Search results for: cryogenic machining

Authors: F. S. Alavi

Abstract:

In this study, MATLAB engineering software was used in order to model an industrial Ambient Air Vaporizer (AAV), considering combined convection and conduction heat transfers from the fins and the tube. The developed theoretical model was then used to investigate the effects of various design factors such as gas flow rate, ambient air temperature, fin thickness and etc. on total vaporizer ‘s length required. Cryogenic liquid nitrogen was selected as an input fluid, in all cases. According to the results, increasing the inlet fluid flow rate has direct linear effect on the total required length of vaporizer. Vaporizer’s required length decreases by increasing the size of fin radius or size of fin thickness. The dependency of vaporizer’s length on fin thickness’ size reduces at higher values of thickness and gradually converge to zero. For low flow rates, internal convection heat transfer coefficient depends directly on gas flow rate but it becomes constant, independent on flow rate after a specific value. As the ambient air temperature increases, the external heat transfer coefficient also increases and the total required length of vaporizer decreases.

Keywords: heat exchanger, modeling, heat transfer, design

Procedia PDF Downloads 88

Authors: Bharatendra Rai

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Cutting tools are widely used in manufacturing processes and drilling is the most commonly used machining process. Although drill-bits used in drilling may not be expensive, their breakage can cause damage to expensive work piece being drilled and at the same time has major impact on productivity. Predicting drill-bit breakage, therefore, is important in reducing cost and improving productivity. This study uses twenty features extracted from two degradation signals viz., thrust force and torque. The methodology used involves developing and comparing decision tree, random forest, and multinomial logistic regression models for classifying and predicting drill-bit breakage using degradation signals.

Keywords: degradation signal, drill-bit breakage, random forest, multinomial logistic regression

Procedia PDF Downloads 325

Authors: Rui-Xiong Han, Rui Ge, Shao-Peng Li, Lin Bian, Liang-Rui Sun, Min-Jing Sang, Rui Ye, Ya-Ping Liu, Xiang-Zhen Zhang, Jie-Hao Zhang, Zhuo Zhang, Jian-Qing Zhang, Miao-Fu Xu

Abstract:

The Chinese Accelerator Driven Sub-critical system (C-ADS) uses a high-energy proton beam to bombard the metal target and generate neutrons to deal with the nuclear waste. The Chinese ADS proton linear has two 0~10 MeV injectors and one 10~1500 MeV superconducting linac. Injector-I is studied by the Institute of High Energy Physics (IHEP) under construction in the Beijing, China. The linear accelerator consists of two accelerating cryomodules operating at the temperature of 2 Kelvin. This paper describes the structure and thermal performances analysis of the cryomodule. The analysis takes into account all the main contributors (support posts, multilayer insulation, current leads, power couplers, and cavities) to the static and dynamic heat load at various cryogenic temperature levels. The thermal simulation analysis of the cryomodule is important theory foundation of optimization and commissioning.

Keywords: C-ADS, cryomodule, structure, thermal simulation, static heat load, dynamic heat load

Procedia PDF Downloads 368

Authors: Hadi Rezghimaleki, Masatoshi Kubouchi, Yoshihiko Arao

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The use of natural fiber composites (NFCs) is growing at a fast rate regarding industrial applications and principle researches due to their eco-friendly, renewable nature, and low density/costs. Drilling is one of the most important machining operations that are carried out on natural fiber composites. Delamination is a major concern in the drilling process of NFCs that affects the structural integrity and long-term reliability of the machined components. Flax fiber reinforced epoxy composite laminates were prepared by hot press technique. In this research, we evaluated drilling-induced delamination of flax/epoxy composites by X-ray computed tomography (CT), ultrasonic testing (UT), and optical methods and compared the results.

Keywords: natural fiber composites, flax/epoxy, X-ray CT, ultrasonic testing

Procedia PDF Downloads 271

Authors: Ryspek Usubamatov, Tan San Chin, Sarken Kapaeva

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Productivity of the manufacturing systems depends on technological processes, a technical data of machines and a structure of systems. Technology is presented by the machining mode and data, a technical data presents reliability parameters and auxiliary time for discrete production processes. The term structure of manufacturing systems includes the number of serial and parallel production machines and links between them. Structures of manufacturing systems depend on the complexity of technological processes. Mathematical models of productivity rate for manufacturing systems are important attributes that enable to define best structure by criterion of a productivity rate. These models are important tool in evaluation of the economical efficiency for production systems.

Keywords: productivity, structure, manufacturing systems, structural design

Procedia PDF Downloads 558

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

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

Keywords: boring, chatter, mass damping, passive damping

Procedia PDF Downloads 337

Authors: Aiman Alshare, Sahar Qaadan

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A curvature dependent force correction algorithm for planning force controlled grinding process with off-line programming flexibility is designed for ABB industrial robot, in order to avoid the manual interface during the process. The machining path utilizes a spline curve fit that is constructed from the CAD data of the workpiece. The fitted spline has a continuity of the second order to assure path smoothness. The implemented algorithm computes uniform forces normal to the grinding surface of the workpiece, by constructing a curvature path in the spatial coordinates using the spline method.

Keywords: ABB industrial robot, grinding process, offline programming, CAD data extraction, force correction algorithm

Procedia PDF Downloads 338

Authors: Satyanarayana Kosaraju, Venu Gopal Anne, Sateesh Nagari

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In this paper, the effect of cutting speed, feedrate and rake angle in tool geometry on cutting forces and temperature generated on the tool tip in turning were investigated. The data used for the investigation derived from experiments conducted on precision lathe according to the full factorial design to observe the effect of each factor level on the process performance. During the tests, depth of cut were kept constant and each test was conducted with a sharp coated tool insert. Ti-6Al-4V was used as the workpiece material. The effects of cutting parameters and tool geometry on cutting forces and tool tip temperature were analyzed. The main cutting force was observed to have a decreasing trend and temperature found to be increasing trend as the rake angle increased.

Keywords: cutting force, tool tip temperature, rake angle, machining

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Authors: Raja V., Chokkalingam B.

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

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

Procedia PDF Downloads 432

Authors: C. C. Lv, Y. L. Sun, D. W. Zuo

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Cemented carbide balls are usually implemented in industry under the environment of high speed, high temperature, corrosiveness and strong collisions. However, its application is limited due to high fabrication cost, processing efficiency and quality. A novel eccentric lapping method with two rotatable lapping plates was proposed in this paper. A mathematical model was constructed to analyze the influence of each design parameter on this lapping method. To validate this new lapping method, an orthogonal experiment was conducted with cemented carbide balls (YG6). The simulation model was verified and the optimal lapping parameters were derived. The results show that the surface roundness of the balls reaches to 0.65um from 2um in 1 hour using this lapping method. So, using this novel lapping method, it can effectively improve the machining precision and efficiency of cemented carbide balls.

Keywords: cemented carbide balls, eccentric lapping, high precision, lapping tracks, V-groove

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Authors: Madhu Jain, Rakesh Kumar Meena

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This paper investigates a finite M/G/1 fault tolerant multi-component machining system. The system incorporates the features such as standby support, threshold recovery and imperfect coverage make the study closer to real time systems. The performance prediction of M/G/1 fault tolerant system is carried out using recursive approach by treating remaining service time as a supplementary variable. The numerical results are presented to illustrate the computational tractability of analytical results by taking three different service time distributions viz. exponential, 3-stage Erlang and deterministic. Moreover, the cost function is constructed to determine the optimal choice of system descriptors to upgrading the system.

Keywords: fault tolerant, machine repair, threshold recovery policy, imperfect coverage, supplementary variable technique

Procedia PDF Downloads 264

Authors: Aprilia, Wei Liang Keith Nguyen, Shu Beng Tor, Gerald Gim Lee Seet, Chee Kai Chua

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Automated remanufacturing process is of great interest in today’s marine and offshore industry. Most of the current remanufacturing processes are carried out manually and hence they are error prone, labour-intensive and costly. In this paper, a conceptual framework for automated remanufacturing is presented. This framework involves the integration of 3D non-contact digitization, adaptive surface reconstruction, additive manufacturing and machining operation. Each operation is operated and interconnected automatically as one system. The feasibility of adaptive surface reconstruction on marine and offshore engineering components is also discussed. Several engineering components were evaluated and the results showed that this proposed system is feasible. Conclusions are drawn and further research work is discussed.

Keywords: adaptive surface reconstruction, automated remanufacturing, automatic repair, reverse engineering

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Authors: Lu Xi, Li Pan, Wen Mengmeng

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The stiffness of each component has different influences on the stiffness of the machine tool. Taking the five-axis gantry machining center as an example, we made the modal analysis of the machine tool, followed by raising and lowering the stiffness of the pillar, slide plate, beam, ram and saddle so as to study the stiffness matching among these components on the standard of whether the stiffness of the modified machine tool changes more than 50% relative to the stiffness of the original machine tool. The structural optimization of the machine tool can be realized by changing the stiffness of the components whose stiffness is mismatched. For example, the stiffness of the beam is mismatching. The natural frequencies of the first six orders of the beam increased by 7.70%, 0.38%, 6.82%, 7.96%, 18.72% and 23.13%, with the weight increased by 28Kg, leading to the natural frequencies of several orders which had a great influence on the dynamic performance of the whole machine increased by 1.44%, 0.43%, 0.065%, which verified the correctness of the optimization method based on stiffness matching proposed in this paper.

Keywords: machine tool, optimization, modal analysis, stiffness matching

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Authors: Hasan Al Dabbas

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

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

Procedia PDF Downloads 552

Authors: Huang Haoxin

Abstract:

Large dark current at room temperature has long been the major bottleneck that impedes the development of high-performance infrared photodetectors towards miniaturization and integration. Although infrared photodetectors based on layered 2D narrow bandgap semiconductors have shown admirable advantages compared with those based on conventional compounds, which typically suffer from expensive cryogenic operations, it is still urgent to develop a simple but effective strategy to further reduce the dark current. Herein, a tellurium (Te) based infrared photodetector is reported with a specifically designed asymmetric electrical contact area. The deliberately introduced asymmetric electrical contact raises the electric field intensity difference in the Te channel near the drain and the source electrodes, resulting in spontaneous asymmetric carrier diffusion under global infrared light illumination under zero bias. Specifically, the Te-based photodetector presents promising detector performance at room temperature, including a low dark current of≈1 nA, an ultrahigh photocurrent/dark current ratio of 1.57×10⁴, a high specific detectivity (D*) of 3.24×10⁹ Jones, and relatively fast response speed of ≈720 μs at zero bias. The results prove that the simple design of asymmetric electrical contact areas can provide a promising solution to high-performance 2D semiconductor-based infrared photodetectors working at room temperature.

Keywords: asymmetrical contact, tellurium, dark current, infrared photodetector, sensitivity

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Authors: S. Ghorbani, N. I. Polushin

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

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

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Authors: Li Chin Law, Epaminondas Mastorakos, Mohd Roslee Othman, Antonis Trakakis

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The paper introduces an alternative concept of carbon capture for shipping by using pre-combustion carbon capture technology (Pre-CCS), which was proven to be less energy intensive than post-combustion carbon capture from the engine exhaust. Energy assessment on amine-based post-combustion CCS on LNG-fuelled ships showed that the energy efficiency of CCS ships reduced from 48% to 36.6%. Then, an energy assessment was carried out to compare the power and heat requirements of the most used hydrogen production methods and carbon capture technologies. Steam methane reformer (SMR) was found to be 20% more energy efficient and achieved a higher methane conversion than auto thermal reaction and methane decomposition. Next, pressure swing adsorber (PSA) has shown a lower energy requirement than membrane separation, cryogenic separation, and amine absorption in pre-combustion carbon capture. Hence, an integrated system combining SMR and PSA (SMR-PSA) with waste heat integration (WHR) was proposed. This optimized SMR-based integrated system has achieved 65% of CO₂ reduction with less than 7-percentage point of energy penalty (41.7% of energy efficiency). Further integration of post-combustion CCS with the SMR-PSA integrated system improved carbon capture rate to 86.3% with 9-percentage points of energy penalty (39% energy efficiency). The proposed system was shown to be able to meet the carbon reduction targets set by International Maritime Organization (IMO) with certain energy penalties.

Keywords: shipping, decarbonisation, alternative fuels, low carbon, hydrogen, carbon capture

Procedia PDF Downloads 53

Authors: Djamal Atlaoui, Youcef Bouafia

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This work deals with the experimental study of the mechanical behavior, by shear tests (fracture shear), elements of concrete beams reinforced with fibers in chips. These fibers come from the machining waste of the steel parts. The shear tests are carried out on prismatic specimens of dimensions 10 x 20 x 120 cm³. The fibers are characterized by mechanical resistance and tearing. The optimal composition of the concrete was determined by the workability test. Two fiber contents are selected for this study (W = 0.6% and W = 0.8%) and a BT control concrete (W = 0%) of the same composition as the matrix is developed to serve as a reference with a sand-to-gravel ratio (S/G) of concrete matrix equal to 1. The comparison of the different results obtained shows that the chips fibers confer a significant ductility to the material after cracking of the concrete. Also, the fibers used limit diagonal cracks in shear and improve strength and rigidity.

Keywords: characterization, chips fibers, cracking mode, ductility, undulation, shear

Procedia PDF Downloads 98

Authors: S. Ghorbani, N. I. Polushin

Abstract:

In this study, an approach to identify factors affecting on surface roughness in a machining process is presented. This study is based on 81 data about surface roughness over a wide range of cutting tools (conventional, cutting tool with holes, cutting tool with composite material), workpiece materials (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). A single decision tree (SDT) analysis was done to identify factors for predicting a model of surface roughness, and the CART algorithm was employed for building and evaluating regression tree. Results show that a single decision tree is better than traditional regression models with higher rate and forecast accuracy and strong value.

Keywords: cutting condition, surface roughness, decision tree, CART algorithm

Procedia PDF Downloads 346

Authors: G. Krishna Mohana Rao, P. Ravi Kumar

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Milling is the process of removing unwanted material with suitable tool. Even though the milling process is having wider application, the vibration of machine tool and work piece during the process produces chatter on the products. Various methods of preventing the chatter have been incorporated into machine tool systems. Damper is cut into equal number of parts. Each part is called as finger. Multiple fingers were inserted in the hollow portion of the shank to reduce tool vibrations. In the present work, nonlinear static and dynamic analysis of the damper inserted end milling cutter used to reduce the chatter was done. A comparison is made for the milling cutter with multiple dampers. Surface roughness was determined by machining with multiple finger inserted milling cutters.

Keywords: damping inserts, end milling, vibrations, nonlinear dynamic analysis, number of fingers

Procedia PDF Downloads 496

Authors: Ghulam Murshid, Samil Ullah

Abstract:

Scientific studies suggested that the incremented greenhouse gas concentration in the atmosphere, particularly of carbon dioxide (CO2) is one of the major factors in global warming. The concentration of CO2 in our climate has crossed the milestone level of 400 parts per million (ppm) hence breaking the record of human history. A report by 49 researchers from 10 countries said, 'Global CO2 emissions from burning fossil fuels will rise to a record 36 billion metric tons (39.683 billion tons) this year.' Main contributors of CO2 in to the atmosphere are usage of fossil fuel, transportation sector and power generation plants. Among all available technologies, which include; absorption via chemicals, membrane separation, cryogenic and adsorption are in practice around the globe. Adsorption of CO2 using metal organic frameworks (MOF) is getting interest of researcher around the globe. In the current work, MOF-74 as well as modified MOF-74 with a sterically hindered amine (AMP) was synthesized and characterized. The modification was carried out using a sterically hindered amine in order to study the effect on its adsorption capacity. Resulting samples were characterized by using Fourier Transform Infrared Spectroscopy (FTIR), Field Emission Scanning Electron Microscope (FESEM), Thermal Gravimetric Analyser (TGA) and Brunauer-Emmett-Teller (BET). The FTIR results clearly confirmed the formation of MOF-74 structure and the presence of AMP. FESEM and TEM revealed the topography and morphology of the both MOF-74 and amine modified MOF. BET isotherm result shows that due to the addition of AMP in to the structure, significant enhancement of CO2 adsorption was observed.

Keywords: adsorbents, amine, CO2, global warming

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Authors: Amine Hamdi, Sidi Mohammed Merghache, Brahim Fernini

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During abrasive machining of hard steels by belt grinding, the finished surface texture is influenced by the pressure between the abrasive belt and the workpiece; this pressure is the force applied by the contact roller on the workpiece. Therefore, the contact roller has an important role and has a direct impact on process efficiency. The objective of this article is to study and compare the influence of different contact rollers on the belt ground surface texture. The quality of the surface texture is characterized by eight roughness parameters (Ra, Rz, Rp, Rv, Rsk, Rku, Rsm, and Rdq) and five parameters of the bearing area curve (Rpk, Rk, Rvk, Mr1, and Mr2). The results of the experimental tests indicate a better surface texture obtained by the PA 6 polyamide roller (hardness 60 Shore D) compared to that obtained with other rollers of the same hardness or of different hardness. Simultaneously, optimum medium pressure between the belt and the workpiece allows chip removal without fracturing the abrasive grains. This generates a good surface texture.

Keywords: belt grinding, contact roller, pressure, abrasive belt, surface texture

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Authors: F. Brunke, L. Waalkes, C. Siemers

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Due to reduced stiffness, research on second generation titanium alloys for implant applications, like the metastable β-titanium alloy Ti-15Mo, become more and more important in the recent years. The machinability of these alloys is generally poor leading to problems during implant production and comparably large production costs. Therefore, in the present study, Ti 15Mo was alloyed with 0.8 wt.-% of the rare earth metals lanthanum (Ti-15Mo+0.8La) and neodymium (Ti-15Mo+0.8Nd) to improve its machinability. Their microstructure consisted of a titanium matrix and micrometer-size particles of the rare earth metals and two of their oxides. The particles stabilized the micro structure as grain growth was minimized. As especially the ductility might be affected by the precipitates, the behavior of Ti-15Mo+0.8La and Ti-15Mo+0.8Nd was investigated during static and dynamic deformation at elevated temperature to develop a processing route. The resulting mechanical properties (static strength and ductility) were similar in all investigated alloys.

Keywords: Ti 15Mo, titanium alloys, rare earth metals, free machining alloy

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Authors: Parnian Kianfar, Navid Zarif Karimi, Giangiacomo Minak

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Drilling is one of the most important machining operations as numerous holes must be drilled in order to install mechanical fasteners for assembly in composite structures. Delamination is a major problem associated with the drilling of fiber reinforced composite materials, which degrades the mechanical properties of these materials. In drilling, delamination is initiated when the drilling force exceeds a threshold value, particularly at the critical entry and exit locations of the drill bit. The chisel edge of twist drill is a major contributor to the thrust force which is the primary cause of delamination. The main objective of this paper is to study the effect of chisel edge and pilot hole on thrust force and delamination during drilling of glass fiber reinforced composites. For this purpose, two sets of experiments, with and without pilot hole, were conducted with different drilling conditions. The results show a great reduction in the thrust force when a pilot hole is present which removes the chisel edge contribution.

Keywords: composites, chisel edge, drilling, delamination

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Authors: M. S. Kaiser, S. Reaz Ahmed

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Chip formation characteristics are investigated during surface finishing of high density polyethylene (HDPE) samples using a shaper machine. Both the cutting speed and depth of cut are varied continually to enable observations under various machining conditions. The generated chips are analyzed in terms of their shape, size, and deformation. Their physical appearances are also observed using digital camera and optical microscope. The investigation shows that continuous chips are obtained for all the cutting conditions. It is observed that cutting speed is more influential than depth of cut to cause dimensional changes of chips. Chips curl radius is also found to increase gradually with the increase of cutting speed. The length of continuous chips remains always smaller than the job length, and the corresponding discrepancies are found to be more prominent at lower cutting speed. Microstructures of the chips reveal that cracks are formed at higher cutting speeds and depth of cuts, which is not that significant at low depth of cut.

Keywords: HDPE, surface-finishing, chip formation, deformation, roughness

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

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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

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Authors: J. Uka, B. McKay, T. Minton, O. Adole, R. Lewis, S. J. Glanvill, L. Anguilano

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Effective heat treatment conditions to obtain maximum aluminium swarf recycling are investigated in this work. Aluminium swarf briquettes underwent treatments at different temperatures and cooling times to investigate the improvements obtained in the recovery of aluminium metal. The main issue for the recovery of the metal from swarfs is to overcome the constraints due to the oxide layers present in high concentration in the swarfs since they have a high surface area. Briquettes supplied by Renishaw were heat treated at 650, 700, 750, 800 and 850 ℃ for 1-hour and then cooled at 2.3, 3.5 and 5 ℃/min. The resulting material was analysed using SEM EDX to observe the oxygen diffusion and aluminium coalescence at the boundary between adjacent swarfs. Preliminary results show that, swarf needs to be heat treated at a temperature of 850 ℃ and cooled down slowly at 2.3 ℃/min to have thin and discontinuous alumina layers between the adjacent swarf and consequently allowing aluminium coalescence. This has the potential to save energy and provide maximum financial profit in preparation of swarf briquettes for recycling.

Keywords: reuse, recycle, aluminium, swarf, oxide layers

Procedia PDF Downloads 112

Authors: Lydia Chan, Islam Shyha, Dale Dreyer, John Hamilton, Phil Hackney

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Nickel-based superalloys are generally known to be difficult to cut due to their strength, low thermal conductivity, and high work hardening tendency. Superalloy such as alloy 625 is often used in the oil and gas industry as a surfacing material to provide wear and corrosion resistance to components. The material is typically applied onto a metallic substrate through weld overlay cladding, an arc welding technique. Cladded surfaces are always rugged and carry a tough skin; this creates further difficulties to the machining process. The present work utilised design of experiment to optimise the internal cylindrical rough turning for weld overlay surfaces. An L27 orthogonal array was used to assess effects of the four selected key process variables: cutting insert, depth of cut, feed rate, and cutting speed. The optimal cutting conditions were determined based on productivity and the level of tool wear.

Keywords: cylindrical turning, nickel superalloy, turning of overlay, weld overlay

Procedia PDF Downloads 347

Authors: Eser Yarar, Fahri Vatansever, A. Tamer Erturk, Sedat Karabay

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In this study, drilling behavior of multi-layer orthotropic polyester composites reinforced with woven polyester fiber and PTFE particle was investigated. Conventional drilling methods have low cost and ease of use. Therefore, it is one of the most preferred machining methods. The increasing range of use of composite materials in many areas has led to the investigation of the machinability performance of these materials. The drilling capability of the synthetic polymer composite material was investigated by measuring the cutting forces using different tool diameters, feed rate and high cutting speed parameters. Cutting forces were measured using a dynamometer in the experiments. In order to evaluate the results of the experiment, the Taguchi experimental design method was used. According to the results, the optimum cutting parameters were obtained for 0.1 mm/rev, 1070 rpm and 2 mm diameter drill bit. Verification tests were performed for the optimum cutting parameters obtained according to the model. Verification experiments showed the success of the established model.

Keywords: cutting force, drilling, polimer composite, Taguchi

Procedia PDF Downloads 139

Authors: Khavieya Anandhan, Soundarapandian Santhanakrishnan, Vijayaraghavan Laxmanan

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In general, measurement of surfaces is carried out by using traditional methods such as contact type stylus instruments. This prevalent approach is challenged by using non-contact instruments such as optical profiler, co-ordinate measuring machine, laser triangulation sensors, machine vision system, etc. Recently, confocal sensor is trying to be used in the surface metrology field. This sensor, such as a confocal sensor, is explored in this study to determine the surface roughness value for various turned surfaces. Turning is a crucial machining process to manufacture products such as grooves, tapered domes, threads, tapers, etc. The roughness value of turned surfaces are in the range of range 0.4-12.5 µm, were taken for analysis. Three instruments were used, namely, perthometer, optical profiler, and confocal sensor. Among these, in fact, a confocal sensor is least explored, despite its good resolution about 5 nm. Thus, such a high-precision sensor was used in this study to explore the possibility of measuring turned surfaces. Further, using this data, measurement uncertainty was also studied.

Keywords: confocal sensor, optical profiler, surface roughness, turned surfaces

Procedia PDF Downloads 115