Search results for: ultrasonic machining

Authors: M. S. Gaafar, S. Y. Marzouk, I. S. Mahmoud, S. Al-Zobaidi

Abstract:

Makishima and Mackenzie model was used to simulation of acoustic properties (longitudinal and shear ultrasonic wave velocities, elastic moduli theoretically for many tellurite and borate glasses. The model was proposed mainly depending on the values of the experimentally measured density, which are obtained before. In this search work, we are trying to obtain the values of densities of amorphous glasses (as the density depends on the geometry of the network structure of these glasses). In addition, the problem of simulating the slope of linear regression between the experimentally determined bulk modulus and the product of packing density and experimental Young's modulus, were solved in this search work. The results showed good agreement between the experimentally measured values of densities and both ultrasonic wave velocities, and those theoretically determined.

Keywords: glasses, ultrasonic wave velocities, elastic modulus, Makishima & Mackenzie Model

Procedia PDF Downloads 386

Authors: David Robert Irvine

Abstract:

In the dental restoration sector, there has been a shift to using zirconia. With the ever increasing need to decrease lead times to deliver restorations faster the zirconia is machined in its pre-sintered state instead of grinding the very hard sintered state. As with all machining, there is tool wear and while investigating the tooling used to machine pre-sintered zirconia it became apparent that the wear rate is based more on material build up and abrasion than it is on plastic deformation like conventional metal machining. It also came to light that the tool material can currently not be selected based on wear resistance, as there is no data. Different works have analysed the effect of the individual wear mechanism separately using similar if not the same material. In this work, the testing method used to analyse the wear was a modified from ISO 8688:1989 to use the pre-sintered zirconia and the cutting conditions used in dental to machine it. This understanding was developed through a series of tests based in machining operations, to give the best representation of the multiple wear factors that can occur in machining of pre-sintered zirconia such as 3 body abrasion, material build up, surface welding, plastic deformation, tool vibration and thermal cracking. From the testing, it found that carbide grades with low trans-granular rupture toughness would fail due to abrasion while those with high trans-granular rupture toughness failed due to edge chipping from build up or thermal properties. The results gained can assist the development of these tools and the restorative dental process. This work was completed with the aim of assisting in the selection of tool material for future tools along with a deeper understanding of the properties that assist in abrasive wear resistance and material build up.

Keywords: abrasive wear, cemented carbide, pre-sintered zirconia, tool wear

Procedia PDF Downloads 160

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

Abstract:

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

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

Procedia PDF Downloads 433

Authors: Pramod Keshav Kolase, Atul K. Desai

Abstract:

This paper presents the experimental investigation results of Ultrasonic Pulse Velocity (UPV) tests conducted on roller compacted concrete pavement (RCCP) material containing Class F fly ash of as mineral admixture and triangular polyester fiber as a secondary reinforcement. The each mix design series fly ash content is varied from 0% to 45 % and triangular polyester fiber 0% to 0.75% by volume fraction. In each series and for different ages of curing (i.e. 7, 28 and 90 days) forty-eight cube specimens are cast and tested for compressive strength and UPV. The UPV of fly ash was found to be lower for all mixtures at 7 days in comparison with control mix concrete. But at 28, 56 days and 90 days the UPV were significantly improved for all the mixes. Relationships between compressive strength of RCCP and UPV and Dynamic Elastic Modulus are proposed for all series mixes.

Keywords: compressive strength, dynamic elastic modulus, fly ash, fiber, roller compacted concrete, ultrasonic pulse velocity

Procedia PDF Downloads 219

Authors: M. S. Gaafar, S. Y. Marzouk

Abstract:

Sodium borosilicate glasses doped with different content of NdF3 mol % have been prepared by rapid quenching method. Ultrasonic velocities (both longitudinal and shear) measurements have been carried out at room temperature and at ultrasonic frequency of 4 MHz. Elastic moduli, Debye temperature, softening temperature and Poisson's ratio have been obtained as a function of NdF3 modifier content. Results showed that the elastic moduli, Debye temperature, softening temperature and Poisson's ratio have very slight change with the change of NdF3 mol % content. Based on FTIR spectroscopy and theoretical (Bond compression) model, quantitative analysis has been carried out in order to obtain more information about the structure of these glasses. The study indicated that the structure of these glasses is mainly composed of SiO4 units with four bridging oxygens (Q4), and with three bridging and one nonbridging oxygens (Q3).

Keywords: borosilicate glasses, ultrasonic velocity, elastic moduli, FTIR spectroscopy, bond compression model

Procedia PDF Downloads 414

Authors: Manoj Reghu, Prabhu Rajagopal, C. V. Krishnamurthy, Krishnan Balasubramaniam

Abstract:

A thorough understanding of guided ultrasonic wave behavior in structures is essential for the application of existing Non Destructive Evaluation (NDE) technologies, as well as for the development of new methods. However, the analysis of guided wave phenomena is challenging because of their complex dispersive and multimodal nature. Although numerical solution procedures have proven to be very useful in this regard, the increasing complexity of features and defects to be considered, as well as the desire to improve the accuracy of inspection often imposes a large computational cost. Hybrid models that combine numerical solutions for wave scattering with faster alternative methods for wave propagation have long been considered as a solution to this problem. However usually such models require modification of the base code of the solution procedure. Here we aim to develop Generic Hybrid models that can be directly applied to any two different solution procedures. With this goal in mind, a Numerical Hybrid model and an Analytical-Numerical Hybrid model has been developed. The concept and implementation of these Hybrid models are discussed in this paper.

Keywords: guided ultrasonic waves, Finite Element Method (FEM), Hybrid model

Procedia PDF Downloads 466

Authors: Mohamed Seghouani, Ahmed Tafraoui, Soltane Lebaili

Abstract:

The purpose of this study widened knowledge on the use of the cutting tools out of metal carbide and to define it the influence of the elements of the mode of cut on the behavior of these tools during the machining of treated steel XC38 and untreated. This work aims at evolution determined in experiments of the wear of a cutting tool out of metal carbide with plate reported of P30 nuance for an operation of slide-lathing in turning on soaked and not hardened steel XC38 test-tubes. This research is based on the model of Taylor to determine the life span of the cutting tool according to the various parameters of cut, like the cutting speed Vc, the advance of cut a, the depth of cutting P. In order to express the operational limits of the tool for slide-lathing in a preventive way. The model makes it possible to determine the time of change of the tool and to regard it as a constraint for the respect of the roughness of the workpiece during a work of series in conventional machining.

Keywords: machining, wear, lifespan, model of Taylor, cutting tool, carburize metal

Procedia PDF Downloads 392

Authors: Ehsan Kadkhodaie, Shahin Parvar, Soroush Senemar, Mostafa Shriat, Abdolrasoul Malekpour

Abstract:

The role of oil in supra distribution transformers is so critical and, several standards in determining the quality of oil have been offered. So far, moisture, viscosity and insulation protection of the oil have been measured based on mechanical and chemical methods and systems such as kart fisher, falling ball and TDM 4000 that most of these techniques are destructive and have many problems such as pollution. In this study, due to the properties of oil and also physical behavior of ultrasound wave new method was designed to in the determination of oil indicators including viscosity and moisture. The results show the oil viscosity can be found from the relationship μ = 42.086/√EE and moisture from (PLUS+) = −15.65 (PPM) + 26040 relationship.

Keywords: oil, viscosity, moisture, ultrasonic waves

Procedia PDF Downloads 581

Authors: Mohammed T. Hayajneh

Abstract:

Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al₂O₃ particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.

Keywords: composite, fuzzy, tool life, wear

Procedia PDF Downloads 296

Authors: Chun-Ying Lee, Kun-Hsien Lee, Bor-Wei Wang

Abstract:

The process of post-supercritical CO₂ electroplating uses the electrolyte solution after being mixed with supercritical CO₂ and released to atmospheric pressure. It utilizes the microbubbles that form when oversaturated CO₂ in the electrolyte returns to gaseous state, which gives the similar effect of pulsed electroplating. Under atmospheric pressure, the CO₂ bubbles gradually diffuse. Therefore, the introduction of ultrasound and/or other agitation can potentially excite the CO₂ microbubbles to achieve an electroplated surface of even higher quality. In this study, during the electroplating process, three different modes of agitation: magnetic stirrer agitation, ultrasonic agitation and a combined mode (magnetic + ultrasonic) were applied, respectively, in order to obtain an optimal surface morphology and mechanical properties for the electroplated Ni coating. It is found that the combined agitation mode at a current density of 40 A/dm² achieved the smallest grain size, lower surface roughness, and produced an electroplated Ni layer that achieved hardness of 320 HV, much higher when compared with conventional method, which were usually in the range of 160 to 300 HV. However, at the same time, the electroplating with combined agitation developed a higher internal stress of 320 MPa due to the lower current efficiency of the process and finer grain in the coating. Moreover, a new control methodology for tailoring the coating’s mechanical property through its thickness was demonstrated by the timely introduction of ultrasonic agitation during the electroplating process with post supercritical CO₂ mixed electrolyte.

Keywords: nickel electroplating, micro-bubbles, supercritical carbon dioxide, ultrasonic agitation

Procedia PDF Downloads 278

Authors: Yu-Lin Shen, Ming-Kuen Chang

Abstract:

In addition to a considerable amount of machinery and equipment, intricacies of the transmission pipeline exist in Petrochemical plants. Long term corrosion may lead to pipeline thinning and rupture, causing serious safety concerns. With the advances in non-destructive testing technology, more rapid and long-range ultrasonic detection techniques are often used for pipeline inspection, EMAT without coupling to detect, it is a non-contact ultrasonic, suitable for detecting elevated temperature or roughened e surface of line. In this study, we prepared artificial defects in pipeline for Electromagnetic Acoustic Transducer Testing (EMAT) to survey the relationship between the defect location, sizing and the EMAT signal. It was found that the signal amplitude of EMAT exhibited greater signal attenuation with larger defect depth and length.. In addition, with bigger flat hole diameter, greater amplitude attenuation was obtained. In summary, signal amplitude attenuation of EMAT was affected by the defect depth, defect length and the hole diameter and size.

Keywords: EMAT, artificial defect, NDT, ultrasonic testing

Procedia PDF Downloads 333

Authors: Sundara Subramanian Karuppasamy, Che Hua Yang

Abstract:

In this work, the laser ultrasound technique has been used for analyzing and imaging the inner defects in metal blocks. To detect the defects in blocks, traditionally the researchers used piezoelectric transducers for the generation and reception of ultrasonic signals. These transducers can be configured into the sparse and phased array. But these two configurations have their drawbacks including the requirement of many transducers, time-consuming calculations, limited bandwidth, and provide confined image resolution. Here, we focus on the non-contact method for generating and receiving the ultrasound to examine the inner defects in aluminum blocks. A Q-switched pulsed laser has been used for the generation and the reception is done by using Laser Doppler Vibrometer (LDV). Based on the Doppler effect, LDV provides a rapid and high spatial resolution way for sensing ultrasonic waves. From the LDV, a series of scanning points are selected which serves as the phased array elements. The side-drilled hole of 10 mm diameter with a depth of 25 mm has been introduced and the defect is interrogated by the linear array of scanning points obtained from the LDV. With the aid of the Synthetic Aperture Focusing Technique (SAFT) algorithm, based on the time-shifting principle the inspected images are generated from the A-scan data acquired from the 1-D linear phased array elements. Thus the defect can be precisely detected with good resolution.

Keywords: laser ultrasonics, linear phased array, nondestructive testing, synthetic aperture focusing technique, ultrasonic imaging

Procedia PDF Downloads 134

Authors: Ibrahim Al-Suraihy, Abdellaziz Doghmane, Zahia Hadjoub

Abstract:

We discuss in this work the elastic properties by using acoustic microscopes to measure Rayleigh and longitudinal wave velocities in a no radiated and radiated sodium borate glasses X2Na2O-X2B2O3 with 0 ≤ x ≤ 27 (mol %) at microscopic resolution. The acoustic material signatures were first measured, from which the characteristic surface velocities were determined.Longitudinal and shear ultrasonic velocities were measured in a different composition of sodium borate glass samples before and after irradiation with γ-rays. Results showed that the effect due to increasing sodium oxide content on the ultrasonic velocity appeared more clearly than due to γ-radiation. It was found that as Na2O composition increases, longitudinal velocities vary from 3832 to 5636 m/s in irradiated sample and it vary from 4010 to 5836 m/s in high radiated sample by 10 dose whereas shear velocities vary from 2223 to 3269 m/s in irradiated sample and it vary from 2326 m/s in low radiation to 3385 m/s in high radiated sample by 10 dose. The effect of increasing sodium oxide content on ultrasonic velocity was very clear. The increase of velocity was attributed to the gradual increase in the rigidity of glass and hence strengthening of network due to gradual change of boron atoms from the three-fold to the four-fold coordination of oxygen atoms. The ultrasonic velocities data of glass samples have been used to find the elastic modulus. It was found that ultrasonic velocity, elastic modulus and microhardness increase with increasing barium oxide content and increasing γ-radiation dose.

Keywords: mechanical properties X2Na2O-X2B2O3, acoustic signature, SAW velocities, additives, gamma-radiation dose

Procedia PDF Downloads 396

Authors: Justin Morton, Mohammad Khavari, Abhinav Priyadarshi, Nicole Grobert, Dmitry G. Eskin, Jiawei Mi, Kriakos Porfyrakis, Paul Prentice

Abstract:

Ultrasonic cavitation is used for various processes and applications. Recently, ultrasonic assisted liquid phase exfoliation has been implemented to produce two dimensional nanomaterials. Depending on parameters such as input transducer power and the operational frequency used to induce the cavitation, bubble dynamics can be controlled and optimised. Using ultra-high-speed imagining and acoustic pressure measurements, a dual-frequency systemand its effect on bubble dynamics was investigated. A high frequency transducer (1.174 MHz) showed that bubble fragments and satellite bubbles induced from a low frequency transducer (24 kHz) were able to extend their lifecycle. In addition, this combination of ultrasonic frequencies generated higher acoustic emissions (∼24%) than the sum of the individual transducers. The dual-frequency system also produced an increase in cavitation zone size of∼3 times compared to the low frequency sonotrode. Furthermore, the high frequency induced cavitation bubbleswere shown to rapidly oscillate, although remained stable and did not transiently collapse, even in the presence of a low pressure field. Finally, the spatial distribution of satellite and fragment bubbles from the sonotrode were shown to increase, extending the active cavitation zone. These observations elucidated the benefits of using a dual-frequency system for generating nanomaterials with the aid of ultrasound, in deionised water.

Keywords: dual-frequency, cavitation, bubble dynamics, graphene

Procedia PDF Downloads 195

Authors: Pushpendra S. Bharti

Abstract:

Process yield of electric discharge machining (EDM) is directly related to optimal combination(s) of process parameters. Optimization of process parameters of EDM is a multi-objective optimization problem owing to the contradictory behavior of performance measures. This paper employs Grey Relation Analysis (GRA) method as a multi-objective optimization technique for the optimal selection of process parameters combination. In GRA, multi-response optimization is converted into optimization of a single response grey relation grade which ultimately gives the optimal combination of process parameters. Experiments were carried out on die-sinking EDM by taking D2 steel as work piece and copper as electrode material. Taguchi's orthogonal array L36 was used for the design of experiments. On the experimental values, GRA was employed for the parametric optimization. A significant improvement has been observed and reported in the process yield by taking the parametric combination(s) obtained through GRA.

Keywords: electric discharge machining, grey relation analysis, material removal rate, optimization

Procedia PDF Downloads 409

Authors: Kwarciak-Kozlowska A., Slawik-Dembiczak L., Galwa-Widera M.

Abstract:

Complex and variable during operation of the landfill leachate composition prevents the use of a single universal method of their purification. Due to the presence of difficult biodegradable these substances in the wastewater, cleaning of them often requires the use of biological methods (activated sludge or anaerobic digestion), also often supporting by physicochemical processes. Currently, more attention is paid to the development of unconventional methods of disposal of sewage m.in ultleniania advanced methods including the use of ultrasonic waves. It was assumed that the ultrasonic waves induce change in the structure of organic compounds and contribute to the acceleration of biodegradability, including refractive substances in the leachate, so that will increase the effectiveness of their treatment in biological processes. We observed a marked increase in BOD leachate when subjected to the action of utradźwięowego. Ratio BOD / COD was 27% higher compared to the value of this ratio for leachate nienadźwiękawianych. It was found that the process of sonification leachate clearly influenced the formation and release of aliphatic compounds. These changes suggest a possible violation of the chemical structure of organic compounds in the leachate thereby give compounds of the chemical structure more susceptible to biodegradation.

Keywords: IR spectra, landfill leachate, organic pollutants, ultrasound

Procedia PDF Downloads 429

Authors: Yu-Lin Shen, Ming-Kuen Chang

Abstract:

In addition to a considerable amount of machinery and equipment, intricacies of the transmission pipeline exist in Petrochemical plants. Long term corrosion may lead to pipeline thinning and rupture, causing serious safety concerns. With the advances in non-destructive testing technology, more rapid and long-range ultrasonic detection techniques are often used for pipeline inspection, EMAT without coupling to detect, it is a non-contact ultrasonic, suitable for detecting elevated temperature or roughened e surface of line. In this study, we prepared artificial defects in pipeline for Electromagnetic Acoustic Transducer testing (EMAT) to survey the relationship between the defect location, sizing and the EMAT signal. It was found that the signal amplitude of EMAT exhibited greater signal attenuation with larger defect depth and length. In addition, with bigger flat hole diameter, greater amplitude attenuation was obtained. In summary, signal amplitude attenuation of EMAT was affected by the defect depth, defect length and the hole diameter and size.

Keywords: EMAT, artificial defect, NDT, ultrasonic testing

Procedia PDF Downloads 350

Authors: Muhammad Jamil, Ning He, Wei Zhao

Abstract:

Ti-6Al-4V has poor thermal conductivity (6.7W/mK) accumulates shear and friction heat at the tool-chip interface zone. To dissipate the heat generation and friction effect, cryogenic cooling, Minimum quantity lubrication (MQL), nanofluids, hybrid cryogenic-MQL, solid lubricants, etc are applied frequently to underscore their significant effect on improving the machinability of Ti-6Al-4V. Nowadays, hybrid lubri-cooling is getting attention from researchers to explore their effect on machining Ti-6Al-4V.

Keywords: hybrid lubri-cooling, tool wear, surface roughness, minimum quantity lubrication

Procedia PDF Downloads 144

Authors: D. Deepak, N. Yagnesh Sharma

Abstract:

Abrasive Water Jet (AWJ) machining is a relatively new nontraditional machine tool used in machining of fiber reinforced composite. The quality of machined surface depends on jet exit kinetic energy which depends on various operating and material parameters. In the present work the effect abrasive parameters such as its size, concentration and type on jet kinetic energy is investigated using computational fluid dynamics (CFD). In addition, the effect of these parameters on wall shear stress developed inside the nozzle is also investigated. It is found that for the same operating parameters, increase in the abrasive volume fraction (concentration) results in significant decrease in the wall shear stress as well as the jet exit kinetic energy. Increase in the abrasive particle size results in marginal decrease in the jet exit kinetic energy. Numerical simulation also indicates that garnet abrasives produce better jet exit kinetic energy than aluminium oxide and silicon carbide.

Keywords: abrasive water jet machining, jet kinetic energy, operating pressure, wall shear stress, Garnet abrasive

Procedia PDF Downloads 378

Authors: Youji Miyake

Abstract:

In aircraft assembly, a large number of preparatory holes are required for screw and rivet joints. Currently, many holes are drilled manually because it is difficult to machine the holes using conventional computerized numerical control(CNC) machines. The application of industrial robots to drill the hole has been considered as an alternative to the CNC machines. However, the rigidity of robot arms is so low that vibration is likely to occur during drilling. In this study, it is proposed constant-load feed machining as a method to perform high-precision drilling while minimizing the thrust force, which is considered to be the cause of vibration. In this method, the drill feed is realized by a constant load applied onto the tool so that the thrust force is theoretically kept below the applied load. The performance of the proposed method was experimentally examined through the deep hole drilling of plastic and simultaneous drilling of metal/plastic stack plates. It was confirmed that the deep hole drilling and simultaneous drilling could be performed without generating vibration by controlling the tool feed rate in the appropriate range.

Keywords: constant load feed machining, robotic drilling, deep hole, simultaneous drilling

Procedia PDF Downloads 195

Authors: Bin Shi, Mouhab Meshreki, Grégoire Bazin, Helmi Attia

Abstract:

Large monolithic components are widely used in the aerospace industry in order to reduce airplane weight. Milling is an important operation in manufacturing of the monolithic parts. More than 90% of the material could be removed in the milling operation to obtain the final shape. This results in low rigidity and post-machining distortion. The post-machining distortion is the deviation of the final shape from the original design after releasing the clamps. It is a major challenge in machining of the monolithic parts, which costs billions of economic losses every year. Three sources are directly related to the part distortion, including initial residual stresses (RS) generated from previous manufacturing processes, machining-induced RS and thermal load generated during machining. A finite element model was developed to simulate a milling process and predicate the post-machining distortion. In this study, a rolled-aluminum plate AA7175 with a thickness of 60 mm was used for the raw block. The initial residual stress distribution in the block was measured using a layer-removal method. A stress-mapping technique was developed to implement the initial stress distribution into the part. It is demonstrated that this technique significantly accelerates the simulation time. Machining-induced residual stresses on the machined surface were measured using MTS3000 hole-drilling strain-gauge system. The measured RS was applied on the machined surface of a plate to predict the distortion. The predicted distortion was compared with experimental results. It is found that the effect of the machining-induced residual stress on the distortion of a thick plate is very limited. The distortion can be ignored if the wall thickness is larger than a certain value. The RS generated from the thermal load during machining is another important factor causing part distortion. Very limited number of research on this topic was reported in literature. A coupled thermo-mechanical FE model was developed to evaluate the thermal effect on the plastic deformation of a plate. A moving heat source with a feed rate was used to simulate the dynamic cutting heat in a milling process. When the heat source passed the part surface, a small layer was removed to simulate the cutting operation. The results show that for different feed rates and plate thicknesses, the plastic deformation/distortion occurs only if the temperature exceeds a critical level. It was found that the initial residual stress has a major contribution to the part distortion. The machining-induced stress has limited influence on the distortion for thin-wall structure when the wall thickness is larger than a certain value. The thermal load can also generate part distortion when the cutting temperature is above a critical level. The developed numerical model was employed to predict the distortion of a frame part with complex structures. The predictions were compared with the experimental measurements, showing both are in good agreement. Through optimization of the position of the part inside the raw plate using the developed numerical models, the part distortion can be significantly reduced by 50%.

Keywords: modelling, monolithic parts, optimization, post-machining distortion, residual stresses

Procedia PDF Downloads 55

Authors: Tarek M. Ahmed, Ahmed S. El Mesalamy, Amro M. Youssef, Tawfik T. El Midany

Abstract:

Abrasive waterjet (AWJ) machining is considered as one of the most powerful cutting processes. It can be used for cutting heat sensitive, hard and reflective materials. Aluminum 2024 is a high-strength alloy which is widely used in aerospace and aviation industries. This paper aims to improve aluminum alloy and to investigate the effect of AWJ control parameters on surface geometry quality. Design of experiments (DoE) is used for establishing an experimental matrix. Statistical modeling is used to present a relation between the cutting parameters (pressure, speed, and distance between the nozzle and cut surface) and responses (taper angle and surface roughness). The results revealed a tangible improvement in productivity by using AWJ processing. The taper kerf angle can be improved by decreasing standoff distance and speed and increasing water pressure. While decreasing (cutting speed, pressure and distance between the nozzle and cut surface) improve the surface roughness in the operating window of cutting parameters.

Keywords: abrasive waterjet machining, machining of aluminum alloy, non-traditional cutting, statistical modeling

Procedia PDF Downloads 250

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

Abstract:

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)

Procedia PDF Downloads 283

Authors: Zs. Kovács, Zs. J. Viharos, J. Kodácsy

Abstract:

As a well-known conventional finishing process, the grinding is commonly used to manufacture seal mating surfaces and bearing surfaces, but is also creates twisted surfaces. The machined surfaces by turning or grinding usually have twist structure on the surfaces, which can convey lubricants such as conveyor screw. To avoid this phenomenon, have to use special techniques or machines, for example start-stop turning, tangential turning, ultrasonic protection or special toll geometries. All of these solutions have high cost and difficult usability. In this paper, we describe a system and summarize the results of the experimental research carried out mainly in the field of Magnetic Abrasive Polishing (MAP) and Magnetic Roller Burnishing (MRB). These technologies are simple and also green while able to produce twist-free surfaces. During the tests, C45 normalized steel was used as workpiece material which was machined by simple and Wiper geometrical turning inserts in a CNC turning lathe. After the turning, the MAP and MRB technologies can be used directly to reduce the twist of surfaces. The evaluation was completed by advanced measuring and IT equipment.

Keywords: magnetism, finishing, polishing, roller burnishing, twist-free

Procedia PDF Downloads 576

Authors: Yu-Lin Shen, Ming-Kuen Chang

Abstract:

In addition to a considerable amount of machinery and equipment, intricacies of the transmission pipeline exist in Petrochemical plants. Long term corrosion may lead to pipeline thinning and rupture, causing serious safety concerns. With the advances in non-destructive testing technology, more rapid and long-range ultrasonic detection techniques are often used for pipeline inspection, EMAT without coupling to detect, it is a non-contact ultrasonic, suitable for detecting elevated temperature or roughened e surface of line. In this study, we prepared artificial defects in pipeline for Electro Magnetic Acoustic Transducer Testing (EMAT) to survey the relationship between the defect location, sizing and the EMAT signal. It was found that the signal amplitude of EMAT exhibited greater signal attenuation with larger defect depth and length.. In addition, with bigger flat hole diameter, greater amplitude attenuation was obtained. In summary, signal amplitude attenuation of EMAT was affected by the defect depth, defect length and the hole diameter and size.

Keywords: EMAT, NDT, artificial defect, ultrasonic testing

Procedia PDF Downloads 475

Authors: Regina Rekuviene, Vykintas Samaitis, Liudas Mažeika, Audrius Jankauskas, Virginija Jankauskaitė, Laura Gegeckienė, Abdolali Sadaghiani, Shaghayegh Saeidiharzand

Abstract:

Icing brings significant damage to aviation and renewable energy installations. Air-conditioning, refrigeration, wind turbine blades, airplane and helicopter blades often suffer from icing phenomena, which cause severe energy losses and impair aerodynamic performance. The icing process is a complex phenomenon with many different causes and types. Icing mechanisms, distributions, and patterns are still relevant to research topics. The adhesion strength between ice and surfaces differs in different icing environments. This makes the task of anti-icing very challenging. The techniques for various icing environments must satisfy different demands and requirements (e.g., efficient, lightweight, low power consumption, low maintenance and manufacturing costs, reliable operation). It is noticeable that most methods are oriented toward a particular sector and adapting them to or suggesting them for other areas is quite problematic. These methods often use various technologies and have different specifications, sometimes with no clear indication of their efficiency. There are two major groups of anti-icing methods: passive and active. Active techniques have high efficiency but, at the same time, quite high energy consumption and require intervention in the structure’s design. It’s noticeable that vast majority of these methods require specific knowledge and personnel skills. The main effect of passive methods (ice-phobic, superhydrophobic surfaces) is to delay ice formation and growth or reduce the adhesion strength between the ice and the surface. These methods are time-consuming and depend on forecasting. They can be applied on small surfaces only for specific targets, and most are non-biodegradable (except for anti-freezing proteins). There is some quite promising information on ultrasonic ice mitigation methods that employ UGW (Ultrasonic Guided Wave). These methods are have the characteristics of low energy consumption, low cost, lightweight, and easy replacement and maintenance. However, fundamental knowledge of ultrasonic de-icing methodology is still limited. The objective of this work was to identify the ice formation processes and its progress by employing ultrasonic guided wave technique. Throughout this research, the universal set-up for acoustic measurement of ice formation in a real condition (temperature range from +240 C to -230 C) was developed. Ultrasonic measurements were performed by using high frequency 5 MHz transducers in a pitch-catch configuration. The selection of wave modes suitable for detection of ice formation phenomenon on copper metal surface was performed. Interaction between the selected wave modes and ice formation processes was investigated. It was found that selected wave modes are sensitive to temperature changes. It was demonstrated that proposed ultrasonic technique could be successfully used for the detection of ice layer formation on a metal surface.

Keywords: ice formation processes, ultrasonic GW, detection of ice formation, ultrasonic testing

Procedia PDF Downloads 64

Authors: N. H. Alias, S. A. Aziz, Y. Abdullah, H. M. Kamari, S. Sani, M. P. Ismail, N. U. Saidin, N. A. A. Salim, N. E. E. Abdullah

Abstract:

Gamma (γ) irradiation study has been investigated on the 6 rectangular shape of the standard X-Ray lead glass with 5/16” thick, providing 2.00 mm lead shielding value; at selected Sievert doses (C1; 0, C2; 0.07, C3; 0.035, C4; 0.07, C5; 0.105 and C6; 0.14) by using (XRD) X-ray Diffraction techniques, ultrasonic and (UV-VIS) Ultraviolet-Visible Spectroscopy. Concentration of lead in 0.5 N acid nitric (HNO3) environments is then studied by means of Atomic Absorption Spectroscopy (AAS) as to observe the glass corrosion behavior after irradiation at room temperature. This type of commercial glass is commonly used as radiation shielding glass in medical application.

Keywords: gamma irradiation, lead glass, leaching, structural

Procedia PDF Downloads 434

Authors: Yongrong Li, Ralf Domroes

Abstract:

Due to significant energy savings, enablement of higher machining speed as well as environmentally friendly features, Minimum Quantity Lubrication (MQL) has been used for many machining processes efficiently. However, in the deep hole drilling field (small tool diameter D < 5 mm) and long tool (length L > 25xD) it is always a bottle neck for a single channel MQL system. The single channel MQL, based on the Venturi principle, faces a lack of enough oil quantity caused by dropped pressure difference during the deep hole drilling process. In this paper, a system concept based on a bypass design has explored its possibility to dynamically reach the required pressure difference between the air inlet and the inside of aerosol generator, so that the deep hole drilling demanded volume of oil can be generated and delivered to tool tips. The system concept has been investigated in static and dynamic laboratory testing. In the static test, the oil volume with and without bypass control were measured. This shows an oil quantity increasing potential up to 1000%. A spray pattern test has demonstrated the differences of aerosol particle size, aerosol distribution and reaction time between single channel and bypass controlled single channel MQL systems. A dynamic trial machining test of deep hole drilling (drill tool D=4.5mm, L= 40xD) has been carried out with the proposed system on a difficult machining material AlSi7Mg. The tool wear along a 100 meter drilling was tracked and analyzed. The result shows that the single channel MQL with a bypass control can overcome the limitation and enhance deep hole drilling with a small tool. The optimized combination of inlet air pressure and bypass control results in a high quality oil delivery to tool tips with a uniform and continuous aerosol flow.

Keywords: deep hole drilling, green production, Minimum Quantity Lubrication (MQL), near dry machining

Procedia PDF Downloads 205

Authors: Rongli Gai, Zhiyuan Chang

Abstract:

At this stage, in view of various situations in the interpolation process, most researchers use self-adaptation to adjust the interpolation process, which is also one of the current and future research hotspots in the field of CNC machining. In the interpolation process, according to the overview of the spline curve interpolation algorithm, the adaptive analysis is carried out from the factors affecting the interpolation process. The adaptive operation is reflected in various aspects, such as speed, parameters, errors, nodes, feed rates, random Period, sensitive point, step size, curvature, adaptive segmentation, adaptive optimization, etc. This paper will analyze and summarize the research of adaptive imputation in the direction of the above factors affecting imputation.

Keywords: adaptive algorithm, CNC machining, interpolation constraints, spline curve interpolation

Procedia PDF Downloads 205

Authors: Bhupinder Singh, Joy Prakash Misra

Abstract:

This article provides the information regarding machining of hastelloy-X on wire electro spark machining (WEDM). Experimental investigation has been carried out by varying pulse-on time (TON), pulse-off time (TOFF), peak current (IP) and spark gap voltage (SV). Effect of these parameters is studied on material removal rate (MRR). Experiments are designed as per box-behnken design (BBD) technique of response surface methodology (RSM). Analysis of variance (ANOVA) results indicates that TON, TOFF, IP, SV, TON x IP are significant parameters that influenced the MRR, and it is depicted that value of MRR is more at high discharge energy (HDE) and less at low discharge energy (LDE). Furthermore, miniature impeller and miniature gear (OD≤10MM) is fabricated by WEDM at optimized condition.

Keywords: advanced manufacturing, WEDM, super alloy, gear

Procedia PDF Downloads 226