of materials, therefore it is more appropriate for custom- made products. The same laser cutting machine is also capable in cutting fine material such as fine silk, cotton, leather, polyester, etc. Lack of explorations and knowledge besides being unaware about this technology had caused many of the designers not to use this laser cutting method in their collections. The objectives of this study are: 1) To identify the potential of laser cutting technique in Custom-Made Garments for men’s casual wear: 2) To experiment the laser cutting technique in custom made garments: 3) To offer guidelines and formula for men’s custom- made casualwear designs with aesthetic value. In order to achieve the objectives, this research has been conducted by using mixed methods which are interviews with two (2) local experts in the apparel manufacturing industries and interviews via telephone with five (5) local respondents who are local emerging fashion designers, the questionnaires were distributed to one hundred (100) respondents around Klang Valley, in order to gain the information about their understanding and awareness regarding laser cutting technology. The experiment was conducted by using natural and man- made fibers. As a conclusion, all of the objectives had been achieved in producing custom-made men’s casualwear and with the production of these attires it will help to educate and enhance the innovation in fine technology. Therefore, there will be a good linkage and collaboration between the design experts and the manufacturing companies.

Keywords: custom-made, fashion, laser cut, men’s wear

Procedia PDF Downloads 417

Authors: Chaca Nugraha Zaid, Hikmat Ronaldo, Emerald Falah Brayoga, Azizah Eddy Setiawati, Soviandini Dwiki Kartika Putri, Novita Wijayanti

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In the tofu stick production, the manual cutting process takes a half of working day or 4 hours for 21 kg of tofu. This issue has hampered the small and medium enterprises (SMEs) to increase the capacity of production to fulfill the market demand. In order to address the issue, the cutting process should be automized to create fast, efficient, and effective tools. This innovation to tackle this problem is an automatic cutter tool that is able to move continuously to cut the tofu into stick size. The tool uses the 78,5-watt electric motor and automatic sensors to drive the cutting tool automatically, resulting faster process time with more uniform size compared to the manual cutter. The component of this tool, i.e., cutting knife and the driver, electric motor, limit switch sensors, riley, Arduino nano, and power supply. The cutting speed cutting speed of this tool is 101,25 mm/s producing 64 tofu sticks. Benefits that can be obtained from the use of automatic tofu stick cutter, i.e. (1) Faster process (2) More uniform cutting result; (3) The quality of the tofu stick is maintained due to minimal contact with humans so that contamination can be suppressed; (4) The cutting knife can be modified to the desired size of the owner.

Keywords: automatic, cutter, small and medium enterprise, tofu stick

Procedia PDF Downloads 146

Authors: Jon-Chao Hong, Tsai-Ru Fan, Shih-Min Hsu

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Virtual reality (VR) can generate mirror neurons that facilitate learners to transfer virtual skills to a real environment in skill training, and most studies approved the positive effect of applying in many domains. However, rare studies have focused on the experiential values of participants from a gender perspective. To address this issue, the present study used a VR program named kitchen assistant training, focusing on cutting vegetables and invited 400 students to practice for 20 minutes. Useful data from 367 were subjected to statistical analysis. The results indicated that male participants. From the comparison of average, it seems that females perceived higher than males in learning effectiveness. Expectedly, the VR-Cutting vegetables can be used for pre-training of real vegetable cutting.

Keywords: exponential value, facilitate learning, gender difference, virtual reality

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Authors: Murat Sarıkaya, Abdulkadir Güllü

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Haynes 25 alloy (also known as L-605 alloy) is cobalt based super alloy which has widely applications such as aerospace industry, turbine and furnace parts, power generators and heat exchangers and petroleum refining components due to its excellent characteristics. However, the workability of this alloy is more difficult compared to normal steels or even stainless. In present work, an experimental investigation was performed under cryogenic cooling to determine cutting tool wear patterns and obtain optimal cutting parameters in turning of cobalt based superalloy Haynes 25. In experiments, uncoated carbide tool was used and cutting speed (V) and feed rate (f) were considered as test parameters. Tool wear (VBmax) were measured for process performance indicators. Analysis of variance (ANOVA) was performed to determine the importance of machining parameters.

Keywords: cryogenic machining, difficult-to-cut alloy, tool wear, turning

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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

Procedia PDF Downloads 281

Authors: Kai-Shiang Chang, Shiao-Shing Chen, Saikat Sinha Ray, Hung-Te Hsu

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In recent years, membrane bioreactors (MBR) have been widely utilized as it can effectively replace conventional activated sludge process (CAS). Membrane bioreactor (MBR) is found to be more effective technology compared to other conventional activated sludge process and advanced membrane separation technique. Additionally, as far as the MBR is concerned, it is having excellent control of sludge retention time (SRT) and hydraulic retention time (HRT) and conducive to the retention of high concentration of sludge biomass. The membrane bioreactor (MBR) can effectively reduce footprint in terms of area and omit the secondary processing procedures in the conventional activated sludge process (CAS). Currently, as per the membrane technology, the ceramic membrane is found to have highly strong anti-acid-base properties, and it is more suitable than polymeric membrane while using for backwash and chemical cleaning. This study is based upon the treatment of Cutting Fluid wastewater, as the Cutting Fluid is widely used in the cutting equipment. However, the Cutting Fluid wastewater is very difficult to treat. In this study, the ceramic membrane was used and combine with of MBR system to treat the Cutting Fluid wastewater. In this present study, different kind of chemical coagulants have been utilized for pretreatment purpose in order to get the supernatant and simultaneously this wastewater (supernatant) was treated by MBR process. Nevertheless, ceramic membrane has three advantages such as high mechanical strength, drug resistance and reuse. During the experiment, the backwash technique was used for every interval of 10 minutes in order to avoid fouling of the membrane. In this study, during pretreatment the Chemical Oxygen Demand (COD) removal efficiency was found to be 71-86% and oil removal efficiency was analyzed to be 83-92%. This pretreatment study suggests that it is quiet effective methodology to reduce COD and oil concentration. Finally, In the MBR system when the HRT is more than 7.5 hour, the COD removal efficiency was found to be 87-93% and could achieve 100% oil removal efficiency. Coagulation test series were seen in Refs coagulants for the treatment of wastewater containing cutting oil with better oil and COD removal efficiency. The results also showed that the oil removal efficiency in the MBR system could reduce the oil content to less than 1 mg / L when the oil quality was 126 mg / L. Therefore, in this paper, the performance of membrane bioreactor by utilizing ceramic membrane has been demonstrated for treatment of Cutting Fluid wastewater.

Keywords: membrane bioreactor, cutting fluid, oil, chemical oxygen demand

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Authors: Fanyuan Shao, Wei Liu, Deli Gao

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Polycrystalline diamond composite (PDC) cutter is made of diamond powder as raw material, cobalt metal or non-metallic elements as a binder, mixed with WC cemented carbide matrix assembly, through high temperature and high-pressure sintering. PDC bits with PDC cutters are widely used in oil and gas drilling because of their high hardness, good wear resistance and excellent impact toughness. And PDC cutter is the main cutting tool of bit, which seriously affects the service of the PDC bit. The wear resistance of the PDC cutter is measured by cutting granite with a vertical turret lathe (VTL). This experiment can achieve long-distance cutting to obtain the relationship between the wear resistance of the PDC cutter and cutting distance, which is more closely to the real drilling situation. Load cell and 3D optical profiler were used to obtain the value of cutting forces and wear area, respectively, which can also characterize the damage and wear of the PDC cutter. PDC cutters were cut via electrical discharge machining (EDM) and then flattened and polished. A scanning electron microscope (SEM) was used to observe the distribution of binder cobalt and the size of diamond particles in a diamond PDC cutter. The cutting experimental results show that the wear area of the PDC cutter has a good linear relationship with the cutting distance. Simultaneously, the larger the wear area is and the greater the cutting forces are required to maintain the same cutting state. The size and distribution of diamond particles in the polycrystalline diamond layer have a great influence on the wear resistance of the diamond layer. And PDC cutter with fine diamond grains shows more wear resistance than that with coarse grains. The deep leaching process is helpful to reduce the effect of binder cobalt on the wear resistance of the polycrystalline diamond layer. The experimental study can provide an important basis for the application of PDC cutters in oil and gas drilling.

Keywords: polycrystalline diamond compact, scanning electron microscope, wear resistance, cutting distance

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Authors: Chris M. Taylor, Ian Cook, Raul Alegre, Pedro Arrazola, Phil Spiers

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Noteworthy results have been obtained in the turning and drilling of hardened high-strength steels using tungsten carbide based cutting tools. In a finish turning process, it was seen that surface roughness and tool flank wear followed very different trends against cutting time. The suggested explanation for this behaviour is that the profile cut into the workpiece surface is determined by the tool’s cutting edge profile. It is shown that the profile appearing on the cut surface changes rapidly over time, so the profile of the tool cutting edge should also be changing rapidly. Workpiece material adhered onto the cutting tool, which is also known as a built-up edge, is a phenomenon which could explain the observations made. In terms of tool damage modes, workpiece material adhesion is believed to have contributed to tool wear in examples provided from finish turning, thread turning and drilling. Additionally, evidence of tool fracture and tool abrasion were recorded.

Keywords: turning, drilling, adhesion, wear, hard steels

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Authors: Raja V., Chokkalingam B.

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For rough cutting, in many industries and educational institutions using carbon steels or HSS single point cutting tools in center lathe machine. In power hacksaw blades, only the cutter teeth region used to parting off the given material. The portions other than the teeth can be used as a single point cutting tool for rough turning and facing on soft materials. The hardness and Tensile strength of this used Power hacksaw blade is almost same as conventional cutting tools. In this paper, the effect of power hacksaw blades over conventional tool has been compared. Thickness of the blade (1.6 mm) is very small compared to its length and width. Hence, a special tool holding device is designed to hold the tool.

Keywords: hardness, high speed steels, power hacksaw blade, tensile strength

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Authors: S. Srinivas, N. Ramesh Babu

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This paper presents a model to predict the depth of penetration in polycrystalline ceramic material cut by abrasive waterjet. The proposed model considered the interaction of cylindrical jet with target material in upper region and neglected the role of threshold velocity in lower region. The results predicted with the proposed model are validated with the experimental results obtained with Silicon Carbide (SiC) blocks.

Keywords: abrasive waterjet cutting, analytical modeling, ceramics, micro-cutting and inter-grannular cracking

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Authors: Nurul Na'imy Wan, Mohamad Sazali Said, Jaharah Ab. Ghani, Rusli Othman

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This paper presents the surface roughness of the aluminium silicon alloy (AlSi) matrix composite which has been reinforced with aluminium nitride (AlN). Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to a standard orthogonal array L27 of Taguchi method using TiN coating tool of insert. The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of cutting speeds, feed rates and depths of cut in measuring the surface roughness during the milling operation. The surface roughness was observed using Mitutoyo Formtracer CS-500 and analyzed using the Taguchi method. From the Taguchi analysis, it was found that cutting speed of 230 m/min, feed rate of 0.4 mm/tooth, depth of cut of 0.3 mm were the optimum machining parameters using TiN coating insert.

Keywords: AlSi/AlN metal matrix composite (MMC), surface roughness, Taguchi method, machining parameters

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Authors: M. Benghersallah, G. List, G. Sutter

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The present work is an experimental study on the dry high speed turning of Ti-6Al-4V titanium alloy. The objective of this study is to see for high cutting speeds, how wear occurs on the face of insert and how to evolve cutting forces and chip formation. Cutting speeds tested is 600, 800, 1000, and 1200 m/min in orthogonal turning with a carbide insert tool H13A uncoated on a cylindrical titanium alloy part. Investigation on the wear inserts with 3D scanning microscope revered the crater formation is instantaneous and a chip adhesion (welded chip) causes detachment of carbide particles. Cutting forces increase and stabilize before removing the tool. The chip reaches a very high temperature.

Keywords: titanium alloy, dry hjgh speed turning, wear insert, MQL technique

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Authors: M. Pappa, C. Efstathiou, G. Livanos, P. Xidas, D. Vakondios, E. Maravelakis, M. Zervakis, A. Antoniadis

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The choice of cutting tools in manufacturing processes is an essential parameter on which the required manufacturing time, the consumed energy and the cost effort all depend. If the number of tool changing times could be minimized or even eliminated by using a single convex tool providing multiple profiles, then a significant benefit of time and energy saving, as well as tool cost, would be achieved. A typical machine contains a variety of tools in order to deal with different curvatures and material removal rates. In order to minimize the required cutting tool changes, Actively Deformable micro-Cutters (ADmC) will be developed. The design of the Actively Deformable micro-Cutters will be based on the same cutting technique and mounting method as that in typical cutters.

Keywords: deformable cutters, cutting tool, milling, turning, manufacturing

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Authors: Deba Kumar Sarma, Sanjib Kr. Rajbongshi

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Surface finish is an important product quality in machining. At first, experiments were carried out to investigate the effect of the cutting tool nose radius (considering 1mm and 0.65mm) in prediction of surface finish with process parameters of cutting speed, feed and depth of cut. For all possible cutting conditions, full factorial design was considered as two levels four parameters. Commercial Mild Steel bar and High Speed Steel (HSS) material were considered as work-piece and cutting tool material respectively. In order to obtain functional relationship between process parameters and surface roughness, neural network was used which was found to be capable for the prediction of surface roughness within a reasonable degree of accuracy. It was observed that tool nose radius of 1mm provides better surface finish in comparison to 0.65 mm. Also, it was observed that feed rate has a significant influence on surface finish.

Keywords: full factorial design, neural network, nose radius, surface finish

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Authors: Seyed Hamed Hashemi Sohi, Gerald Jo Denoga

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Machining or metal cutting is one of the most widely used production processes in industry. The quality of the process and the resulting machined product depends on parameters like tool geometry, material, and cutting conditions. However, the relationships of these parameters to the cutting process are often based mostly on empirical knowledge. In this study, computer modeling and simulation using LS-DYNA software and a Smoothed Particle Hydrodynamic (SPH) methodology, was performed on the orthogonal metal cutting process to analyze three-dimensional deformation of AISI 1045 medium carbon steel during machining. The simulation was performed using the following constitutive models: the Power Law model, the Johnson-Cook model, and the Zerilli-Armstrong models (Z-A). The outcomes were compared against the simulated results obtained by Cenk Kiliçaslan using the Finite Element Method (FEM) and the empirical results of Jaspers and Filice. The analysis shows that the SPH method combined with the Zerilli-Armstrong constitutive model is a viable alternative to simulating the metal cutting process. The tangential force was overestimated by 7%, and the normal force was underestimated by 16% when compared with empirical values. The simulation values for flow stress versus strain at various temperatures were also validated against empirical values. The SPH method using the Z-A model has also proven to be robust against issues of time-scaling. Experimental work was also done to investigate the effects of friction, rake angle and tool tip radius on the simulation.

Keywords: metal cutting, smoothed particle hydrodynamics, constitutive models, experimental, cutting forces analyses

Procedia PDF Downloads 237

Authors: Hany Mohamed Abdu, Mohamed Hassan Gadallah, El-Giushi Mokhtar, Yehia Mahmoud Ismail

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Laser beam cutting is one nontraditional machining process. This paper optimizes the parameters of Laser beam cutting machining parameters of Stainless steel (316L) by considering the effect of input parameters viz. power, oxygen pressure, frequency and cutting speed. Statistical design of experiments are carried in three different levels and process responses such as 'Average kerf taper (Ta)' and 'Surface Roughness (Ra)' are measured accordingly. A quadratic mathematical model (RSM) for each of the responses is developed as a function of the process parameters. Responses predicted by the models (as per Taguchi’s L27 OA) are employed to search for an optimal parametric combination to achieve desired yield of the process. RSM models are developed for mean responses, S/N ratio, and standard deviation of responses. Optimization models are formulated as single objective problem subject to process constraints. Models are formulated based on Analysis of Variance (ANOVA) using MATLAB environment. Optimum solutions are compared with Taguchi Methodology results.

Keywords: optimization, laser cutting, robust design, kerf width, Taguchi method, RSM and DOE

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Authors: Arjun, Gautam, Sanjeev Naval

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Concrete technology has been changing rapidly and constantly since its discovery. Concrete is the most widely used man-made construction material, versatility of making concrete is the 2nd largest consumed material on earth. In this paper an effort has been made to use metal aggregates in concrete has been discussed, the metal aggregates has been named as “BAUT” which had outstandingly qualities to resist shear, tension and compression forces. In this paper, COARSE BAUT AGGREGATES (C.B.A.) 10mm & 20mm and FINE BAUT AGGREGATES (F.B.A.) 3mm were divided and used for making high performance concrete (H.P.C). This “BAUT” had cutting edge technology through draft and design by the use of Auto CAD, ANSYS software can be used effectively In this research paper we study high performance concrete (H.P.C) with “BAUT” and consider the grade of M65 and finally we achieved the result of 90-95 Mpa (high compressive strength) for mega structures and irregular structures where center of gravity (CG) is not balanced. High Performance BAUT Concrete is the extraordinary qualities like long-term performance, no sorptivity by BAUT AGGREGATES, better rheological, mechanical and durability proportion that conventional concrete. This high strength BAUT concrete using “BAUT” is applied in the construction of mega structure like skyscrapers, dam, marine/offshore structures, nuclear power plants, bridges, blats and impact resistance structures. High Performance BAUT Concrete which is a controlled concrete possesses invariable high strength, reasonable workability and negligibly permeability as compare to conventional concrete by the mix of Super Plasticizers (SMF), silica fume and fly ash.

Keywords: BAUT, High Strength Concrete, High Performance Concrete, Fine BAUT Aggregate, Coarse BAUT Aggregate, metal aggregates, cutting edge technology

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Authors: Junior Nomani

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This paper presents a novel approach to modelling the metal cutting of duplex stainless steels, a two-phase alloy regarded as a difficult-to-machine material. Calculation and control of shear strain and stresses during cutting are essential to achievement of ideal cutting conditions. Too low or too high leads to higher required cutting force or excessive heat generation causing premature tool wear failure. A 2D finite element cutting model was created based on electron backscatter diffraction (EBSD) data imagery of duplex microstructure. A mesh was generated using ‘object-oriented’ software OOF2 version V2.1.11, converting microstructural images to quadrilateral elements. A virtual workpiece was created on ABAQUS modelling software where a rigid body toolpiece advanced towards workpiece simulating chip formation, generating serrated edge chip formation cutting. Model results found calculated stress strain contour plots correlated well with similar finite element models tied with austenite stainless steel alloys. Virtual chip form profile is also similar compared experimental frozen machining chip samples. The output model data provides new insight description of strain behavior of two phase material on how it transitions from workpiece into the chip.

Keywords: Duplex stainless steel, ABAQUS, OOF2, Chip formation

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Authors: Nurul Na'imy Wan, Mohamad Sazali Said, Jaharah Ab. Ghani, Mohd Asri Selamat

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This paper presents the surface roughness of the Aluminium silicon alloy (AlSi) matrix composite which has been reinforced with aluminium nitride (AlN), with three types of carbide inserts. Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to the Taguchi method, using a standard orthogonal array L27 (34). The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of machining parameters in measuring the surface roughness during the milling operation. The analysis of results, using the Taguchi method concluded that a combination of low feed rate, medium depth of cut, low cutting speed, and insert TiB2 give a better value of surface roughness. From Taguchi method, it was found that cutting speed of 230m/min, feed rate of 0.4 mm/tooth, depth of cut of 0.5mm and type of insert of TiB2 were the optimal machining parameters that gave the optimal value of surface roughness.

Keywords: AlSi/AlN Metal Matrix Composite (MMC), surface roughness, Taguchi method

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Authors: Gizem Eser Erdek

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This study is research on predicting the remaining life of industrial cutting tools used in the industrial production process with deep learning methods. When the life of cutting tools decreases, they cause destruction to the raw material they are processing. This study it is aimed to predict the remaining life of the cutting tool based on the damage caused by the cutting tools to the raw material. For this, hole photos were collected from the hole-drilling machine for 8 months. Photos were labeled in 5 classes according to hole quality. In this way, the problem was transformed into a classification problem. Using the prepared data set, a model was created with convolutional neural networks, which is a deep learning method. In addition, VGGNet and ResNet architectures, which have been successful in the literature, have been tested on the data set. A hybrid model using convolutional neural networks and support vector machines is also used for comparison. When all models are compared, it has been determined that the model in which convolutional neural networks are used gives successful results of a %74 accuracy rate. In the preliminary studies, the data set was arranged to include only the best and worst classes, and the study gave ~93% accuracy when the binary classification model was applied. The results of this study showed that the remaining life of the cutting tools could be predicted by deep learning methods based on the damage to the raw material. Experiments have proven that deep learning methods can be used as an alternative for cutting tool life estimation.

Keywords: classification, convolutional neural network, deep learning, remaining life of industrial cutting tools, ResNet, support vector machine, VggNet

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Authors: Hasan Al Dabbas

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In this paper, it is addressed that the mechanical machinery captures a major share of innovation in drilling and milling chucks technology. Users demand higher speeds in milling because they are cutting more aluminum and are relying on higher speeds to eliminate secondary finishing operations. To meet that demand, milling-machine builders have enhanced their machine’s rigidity. Moreover, faster cutting has caught up with boring mills. Cooling these machine’s internal components is a challenge at high speeds. Another trend predicted that it is more use of controlled axes to let the machines do many more operations on 5 sides without having to move or re-fix the work. Advances of technology in mechanical engineering have helped to make high-speed machining equipment. To accompany these changes in milling and drilling machines chucks, the demand of easiest software is increased. An open architecture controller is being sought that would allow flexibility and information exchange.

Keywords: drilling, milling, chucks, cutting edges, tools, machines

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Authors: Vimanyu Chadha, Ranganath M. Singari

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Drilling composite materials is a frequently practiced machining process during assembling in various industries such as automotive and aerospace. However, drilling of glass fiber reinforced plastic (GFRP) composites is significantly affected by damage tendency of these materials under cutting forces such as thrust force and torque. The aim of this paper is to investigate the influence of the various cutting parameters such as cutting speed and feed rate; subsequently also to study the influence of number of layers on delamination produced while drilling a GFRP composite. A plan of experiments, based on Taguchi techniques, was instituted considering drilling with prefixed cutting parameters in a hand lay-up GFRP material. The damage induced associated with drilling GFRP composites were measured. Moreover, Analysis of Variance (ANOVA) was performed to obtain minimization of delamination influenced by drilling parameters and number layers. The optimum drilling factor combination was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that feed rate was the most influential factor on the delamination. The best results of the delamination were obtained with composites with a greater number of layers at lower cutting speeds and feed rates.

Keywords: analysis of variance, delamination, design optimization, drilling, glass fiber reinforced plastic composites, Taguchi method

Procedia PDF Downloads 234

Authors: Mohsen Marani Barzani, Ahmed A. D. Sarhan, Saeed Farahany, Ramesh Singh

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Surface roughness and chip morphology are important output in manufacturing product. In this paper, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness and chip morphology in turning the Al-Si cast alloy and Sr-containing. Experimental trials carried out using coated carbide inserts. Experiments accomplished under oblique dry cutting when various cutting speeds 70, 130 and 250 m/min and feed rates of 0.05, 0.1 and 0.15 mm/rev were used, whereas depth of cut kept constant at 0.05 mm. The results showed that Sr-containing Al-Si alloy have poor surface roughness in comparison to Al-Si alloy (base alloy). The surface roughness values reduce with cutting speed increment from 70 to 250 m/min. the size of chip changed with changing silicon shape in Al matrix. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.

Keywords: strontium, surface roughness, chip, morphology, turning

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Authors: Ricardo Torcato, Helder Morais

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The manufacture of crystal glass parts is based on obtaining the rough geometry by blowing and/or injection, generally followed by a set of manual finishing operations using cutting and grinding tools. The forming techniques used do not allow the obtainment, with repeatability, of parts with complex shapes and the finishing operations use intensive specialized labor resulting in high cycle times and production costs. This work aims to explore the digital manufacture of crystal glass parts by investigating new subtractive techniques for the automated, flexible finishing of these parts. Finishing operations are essential to respond to customer demands in terms of crystal feel and shine. It is intended to investigate the applicability of different computerized finishing technologies, namely milling and grinding in a CNC machining center with or without ultrasonic assistance, to crystal processing. Research in the field of grinding hard and brittle materials, despite not being extensive, has increased in recent years, and scientific knowledge about the machinability of crystal glass is still very limited. However, it can be said that the unique properties of glass, such as high hardness and very low toughness, make any glass machining technology a very challenging process. This work will measure the performance improvement brought about by the use of ultrasound compared to conventional crystal grinding. This presentation is focused on the mechanical characterization and analysis of the cutting forces in CNC machining of superior crystal glass (Pb ≥ 30%). For the mechanical characterization, the Vickers hardness test provides an estimate of the material hardness (Hv) and the fracture toughness based on cracks that appear in the indentation. Mechanical impulse excitation test estimates the Young’s Modulus, shear modulus and Poisson ratio of the material. For the cutting forces, it a dynamometer was used to measure the forces in the face grinding process. The tests were made based on the Taguchi method to correlate the input parameters (feed rate, tool rotation speed and depth of cut) with the output parameters (surface roughness and cutting forces) to optimize the process (better roughness using the cutting forces that do not compromise the material structure and the tool life) using ANOVA. This study was conducted for conventional grinding and for the ultrasonic grinding process with the same cutting tools. It was possible to determine the optimum cutting parameters for minimum cutting forces and for minimum surface roughness in both grinding processes. Ultrasonic-assisted grinding provides a better surface roughness than conventional grinding.

Keywords: CNC machining, crystal glass, cutting forces, hardness

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Authors: M. A. Hafiz, P. T. Matevenga

Abstract:

Micro-level machining of metals is a developing field which has shown to be a prospective approach to produce features on the parts in the range of a few to a few hundred microns with acceptable machining quality. It is known that the mechanics (i.e. the material removal mechanism) of micro-machining and conventional machining have significant differences due to the scaling effects associated with tool-geometry, tool material and work piece material characteristics. Shape memory alloys (SMAs) are those metal alloys which display two exceptional properties, pseudoelasticity and the shape memory effect (SME). Nickel-titanium (NiTi) alloys are one of those unique metal alloys. NiTi alloys are known to be difficult-to-cut materials specifically by using conventional machining techniques due to their explicit properties. Their high ductility, high amount of strain hardening, and unusual stress–strain behaviour are the main properties accountable for their poor machinability in terms of tool wear and work piece quality. The motivation of this research work was to address the challenges and issues of micro-machining combining with those of machining of NiTi alloy which can affect the desired performance level of machining outputs. To explore the significance of range of cutting conditions on surface roughness and tool wear, machining tests were conducted on NiTi. Influence of different cutting conditions and cutting tools on surface and sub-surface deformation in work piece was investigated. Design of experiments strategy (L9 Array) was applied to determine the key process variables. The dominant cutting parameters were determined by analysis of variance. These findings showed that feed rate was the dominant factor on surface roughness whereas depth of cut found to be dominant factor as far as tool wear was concerned. The lowest surface roughness was achieved at the feed rate of equal to the cutting edge radius where as the lowest flank wear was observed at lowest depth of cut. Repeated machining trials have yet to be carried out in order to observe the tool life, sub-surface deformation and strain induced hardening which are also expecting to be amongst the critical issues in micro machining of NiTi. The machining performance using different cutting fluids and strategies have yet to be studied.

Keywords: nickel titanium, micro-machining, surface roughness, machinability

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Authors: Karim Kheloufi, El Hachemi Amara

Abstract:

In the present study, a three-dimensional transient numerical model was developed to study the temperature field and cutting kerf shape during laser fusion cutting. The finite volume model has been constructed, based on the Navier–Stokes equations and energy conservation equation for the description of momentum and heat transport phenomena, and the Volume of Fluid (VOF) method for free surface tracking. The Fresnel absorption model is used to handle the absorption of the incident wave by the surface of the liquid metal and the enthalpy-porosity technique is employed to account for the latent heat during melting and solidification of the material. To model the physical phenomena occurring at the liquid film/gas interface, including momentum/heat transfer, a new approach is proposed which consists of treating friction force, pressure force applied by the gas jet and the heat absorbed by the cutting front surface as source terms incorporated into the governing equations. All these physics are coupled and solved simultaneously in Fluent CFD®. The main objective of using a transient phase change model in the current case is to simulate the dynamics and geometry of a growing laser-cutting generated kerf until it becomes fully developed. The model is used to investigate the effect of some process parameters on temperature fields and the formed kerf geometry.

Keywords: laser cutting, numerical simulation, heat transfer, fluid flow

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Authors: M. S. Said, J. A. Ghani, C. H. Che Hassan, N. N. Wan, M. A. Selamat, R. Othman

Abstract:

Metal Matrix Composite (MMCs) have attracted considerable attention as a result of their ability to provide high strength, high modulus, high toughness, high impact properties, improved wear resistance and good corrosion resistance than unreinforced alloy. Aluminium Silicon (Al/Si) alloys Metal Matrix composite (MMC) has been widely used in various industrial sectors such as transportation, domestic equipment, aerospace, military, construction, etc. Aluminium silicon alloy is MMC reinforced with aluminium nitride (AlN) particle and becomes a new generation material for automotive and aerospace applications. The AlN material is one of the advanced materials with light weight, high strength, high hardness and stiffness qualities which have good future prospects. However, the high degree of ceramic particles reinforcement and the irregular nature of the particles along the matrix material that contribute to its low density, is the main problem that leads to the machining difficulties. This paper examines tool wear when milling AlSi/AlN Metal Matrix Composite using a TiB2 coated carbide cutting tool. The volume of the AlN reinforced particle was 10%. The milling process was carried out under dry cutting condition. The TiB2 coated carbide insert parameters used were the cutting speed of (230 m/min, feed rate 0.4mm tooth, DOC 0.5mm, 300 m/min, feed rate 0.8mm/tooth, DOC 0.5mm and 370 m/min, feed rate 0.8, DOC 0.4m). The Sometech SV-35 video microscope system was used for tool wear measurements respectively. The results have revealed that the tool life increases with the cutting speed (370 m/min, feed rate 0.8 mm/tooth and depth of cut 0.4mm) constituted the optimum condition for longer tool life which is 123.2 min. While at medium cutting speed, it is found that the cutting speed of 300m/min, feed rate 0.8 mm/tooth and depth of cut 0.5mm only 119.86 min for tool wear mean while the low cutting speed give 119.66 min. The high cutting speed gives the best parameter for cutting AlSi/AlN MMCs materials. The result will help manufacture to machining the AlSi/AlN MMCs materials.

Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, TiB2 coated carbide tool, manufacturing engineering

Procedia PDF Downloads 403