Search results for: machining power consumption

Authors: Theena Thayalan, K. N. Ramesh Babu

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Machining induced residual stress (RS) is one of the most important surface integrity parameters that characterize the near surface layer of a mechanical component, which plays a crucial role in controlling the performance, especially its fatigue life. Since experimental determination of RS is expensive and time consuming, it would be of great benefit if they could be predicted. In such case, it would be possible to select the cutting parameters required to produce a favorable RS profile. In the present study, an effort has been made to develop a 'two dimensional finite element model (FEM)' to simulate orthogonal cutting process and to predict surface and sub-surface RS using the commercial FEA software DEFORM-2D. The developed finite element model has been validated through experimental investigation of RS. In the experimentation, the orthogonal cutting tests were carried out on AISI 4340 by varying the cutting speed (VC) and uncut chip thickness (f) at three levels and the surface & sub-surface RS has been measured using XRD and Electro polishing techniques. The comparison showed that the RS obtained using developed numerical model is in reasonable agreement with that of experimental data.

Keywords: FEM, machining, residual stress, XRF

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Authors: Abdallah M. Abdelkawy, Tarek M. El Hossainya, I. El Mahallawib

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Recently, significant achievements have been made in development and manufacturing of nano-dispersed metal matrix nanocomposites (MMNCs). They gain their importance due to their high strength to weight ratio. The machining problems of these new materials are less widely investigated, thus this work focuses on machining of them. Aluminum-Silicon (A356)/ MMNC dispersed with alumina (Al2O3) is important in many applications include engine blocks. The final finish process of this application depends heavily on machining. The most important machining parameter studied includes: cutting force and surface roughness. Experimental trails are performed on the number of special samples of MMNC (with different Al2O3%) where the relation between Al2O3% and cutting speed, feed rate and cutting depth with cutting force and surface roughness were studied. The data obtained were statistically analyzed using Analysis of variance (ANOVA) to define the significant factors on both cutting force and surface roughness and their level of confident. Response Surface Methodology (RSM) is used to build a model relating cutting conditions and Al2O3% to the cutting force and surface roughness. The results have shown that feed and depth of cut have the major contribution on the cutting force and the surface roughness followed by cutting speed and nano-percent in MMNCs.

Keywords: machinability, cutting force, surface roughness, Ra, RSM, ANOVA, MMNCs

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Authors: Parisa Javid

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In architecture, daylight contributes to humans' mental and physical well-being and reduces the consumption of fossil fuels. Accordingly, Iran's rich architecture has valuable achievements and experiences that should be recognized and introduced to the Iranian and international architecture communities. There are many ways to reduce energy consumption in buildings, but electricity accounts for a large part of that consumption. Lighting up spaces with natural light is a significant factor in reducing energy consumption and preventing electricity dissipation. Aside from being expensive, electric lighting systems cause excessive heat and physical injury (eyes). This study is based on library records and documents. Modern lighting systems are used to reduce energy consumption in the interior of a building to allow for optimal transmission of natural light. It discusses how to use natural light in architecture and the benefits of natural light in buildings. Solar energy can be used more efficiently, and electrical power can be saved in residential, administrative, commercial, and educational buildings by using new methods such as light tubes and mirror directors. Modern lighting systems, natural light, and reduced energy consumption are keywords for these systems, which quickly return their investment.

Keywords: modern lighting systems, natural light, reduced energy consumption

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Authors: C. Brecher, M. Fey, F. Du Bois-Reymond, S. Neus

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Additive manufacturing has emerged into a fast-growing section within the manufacturing technologies. Established machine tool manufacturers, such as DMG MORI, recently presented machine tools combining milling and laser welding. By this, machine tools can realize a higher degree of flexibility and a shorter production time. Still there are challenges that have to be accounted for in terms of maintaining the necessary machining accuracy - especially due to thermal effects arising through the use of high power laser processing units. To study the thermal behavior of laser-integrated machine tools, it is essential to analyze and simulate the thermal behavior of machine components, individual and assembled. This information will help to design a geometrically stable machine tool under the influence of high power laser processes. This paper presents an approach to decrease the loss of machining precision due to thermal impacts. Real effects of laser machining processes are considered and thus enable an optimized design of the machine tool, respective its components, in the early design phase. Core element of this approach is a matched FEM model considering all relevant variables arising, e.g. laser power, angle of laser beam, reflective coefficients and heat transfer coefficient. Hence, a systematic approach to obtain this matched FEM model is essential. Indicating the thermal behavior of structural components as well as predicting the laser beam path, to determine the relevant beam intensity on the structural components, there are the two constituent aspects of the method. To match the model both aspects of the method have to be combined and verified empirically. In this context, an essential machine component of a five axis machine tool, the turn-swivel table, serves as the demonstration object for the verification process. Therefore, a turn-swivel table test bench as well as an experimental set-up to measure the beam propagation were developed and are described in the paper. In addition to the empirical investigation, a simulative approach of the described types of experimental examination is presented. Concluding, it is shown that the method and a good understanding of the two core aspects, the thermo-elastic machine behavior and the laser beam path, as well as their combination helps designers to minimize the loss of precision in the early stages of the design phase.

Keywords: additive manufacturing, laser beam machining, machine tool, thermal effects

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Authors: Javier A. Dominguez Caballero, Graeme A. Manson, Matthew B. Marshall

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Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.

Keywords: ceramic cutting tools, high speed machining, image processing, tool condition monitoring, tool wear

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Authors: Milad Kaboli

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A new CMOS low voltage current-mode four-quadrant analog multiplier based on the squarer circuit with voltage output is presented. The proposed circuit is composed of a pair of current subtractors, a pair differential-input V-I converters and a pair of voltage squarers. The circuit was simulated using HSPICE simulator in standard 0.18 μm CMOS level 49 MOSIS (BSIM3 V3.2 SPICE-based). Simulation results show the performance of the proposed circuit and experimental results are given to confirm the operation. This topology of multiplier results in a high-frequency capability with low power consumption. The multiplier operates for a power supply ±1.2V. The simulation results of analog multiplier demonstrate a THD of 0.65% in 10MHz, a −3dB bandwidth of 1.39GHz, and a maximum power consumption of 7.1mW.

Keywords: analog processing circuit, WTA, LTA, low voltage

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Authors: Soufiane Benoumhani, Nadia Saifi, Boubekeur Dokkar, Mohamed Cherif Benzid

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This work presents the design and simulation of electric equipment for a hybrid solar vehicle. The new drive train of this vehicle is a parallel hybrid system which means a vehicle driven by a great percentage of an internal combustion engine with 49.35 kW as maximal power and electric motor only as assistance when is needed. This assistance is carried out on the rear axle by a single electric motor of 7.22 kW as nominal power. The motor is driven by 12 batteries connecting in series, which are charged by three PV panels (300 W) installed on the roof and hood of the vehicle. The individual components are modeled and simulated by using the Matlab Simulink environment. The whole system is examined under different load conditions. The reduction of CO₂ emission is obtained by reducing fuel consumption. With the use of this hybrid system, fuel consumption can be reduced from 6.74 kg/h to 5.56 kg/h when the electric motor works at 100 % of its power. The net benefit of the system reaches 1.18 kg/h as fuel reduction at high values of power and torque.

Keywords: light car, hybrid system, PV panel, electric motor

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Authors: A. Suresh, Sreehari Rao Patri, K. S. R. Krishnaprasad

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An ultra low power capacitor less low-dropout voltage regulator with improved transient response using gain enhanced feed forward path compensation is presented in this paper. It is based on a cascade of a voltage amplifier and a transconductor stage in the feed forward path with regular error amplifier to form a composite gain-enhanced feed forward stage. It broadens the gain bandwidth and thus improves the transient response without substantial increase in power consumption. The proposed LDO, designed for a maximum output current of 100 mA in UMC 180 nm, requires a quiescent current of 69 µA. An undershoot of 153.79mV for a load current changes from 0mA to 100mA and an overshoot of 196.24mV for current change of 100mA to 0mA. The settling time is approximately 1.1 µs for the output voltage undershoot case. The load regulation is of 2.77 µV/mA at load current of 100mA. Reference voltage is generated by using an accurate band gap reference circuit of 0.8V.The costly features of SOC such as total chip area and power consumption is drastically reduced by the use of only a total compensation capacitance of 6pF while consuming power consumption of 0.096 mW.

Keywords: capacitor-less LDO, frequency compensation, transient response, latch, self-biased differential amplifier

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

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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

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Authors: Ahmed Shariful Alam, Abu Hena M. Mustafa Kamal, M. Abdul Rahman, M. Nasmus Sakib Khan Shabbir, Atiqul Islam

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According to the rules of quantum mechanics there is a non-vanishing probability of for an electron to tunnel through a thin insulating barrier or a thin capacitor which is not possible according to the laws of classical physics. Tunneling of electron through a thin insulating barrier or tunnel junction is a random event and the magnitude of current flowing due to the tunneling of electron is very low. As the current flowing through a Single Electron Transistor (SET) is the result of electron tunneling through tunnel junctions of its source and drain the supply voltage requirement is also very low. As a result, the power consumption across a Single Electron Transistor is ultra-low in comparison to that of a MOSFET. In this paper simulations have been done with PSPICE for an inverter built with both SETs and MOSFETs. 35mV supply voltage was used for a SET built inverter circuit and the supply voltage used for a CMOS inverter was 3.5V.

Keywords: ITRS, enhancement type MOSFET, island, DC analysis, transient analysis, power consumption, background charge co-tunneling

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Authors: Evelyn Nwamaka Ogbeide-Osaretin, Bright Orhewere

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This study examined the role of the population in the linkage between energy consumption and economic development in Nigeria. Time series data on energy consumption, population, and economic development were used for the period 1995 to 2020. The Autoregressive Distributed Lag -Error Correction Model (ARDL-ECM) was engaged. Economic development had a negative substantial impact on energy consumption in the long run. Population growth had a positive significant effect on energy consumption. Government expenditure was also found to impact the level of energy consumption, while energy consumption is not a function of oil price in Nigeria.

Keywords: dynamic analysis, energy consumption, population, economic development, Nigeria

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Authors: Vanaja Rao

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In the recent times, the need for the integration of Renewable Energy Sources (RES) in a Smart Grid is on the rise. As a result of this, associated energy storage systems are known to play important roles in sustaining the efficient operation of such RES like wind power and solar power. This paper investigates the importance of location selection of Energy Storage Systems (ESSs) in a Smart Grid. Three scenarios of ESS location is studied and analyzed in a Smart Grid, which are – 1. Near the generation/source, 2. In the middle of the Grid and, 3. Near the demand/consumption. This is explained with the aim of assisting any Distribution Network Operator (DNO) in deploying the ESSs in a power network, which will significantly help reduce the costs and time of planning and avoid any damages incurred as a result of installing them at an incorrect location of a Smart Grid. To do this, the outlined scenarios mentioned above are modelled and analyzed with the National Grid’s datasets of energy generation and consumption in the UK power network. As a result, the outcome of this analysis aims to provide a better overview for the location selection of the ESSs in a Smart Grid. This ensures power system stability and security along with the optimum usage of the ESSs.

Keywords: distribution networks, energy storage system, energy security, location planning, power stability, smart grid

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Authors: Vinay Patil, Swapnil Kekade, Ashish Supare, Vinayak Pawar, Shital Jadhav, Rajkumar Singh

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In recent days, bainitic steel is used in automobile and non-automobile sectors due to its high strength. Bainitic steel is difficult to machine because of its high hardness, hence in this paper machinability of bainitic steel is studied by using Taguchi design of experiments (DOE) approach. Convectional turning experiments were done by using L16 orthogonal array for three input parameters viz. cutting speed, depth of cut and feed. The Taguchi method is applied to study the performance characteristics of machining parameters with surface roughness (Ra), cutting force and tool wear rate. By using Taguchi analysis, optimized process parameters for best surface finish and minimum cutting forces were analyzed.

Keywords: conventional turning, Taguchi method, S/N ratio, bainitic steel machining

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Authors: Nadezhda Nikolaeva, Tatyana Alexandrova, Alexandr Alexandrov

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Processing of high-silicon bauxite on the base of the traditional clinkering method is related to high power consumption and capital investments, which makes production of alumina from those ores non-competitive in terms of basic economic showings. For these reasons, development of technological solutions enabling to process bauxites with various chemical and mineralogical structures efficiently with low level of thermal power consumption is important. Flow sheet of the studies on washability of ores from the Timanskoe and the Severo-Onezhskoe deposits is on the base of the flotation method.

Keywords: low-quality bauxite, resource-saving technology, optimization, aluminum, conditioning of composition, separation characteristics

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Authors: Yuichi Miyamoto

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In regards to the energy sector in the modern period, two points were raised. First is a vast and growing energy demand, and second is an environmental impact associated with it. The enormous consumption of fossil fuel to the mobile unit is leading to its rapid depletion. Nuclear power is not the only problem. A modal shift that utilizes personal transporters and independent power, in order to realize a sustainable society, is very effective. The paper proposes that the world will continue to work on this. Energy of the future society, innovation in battery technology and the use of natural energy is a big key. And it is also necessary in order to save on energy consumption.

Keywords: natural energy, modal shift, personal transportation, battery

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Authors: Fariborz Ahmadi, Hamid Salehi, Khosrow Karimi

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A sensor network is set of sensor nodes that cooperate together to perform a predefined tasks. The important problem in this network is power consumption. So, in this paper one algorithm based on the eurygaster life is introduced to minimize power consumption by the nodes of these networks. In this method the search space of problem is divided into several partitions and each partition is investigated separately. The evaluation results show that our approach is more efficient in comparison to other evolutionary algorithm like genetic algorithm.

Keywords: evolutionary computation, genetic algorithm, particle swarm optimization, sensor network optimization

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Authors: Arsenio Jose Mindu

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The concern to carry out a study related to Energy Efficiency arose based on the various debates in international television networks and not only, but also in several forums of national debates. The concept of Energy Efficiency is not yet widely disseminated and /or taken into account in terms of energy consumption, not only at the domestic level but also at the industrial level in Mozambique. In the context of the energy audit, the time during which each of the appliances is connected to the voltage source, the time during which they are in standby mode was recorded on a spreadsheet basis. Based on these data, daily and monthly consumption was calculated. In order to have more accurate information on the daily levels of daily consumption, the electricity consumption was read every hour of the day (from 5:00 am to 11:00 pm), since after 23:00 the energy consumption remains constant. For ten days. Based on the daily energy consumption and the maximum consumption power, the design of the photovoltaic system for the residence was made. With the implementation of the photovoltaic system in order to guarantee energy efficiency, there was a significant reduction in the use of electricity from the public grid, increasing from approximately 17 kwh per day to around 11 kwh, thus achieving an energy efficiency of 67.4 %. That is to say, there was a reduction not only in terms of the amount of energy consumed but also of the monthly expenses with electricity, having increased from around 2,500,00Mt (2,500 meticais) to around 800Mt per month.

Keywords: energy efficiency, photovoltaic system, residential sector, Mozambique

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Authors: V. Nagammai

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Very-large-scale integration (VLSI) is the process of creating an integrated circuit (IC) by combining thousands of transistors into a single chip. Development of technology increases the complexity in IC manufacturing which may vary the power consumption, increase the size and latency period. Topology defines a number of connections between network. In this project, NoC topology is generated using atlas tool which will increase performance in turn determination of constraints are effective. The routing is performed by XY routing algorithm and wormhole flow control. In NoC topology generation, the value of power, area and latency are predetermined. In previous work, placement, routing and shortest path evaluation is performed using an algorithm called floor planning with cluster reconstruction and path allocation algorithm (FCRPA) with the account of 4 3x3 switch, 6 4x4 switch, and 2 5x5 switches. The usage of the 4x4 and 5x5 switch will increase the power consumption and area of the block. In order to avoid the problem, this paper has used one 8x8 switch and 4 3x3 switches. This paper uses IPRCA which of 3 steps they are placement, clustering, and shortest path evaluation. The placement is performed using min – cut placement and clustering are performed using an algorithm called cluster generation. The shortest path is evaluated using an algorithm called Dijkstra's algorithm. The power consumption of each block is determined. The experimental result shows that the area, power, and wire length improved simultaneously.

Keywords: application specific noc, b* tree representation, floor planning, t tree representation

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Authors: Adam Janásek, Marek Pagáč

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The article is looking for an experimental determination of tool life tests for ceramic cutting inserts. Mentioned experimental determination should provide an added information about cutting process. The mechanism of tool wear, cutting temperature in machining, quality machined surface and machining process itself is the information, which are important for whole manufacturing process. Mainly, the roughness plays very important role in determining how a real object will interact with its environment. The main aim was to determine the number of machined inserts, tool life and micro-geometry, as well. On the basis of previous tests the tool-wear was measured at constant cutting parameter which is more typical for high volume manufacturing processes.

Keywords: ceramic, insert, machining, surface roughness, tool-life, tool-wear

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Authors: Sarika Bahadure

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Sustainability starts with conserving resources for future generations. Since human’s existence on this earth, he has been consuming natural resources. The resource consumption pace in the past was very slow, but industrialization in 18^th century brought a change in the human lifestyle. New inventions and discoveries upgraded the human workforce to machines. The mass manufacture of goods provided easy access to products. In the last few decades, the globalization and change in technologies brought consumer oriented market. The consumption of resources has increased at a very high scale. This overconsumption pattern brought economic boom and provided multiple opportunities, but it also put stress on the natural resources. This paper tries to put forth the facts and figures of the population growth and consumption of resources with examples. This is explained with the help of the mathematical expression of doubling known as exponential growth. It compares the carrying capacity of the earth and resource consumption of humans’ i.e. ecological footprint and bio-capacity. Further, it presents the need to conserve natural resources and re-examine sustainable resource use approach for sustainability.

Keywords: consumption, exponential growth, population, resources, sustainability

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Authors: Watcharet Kongwarakom, Tosaphol Ratniyomchai, Thanatchai Kulworawanichpong

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This paper presents a design and analysis of wireless charging lane system (WCLS) for light rail transit (LRT) by considering the performance of wireless charging, traffic conditions and energy consumption drawn by the LRT system. The dynamic of the vehicle movement in terms of the vehicle speed profile during running on the WCLS, a dwell time during stopping at the station for taking the WCLS and the capacity of the WCLS in each section are taken into account to alignment design of the WCLS. This paper proposes a case study of the design of the WCLS into 2 sub-cases including continuous and discontinuous WCLS with the same distance of WCLS in total. The energy consumption by the LRT through the WCLS with the different designs of the WCLS is compared to find out the better configuration of those two cases by considering the best performance of the power transfer between the LRT and the WCLS.

Keywords: Light rail transit, Wireless charging lane, Energy consumption, Power transfer

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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: Siamak Eskandari, Neda Ebadi

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Among common electronic parts which have been invented and have made a great revolution in the lighting system through the world, certainly LEDs have no rival. These small parts with their very low power consumption, very dazzling and powerful light and small size and with their extremely high lifetime- compared to incandescent bulbs and compact fluorescent lamp (CFLs) have undoubtedly revolutionized the lighting industry of the world. Based on conducted studies and experiments, in addition to their acceptable light and low power consumption -compared to incandescent bulbs and CFLs-, they have very low and in some cases zero environmental pollution and negative effects on human beings. Because of their longevity, in the case of using high-quality circuits and proper and consistent use of LEDs in conventional and intelligent buildings, there will be no need to replace the burnout lamps, for a long time (10 years). In this study which was conducted on 10-watt power LEDs with suitable heatsink/cooling, considerable amount of heat was generated during lighting after 5 minutes and 45 seconds. The temperature rose to above 99 degrees Celsius and this amount of heat can raise the water temperature to 60 degrees Celsius and more. Based on conducted experiments, this can provide the heat required for bathing, washing, radiators (in cold seasons) easily and only by imposing very low cost and it will be a big step in the optimization of energy consumption in the future.

Keywords: energy, light, water, optimization of power LED

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Authors: Renata Konadu

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In Ghana, electricity has become the main form of energy which all sectors of the economy rely on for their businesses. Therefore, as the economy grows, the demand and consumption of electricity also grow alongside due to the heavy dependence on it. However, since the supply of electricity has not increased to match the demand, there has been frequent power outages and load shedding affecting business performances. To solve this problem and advance policies to secure electricity in Ghana, it is imperative that those factors that cause consumption to increase be analysed by considering the three classes of consumers; residential, industrial and non-residential. The main argument, however, is that, export of electricity to other neighbouring countries should be included in the electricity consumption model and considered as one of the significant factors which can decrease or increase consumption. The author made use of multivariate time series data from 1980-2010 and econometric models such as Ordinary Least Squares (OLS) and Vector Error Correction Model. Findings show that GDP growth, urban population growth, electricity exports and industry value added to GDP were cointegrated. The results also showed that there is unidirectional causality from electricity export and GDP growth and Industry value added to GDP to electricity consumption in the long run. However, in the short run, there was found to be a directional causality among all the variables and electricity consumption. The results have useful implication for energy policy makers especially with regards to electricity consumption, demand, and supply.

Keywords: electricity consumption, energy policy, GDP growth, vector error correction model

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Authors: Pawel Twardowski, Tadeusz Chwalczuk, Szymon Wojciechowski

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Inconel 718 is a material characterized by the unique mechanical properties, high temperature strength, high thermal conductivity and the corrosion resistance. However, these features affect the low machinability of this material, which is usually manifested by the intense tool wear and low surface finish. Therefore, this paper is focused on the evaluation of surface roughness during hybrid machining of Inconel 718. The primary aim of the study was to determine the relations between the vibrations generated during hybrid turning and the formed surface roughness. Moreover, the comparison of tested machining techniques in terms of vibrations, tool wear and surface roughness has been made. The conducted tests included the face turning of Inconel 718 with laser assistance in the range of variable cutting speeds. The surface roughness was inspected with the application of stylus profile meter and accelerations of vibrations were measured with the use of three-component piezoelectric accelerometer. The carried out research shows that application of laser assisted machining can contribute to the reduction of surface roughness and cutting vibrations, in comparison to conventional turning. Moreover, the obtained results enable the selection of effective cutting speed allowing the improvement of surface finish and cutting dynamics.

Keywords: hybrid machining, nickel alloys, surface roughness, turning, vibrations

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Authors: T. V. K. Gupta, J. Ramkumar, Puneet Tandon, N. S. Vyas

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Abrasive Water Jet Machining (AWJM) is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application i.e. abrasive size, flow rate, standoff distance, and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate, and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.

Keywords: abrasive flow rate, surface finish, abrasive size, standoff distance, traverse speed

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Authors: Hong Lu, Yongquan Zhang, Wei Fan, Xiangang Su

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Bent mandrel has been widely used as precise mould in automobile industry, shipping industry and aviation industry. To improve the versatility and efficiency of turning method of bent mandrel with fixed rotational center, an instantaneous machining model based on cutting parameters and machine dimension is prospered in this paper. The spiral-like tool path generation approach in non-axisymmetric turning process of bent mandrel is developed as well to deal with the error of part-to-part repeatability in existed turning model. The actual cutter-location points are calculated by cutter-contact points, which are obtained from the approach of spiral sweep process using equal-arc-length segment principle in polar coordinate system. The tool offset is set to avoid the interference between tool and work piece is also considered in the machining model. Depend on the spindle rotational angle, synchronization control of X-axis, Z-axis and C-axis is adopted to generate the tool-path of the turning process. The simulation method is developed to generate NC program according to the presented model, which includes calculation of cutter-location points and generation of tool-path of cutting process. With the approach of a bent mandrel taken as an example, the maximum offset of center axis is 4mm in the 3D space. Experiment results verify that the machining model and turning method are appropriate for the characteristics of bent mandrel.

Keywords: bent mandrel, instantaneous machining model, simulation method, tool-path generation

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Authors: N.Revathy, C.Gomathi

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This work aims for a tunable capacitor as a sensor which can vary the control voltage of a voltage control oscillator in a ultra wide band (UWB) transmitter. In this paper power consumption is concentrated. The reason for choosing a capacitive sensing is it give slow temperature drift, high sensitivity and robustness. Previous works report a resistive sensing in a voltage control oscillator (VCO) not aiming at power consumption. But this work aims for power consumption of a capacitive sensing in ultra wide band transmitter. The ultra wide band transmitter to be used is a direct modulation of pulses. The VCO which is the heart of pulse generator of UWB transmitter works on the principle of voltage to frequency conversion. The VCO has and odd number of inverter stages which works on the control voltage input this input is now from a variable capacitor and the buffer stages is reduced from the previous work to maintain the oscillating frequency. The VCO is also aimed to consume low power. Then the concentration in choosing a variable capacitor is aimed. A compact model of a capacitor with the transient characteristics is to be designed with a movable dielectric and multi metal membranes. Previous modeling of the capacitor transient characteristics is with a movable membrane and a fixed membrane. This work aims at a membrane with a wide tuning suitable for ultra wide band transmitter.This is used in this work because a capacitive in a ultra wide transmitter need to be tuned in such a way that all satisfies FCC regulations.

Keywords: capacitive sensing, ultra wide band transmitter, voltage control oscillator, FCC regulation

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Authors: Christoph Ramsauer, Jaydeep Karandikar, Tony Schmitz, Friedrich Bleicher

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Machining stability is an important limitation to discrete part machining. In this work, a networked implementation of milling stability optimization with Bayesian learning is presented. The milling process was monitored with a wireless sensory tool holder instrumented with an accelerometer at the Vienna University of Technology, Vienna, Austria. The recorded data from a milling test cut is used to classify the cut as stable or unstable based on the frequency analysis. The test cut result is fed to a Bayesian stability learning algorithm at the University of Tennessee, Knoxville, Tennessee, USA. The algorithm calculates the probability of stability as a function of axial depth of cut and spindle speed and recommends the parameters for the next test cut. The iterative process between two transatlantic locations repeats until convergence to a stable optimal process parameter set is achieved.

Keywords: machining stability, machine learning, sensor, optimization

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Authors: Pushpendra S. Bharti, S. Maheshwari

Abstract:

Electric discharge machining (EDM) is one of the most widely used non-conventional manufacturing process to shape difficult-to-cut materials. The process yield, in terms of material removal rate, surface roughness and tool wear rate, of EDM may considerably be improved by selecting the optimal combination(s) of process parameters. This paper employs Multi-response signal-to-noise (MRSN) ratio technique to find the optimal combination(s) of the process parameters during EDM of Inconel 718. Three cases v.i.z. high cutting efficiency, high surface finish, and normal machining have been taken and the optimal combinations of input parameters have been obtained for each case. Analysis of variance (ANOVA) has been employed to find the dominant parameter(s) in all three cases. The experimental verification of the obtained results has also been made. MRSN ratio technique found to be a simple and effective multi-objective optimization technique.

Keywords: electric discharge machining, material removal rate, surface roughness, too wear rate, multi-response signal-to-noise ratio, multi response signal-to-noise ratio, optimization

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