Search results for: rotary cutting test

Authors: Shiva Abdoli, Daniel T.Semere

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Several researches have been conducted to study consumption of energy in cutting process. Most of these researches are focusing to measure the consumption and propose consumption reduction methods. In this work, the relation between the cutting parameters and the consumption is investigated in order to establish a generalized energy consumption model that can be used for process and production planning in real production lines. Using the generalized model, the process planning will be carried out by taking into account the energy as a function of the selected process parameters. Similarly, the generalized model can be used in production planning to select the right operational parameters like batch sizes, routing, buffer size, etc. in a production line. The description and derivation of the model as well as a case study are given in this paper to illustrate the applicability and validity of the model.

Keywords: process parameters, cutting process, energy efficiency, Material Removal Rate (MRR)

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Authors: V. Prasannavenkadesan, A. Elango, S. Chockalingam

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During machining process, chatter is an unavoidable phenomenon. Boring bars possess the cantilever shape and due to this, it is subjected to chatter. The adverse effect of chatter includes the increase in temperature which will leads to excess tool wear. To overcome these problems, in this investigation, Cartridge brass (Cu – 70% and Zn – 30%) is passively fixed on the boring bar and also clearance is provided in order to reduce the displacement, tool wear and cutting temperature. A conventional all geared lathe is attached with vibrometer and pyrometer is used to measure the displacement and temperature. The influence of input parameters such as cutting speed, depth of cut and clearance on temperature, tool wear and displacement are investigated for various cutting conditions. From the result, the optimum conditions to obtain better damping in boring process for chatter reduction is identified.

Keywords: boring, chatter, mass damping, passive damping

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Authors: Branislav Kovačević, Andrej Pilipović, Zoran Novčić, Marina Milović, Lazar Kesić, Milan Drekić, Saša Pekeč, Leopold Poljaković Pajnik, Saša Orlović

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Poplars present one of the most important tree species used for phytoremediation in the northern hemisphere. They can be used either as direct “cleaners” of the contaminated soils or as buffer zones preventing the contaminant plume to the surrounding environment. In order to produce appropriate planting material for this purpose, there is a long process of the breeding of the most favorable candidates. Although the development of the poplar propagation technology has been evolving for decades, white poplar nursery production, as well as the establishment of short-rotation coppice plantations, still considerably depends on the success of hardwood cuttings’ survival. This is why easy rooting is among the most desirable properties in white poplar breeding. On the other hand, there are many opportunities for the optimization of the technological procedures in order to meet the demands of particular genotype (clonal technology). In this study the effect of the term of hardwood cuttings’ preparation of four white poplar clones on their survival and further growth of rooted cuttings in nursery conditions were tested. There were three terms of cuttings’ preparation: the beginning of February (2nd Feb 2023), the beginning of March (3rd Mar 2023) and the end of March (21nd Mar 2023), which is regarded as the standard term. The cuttings were stored in cool chamber at 2±2°C. All cuttings were planted on the same date (11th Apr 2023), in soil prepared with rotary tillage, and then cultivated by usual nursey procedures. According to the results obtained after the bud set (29th Sept 2023) there were significant differences in the survival and growth of rooted cuttings between examined terms of cutting preparation. Also, there were significant differences in the reaction of examined clones on terms of cutting preparation. In total, the best results provided cuttings prepared at the first term (2nd Feb 2023) (survival rate of 39.4%), while performance after two later preparation terms was significantly poorer (20.5% after second and 16.5% after third term). These results stress the significance of dormancy preservation in cuttings of examined white poplar clones for their survival, which could be especially important in context of climate change. Differences in clones’ reaction to term of cutting preparation suggest necessity of adjustment of the technology to the needs of particular clone i.e. design of clone specific technology.

Keywords: rooting, Populus alba, nursery, clonal technology

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Authors: Marcin Zieliński, Marcin Dębowski, Mirosław Krzemieniewski

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This publication presents a device designed for mechanical fragmentation of plant substrate before methane fermentation. The device is equipped with a perforated rotary cylindrical drum coated with a thermal layer, connected to a substrate feeder and driven by a motoreducer. The drum contains ball- or cylinder-shaped weights of different diameters, while its interior is mounted with lateral permanent magnets with an attractive force ranging from 100 kg to 2 tonnes per m2 of the surface. Over the perforated rotary drum, an infrared radiation generator is mounted, producing 0.2 kW to 1 kW of infrared radiation per 1 m2 of the perforated drum surface. This design reduces the energy consumption required for the biomass destruction process by 10-30% in comparison to the conventional ball mill. The magnetic field generated by the permanent magnets situated within the perforated rotary drum promotes this process through generation of free radicals that act as powerful oxidants, accelerating the decomposition rate. Plant substrate shows increased susceptibility to biodegradation when subjected to magnetic conditioning, reducing the time required for biomethanation by 25%. Additionally, the electromagnetic radiation generated by the radiator improves substrate destruction by 10% and the efficiency of the process. The magnetic field and the infrared radiation contribute synergically to the increased efficiency of destruction and conversion of the substrate.

Keywords: biomass pretreatment, mechanical fragmentation, biomass, methane fermentation

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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: Manikandakumar Shunmugavel, Ashwin Polishetty, Moshe Goldberg, Junior Nomani, Guy Littlefair

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Selective laser melting (SLM), a promising additive manufacturing (AM) technology, has a huge potential in the fabrication of Ti-6Al-4V near-net shape components. However, poor surface finish of the components fabricated from this technology requires secondary machining to achieve the desired accuracy and tolerance. Therefore, a systematic understanding of the machinability of SLM fabricated Ti-6Al-4V components is paramount to improve the productivity and product quality. Considering the significance of machining in SLM fabricated Ti-6Al-4V components, this research aim is to study the influence of build orientation on machinability characteristics by performing low speed orthogonal cutting tests. In addition, the machinability of SLM fabricated Ti-6Al-4V is compared with conventionally produced wrought Ti-6Al-4V to understand the influence of SLM technology on machining. This paper is an attempt to provide evidence to the hypothesis associated that build orientation influences cutting forces, chip formation and surface integrity during orthogonal cutting of SLM Ti-6Al-4V samples. Results obtained from the low speed orthogonal cutting tests highlight the practical importance of microstructure and build orientation on machinability of SLM Ti-6Al-4V.

Keywords: additive manufacturing, build orientation, machinability, titanium alloys (Ti-6Al-4V)

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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: Thales Maluf, Nazem Nascimento

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The development of society relies heavily on the total amount of energy obtained and its consumption. Over the years, there has been an advancement on energy attainment, which is directly related to some natural resources and developing systems. Some of these resources should be highlighted for its remarkable presence in world´s energy grid, such as water, petroleum, and gas, while others deserve attention for representing an alternative to diversify the energy grid, like geothermal sources. Therefore, because all these resources can be extracted from the underground, drilling wells is a mandatory activity in terms of exploration, and it involves a previous geological study and an adequate preparation. It also involves a cleaning process and an extraction process that can be executed by different procedures. For that reason, this research aims the enhancement of exploration processes through a comparative analysis of drilling costs and techniques used to produce them. The analysis itself is based on a bibliographical review based on books, scientific papers, schoolwork and mainly explore drilling methods and technologies, equipment used, well measurements, extraction methods, and production costs. Besides techniques and costs regarding the drilling processes, some properties and general characteristics of these sources are also compared. Preliminary studies show that there are some major differences regarding the exploration processes, mostly because these resources are naturally distinct. Water wells, for instance, have hundreds of meters of length because water is stored close to the surface, while oil, gas, and geothermal production wells can reach thousands of meters, which make them more expensive to be drilled. The drilling methods present some general similarities especially regarding the main mechanism of perforation, but since water is a resource stored closer to the surface than the other ones, there is a wider variety of methods. Water wells can be drilled by rotary mechanisms, percussion mechanisms, rotary-percussion mechanisms, and some other simpler methods. Oil and gas production wells, on the other hand, require rotary or rotary-percussion drilling with a proper structure called drill rig and resistant materials for the drill bits and the other components, mostly because they´re stored in sedimentary basins that can be located thousands of meters under the ground. Geothermal production wells also require rotary or rotary-percussion drilling and require the existence of an injection well and an extraction well. The exploration efficiency also depends on the permeability of the soil, and that is why it has been developed the Enhanced Geothermal Systems (EGS). Throughout this review study, it can be verified that the analysis of the extraction processes of energy resources is essential since these resources are responsible for society development. Furthermore, the comparative analysis of costs and well drilling techniques for water, geothermal energy, oil, and gas production, which is the main goal of this research, can enable the growth of energy generation field through the emergence of ideas that improve the efficiency of energy generation processes.

Keywords: drilling, water, oil, Gas, geothermal energy

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Authors: A. Achour L. Chekour, A. Mekroud

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Tribology, the science of lubrication, friction and wear, plays an important role in science "crossroads" initiated by the recent developments in the industry. Its multidisciplinary nature reinforces its scientific interest. It covers all the sciences that deal with the contact between two solids loaded and relative motion. It is thus one of the many intersections more clearly established disciplines such as solid mechanics and the fluids, rheological, thermal, materials science and chemistry. As for his experimental approach, it is based on the physical and processing signals and images. The optimization of operating conditions by cutting tool must contribute significantly to the development and productivity of advanced automation of machining techniques because their implementation requires sufficient knowledge of how the process and in particular the evolution of tool wear. In addition, technological advances have developed the use of very hard materials, refractory difficult machinability, requiring highly resistant materials tools. In this study, we present the behavior wear a machining tool during the roughing operation according to the cutting parameters. The interpretation of the experimental results is based mainly on observations and analyzes of sharp edges e tool using the latest techniques: scanning electron microscopy (SEM) and optical rugosimetry laser beam.

Keywords: friction, wear, tool, cutting

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Authors: Ashish Ankus Yerunkar, Ravi Terkar

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Study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality as well as productivity with special emphasis on reduction of cutting tool flank wear, because reduction in flank wear ensures increase in tool life. The predicted optimal setting ensured minimization of surface roughness. Purpose of this paper is focused on the analysis of optimum cutting conditions to get lowest surface roughness in turning SCM 440 alloy steel by Taguchi method. Design for the experiment was done using Taguchi method and 18 experiments were designed by this process and experiments conducted. The results are analyzed using ANOVA method. Taguchi method has depicted that the depth of cut has significant role to play in producing lower surface roughness followed by feed. The Cutting speed has lesser role on surface roughness from the tests. The vibrations of the machine tool, tool chattering are the other factors which may contribute poor surface roughness to the results and such factors ignored for analyses. The inferences by this method will be useful to other researches for similar type of study and may be vital for further research on tool vibrations, cutting forces etc.

Keywords: surface roughness (ra), machining, dry turning, taguchi method, turning process, anova method, mahr perthometer

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Authors: Navid Zarif Karimi, Hossein Heidary, Giangiacomo Minak, Mehdi Ahmadi

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In this paper analytical model based on the mechanics of oblique cutting, linear elastic fracture mechanics (LEFM) and bending plate theory has been presented to determine the critical feed rate causing delamination in drilling of composite materials. Most of the models in this area used LEFM and bending plate theory; hence, they can only determine the critical thrust force which is an incorporable parameter. In this model by adding cutting oblique mechanics to previous models, critical feed rate has been determined. Also instead of simplification in loading condition, actual thrust force induced by chisel edge and cutting lips on composite plate is modeled.

Keywords: composite material, delamination, drilling, thrust force

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Authors: Goutam Dubey, Varun Dutta

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In the present study, rotary-electro discharge machining of EN31 tool steel has been carried out using a pure copper electrode. Various response variables such as Material Removal Rate (MRR), Tool Wear Rate (TWR), and Machining Rate (MR) have been studied against the selected process variables. The selected process variables were peak current (I), voltage (V), duty cycle, and electrode rotation (N). EN31 Tool Steel is hardened, high carbon steel which increases its hardness and reduces its machinability. Reduced machinability means it not economical to use conventional methods to machine EN31 Tool Steel. So, non-conventional methods play an important role in machining of such materials.

Keywords: electric discharge machining, EDM, tool steel, tool wear rate, optimization techniques

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Authors: Kamand Bagherian, Nariman Niknejad

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A vibration isolation technology for precise position control of a rotary system powered by two permanent magnet DC (PMDC) motors is proposed, where this system is mounted on an oscillatory frame. To achieve vibration isolation for this system, active damping and disturbance rejection (ADDR) technology is presented which introduces a cooperation of a main and an auxiliary PMDC, controlled by discrete-time sliding mode control (DTSMC) based schemes. The controller of the main actuator tracks a desired position and the auxiliary actuator simultaneously isolates the induced vibration, as its controller follows a torque trend. To determine this torque trend, a combination of two algorithms is introduced by the ADDR technology. The first torque-trend producing algorithm rejects the disturbance by counteracting the perturbation, estimated using a model-based observer. The second torque trend applies active variable damping to minimize the oscillation of the output shaft. In this practice, the presented technology is implemented on a rotary system with a pendulum attached, mounted on a linear actuator simulating an oscillation-transmitting structure. In addition, the obtained results illustrate the functionality of the proposed technology.

Keywords: active damping, discrete-time nonlinear controller, disturbance tracking algorithm, oscillation transmitting support, position control, stability robustness, vibration isolation

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Authors: Hayyan I Al Taweil

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Background: The most common of bacterium in kitchen sponges and cutting surfaces which can play a task within the cross-contamination of foods, fomites and hands by foodborne pathogens. Aims and Objectives: This study investigated the incidence of bacterium in kitchen Sponge, and cutting surfaces. Material and methods: a complete of twenty four kitchen Sponges were collected from home kitchens and therefore the numbers of mesotrophic microorganism, coliform microorganism, E. coli, Salmonella, genus {pseudomonas|bacteria genus} and staphylococci in every kitchen Sponges were determined. Microbiological tests of all sponges for total mesophilic aerobic microorganism, S. aureus, Pseudomonas, Salmonella spp., and E. coli were performed on days 3, 7, and 14 by sampling. The sponges involved in daily use in kitchens countenosely with the dishwasher detergent a minimum of doubly daily Results: Results from the overall mesophilic aerobic microorganism, indicate a major increase within the variety of log CFU/ml. the amount of E. coli was reduced, Salmonella spp. was stabled, S. aureus was enhanced from the sponges throughout fourteen days. Genus Pseudomonas was enhanced and was the dominant micro flora within the sponges throughout fourteen days.

Keywords: Kitchen Sponges, Microbiological Contamination, Disinfection; cutting surface; , Cross-Contamination

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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: C. Boubechou, A. Bouchoucha, H. Zaidi

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The aim of this paper is to study the tribological behavior of a dynamic contact steel-brass couple with electric current. This study looks at a dry contact brass-steel couple where friction and wear are studied in terms of mechanical and electrical parameters. For this reason, a tribometer, pin-rotary disc is used in an atmospheric atmosphere. The test parameters are as follows: the normal load (5-30N), the sliding speed (0.1 to 0.5 m / s) and the electric current (3-10A). The duration of each test is 30 minutes. The experimental results show that these parameters have a significant effect on the tribological behavior of the couple studied. The discussion of results is based on observations, using an optical microscope, MEB and a profilometer, worn surfaces and interface phenomena resulting from the process of sliding contact.

Keywords: brass-steel couple, dry friction, electrical current, morphology, normal load, sliding speeds, wear

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Authors: Hossein Edrisi

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To study the impact of the amount and volume of power of isolation transformer on the lamps in airfield Ground Lighting Systems. A test was conducted in Persian Gulf International Airport, This airport is situated in the south of Iran and it is one of the most cutting-edge airports, the same one that owns modern devices. Iran uses materials and auxiliary equipment which are made by ADB Company from Belgium. Airfield ground lighting (AGL) systems are responsible for providing visual issue to aircrafts and helicopters in the runways. In an AGL system a great deal of lamps are connected in serial circuits to each other and each ring has its individual constant current regulators (CCR), which through that provide energy to the lamps. Control of lamps is crucial for maintenance and operation in the AGL systems. Thanks to the Programmable Logic Controller (PLC) that is a cutting-edge technology can help the system to connect the elements from substations and ATC (TOWER). For this purpose, a test in real conditions of the airport done for all element that used in the airport such as isolation transformer in different power capacity and different consuming power and brightness of the lamps. The data were analyzed with Lux meter and Multimeter. The results had shown that the increase in the power of transformer caused a significant increase in brightness. According to the Ohm’s law and voltage division, without changing the characteristics of the light bulb, it is not possible to change the voltage, just need to change the amount of transformer with which it connects to the lamps. When the voltage is increased, the current through the bulb has to increase as well, because of Ohm's law: I=V/R and I=V/R which means that if V increases, so do I increase. The output voltage on the constant current regulator emerges between the lamps and the transformers.

Keywords: AGL, CCR, lamps, transformer, Ohm’s law

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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: Michael K.O. Ayomoh, Khaled A. Abou-El-Hossein., Sameh F.M. Ghobashy

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This paper proposes a numerical modelling scheme for surface roughness prediction. The approach is premised on the use of 3D difference analysis method enhanced with the use of feedback control loop where a set of adaptive weights are generated. The surface roughness values utilized in this paper were adapted from [1]. Their experiments were carried out using S55C high carbon steel. A comparison was further carried out between the proposed technique and those utilized in [1]. The experimental design has three cutting parameters namely: depth of cut, feed rate and cutting speed with twenty-seven experimental sample-space. The simulation trials conducted using Matlab software is of two sub-classes namely: prediction of the surface roughness readings for the non-boundary cutting combinations (NBCC) with the aid of the known surface roughness readings of the boundary cutting combinations (BCC). The following simulation involved the use of the predicted outputs from the NBCC to recover the surface roughness readings for the boundary cutting combinations (BCC). The simulation trial for the NBCC attained a state of total stability in the 7th iteration i.e. a point where the actual and desired roughness readings are equal such that error is minimized to zero by using a set of dynamic weights generated in every following simulation trial. A comparative study among the three methods showed that the proposed difference analysis technique with adaptive weight from feedback control, produced a much accurate output as against the abductive and regression analysis techniques presented in this.

Keywords: Difference Analysis, Surface Roughness; Mesh- Analysis, Feedback control, Adaptive weight, Boundary Element

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Authors: Yilmaz Bayhan, Emin Güzel, Ömer Barış Özlüoymak, Ahmet İnce, Abdullah Sessiz

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In this study, determining of reduced tillage techniques in green bean farming as a second crop after harvesting wheat was targeted. To this aim, four different soil tillage methods namely, heavy-duty disc harrow (HD), rotary tiller (ROT), heavy-duty disc harrow plus rotary tiller (HD+ROT) and no-tillage (NT) (seeding by direct drill) were examined. Experiments were arranged in a randomized block design with three replications. The highest green beans yields were obtained in HD+ROT and NT as 5,862.1 and 5,829.3 Mg/ha, respectively. The lowest green bean yield was found in HD as 3,076.7 Mg/ha. The highest fuel consumption was measured 30.60 L ha^-1 for HD+ROT whereas the lowest value was found 7.50 L ha^-1 for NT. No tillage method gave the best results for fuel consumption and effective power requirement. It is concluded that no-tillage method can be used in second crop green bean in the Thrace Region due to economic and erosion conditions.

Keywords: green bean, soil tillage, yield, vegetative

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Authors: David Downey

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With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical/aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear

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Authors: S. Ghorbani, N. I. Polushin

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The machinability of workpieces (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron) in turning operation has been carried out using different types of cutting tool (conventional, cutting tool with holes in toolholder and cutting tool filled up with composite material) under dry conditions on a turning machine at different stages of spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). Experimentation was performed as per Taguchi’s orthogonal array. To evaluate the relative importance of factors affecting surface roughness the single decision tree (SDT), Decision tree forest (DTF) and Group method of data handling (GMDH) were applied.

Keywords: decision tree forest, GMDH, surface roughness, Taguchi method, turning process

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Authors: Irene Capecchi, Tommaso Borghini, Iacopo Bernetti

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One of the most common pieces of equipment still used today for pruning, felling, and processing trees is the chainsaw in forestry. However, chainsaw use highlights dangers and one of the highest rates of accidents in both professional and non-professional work. Felling is proportionally the most dangerous phase, both in severity and frequency, because of the risk of being hit by the plant the operator wants to cut down. To avoid this, a correct sequence of chainsaw cuts must be taught concerning the different conditions of the tree. Virtual reality (VR) makes it possible to virtually simulate chainsaw use without danger of injury. The limitations of the existing applications are as follow. The existing platforms are not symmetrical collaborative because the trainee is only in virtual reality, and the trainer can only see the virtual environment on a laptop or PC, and this results in an inefficient teacher-learner relationship. Therefore, most applications only involve the use of a virtual chainsaw, and the trainee thus cannot feel the real weight and inertia of a real chainsaw. Finally, existing applications simulate only a few cases of tree felling. The objectives of this research were to implement and test a symmetrical collaborative training application based on VR and mixed reality (MR) with the overlap between real and virtual chainsaws in MR. The research and training platform was developed for the Meta quest 2 head-mounted display. The research and training platform application is based on the Unity 3D engine, and Present Platform Interaction SDK (PPI-SDK) developed by Meta. PPI-SDK avoids the use of controllers and enables hand tracking and MR. With the combination of these two technologies, it was possible to overlay a virtual chainsaw with a real chainsaw in MR and synchronize their movements in VR. This ensures that the user feels the weight of the actual chainsaw, tightens the muscles, and performs the appropriate movements during the test allowing the user to learn the correct body posture. The chainsaw works only if the right sequence of cuts is made to felling the tree. Contact detection is done by Unity's physics system, which allows the interaction of objects that simulate real-world behavior. Each cut of the chainsaw is defined by a so-called collider, and the felling of the tree can only occur if the colliders are activated in the right order simulating a safe technique felling. In this way, the user can learn how to use the chainsaw safely. The system is also multiplayer, so the student and the instructor can experience VR together in a symmetrical and collaborative way. The platform simulates the following tree-felling situations with safe techniques: cutting the tree tilted forward, cutting the medium-sized tree tilted backward, cutting the large tree tilted backward, sectioning the trunk on the ground, and cutting branches. The application is being evaluated on a sample of university students through a special questionnaire. The results are expected to test both the increase in learning compared to a theoretical lecture and the immersive and telepresence of the platform.

Keywords: chainsaw, collaborative symmetric virtual reality, mixed reality, operator training

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Authors: Dejan Tanikić, Jelena Đoković, Saša Kalinović, Miodrag Manić, Saša Ranđelović

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This paper deals with measuring and modelling of the quality of the machined surface of the metal machining process. The average surface roughness (R_a) which represents the quality of the machined part was measured during the dry turning of the AISI 4140 steel. A large number of factors with the unknown relations among them influences this parameter, and that is why mathematical modelling is extremely complicated. Different values of cutting speed, feed rate, depth of cut (cutting regime) and workpiece hardness causes different surface roughness values. Modelling with soft computing techniques may be very useful in such cases. This paper presents the usage of the fuzzy logic-based system for determining metal machining process parameter in order to find the proper values of cutting regimes.

Keywords: fuzzy logic, metal machining, process modeling, surface roughness

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Authors: Mohammad A. Khasawneh

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The design of high pressure water jet based polishing equipment and its fabrication conducted in this study is reported herein, together with some preliminary test results for assessing its applicability for HMA surface polishing. This study also provides preliminary findings concerning the test variables, such as the rotational speed, the water jet pressure, the abrasive agent used, and the impact angel that were experimentally investigated in this study. The preliminary findings based on four trial tests (two on large slab specimens and two on small size gyratory compacted specimens), however, indicate that both friction and texture values tend to increase with the polishing durations for two combinations of pressure and rotation speed of the rotary deck. It seems that the more polishing action the specimen is subjected to; the aggregate edges are created such that the surface texture values are increased with the accompanied increase in friction values. It may be of interest (but which is outside the scope of this study) to investigate if the similar trend exist for HMA prepared with aggregate source that is sand and gravel.

Keywords: high-pressure, water jet, friction, texture, polishing, statistical analysis

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Authors: Haydar S. Al Shabbani, M. Marshall, R. Goodall

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Metal matrix composites (MMCs) have been explored for many applications for many decades. Recently, this includes investigations for thermal applications associated with electronics, such as in heat sinks. Here, to promote thermal conductivity, composites of a metal matrix with diamond particles are used. However, this class of composites has not yet been extensively examined for mechanical and tribological behavior, especially for applications that require extreme mechanical and tribological strength, such as the resistance to abrasive cutting. Therefore, this research seeks to develop a composite material with metal matrix and diamond particles which resist abrasive and cutting forces. The development progresses through a series of steps, exploring methods to process the material, understanding the mechanics of abrasive behavior and optimizing the composite structure to resist abrasive cutting. In processing, infiltration casting under gas pressure has been applied to molten aluminum to obtain a significant penetration of the metal into a preform of diamond particles. Different diamond particle sizes were used with different surface modifications (coated/uncoated), and to compare resulting composites with the same particle sizes. Al-1 wt.% Mg as a matrix alloy was utilised to investigate the possible effect of Mg on bonding phases during the infiltration process. The mechanical behavior and microstructure of the materials produced have been characterised. These tests showed that the surface modification of the diamond particles with a reactive material (Ti-coating) has an important role for enhancing the bonding between the aluminium matrix and diamond reinforcement as apparent under SEM observation. The effect of this improved bond is seen in the cutting resistance of the material.

Keywords: aluminium, composites, diamond, Ti-coated, tribology

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Authors: Manjinder Bajwa, Mahipal Singh, Ashish Tulli

Abstract:

In the research, the effect of varying cutting parameters, design parameters and heat treatment processes were studied on the cutting performance (Tool life) of a PVD coated tool. Thus, in a quest for these phenomenon comparison, a single coated tool and a multicoated tool were analyzed after suitable heat treatment process. TNMG shaped insert with single coating of TiCN and multi-coating of TiAlN/TiN were developed on tungsten carbide substrate. These coated inserts were then successfully annealed and normalized for a temperature of 350°C for 30 minutes and their cutting performance was evaluated as per the flank wear obtained after turning of mild steel. The results showed that heat treatment had a suitable impact on the tool life of the coated insert and also led to increase in the micro-hardness of the tool coatings and decrease in the wear rate.

Keywords: PVD coatings, flank wear, micro-hardness, annealing, normalizing

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Authors: V. Pourmostaghimi, M. Zadshakoyan

Abstract:

Efficiency and productivity of the finish hard turning can be enhanced impressively by utilizing accurate predictive models for cutting tool wear. However, the ability of genetic programming in presenting an accurate analytical model is a notable characteristic which makes it more applicable than other predictive modeling methods. In this paper, the genetic equation for modeling of tool flank wear is developed with the use of the experimentally measured flank wear values and genetic programming during finish turning of hardened AISI D2. Series of tests were conducted over a range of cutting parameters and the values of tool flank wear were measured. On the basis of obtained results, genetic model presenting connection between cutting parameters and tool flank wear were extracted. The accuracy of the genetically obtained model was assessed by using two statistical measures, which were root mean square error (RMSE) and coefficient of determination (R²). Evaluation results revealed that presented genetic model predicted flank wear over the study area accurately (R² = 0.9902 and RMSE = 0.0102). These results allow concluding that the proposed genetic equation corresponds well with experimental data and can be implemented in real industrial applications.

Keywords: cutting parameters, flank wear, genetic programming, hard turning

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Authors: Gopinath Rathod, Vinod Puranik

Abstract:

Growing business recognizes environmental consciousness as an important concept for survival in the competitive scenario. Environmental consciousness is a critical intersection between manufacturing and product design processes with environmental issues and concerns. This article presents a project in which quality function deployment (QFD) for environment (ECQFD) has been applied to rotary switches for enabling environmentally conscious design in the early stage of product development. ECQFD is capable of handling simultaneously the environmental and traditional product quality requirements. ECQFD consists of four phases. ECQFD phases I and II are concerned with the identification of parts that are important in enhancing environmental consciousness. ECQFD phases III and IV are concerned with the evaluation of effect of design improvement on environmental quality requirements. The case study has been practically validated which indicated the receptivity of applying ECQFD in industrial scenario.

Keywords: quality function deployment, environment, product design, design for environment, rotary switches

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Authors: Talal Al-Bazali

Abstract:

Air drilling has recently received increasing acceptance by the oil and gas industry due to its unique advantages. The main advantages of air drilling include the higher rate of penetration, less formation damage, lower risk of loss of circulation. However, these advantages cannot be fully realized if thermal effects in air drilling are not well understood and minimized. Due to its high frictional coefficient, low heat conductivity, and high compressibility, air can impact the temperature distribution of bit and thus affect its bit performances. Based on energy and mass balances, a transient thermal model that predicts bit temperature is presented along with numerical solutions in this paper. In addition, several important parameters that influence bit temperature distribution are analyzed. Simulation results show that the bit temperature increases with increasing weight on bit and rotary speed but decreases as the standpipe pressure and flow rate increase. These results can be used to optimize drilling operations and flow parameters for an improved bit performance as shown in this paper.

Keywords: air drilling, rate of penetration, temperature, rotary speed

Procedia PDF Downloads 264