Search results for: C/SiC cutting performance analysis

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

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

Keywords: composite material, delamination, drilling, thrust force

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Authors: Arjun, Gautam, Sanjeev Naval

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Concrete technology has been changing rapidly and constantly since its discovery. Concrete is the most widely used man-made construction material, versatility of making concrete is the 2nd largest consumed material on earth. In this paper an effort has been made to use metal aggregates in concrete has been discussed, the metal aggregates has been named as “BAUT” which had outstandingly qualities to resist shear, tension and compression forces. In this paper, COARSE BAUT AGGREGATES (C.B.A.) 10mm & 20mm and FINE BAUT AGGREGATES (F.B.A.) 3mm were divided and used for making high performance concrete (H.P.C). This “BAUT” had cutting edge technology through draft and design by the use of Auto CAD, ANSYS software can be used effectively In this research paper we study high performance concrete (H.P.C) with “BAUT” and consider the grade of M65 and finally we achieved the result of 90-95 Mpa (high compressive strength) for mega structures and irregular structures where center of gravity (CG) is not balanced. High Performance BAUT Concrete is the extraordinary qualities like long-term performance, no sorptivity by BAUT AGGREGATES, better rheological, mechanical and durability proportion that conventional concrete. This high strength BAUT concrete using “BAUT” is applied in the construction of mega structure like skyscrapers, dam, marine/offshore structures, nuclear power plants, bridges, blats and impact resistance structures. High Performance BAUT Concrete which is a controlled concrete possesses invariable high strength, reasonable workability and negligibly permeability as compare to conventional concrete by the mix of Super Plasticizers (SMF), silica fume and fly ash.

Keywords: BAUT, High Strength Concrete, High Performance Concrete, Fine BAUT Aggregate, Coarse BAUT Aggregate, metal aggregates, cutting edge technology

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Authors: Ashish Ankus Yerunkar, Ravi Terkar

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

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

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Authors: Junior Nomani

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This paper presents a novel approach to modelling the metal cutting of duplex stainless steels, a two-phase alloy regarded as a difficult-to-machine material. Calculation and control of shear strain and stresses during cutting are essential to achievement of ideal cutting conditions. Too low or too high leads to higher required cutting force or excessive heat generation causing premature tool wear failure. A 2D finite element cutting model was created based on electron backscatter diffraction (EBSD) data imagery of duplex microstructure. A mesh was generated using ‘object-oriented’ software OOF2 version V2.1.11, converting microstructural images to quadrilateral elements. A virtual workpiece was created on ABAQUS modelling software where a rigid body toolpiece advanced towards workpiece simulating chip formation, generating serrated edge chip formation cutting. Model results found calculated stress strain contour plots correlated well with similar finite element models tied with austenite stainless steel alloys. Virtual chip form profile is also similar compared experimental frozen machining chip samples. The output model data provides new insight description of strain behavior of two phase material on how it transitions from workpiece into the chip.

Keywords: Duplex stainless steel, ABAQUS, OOF2, Chip formation

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Authors: S. Jahangir, S. H. I. Jaffery, M. Khan, Z. Zareef, A. Yar, A. Mubashir, S. Butt, L. Ali

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In this work, drilling responses and behavior of MMC was investigated in Al-Mg2Si composites. For the purpose Al-15% wt. Mg2Si, was selected from the hypereutectic region of Al- Mg2Si phase diagram. Based on hardness and tensile strength, drill bit of appropriate material and morphology was selected. The performance of different drill bits of different morphology and material was studied and analysed using experimental data. For theoretical calculations of axial thrust force and required power calculation, material factor “K” was obtained from different data charts and at the same time cutting forces (drilling forces) were practically obtained using a Peizo electric force dynamometer. These results show the role of reinforcement particles on the machinability of MMCs and provide a useful guide for a better control and optimized drilling parameters for the drilling process. Furthermore, in this work, comparison of MMC with non -reinforced Aluminum Alloy regarding drilling operation was also studied.

Keywords: drilling, metal matrix composite (MMC), cutting forces, thrust force

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Authors: Gizem Eser Erdek

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This study is research on predicting the remaining life of industrial cutting tools used in the industrial production process with deep learning methods. When the life of cutting tools decreases, they cause destruction to the raw material they are processing. This study it is aimed to predict the remaining life of the cutting tool based on the damage caused by the cutting tools to the raw material. For this, hole photos were collected from the hole-drilling machine for 8 months. Photos were labeled in 5 classes according to hole quality. In this way, the problem was transformed into a classification problem. Using the prepared data set, a model was created with convolutional neural networks, which is a deep learning method. In addition, VGGNet and ResNet architectures, which have been successful in the literature, have been tested on the data set. A hybrid model using convolutional neural networks and support vector machines is also used for comparison. When all models are compared, it has been determined that the model in which convolutional neural networks are used gives successful results of a %74 accuracy rate. In the preliminary studies, the data set was arranged to include only the best and worst classes, and the study gave ~93% accuracy when the binary classification model was applied. The results of this study showed that the remaining life of the cutting tools could be predicted by deep learning methods based on the damage to the raw material. Experiments have proven that deep learning methods can be used as an alternative for cutting tool life estimation.

Keywords: classification, convolutional neural network, deep learning, remaining life of industrial cutting tools, ResNet, support vector machine, VggNet

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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

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Authors: Mohsen Marani Barzani, Ahmed A. D. Sarhan, Saeed Farahany, Ramesh Singh

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Surface roughness and chip morphology are important output in manufacturing product. In this paper, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness and chip morphology in turning the Al-Si cast alloy and Sr-containing. Experimental trials carried out using coated carbide inserts. Experiments accomplished under oblique dry cutting when various cutting speeds 70, 130 and 250 m/min and feed rates of 0.05, 0.1 and 0.15 mm/rev were used, whereas depth of cut kept constant at 0.05 mm. The results showed that Sr-containing Al-Si alloy have poor surface roughness in comparison to Al-Si alloy (base alloy). The surface roughness values reduce with cutting speed increment from 70 to 250 m/min. the size of chip changed with changing silicon shape in Al matrix. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.

Keywords: strontium, surface roughness, chip, morphology, turning

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Authors: David Downey

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

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

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Authors: Boughedaoui Rachid, Belaidi Idir, Ouali Mohamed

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The formatting by removal of material remains an indispensable means for obtaining different forms of pieces. The objective of this work is to study the influence of parameters of the vibratory regime of the system PTM 'Piece-Tool-Machine, in the case of the machining of the thin pieces on the surface finish. As a first step, an analytical study of essential dynamic models 2D slice will be presented. The stability lobes will be thus obtained. In a second step, a characterization of PTM system will be realized. This system will be instrumented with accelerometric sensors but also a laser vibrometer so as to have the information closer to the cutting area. Dynamometers three components will be used for the analysis of cutting forces. Surface states will be measured and the condition of the cutting edge will be visualized thanks to a binocular microscope coupled to a data acquisition system. This information will allow quantifying the influence of chatter on the dimensional quality of the parts. From lobes stabilities previously determined experimental validation allow for the development a method for detecting of the phenomenon of chatter and so an approach will be proposed.

Keywords: chatter, dynamic, milling, lobe stability

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Authors: Ajay Pratap Singh Lodhi, Deepak Kumar

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Vegetable oil-based environmentally friendly metalworking fluids (MWFs) are formulated. The tribological performance, cytotoxicity, and corrosion resistance of the formulated fluids (FFs) are evaluated and benchmarked with commercial mineral oil-based MWFs (CF). Results show that FFs exhibited better machining characteristics (roughness, cutting forces, and surface morphology) during machining than CF. MTT assay and Live dead cell assay confirm the cytocompatibility nature of the FFs relative to the toxic CF. Electrochemical analysis shows that FFs and CF exhibited comparable corrosion current density.

Keywords: corrosion inhibitors, cytotoxicity, machining, MTT assay, Taguchi method, vegetable oil

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Authors: Karim Kheloufi, El Hachemi Amara

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In the present study, a three-dimensional transient numerical model was developed to study the temperature field and cutting kerf shape during laser fusion cutting. The finite volume model has been constructed, based on the Navier–Stokes equations and energy conservation equation for the description of momentum and heat transport phenomena, and the Volume of Fluid (VOF) method for free surface tracking. The Fresnel absorption model is used to handle the absorption of the incident wave by the surface of the liquid metal and the enthalpy-porosity technique is employed to account for the latent heat during melting and solidification of the material. To model the physical phenomena occurring at the liquid film/gas interface, including momentum/heat transfer, a new approach is proposed which consists of treating friction force, pressure force applied by the gas jet and the heat absorbed by the cutting front surface as source terms incorporated into the governing equations. All these physics are coupled and solved simultaneously in Fluent CFD®. The main objective of using a transient phase change model in the current case is to simulate the dynamics and geometry of a growing laser-cutting generated kerf until it becomes fully developed. The model is used to investigate the effect of some process parameters on temperature fields and the formed kerf geometry.

Keywords: laser cutting, numerical simulation, heat transfer, fluid flow

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Authors: Philipp Zopf, Franz Haas

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Manufacturing of very hard and refractory materials like ceramics, glass or carbide poses particular challenges on tools and machines. The company Sauer GmbH developed especially for this application area ultrasonic tool holders working in a frequency range from 15 to 60 kHz and superimpose the common tool movement in the vertical axis. This technique causes a structural weakening in the contact area and facilitates the machining. The possibility of the force reduction for these special materials especially in drilling of carbide with diamond tools up to 30 percent made the authors try to expand the application range of this method. To make the results evaluable, the authors decide to start with existing processes in which the positive influence of the ultrasonic assistance is proven to understand the mechanism. The comparison of a grinding process the Institute use to machine materials mentioned in the beginning and steel could not be more different. In the first case, the authors use tools with geometrically undefined edges. In the second case, the edges are geometrically defined. To get valid results of the tests, the authors decide to investigate two manufacturing methods, drilling and milling. The main target of the investigation is to reduce the cutting force measured with a force measurement platform underneath the workpiece. Concerning to the direction of the ultrasonic assistance, the authors expect lower cutting forces and longer endurance of the tool in the drilling process. To verify the frequencies and the amplitudes an FFT-analysis is performed. It shows the increasing damping depending on the infeed rate of the tool. The reducing of amplitude of the cutting force comes along.

Keywords: drilling, machining, milling, ultrasonic

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Authors: M. S. Said, J. A. Ghani, C. H. Che Hassan, N. N. Wan, M. A. Selamat, R. Othman

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Metal Matrix Composite (MMCs) have attracted considerable attention as a result of their ability to provide high strength, high modulus, high toughness, high impact properties, improved wear resistance and good corrosion resistance than unreinforced alloy. Aluminium Silicon (Al/Si) alloys Metal Matrix composite (MMC) has been widely used in various industrial sectors such as transportation, domestic equipment, aerospace, military, construction, etc. Aluminium silicon alloy is MMC reinforced with aluminium nitride (AlN) particle and becomes a new generation material for automotive and aerospace applications. The AlN material is one of the advanced materials with light weight, high strength, high hardness and stiffness qualities which have good future prospects. However, the high degree of ceramic particles reinforcement and the irregular nature of the particles along the matrix material that contribute to its low density, is the main problem that leads to the machining difficulties. This paper examines tool wear when milling AlSi/AlN Metal Matrix Composite using a TiB2 coated carbide cutting tool. The volume of the AlN reinforced particle was 10%. The milling process was carried out under dry cutting condition. The TiB2 coated carbide insert parameters used were the cutting speed of (230 m/min, feed rate 0.4mm tooth, DOC 0.5mm, 300 m/min, feed rate 0.8mm/tooth, DOC 0.5mm and 370 m/min, feed rate 0.8, DOC 0.4m). The Sometech SV-35 video microscope system was used for tool wear measurements respectively. The results have revealed that the tool life increases with the cutting speed (370 m/min, feed rate 0.8 mm/tooth and depth of cut 0.4mm) constituted the optimum condition for longer tool life which is 123.2 min. While at medium cutting speed, it is found that the cutting speed of 300m/min, feed rate 0.8 mm/tooth and depth of cut 0.5mm only 119.86 min for tool wear mean while the low cutting speed give 119.66 min. The high cutting speed gives the best parameter for cutting AlSi/AlN MMCs materials. The result will help manufacture to machining the AlSi/AlN MMCs materials.

Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, TiB2 coated carbide tool, manufacturing engineering

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Authors: František Šebek, Petr Kubík, Jindřich Petruška, Jiří Hůlka

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Present study is aimed on the cutting process of circular cross-section rods where the fracture is used to separate one rod into two pieces. Incorporating the phenomenological ductile fracture model into the explicit formulation of finite element method, the process can be analyzed without the necessity of realizing too many real experiments which could be expensive in case of repetitive testing in different conditions. In the present paper, the steel AISI 1045 was examined and the tensile tests of smooth and notched cylindrical bars were conducted together with biaxial testing of the notched tube specimens to calibrate material constants of selected phenomenological ductile fracture models. These were implemented into the Abaqus/Explicit through user subroutine VUMAT and used for cutting process simulation. As the calibration process is based on variables which cannot be obtained directly from experiments, numerical simulations of fracture tests are inevitable part of the calibration. Finally, experiments regarding the cutting process were carried out and predictive capability of selected fracture models is discussed. Concluding remarks then make the summary of gained experience both with the calibration and application of particular ductile fracture criteria.

Keywords: ductile fracture, phenomenological criteria, cutting process, explicit formulation, AISI 1045 steel

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Authors: Armagan Gokcearslan

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The art of animation has developed very rapidly from the aspects of script, sound and music, motion, character design, techniques being used and technological tools being developed since the first years until today. Technical variety attracts a particular attention in the art of animation. Being perceived as a kind of illusion in the beginning; animations commonly used the Flash Sketch technique. Animations artists using the Flash Sketch technique created scenes by drawing them on a blackboard with chalk. The Flash Sketch technique was used by primary animation artists like Emile Cohl, Winsor McCay ande Blackton. And then tools like Magical Lantern, Thaumatrope, Phenakisticope, and Zeotrap were developed and started to be used intensely in the first years of the art of animation. Today, on the other hand, the art of animation is affected by developments in the computer technology. It is possible to create three-dimensional and two-dimensional animations with the help of various computer software. Cut-out technique is among the important techniques being used in the art of animation. Cut-out animation technique is based on the art of paper cutting. Examining cut-out animations; it is observed that they technically resemble the art of paper cutting. The art of paper cutting has a rooted history. It is possible to see the oldest samples of paper cutting in the People’s Republic of China in the period after the 2. century B.C. when the Chinese invented paper. The most popular artist using the cut-out animation technique is the German artist Lotte Reiniger. This study titled “Cut-out Animation as a Technic and Development Inside History Process” will embrace the art of paper cutting, the relationship between the art of paper cutting and cut-out animation, its development within the historical process, animation artists producing artworks in this field, important cut-out animations, and their technical properties.

Keywords: cut-out, paper art, animation, technic

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Authors: Rajaram Kr. Gupta, Bhupendra Kumar, T. V. K. Gupta, D. S. Ramteke

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Machining of hard materials is a recent technology for direct production of work-pieces. The primary challenge in machining these materials is selection of cutting tool inserts which facilitates an extended tool life and high-precision machining of the component. These materials are widely for making precision parts for the aerospace industry. Nickel-based alloys are typically used in extreme environment applications where a combination of strength, corrosion resistance and oxidation resistance material characteristics are required. The present paper reports the theoretical and experimental investigations carried out to understand the influence of machining parameters on the response parameters. Considering the basic machining parameters (speed, feed and depth of cut) a study has been conducted to observe their influence on material removal rate, surface roughness, cutting forces and corresponding tool wear. Experiments are designed and conducted with the help of Central Composite Rotatable Design technique. The results reveals that for a given range of process parameters, material removal rate is favorable for higher depths of cut and low feed rate for cutting forces. Low feed rates and high values of rotational speeds are suitable for better finish and higher tool life.

Keywords: speed, feed, depth of cut, roughness, cutting force, flank wear

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Authors: Gastão Soares Ximenes de Oliveira, Richar Nicolás Durán, Romeo Micah Szmoski, Eloiza Aparecida Avila de Matos, Elano Gustavo Rein

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This article aims to present an experimental method to determine Planck's constant by calculating the cutting potential V₀ from LEDs with different wavelengths. The experiment is designed using Arduino as a central tool in order to make the experimental activity more engaging and attractive for students with the use of digital technologies. From the characteristic curves of each LED, graphical analysis was used to obtain the cutting potential, and knowing the corresponding wavelength, it was possible to calculate Planck's constant. This constant was also obtained from the linear adjustment of the cutting potential graph by the frequency of each LED. Given the relevance of Planck's constant in physics, it is believed that this experiment can offer teachers the opportunity to approach concepts from modern physics, such as the quantization of energy, in a more accessible and applied way in the classroom. This will not only enrich students' understanding of the fundamental nature of matter but also encourage deeper engagement with the principles of quantum physics.

Keywords: physics teaching, educational technology, modern physics, Planck constant, Arduino

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Authors: A. A. Selaimia, H. Bensouilah, M. A. Yallese, I. Meddour, S. Belhadi, T. Mabrouki

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The objective of this work is to model the output responses namely; surface roughness (Ra), cutting force (Fc), during the face milling of the austenitic stainless steel X2CrNi18-9 with coated carbide tools (GC4040). For raison, response surface methodology (RMS) is used to determine the influence of each technological parameter. A full factorial design (L27) is chosen for the experiments, and the ANOVA is used in order to evaluate the influence of the technological cutting parameters namely; cutting speed (Vc), feed per tooth, and depth of cut (ap) on the out-put responses. The results reveal that (Ra) is mostly influenced by (fz) and (Fc) is found considerably affected by (ap).

Keywords: austenitic stainless steel, ANOVA, coated carbide, response surface methodology (RSM)

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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: Panagiotis Kyratsis, Konstantinos Kakoulis

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Nowadays, the rapid development of CAD systems’ programming environments results in the creation of multiple downstream applications, which are developed and becoming increasingly available. CAD based manufacturing simulations is gradually following the same trend. Drilling is the most popular hole-making process used in a variety of industries. A specially built piece of software that deals with the drilling kinematics is presented. The cutting forces are calculated based on the tool geometry, the cutting conditions and the tool/work piece materials. The results are verified by experimental work. Finally, the response surface methodology (RSM) is applied and mathematical models of the total thrust force and the thrust force developed because of the main cutting edges are proposed.

Keywords: CAD, application programming interface, response surface methodology, drilling, RSM

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Authors: Tadahiro Wada, Hiroyuki Hanyu

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In this study, to clarify the effectiveness of an aluminum/chromium/tungsten-based-coated tool for cutting sintered steel, tool wear was experimentally investigated. The sintered steel was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and (Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the physical vapor deposition (PVD) method. Moreover, the tool wear of the aluminum/chromium/tungsten-based-coated item was compared with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool wear mechanism of the aluminum/chromium/tungsten-coating film for cutting sintered steel, Scanning Electron Microscope observation and Energy Dispersive x-ray Spectroscopy mapping analysis were conducted on the abraded surface. The following results were obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated tool was the slowest among that of the five coated tools. (2) Adding carbon (C) to the aluminum/chromium/tungsten-based-coating film was effective for improving the wear-resistance. (3) The main wear mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)- and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.

Keywords: cutting, physical vapor deposition coating method, tool wear, tool wear mechanism, (Al, Cr, W)N-coating film, (Al, Cr, W)(C, N)-coating film, sintered steel

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Authors: Michal Brazda, Miroslav Urbanek, Martina Koukolikova

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This work focuses on the development of functional surfaces and edges for cutting and forming tools created through the Directed Energy Deposition (DED) technology. In the context of growing challenges in modern engineering, additive technologies, especially DED, present an innovative approach to manufacturing tools for forming and cutting. One of the key features of DED is its ability to precisely and efficiently deposit Fully dense metals from powder feedstock, enabling the creation of complex geometries and optimized designs. Gradually, it becomes an increasingly attractive choice for tool production due to its ability to achieve high precision while simultaneously minimizing waste and material costs. Tools created using DED technology gain significant durability through the utilization of high-performance materials such as nickel alloys and tool steels. For high-temperature applications, Nimonic 80A alloy is applied, while for cold applications, M2 tool steel is used. The addition of ceramic materials, such as tungsten carbide, can significantly increase the tool's resistance. The introduction of functionally graded materials is a significant contribution, opening up new possibilities for gradual changes in the mechanical properties of the tool and optimizing its performance in different sections according to specific requirements. In this work, you will find an overview of individual applications and their utilization in the industry. Microstructural analyses have been conducted, providing detailed insights into the structure of individual components alongside examinations of the mechanical properties and tool life. These analyses offer a deeper understanding of the efficiency and reliability of the created tools, which is a key element for successful development in the field of cutting and forming tools. The production of functional surfaces and edges using DED technology can result in financial savings, as the entire tool doesn't have to be manufactured from expensive special alloys. The tool can be made from common steel, onto which a functional surface from special materials can be applied. Additionally, it allows for tool repairs after wear and tear, eliminating the need for producing a new part and contributing to an overall cost while reducing the environmental footprint. Overall, the combination of DED technology, functionally graded materials, and verified technologies collectively set a new standard for innovative and efficient development of cutting and forming tools in the modern industrial environment.

Keywords: additive manufacturing, directed energy deposition, DED, laser, cutting tools, forming tools, steel, nickel alloy

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Authors: Jehnming Lin

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The effects of the contact ball-lens on the soda lime glass in laser thermal cleavage with a cw Nd-YAG laser were investigated in this study. A contact ball-lens was adopted to generate a bending force on the crack formation of the soda-lime glass in the laser cutting process. The Nd-YAG laser beam (wavelength of 1064 nm) was focused through the ball-lens and transmitted to the soda-lime glass, which was coated with a carbon film on the surface with a bending force from a ball-lens to generate a tensile stress state on the surface cracking. The fracture was controlled by the contact ball-lens and a straight cutting was tested to demonstrate the feasibility. Experimental observations on the crack propagation from the leading edge, main section and trailing edge of the glass sheet were compared with various mechanical and thermal loadings. Further analyses on the stress under various laser powers and contact ball loadings were made to characterize the innovative technology. The results show that the distributions of the side crack at the leading and trailing edges are mainly dependent on the boundary condition, contact force, cutting speed and laser power. With the increase of the mechanical and thermal loadings, the region of the side cracks might be dramatically reduced with proper selection of the geometrical constraints. Therefore, the application of the contact ball-lens is a possible way to control the fracture in laser cleavage with improved cutting qualities.

Keywords: laser cleavage, stress analysis, crack visualization, laser

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Authors: Stefano Frassinelli, Alessandro Niccolai, Riccardo E. Zich

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Sport performance analysis is a technique that is becoming every year more important for athletes of every level. Many techniques have been developed to measure and analyse efficiently the performance of athletes in some sports, but in combat sports these techniques found in many times their limits, due to the high interaction between the two opponents during the competition. In this paper the problem will be framed. Moreover the physical performance measurement problem will be analysed and three different techniques to manage it will be presented. All the techniques have been used to analyse the performance of 22 high level Judo athletes.

Keywords: sport performance, physical performance, judo, performance coefficients

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Authors: Mahmoud Rabh

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Garnet has been used for decades as an abrasive in water jet cutting and sand blasting because of its superior physical properties. When added to use in water-cutting process of marble. A standard commercial sample of the mineral was tested in terms of the hardness and abrasiveness properties. The sample was sized to 4 fractions having the size of < 60 um, > 60 < 100 um, > 100 < 180 um > 1280 < 250 and 250 um designated the symbols, FF, MF, MC and C respectively. Each sample was separately heated in controlled conditions at temperatures up to 1000 °C at a heating rate of 10°C/min in an electrically heated chamber furnace. Soaking time at the maximum temperature was up to 6 h. Hardness and abrasiveness properties of the heat treated samples were tested to cut marble having a thickness of 25 mm. Results revealed that H/A of the natural garnet mineral increased by heating at temperatures up to 600°C and exhibited pronounced decrease with higher temperatures up to 1000 °C. Results were explained in the light of a structural irreversible dislocation (SD) of the crystals of garnet almandine Fe2+3Al2Si3O12 and pyrope Mg3Al2Si3O12. Characterization of the mineral was carried out with the help of XRD, SEM and FT-IR measurements.

Keywords: garnet abrasive, heat treatment, water jet cutting, hardness abrasiveness

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Authors: A. Bari

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Integer programming is a branch of mathematical programming techniques in operations research in which some or all of the variables are required to be integer valued. Various cuts have been used to solve these problems. We have also developed cuts known as NAZ cut & A-T cut to solve the integer programming problems. These cuts are used to reduce the feasible region and then reaching the optimal solution in minimum number of steps.

Keywords: Integer Programming, NAZ cut, A-T cut, Cutting plane method

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Authors: Joseph Chen, N. Hundal

Abstract:

Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.

Keywords: surface roughness, Taguchi parameter design, turning center, turn-milling operations, vertical machining center

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Authors: Wajid Ali Khan

Abstract:

Extensive experimentation and numerical investigation are performed to predict the machining-induced residual stresses in the end milling of AISI 1045 steel, and an optimization code has been developed using the particle swarm optimization technique. Experiments were conducted using a single factor at a time and design of experiments approach. Regression analysis was done, and a mathematical model of the cutting process was developed, thus predicting the machining-induced residual stress with reasonable accuracy. The mathematical model served as the objective function to be optimized using particle swarm optimization. The relationship between the different cutting parameters and the output variables, force, and residual stresses has been studied. The combined effect of the process parameters, speed, feed, and depth of cut was examined, and it is understood that 85% of the variation of these variables can be attributed to these machining parameters under research. A 3D finite element model is developed to predict the cutting forces and the machining-induced residual stresses in end milling operation. The results were validated experimentally and against the Johnson-cook model available in the literature.

Keywords: residual stresses, end milling, 1045 steel, optimization

Procedia PDF Downloads 82

Authors: Shiva Abdoli, Daniel T.Semere

Abstract:

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

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

Procedia PDF Downloads 472