Search results for: cutting performance

Authors: Amirhossein Lotfi, Huaizhong Li, Dzung Viet Dao

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Interest in natural fiber-reinforced composites (NFRC) is progressively growing both in terms of academia research and industrial applications thanks to their abundant advantages such as low cost, biodegradability, eco-friendly nature and relatively good mechanical properties. However, their widespread use is still presumed as challenging because of the specificity of their non-homogeneous structure, limited knowledge on their machinability characteristics and parameter settings, to avoid defects associated with the machining process. The present work is aimed to investigate the effect of the cutting tool geometry and material on the drilling-induced delamination, thrust force and hole quality produced when drilling a fully biodegradable flax/poly (lactic acid) composite laminate. Three drills with different geometries and material were used at different drilling conditions to evaluate the machinability of the fabricated composites. The experimental results indicated that the choice of cutting tool, in terms of material and geometry, has a noticeable influence on the cutting thrust force and subsequently drilling-induced damages. The lower value of thrust force and better hole quality was observed using high-speed steel (HSS) drill, whereas Carbide drill (with point angle of 130^o) resulted in the highest value of thrust force. Carbide drill presented higher wear resistance and stability in variation of thrust force with a number of holes drilled, while HSS drill showed the lower value of thrust force during the drilling process. Finally, within the selected cutting range, the delamination damage increased noticeably with feed rate and moderately with spindle speed.

Keywords: natural fiber reinforced composites, delamination, thrust force, machinability

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Authors: Gaurav D. Sonawane, Vikas G. Sargade

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The present investigation is a study of the effect of advanced Physical Vapor Deposition (PVD) coatings on cutting temperature residual stresses and surface roughness during Duplex Stainless Steel (DSS) 2205 turning. Austenite stabilizers like nickel, manganese, and molybdenum reduced the cost of DSS. Surface Integrity (SI) plays an important role in determining corrosion resistance and fatigue life. Resistance to various types of corrosion makes DSS suitable for applications with critical environments like Heat exchangers, Desalination plants, Seawater pipes and Marine components. However, lower thermal conductivity, poor chip control and non-uniform tool wear make DSS very difficult to machine. Cemented carbide tools (M grade) were used to turn DSS in a dry environment. AlTiN and AlTiCrN coatings were deposited using advanced PVD High Pulse Impulse Magnetron Sputtering (HiPIMS) technique. Experiments were conducted with cutting speed of 100 m/min, 140 m/min and 180 m/min. A constant feed and depth of cut of 0.18 mm/rev and 0.8 mm were used, respectively. AlTiCrN coated tools followed by AlTiN coated tools outperformed uncoated tools due to properties like lower thermal conductivity, higher adhesion strength and hardness. Residual stresses were found to be compressive for all the tools used for dry turning, increasing the fatigue life of the machined component. Higher cutting temperatures were observed for coated tools due to its lower thermal conductivity, which results in very less tool wear than uncoated tools. Surface roughness with uncoated tools was found to be three times higher than coated tools due to lower coefficient of friction of coating used.

Keywords: cutting temperature, DSS2205, dry turning, HiPIMS, surface integrity

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Authors: Arjun, A. D. Singh

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Concrete the basic material using in construction across the global these days. The purpose of this special concrete is to provide extra strength and stability for irregular structure where the center of gravity is disturbed. In this paper an effort has been made to use different type of material aggregates has been discussed. We named As "STAR Aggregates" which has qualities to resist Shear, tension and compression forces. We have been divided into coarse aggregates and fine aggregates according to their sizes. Star Aggregates has interlocking behavior and cutting edge technology. Star aggregates had been draft and deign in Auto CAD and then analysis in ANSYS software. by using special aggregates we deign concrete grade of M40 for mega structures and irregular structure. This special concrete with STAR aggregates use in construction for irregular structure like Bridges, Skyscrapers or in deigned buildings.

Keywords: star aggregates, high performance concrete, material aggregates, interlocking

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Authors: M. N. Islam, B. Boswell, Y. R. Ginting

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The influence of canned cycles and cutting parameters on hole quality in cryogenic drilling has been investigated experimentally and analytically. A three-level, three-parameter experiment was conducted by using the design-of-experiment methodology. The three levels of independent input parameters were the following: for canned cycles—a chip-breaking canned cycle (G73), a spot drilling canned cycle (G81), and a deep hole canned cycle (G83); for feed rates—0.2, 0.3, and 0.4 mm/rev; and for cutting speeds—60, 75, and 100 m/min. The selected work and tool materials were aluminum 6061-6T and high-speed steel (HSS), respectively. For cryogenic cooling, liquid nitrogen (LN2) was used and was applied externally. The measured output parameters were the three widely used quality characteristics of drilled holes—diameter error, circularity, and surface roughness. Pareto ANOVA was applied for analyzing the results. The findings revealed that the canned cycle has a significant effect on diameter error (contribution ratio 44.09%) and small effects on circularity and surface finish (contribution ratio 7.25% and 6.60%, respectively). The best results for the dimensional accuracy and surface roughness were achieved by G81. G73 produced the best circularity results; however, for dimensional accuracy, it was the worst level.

Keywords: circularity, diameter error, drilling canned cycle, pareto ANOVA, surface roughness

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Authors: Muhammet Emre Turan, Sait Özçelik, Yavuz Sun

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In railway rails, residual stress was measured and the values of residual stress were associated with hardness and micro structure in this study. At first, three rails as one meter long were taken and residual stresses were measured by cutting method according to the EN 13674-1 standardization. In this study, strain gauge that is an electrical apparatus was used. During the cutting, change in resistance in rail gave us residual stress value via computer program. After residual stress measurement, Brinell hardness distribution were performed for head parts of rails. Thus, the relationship between residual stress and hardness were established. In addition to that, micro structure analysis was carried out by optical microscope. The results show that, the micro structure and hardness value was changed with residual stress.

Keywords: residual stress, hardness, micro structure, rail, strain gauge

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Authors: S. D. El Wakil, M. Pladsen

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Fiber reinforced polymeric (FRP) composites are finding wide-spread industrial applications because of their exceptionally high specific strength and specific modulus of elasticity. Nevertheless, it is very seldom to get ready-for-use components or products made of FRP composites. Secondary processing by machining, particularly drilling, is almost always required to make holes for fastening components together to produce assemblies. That creates problems since the FRP composites are neither homogeneous nor isotropic. Some of the problems that are encountered include the subsequent damage in the region around the drilled hole and the drilling – induced delamination of the layer of ply, that occurs both at the entrance and the exit planes of the work piece. Evidently, the functionality of the work piece would be detrimentally affected. The current work was carried out with the aim of eliminating or at least minimizing the work piece damage associated with drilling of FPR composites. Each test specimen involves a woven reinforced graphite fiber/epoxy composite having a thickness of 12.5 mm (0.5 inch). A large number of test specimens were subjected to drilling operations with different combinations of feed rates and cutting speeds. The drilling induced damage was taken as the absolute value of the difference between the drilled hole diameter and the nominal one taken as a percentage of the nominal diameter. The later was determined for each combination of feed rate and cutting speed, and a matrix comprising those values was established, where the columns indicate varying feed rate while and rows indicate varying cutting speeds. Next, the analysis of variance (ANOVA) approach was employed using Minitab software, in order to obtain the combination that would improve the drilling induced damage. Experimental results show that low feed rates coupled with low cutting speeds yielded the best results.

Keywords: drilling of composites, dimensional accuracy of holes drilled in composites, delamination and charring, graphite-epoxy composites

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Authors: Mindaye Teshome, Evaldo Muñoz Braz, Carlos M. M. Eleto Torres, Patricia Mattos

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Sustainable forest management planning requires up-to-date information on the structure, standing volume, biomass, and growth rate of trees from a given forest. This kind of information is lacking in many forests in Ethiopia. The objective of this study was to quantify the population structure, diameter growth rate, and standing volume of wood from Juniperus procera trees in the Chilimo forest. A total of 163 sample plots were set up in the forest to collect the relevant vegetation data. Growth ring measurements were conducted on stem disc samples collected from 12 J. procera trees. Diameter and height measurements were recorded from a total of 1399 individual trees with dbh ≥ 2 cm. The growth rate, maximum current and mean annual increments, minimum logging diameter, and cutting cycle were estimated, and alternative cutting cycles were established. Using these data, the harvestable volume of wood was projected by alternating four minimum logging diameters and five cutting cycles following the stand table projection method. The results show that J. procera trees have an average density of 183 stems ha⁻¹, a total basal area of 12.1 m² ha⁻¹, and a standing volume of 98.9 m³ ha⁻¹. The mean annual diameter growth ranges between 0.50 and 0.65 cm year⁻¹ with an overall mean of 0.59 cm year⁻¹. The population of J. procera tree followed a reverse J-shape diameter distribution pattern. The maximum current annual increment in volume (CAI) occurred at around 49 years when trees reached 30 cm in diameter. Trees showed the maximum mean annual increment in volume (MAI) around 91 years, with a diameter size of 50 cm. The simulation analysis revealed that 40 cm MLD and a 15-year cutting cycle are the best minimum logging diameter and cutting cycle. This combination showed the largest harvestable volume of wood potential, volume increments, and a 35% recovery of the initially harvested volume. It is concluded that the forest is well stocked and has a large amount of harvestable volume of wood from J. procera trees. This will enable the country to partly meet the national wood demand through domestic wood production. The use of the current population structure and diameter growth data from tree ring analysis enables the exact prediction of the harvestable volume of wood. The developed model supplied an idea about the productivity of the J. procera tree population and enables policymakers to develop specific management criteria for wood harvesting.

Keywords: logging, growth model, cutting cycle, minimum logging diameter

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Authors: Juliet Sorensen, Megan Schliep

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Introduction: After a multidisciplinary assessment of health and human rights issues in central Mali, a musical album was created in 2014 in Douentza, Mali to provide health information on female genital mutilation/cutting (FGM/C), malaria, HIV/AIDS, girls’ education, breastfeeding, and sanitation. The objective of this study was to assess the impact of this album. Methods: A mixed-methods assessment was conducted with 149 individuals across 10 villages in Douentza Cercle. Analyses focused on the association of radio listening habits, age, sex, ethnicity and education with a public health knowledge score. Results: Over 90% of respondents reported daily radio listening, many listening five or more hours per day. Potential risks of FGM/C cited by participants included death (59%), difficulty in childbirth (48%), sterility (34%), and fistula (33%); when asked about their level of control over FGM/C, 28% stated they would never cut their daughters. Being a listener for 1-5 hours per day was associated with a 11.5% higher score of 'public health knowledge' compared to those listening only a little or not at all (p < 0.01). Education (marginal versus no formal education) was associated with 7.6% increased score (p < 0.01). Conclusion: Radio appears to be a significant part of community members’ daily routines and may be a valuable medium for transmitting information, particularly for lower literacy individuals.

Keywords: female genital cutting, public health and social justice education, radio, Mali

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Authors: A.Chen Chao-Chang, Phong Pham-Quoc

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Chemical-mechanical polishing (CMP) process has been widely applied on fabricating integrated circuits (IC) with a soft polishing pad combined with slurry composed of micron or nano-scaled abrasives for generating chemical reaction to remove substrate or film materials from wafer. During CMP process, pad uniformity usually works as a datum surface of wafer planarization and pad asperities can dominate the microscopic pad-slurry-wafer interaction. However, pad topography can be changed by related mechanism factors of CMP and it needs to be re-conditioned or dressed by a diamond dresser of well-distributed diamond grits on a disc surface. It is still very complicated to analyze and understand kinematic of diamond dressing process under the effects of input variables including oscillatory of diamond dresser and rotation speed ratio between the pad and the diamond dresser. This paper has developed a generic geometric model to clarify the kinematic modeling of diamond dressing processes such as dresser/pad motion, pad cutting locus, the relative velocity of the diamond abrasive grits on pad surface, and overlap of cutting for prediction of pad surface topography. Simulation results focus on comparing and analysis kinematics of the diamond dressing on certain CMP tools. Results have shown the significant parameters for diamond dressing process and also discussed. Future study can apply on diamond dresser design and experimental verification of pad dressing process.

Keywords: kinematic modeling, diamond dresser, pad cutting locus, CMP

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Authors: Waseem Tahir, Syed Hussain Imran Jaffery, Mohammad Azam

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In this research work, liquid nitrogen gas (LN2) is used as a cryogenic media to optimize the cutting parameters for evaluation of tool flank wear width of Tungsten Carbide Insert (CNMG 120404-WF 4215) while turning a high strength alloy steel. Robust design concept of Taguchi L9 (34) method is applied to determine the optimum conditions. The analysis is revealed that cryogenic impact is more significant in reduction of the tool flank wear. However, High Speed Machining is shown most significant as compare to cooling media on work piece surface roughness.

Keywords: turning, cryogenic cooling, liquid nitrogen, flank wear, surface finish

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Authors: Jenq-Shyong Chen, Ben-Fong Yu

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CNC(computer numerical control) machining centers have been widely used for machining different metal components for various industries. For a specific CNC machine, its everyday job is assigned to cut different products with quite different attributes such as material type, workpiece weight, geometry, tooling, and cutting conditions. Theoretically, the dynamic characteristics of the CNC machine should be properly tuned match each machining job in order to get the optimal machining performance. However, most of the CNC machines are set with only a standard set of CNC parameters. In this study, we have developed an auto-tuning system which can automatically change the CNC parameters and in hence change the machine dynamic characteristics according to the selection of machining modes which are set by the mixed combination of three machine performance indexes: the HO (high surface quality) index, HP (high precision) index and HS (high speed) index. The acceleration, jerk, corner error tolerance, oscillation and dynamic bandwidth of machine’s feed axes have been changed according to the selection of the machine performance indexes. The proposed auto-tuning system of the CNC parameters has been implemented on a PC-based CNC controller and a three-axis machining center. The measured experimental result have shown the promising of our proposed auto-tuning system.

Keywords: auto-tuning, CNC parameters, machining mode, high speed, high accuracy, high surface quality

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Authors: Madiha Ijaz, Muhammad Akram, Sima Mir

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Underground mining of coal is carried out manually in Pakistan. Exposure to ergonomic hazards (musculoskeletal disorders) are very common among the coal cutters of these mines. Cutting coal in narrow spaces poses a great threat to both upper and lower limbs of these workers. To observe the prevalence of such hazards, a thorough study was conducted on 600 workers from 30 mines (20 workers from 1 mine), located in two districts of province Punjab, Pakistan. Rapid Upper Limb Assessment sheet and Rapid Entire Body Assessment sheet were used for the study along with a standard Nordic Musculoskeleton disorder questionnaire. SPSS, 25, software was used for data analysis on upper and lower limb disorders, and regression analysis models were run for upper and lower back pain. According to the results obtained, it was found that work stages (drilling & blasting, coal cutting, timbering & supporting, etc.), wok experience and number of repetitions performed/minute were significant (with p-value 0.00,0.004 and 0.009, respectively) for discomfort in upper and lower limb. Age got p vale 0.00 for upper limb and 0.012 for lower limb disorder. The task of coal cutting was strongly associated with the pain in upper back (with odd ratios13.21, 95% confidence interval (CI)14.0-21.64)) and lower back pain (3.7, 95% confidence interval 1.3-4.2). scored on RULA and REBA sheets, every work-stage was ranked at 7-highest level of risk involved. Workers were young (mean value of age= 28.7 years) with mean BMI 28.1 kg/m2

Keywords: workplace hazards, ergonomic disorders, limb disorders, MSDs.

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Authors: Tie-Gang Wang, De-Qiang Meng, Yan-Mei Liu

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Ternary AlCrN coatings were widely used to prolong cutting tool life because of their high hardness and excellent abrasion resistance. However, the friction between the workpiece and cutter surface was increased remarkably during machining difficult-to-cut materials (such as superalloy, titanium, etc.). As a result, a lot of cutting heat was generated and cutting tool life was shortened. In this work, an appropriate amount of solid lubricant MoS₂ was added into the AlCrN coating to reduce the friction between the tool and the workpiece. A series of Al-Cr-N/MoS₂ self-lubricating coatings with different MoS₂ contents were prepared by high power impulse magnetron sputtering (HiPIMS) and pulsed direct current magnetron sputtering (Pulsed DC) compound system. The MoS₂ content in the coatings was changed by adjusting the sputtering power of the MoS₂ target. The composition, structure and mechanical properties of the Al-Cr-N/MoS2 coatings were systematically evaluated by energy dispersive spectrometer, scanning electron microscopy, X-ray photoelectron spectroscopy, X-ray diffractometer, nano-indenter tester, scratch tester, and ball-on-disk tribometer. The results indicated the lubricant content played an important role in the coating properties. As the sputtering power of the MoS₂ target was 0.1 kW, the coating possessed the highest hardness 14.1GPa, the highest critical load 44.8 N, and the lowest wear rate 4.4×10−3μm2/N.

Keywords: self-lubricating coating, Al-Cr-N/MoS₂ coating, wear rate, friction coefficient

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Authors: D. Kabeya Nahum, L. Y. Kabeya Mukeba

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In this work, the design of surface defects some support of the anchor rod ball joint. The future adhesion contact was rocking in manufacture machining, for giving by the numerical analysis of a short simple solution of thermo-mechanical coupled problem in process engineering. The analysis of geometrical evaluation and the quasi-static and dynamic states are discussed in kinematic dimensional tolerances onto surfaces of part. Geometric modeling using the finite element method (FEM) in rough part of such phase provides an opportunity to solve the nonlinearity behavior observed by empirical data to improve the discrete functional surfaces. The open question here is to obtain spherical geometry of drain wear with the operation of rolling. The formulation with (1 ± 0.01) mm thickness near the drain wear semi-finishing tool for studying different angles, do not help the professional factor in design cutting metal related vibration, friction and interface solid-solid of part and tool during this physical complex process, with multi-parameters no-defined in Sobolev Spaces. The stochastic approach of cracking, wear and fretting due to the cutting forces face boundary layers small dimensions thickness of the workpiece and the tool in the machining position is predicted neighbor to ‘Yakam Matrix’.

Keywords: FEM, geometry, part, simulation, spherical surface engineering, tool, workpiece

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Authors: Asghar Ebrahimzadeh, Sattar Malekian, Mohammad Ali Aazami, Mohammad Bagher Hassanpouraghdam

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Roses are of main ornamental flowers worldwide. Rosa damascena Mill., besides being an ornamental plant, has major pharmaceutical, cosmetic and fragrance applications. Traditional propagation methods of the plant are using suckers, cutting and grafting. In the present experiment, we used the different explants (leaf section, petioles and nodal cutting) for the optimization of this high-valued ornamental from a native clonal plant. Diverse explants were acquired from mature plants during the growing season and were planted on MS medium supplemented with different hormonal combinations. 70% alcohol and sodium hypochloride were utilized for the surface sterilization. For proliferation, BAP and BA (1-5 mg L-1) and NAA (1-2 mg L-1) were tested. The highest proliferation rate was afforded from MS medium supplemented with 1.5 mg L-1 BA and 5 mg L-1 BAP. Callogenesis from leaf samples and petioles was the best with 1/2 MS medium enriched with 1mg L-1 BAP and 4 mg L-1 2,4-D. Rooting was occurred with the highest frequency in a medium containing 0.1 mg L-1 IBA.

Keywords: Rosa damascene, micropropagation, petiole, IBA, BAP

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Authors: Torsten Hermanns, Thoufik Al Khawli, Wolfgang Schulz

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In laser cutting as well as in long pulsed laser drilling of metals, it can be demonstrated that the ablation shape (the shape of cut faces respectively the hole shape) that is formed approaches a so-called asymptotic shape such that it changes only slightly or not at all with further irradiation. These findings are already known from the ultrashort pulse (USP) ablation of dielectric and semiconducting materials. The explanation for the occurrence of an asymptotic shape in laser cutting and long pulse drilling of metals is identified, its underlying mechanism numerically implemented, tested and clearly confirmed by comparison with experimental data. In detail, there now is a model that allows the simulation of the temporal (pulse-resolved) evolution of the hole shape in laser drilling as well as the final (asymptotic) shape of the cut faces in laser cutting. This simulation especially requires much less in the way of resources, such that it can even run on common desktop PCs or laptops. Individual parameters can be adjusted using sliders – the simulation result appears in an adjacent window and changes in real time. This is made possible by an application-specific reduction of the underlying ablation model. Because this reduction dramatically decreases the complexity of calculation, it produces a result much more quickly. This means that the simulation can be carried out directly at the laser machine. Time-intensive experiments can be reduced and set-up processes can be completed much faster. The high speed of simulation also opens up a range of entirely different options, such as metamodeling. Suitable for complex applications with many parameters, metamodeling involves generating high-dimensional data sets with the parameters and several evaluation criteria for process and product quality. These sets can then be used to create individual process maps that show the dependency of individual parameter pairs. This advanced simulation makes it possible to find global and local extreme values through mathematical manipulation. Such simultaneous optimization of multiple parameters is scarcely possible by experimental means. This means that new methods in manufacturing such as self-optimization can be executed much faster. However, the software’s potential does not stop there; time-intensive calculations exist in many areas of industry. In laser welding or laser additive manufacturing, for example, the simulation of thermal induced residual stresses still uses up considerable computing capacity or is even not possible. Transferring the principle of reduced models promises substantial savings there, too.

Keywords: asymptotic ablation shape, interactive process simulation, laser drilling, laser cutting, metamodeling, reduced modeling

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Authors: Gunjita Shami, Noopur Anand

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The pilot run of 50 days was undertaken to test employability potential of people with visual and hearing & speech impairment. Various roles in an apparel manufacturing set up like spreading of fabric for cutting, folding, sealing and labeling cartons, pasting size barcode stickers on packed garments, removing tickets from the garments in the finishing stage were studied. Their performance was quantified basis timesheets for all the days and improvement per day was quantified. Their final day output was compared to that of the able-bodied worker. For example in the carton making activity on day one visually impaired worker was making one box every three minutes which improved to four boxes per minute on day 28 displaying 91.6% improvement compared or an improvement of 3.6% per day which was comparable to the able-bodied seasoned workers, who were making 5 boxes per minute. The performance of persons with hearing and speech impairment in the finishing department was 10% higher than that of able-bodied seasoned workers in the same process. Overall in all the activities the differently abled showed day to day improvement of 65% while able bodied displayed improvement of 52%. On the first day performance of able-bodied worker was 75% better than that of differently abled while on the 50th day it was only 20% better. Therefore the performance of persons with disabilities was found comparable to the able bodied person. The results, though on a small scale, showed a big promise of employment of persons with disability in the apparel industry. Armed with the promising result a full-scale study has been undertaken to identify the roles suitable for certain kind of disability in apparel production, work-aids required to assist the differently abled to improve performance and measures to be undertaken to make production floor 'friendlier' for them. The results have been discussed in this paper which opens doors for integrating differently abled into the world projected and assumed for only able-bodied.

Keywords: apparel sector, differently abled, employability, performance, work-aid

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Authors: Yung C. Lin, Kung D. Wu, Wei C. Shih, Jui P. Hung

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High speed and high precision machining have become the most important technology in manufacturing industry. The surface roughness of high precision components is regarded as the important characteristics of the product quality. However, machining chatter could damage the machined surface and restricts the process efficiency. Therefore, selection of the appropriate cutting conditions is of importance to prevent the occurrence of chatter. In addition, vibration of the spindle tool also affects the surface quality, which implies the surface precision can be controlled by monitoring the vibration of the spindle tool. Based on this concept, this study was aimed to investigate the influence of the machining conditions on the surface roughness and the vibration of the spindle tool. To this end, a series of machining tests were conducted on aluminum alloy. In tests, the vibration of the spindle tool was measured by using the acceleration sensors. The surface roughness of the machined parts was examined using white light interferometer. The response surface methodology (RSM) was employed to establish the mathematical models for predicting surface finish and tool vibration, respectively. The correlation between the surface roughness and spindle tool vibration was also analyzed by ANOVA analysis. According to the machining tests, machined surface with or without chattering was marked on the lobes diagram as the verification of the machining conditions. Using multivariable regression analysis, the mathematical models for predicting the surface roughness and tool vibrations were developed based on the machining parameters, cutting depth (a), feed rate (f) and spindle speed (s). The predicted roughness is shown to agree well with the measured roughness, an average percentage of errors of 10%. The average percentage of errors of the tool vibrations between the measurements and the predictions of mathematical model is about 7.39%. In addition, the tool vibration under various machining conditions has been found to have a positive influence on the surface roughness (r=0.78). As a conclusion from current results, the mathematical models were successfully developed for the predictions of the surface roughness and vibration level of the spindle tool under different cutting condition, which can help to select appropriate cutting parameters and to monitor the machining conditions to achieve high surface quality in milling operation.

Keywords: machining parameters, machining stability, regression analysis, surface roughness

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Authors: W. Hasan, H. Farhat, A. Alhilo, L. Tamimi

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Oil in water (O/W) emulsions are utilized extensively for cooling and lubricating cutting tools during parts machining. A robust Lattice Boltzmann (LBM) thermal-surfactants model, which provides a useful platform for exploring complex emulsions’ characteristics under variety of flow conditions, is used here for the study of the fluid behavior during conventional tools cooling. The transient thermal capabilities of the model are employed for simulating the effects of the flow conditions of O/W emulsions on the cooling of cutting tools. The model results show that the temperature outcome is slightly affected by reversing the direction of upper plate (workpiece). On the other hand, an important increase in effective viscosity is seen which supports better lubrication during the work.

Keywords: hybrid lattice Boltzmann method, Gunstensen model, thermal, surfactant-covered droplet, Marangoni stress

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Authors: Jerah Mystica B. Novenario, Flor A. Ceballo-Alcantara

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Sweetpotato is grown in tropical countries for its edible tubers, which became an important source of food. It is usually propagated through vine cutting which may be obtained from harvested plants or from nurseries intended for cutting production only. The recurrent use of vines may cause increased weevil infestation. The crop is known to be infested with insect pests, more importantly, the sweetpotato weevil, Cylasformicarius, which targets the tubers and thus cause economic losses. Sweetpotato farmers in Tarlac claim that only one sweetpotato cultivar is being attacked by C. formicarius. However, in was found in this experiment that feeding and feeding behavior of the weevil were not affected by the cultivar provided; such that no significant differences were observed on the average amount of tuber consumed by both male (F=0.86; df=2; P=0.45) and female (F=2.71; df=2; P=0.11) and feeding time (F=0.9; df=2; P=0.43). Conversely, in terms of damage assessment, significantly different (F=1.64; df=2; P=0.23) results were noted.

Keywords: cylas formicarius, feeding behavior, insect pest, sweetpotato

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Authors: Szymon Wojciechowski, Damian Przestacki, Tadeusz Chwalczuk

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The paper is focused on the evaluation of surface integrity formed during turning of Inconel 718 with the application of various laser assistance strategies. The primary objective of the work was to determine the relations between the applied machining strategy and the obtained surface integrity, in order to select the effective cutting conditions allowing the obtainment of high surface quality. The carried out experiment included the machining of Inconel 718 in the conventional turning conditions, as well as during the continuous laser assisted machining and sequential laser assistance. The surface integrity was evaluated by the measurements of machined surface topographies, microstructures and the microhardness. Results revealed that surface integrity of Inconel 718 is strongly affected by the selected machining strategy. The significant improvement of the surface roughness formed during machining of Inconel 718, can be reached by the application of simultaneous laser heating and cutting (LAM).

Keywords: Inconel 718, laser assisted machining, surface integrity, turning

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Authors: Zsolt János Viharos, Krisztián Balázs Kis, Imre Paniti, Gábor Belső, Péter Németh, János Farkas

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The paper presents the results and industrial applications in the production setup period estimation based on industrial data inherited from the field of polymer cutting. The literature of polymer cutting is very limited considering the number of publications. The first polymer cutting machine is known since the second half of the 20th century; however, the production of polymer parts with this kind of technology is still a challenging research topic. The products of the applying industrial partner must met high technical requirements, as they are used in medical, measurement instrumentation and painting industry branches. Typically, 20% of these parts are new work, which means every five years almost the entire product portfolio is replaced in their low series manufacturing environment. Consequently, it requires a flexible production system, where the estimation of the frequent setup periods' lengths is one of the key success factors. In the investigation, several (input) parameters have been studied and grouped to create an adequate training information set for an artificial neural network as a base for the estimation of the individual setup periods. In the first group, product information is collected such as the product name and number of items. The second group contains material data like material type and colour. In the third group, surface quality and tolerance information are collected including the finest surface and tightest (or narrowest) tolerance. The fourth group contains the setup data like machine type and work shift. One source of these parameters is the Manufacturing Execution System (MES) but some data were also collected from Computer Aided Design (CAD) drawings. The number of the applied tools is one of the key factors on which the industrial partners’ estimations were based previously. The artificial neural network model was trained on several thousands of real industrial data. The mean estimation accuracy of the setup periods' lengths was improved by 30%, and in the same time the deviation of the prognosis was also improved by 50%. Furthermore, an investigation on the mentioned parameter groups considering the manufacturing order was also researched. The paper also highlights the manufacturing introduction experiences and further improvements of the proposed methods, both on the shop floor and on the quotation preparation fields. Every week more than 100 real industrial setup events are given and the related data are collected.

Keywords: artificial neural network, low series manufacturing, polymer cutting, setup period estimation

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Authors: Happy Zulu

Abstract:

Neuropsychological examination is an important way of formally assessing brain function. While there is so much documentation about the influence that some factors, such as age and education, have on neuropsychological tests (NP), not so much has been done to assess the influence that residency (rural/urban) may have. The specific objectives of this study were to establish if there is a significant difference in mean test scores on NP tests between rural and urban participants and to assess which tests on the Zambia Neurobehavioural Test Battery (ZNTB) are more affected by the participants‘ residency (rural/urban) and to determine the extent to which education, gender, and age predict test performance on NP tests for rural and urban participants. The participants (324) were drawn from both urban and rural areas of Zambia (Rural = 152 and Urban = 172). However, only 234 participants (Rural = 152 and Urban 82) were used for all the analyses in this particular study. The 234 participants were used as the actual proportion of the rural vs urban population in Zambia was 65% : 35%, respectively (CSO, 2003). The rural-urban ratio for the participants that were captured during the data collection process was 152 : 172, respectively. Thus, all the rural participants (152) were included and 90 of the 172 urban participants were randomly excluded so that the rural/urban ratio reached the desired 65% : 35 % which was the required ideal statistic for appropriate representation of the actual population in Zambia. Data on NP tests were analyzed from 234 participants, rural (N=152) reflecting 65% and urban (N=82) reflecting 35%. T-tests indicated that urban participants had superior performances in all the seven NP test domains, and all the mean differences in all these domains were found to be statistically significant. Residency had a large or moderate effect in five domains, while its effect size was small only in two of the domains. A standard multiple regression revealed that education, age and residency as predictor variables made a significant contribution to variance in performance on various domains of the ZNTB. However, the gender of participants was not a major factor in determining one‘s performance on neuropsychological tests. This particular report is part of an ongoing, larger, cutting-edge study aimed at formulating the normative data for Zambia with regard to performance on neuropsychological tests. This is necessary for appropriate, effective, and efficient assessment or diagnosis of various neurocognitive and neurobehavioural deficits that a number of people may currently be suffering from. It has been shown in this study that it is vital to make careful analyses of the variables that may be associated with one‘s performance on neuropsychological tests.

Keywords: neuropsychology, neurobehavioural, residency, Zambia

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Authors: Tung-Hui Hsu, Wen-Yuh Jywe

Abstract:

Five-axis computer numerical control (CNC) machine tools (three linear and two rotary axes) are ideally suited to the fabrication of complex work pieces, such as dies, turbo blades, and cams. The locations of the axis average line and centerline of the rotary axes strongly influence the performance of these machines; however, techniques to compensate for eccentric error in the rotary axes remain weak. This paper proposes optical (Non-Bar) techniques capable of calibrating five-axis CNC machine tools and compensating for eccentric error in the rotary axes. This approach employs the measurement path in ISO/CD 10791-6 to determine the eccentric error in two rotary axes, for which compensatory measures can be implemented. Experimental results demonstrate that the proposed techniques can improve the performance of various five-axis CNC machine tools by more than 90%. Finally, a result of the cutting test using a B-type five-axis CNC machine tool confirmed to the usefulness of this proposed compensation technique.

Keywords: calibration, compensation, rotary axis, five-axis computer numerical control (CNC) machine tools, eccentric error, optical calibration system, ISO/CD 10791-6

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Authors: Ching-Feng Chen, Ching-Chih Tsai

Abstract:

With the size of the transistor gradually approaching the physical limit, it challenges the persistence of Moore’s Law due to the development of the high numerical aperture (high-NA) lithography equipment and other issues such as short channel effects. In the context of the ever-increasing technical requirements of portable devices and high-performance computing, relying on the law continuation to enhance the chip density will no longer support the prospects of the electronics industry. Weighing the chip’s power consumption-performance-area-cost-cycle time to market (PPACC) is an updated benchmark to drive the evolution of the advanced wafer nanometer (nm). The advent of two and half- and three-dimensional (2.5 and 3D)- Very-Large-Scale Integration (VLSI) packaging based on Through Silicon Via (TSV) technology has updated the traditional die assembly methods and provided the solution. This overview investigates the up-to-date and cutting-edge packaging technologies for 2.5D and 3D integrated circuits (ICs) based on the updated transistor structure and technology nodes. The author concludes that multi-chip solutions for 2.5D and 3D IC packagings are feasible to prolong Moore’s Law.

Keywords: moore’s law, high numerical aperture, power consumption-performance-area-cost-cycle time to market, 2.5 and 3D- very-large-scale integration, packaging, through silicon via

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Authors: Amjad Nusayr

Abstract:

Software security is a general term used to any type of software architecture or model in which security aspects are incorporated in this architecture. These aspects are not part of the main logic of the underlying program. Software security can be achieved using a combination of approaches, including but not limited to secure software designs, third part component validation, and secure coding practices. Memory safety is one feature in software security where we ensure that any object in memory has a valid pointer or a reference with a valid type. Aspect-Oriented Programming (AOP) is a paradigm that is concerned with capturing the cross-cutting concerns in code development. AOP is generally used for common cross-cutting concerns like logging and DB transaction managing. In this paper, we introduce the concepts that enable AOP to be used for the purpose of memory and type safety. We also present ideas for extending AOP in software security practices.

Keywords: aspect oriented programming, programming languages, software security, memory and type safety

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Authors: Rahul R. Gurpude, Pallvita Yadav, Amrut Mulay

Abstract:

In recent years, there has been a growing focus on advanced manufacturing processes, and one such emerging process is wire electric discharge machining (WEDM). WEDM is a precision machining process specifically designed for cutting electrically conductive materials with exceptional accuracy. It achieves material removal from the workpiece metal through spark erosion facilitated by electricity. Initially developed as a method for precision machining of hard materials, WEDM has witnessed significant advancements in recent times, with numerous studies and techniques based on electrical discharge phenomena being proposed. These research efforts and methods in the field of ED encompass a wide range of applications, including mirror-like finish machining, surface modification of mold dies, machining of insulating materials, and manufacturing of micro products. WEDM has particularly found extensive usage in the high-precision machining of complex workpieces that possess varying hardness and intricate shapes. During the cutting process, a wire with a diameter ranging from 0.18mm is employed. The evaluation of EDM performance typically revolves around two critical factors: material removal rate (MRR) and surface roughness (SR). To comprehensively assess the impact of machining parameters on the quality characteristics of EDM, an Analysis of Variance (ANOVA) was conducted. This statistical analysis aimed to determine the significance of various machining parameters and their relative contributions in controlling the response of the EDM process. By undertaking this analysis, optimal levels of machining parameters were identified to achieve desirable material removal rates and surface roughness.

Keywords: WEDM, MRR, optimization, surface roughness

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Authors: Rafał Kamiński, Joel Rech, Philippe Bertrand, Christophe Desrayaud

Abstract:

Additive manufacturing is a hot topic for industry. Among the additive techniques, Selective Laser Melting (SLM) becomes even more popular, especially for making parts for aerospace applications, thanks to its design freedom (customized and light structures) and its reduced time to market. However, some functional surfaces have to be machined to achieve small tolerances and low surface roughness to fulfill industry specifications. The complex shapes designed for SLM (ex: titanium turbine blades) necessitate the use of ball end milling operations like in the conventional process after forging. However, the metallurgical state of TA6V is very different from the one obtained usually from forging, because of the laser sintering layer by layer. So this paper aims to investigate the influence of new TA6V metallurgies produced by SLM on the machinability in ball end milling. Machinability is considered as the property of a material to obtain easily and by a cheap way a functional surface. This means, for instance, the property to limit cutting tool wear rate and to get smooth surfaces. So as to reach this objective, SLM parts have been produced and heat treated with various conditions leading to various metallurgies that are compared with a standard equiaxed α+β wrought microstructure. The machinability is analyzed by measuring surface roughness, tool wear and cutting forces for a range of cutting conditions (depth of cut 'ap', feed per tooth 'fz', spindle speed 'N') in accordance with industrial practices. This work has revealed that TA6V produced by SLM can lead to a better machinability that standard wrought alloys.

Keywords: ball milling, selective laser melting, surface roughness, titanium, wear

Procedia PDF Downloads 255

Authors: Onan Kilicaslan, Anil Kabaklarli, Levent Subasi, Erdem Bektas, Rifat Yilmaz

Abstract:

The Aluminum-Copper casting alloys are well known for their high mechanical strength, especially when compared to more commonly used Aluminum-Silicon alloys. A201 is one of the best in terms of strength vs. weight ratio among other aluminum alloys, which makes it suitable for premium quality casting applications in aerospace and automotive industries. It is reported that A201 has low castability, but it is easy to machine. However, there is a need to specifically determine the process window for feasible machining. This research investigates the machinability of A201 alloy after T7 heat treatment in terms of chip/burr formation, surface roughness, hardness, and microstructure. The samples are cast with low-pressure sand casting method and milling experiments are performed with uncoated carbide tools using different cutting speeds and feeds. Statistical analysis is used to correlate the machining parameters to surface integrity. It is found that there is a strong dependence of the cutting conditions on machinability and a process window is determined.

Keywords: A201-T7, machinability, milling, surface integrity

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Authors: Faizah Almalki, Simeon Gill, Steve G. Hayes, Lisa Taylor

Abstract:

A core element of cultural identity is the traditional costumes that provide insight into the heritage that has been acquired over time. This heritage is apparent in the use of colour, the styles and the functions of the clothing and it also reflects the skills of those who created the items and the time taken to produce them. Modern flat pattern drafting methods for making garment patterns are simple in comparison to the relatively laborious traditional approaches that would require personal interaction with the wearer throughout the production process. The current study reflects on the main elements of the pattern cutting system and how this has evolved in Saudi Arabia to affect the design of the Sawan garment. Analysis of the traditional methods for constructing Sawan garments was undertaken through observation of the practice and the garments and consulting documented guidance. This provided a foundation through which to explore how modern technology can be applied to improve the process. In this research, modern methods are proposed for producing traditional Saudi garments more efficiently while retaining elements of the conventional style and design. The current study has documented the vital aspects of Sawan garment style. The result showed that the method had been used to take the body measurements and pattern making was elementary and offered simple geometric shape and the Sawan garment is composed of four pieces. Consequently, this research allows for classical pattern shapes to be embedded in garments now worn in Saudi Arabia and for the continuation of cultural heritage.

Keywords: traditional Sawan garment technique, modern pattern cutting technique, the shape of the garment and software, Lectra Modaris

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