Search results for: high energy milling

Authors: Zohaib Ellahi, Guolong Zhao

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Ceramic matrix composite (CMC) material possesses high strength, wear resistance and anisotropy thus machining of this material is very difficult and demands high cost. In this research, FEM simulations and physical experiments have been carried out to assess the machinability of carbon fiber reinforced silicon carbide (C/SiC) using polycrystalline diamond (PCD) tool in slot milling process. Finite element model has been generated in Abaqus/CAE software and milling operation performed by using user defined material subroutine. Effect of different milling parameters on cutting forces and stresses has been calculated through FEM simulations and compared with experimental results to validate the finite element model. Cutting forces in x and y-direction were calculated through both experiments and finite element model and found a good agreement between them. With increase in cutting speed resultant cutting forces are decreased. Resultant cutting forces are increased with increased feed per tooth and depth of cut. When machining performed along the fiber direction stresses generated near the tool edge were minimum and increases with fiber cutting angle.

Keywords: experimental & numerical investigation, C/SiC cutting performance analysis, milling of CMCs, CMC composite stress analysis

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Authors: Mohieddine Benghersallah, Mohamed Zakaria Zahaf, Ali Medjber, Idriss Tibakh

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The objective of this study is to analyse the effects of cutting parameters on surface roughness in dry face milling using statistical techniques. We studied the effect of the microstructure of AISI 52100 steel on machinability before and after hardening. The machining tests were carried out on a high rigidity vertical milling machine with a 25 mm diameter face milling cutter equipped with micro-grain bicarbide inserts with PVD (Ti, AlN) coating in GC1030 grade. A Taguchi L9 experiment plan is adopted. Analysis of variance (ANOVA) was used to determine the effects of cutting parameters (Vc, fz, ap) on the roughness (Ra) of the machined surface. Regression analysis to assess the machinability of steel presented mathematical models of roughness and the combination of parameters to minimize it. The recorded results show that feed per tooth has the most significant effect on the surface condition for both steel treatment conditions. The best roughnesses were obtained for the hardened AISI 52100 steel.

Keywords: machinability, heat treatment, microstructure, surface roughness, Taguchi method

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Authors: Sangamesh G. Sakri, Akash N. Patil, Sadashivappa M. Kotli

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Agro based industries in India are considered as the micro, small and medium enterprises (MSME). In India, MSMEs contribute approximately 8 percent of the country’s GDP, 42 percent of the manufacturing output and 40 percent of exports. The toor dal (scientific name Cajanus cajan, commonly known as yellow gram, pigeon pea) is the second largest pulse crop in India accounting for about 20% of total pulse production. The toor dal milling industry in India is one of the major agro-processing industries in the country. Most of the dal mills are concentrated in pulse producing areas, which are spread all over the country. In Karnataka state, Gulbarga is a district, where toor dal is the main crop and is grown extensively. There are more than 500 dal mills in and around the Gulbarga district to process dal. However, the majority of these dal milling units use traditional methods of processing which are energy and capital intensive. There exists a huge energy saving potential in these mills. An energy audit is conducted on a dal mill in Gulbarga to understand the energy consumption pattern to assess the energy saving potential, and an economic analysis is conducted to identify energy conservation opportunities.

Keywords: conservation, demand side management, load curve, toor dal

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Authors: Jui-Pui Hung, Yong-Run Chen, Wei-Cheng Shih, Shen-He Tsui, Kung-Da Wu

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This paper presents the effect on the tooling conditions on the machining stabilities of a milling machine tool. The machining stability was evaluated in different feeding direction in the X-Y plane, which was referred as the orientation-dependent machining stability. According to the machining mechanics, the machining stability was determined by the frequency response function of the cutter. Thus, we first conducted the vibration tests on the spindle tool of the milling machine to assess the tool tip frequency response functions along the principal direction of the machine tool. Then, basing on the orientation dependent stability analysis model proposed in this study, we evaluated the variation of the dynamic characteristics of the spindle tool and the corresponding machining stabilities at a specific feeding direction. Current results demonstrate that the stability boundaries and limited axial cutting depth of a specific cutter were affected to vary when it was fixed in the tool holder with different overhang length. The flute of the cutter also affects the stability boundary. When a two flute cutter was used, the critical cutting depth can be increased by 47 % as compared with the four flute cutter. The results presented in study provide valuable references for the selection of the tooling conditions for achieving high milling performance.

Keywords: tooling condition, machining stability, milling machine, chatter

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Authors: Alan C. Lin, Tzu-Kuan Lin, Tsong Der Lin

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This paper proposes a new method to find the equations of transformation matrix for the rotation angles of the two rotational axes and the coordinates of the three linear axes of an orthogonal multi-axis milling machine. This approach provides intuitive physical meanings for rotation angles of multi-axis machines, which can be used to evaluate the accuracy of the conversion from CL data to NC data.

Keywords: CAM, multi-axis milling machining, transformation matrix, rotation angles

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Authors: Jens Friedrich, Matthias A. Gebele, Armin Lechler, Alexander Verl

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Chatter vibrations and process instabilities are the most important factors limiting the productivity of the milling process. Chatter can leads to damage of the tool, the part or the machine tool. Therefore, the estimation and prediction of the process stability is very important. The process stability depends on the spindle speed, the depth of cut and the width of cut. In milling, the process conditions are defined in the NC-program. While the spindle speed is directly coded in the NC-program, the depth and width of cut are unknown. This paper presents a new simulation based approach for the prediction of the depth and width of cut of a milling process. The prediction is based on a material removal simulation with an analytically represented tool shape and a multi-dexel approach for the work piece. The new calculation method allows the direct estimation of the depth and width of cut, which are the influencing parameters of the process stability, instead of the removed volume as existing approaches do. The knowledge can be used to predict the stability of new, unknown parts. Moreover with an additional vibration sensor, the stability lobe diagram of a milling process can be estimated and improved based on the estimated depth and width of cut.

Keywords: dexel, process stability, material removal, milling

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Authors: Md. Anayet U. Patwari, Mohammad Ahsan Habib, Md. Tanzib Ehsan, Md Golam Ahnaf, Md. S. I. Chowdhury

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Surface roughness is one of the key quality parameters of the finished product. During any machining operation, high temperatures are generated at the tool-chip interface impairing surface quality and dimensional accuracy of products. Cutting fluids are generally applied during machining to reduce temperature at the tool-chip interface. However, usages of cutting fluids give rise to problems such as waste disposal, pollution, high cost, and human health hazard. Researchers, now-a-days, are opting towards dry machining and other cooling techniques to minimize use of coolants during machining while keeping surface roughness of products within desirable limits. In this paper, a concept of using peltier cooling effects during aluminium milling operation has been presented and adopted with an aim to improve surface roughness of the machined surface. Experimental evidence shows that peltier cooling effect provides better surface roughness of the machined surface compared to dry machining.

Keywords: aluminium, milling operation, peltier cooling effect, surface roughness

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Authors: Chularat Leewuttanakul, Khanitta Ruttarattanamongkol, Sasivimon Chittrakorn

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Rice during grain development stage is a rich source of many bioactive compounds. Dough stage rice contains high amounts of photochemical and can be used for rice milling industries. However, rice grain at dough stage had low milling quality due to high moisture content. Thermal processing can be applied to rice grain for improving milled rice yield. This experiment was conducted to study the chemical and physic properties of dough stage rice grain after roasting treatment. Rice were roasted with two different methods including traditional pan roasting at 140 °C for 60 minutes and using the electrical roasting machine at 140 °C for 30, 40, and 50 minutes. The chemical, physical properties, and bioactive compounds of brown rice and milled rice were evaluated. The result of this experiment showed that moisture content of brown and milled rice was less than 10 % and amylose contents were in the range of 26-28 %. Rice grains roasting for 30 min using electrical roasting machine had high head rice yield and length and breadth of grain after milling were close to traditional pan roasting (p > 0.05). The lightness (L*) of rice did not affect by roasting treatment (p > 0.05) and the a* indicated the yellowness of milled rice was lower than brown rice. The bioactive compounds of brown and milled rice significantly decreased with increasing of drying time. Brown rice roasted for 30 minutes had the highest of total phenolic content, antioxidant activity, α-tocopherol, and ɤ-oryzanol content. Volume expansion and elongation of cooked rice decreased as roasting time increased and quality of cooked rice roasted for 30 min was comparable to traditional pan roasting. Hardness of cooked rice as measured by texture analyzer increased with increasing roasting time. The results indicated that rice grains at dough stage, containing a high amount of bioactive compounds, have a great potential for rice milling industries and the electrical roasting machine can be used as an alternative to pan roasting which decreases processing time and labor costs.

Keywords: bioactive compounds, cooked rice, dough stage rice grain, grain development, roasting

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Authors: Jumazulhisham Abdul Shukor, Mohd. Sazali Said, Roshanizah Harun, Shuib Husin, Ahmad Razlee Ab Kadir

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This paper applies Taguchi Optimization Method in determining the best machining parameters for pocket milling process on Polypropylene (PP) using CNC milling machine where the surface roughness is considered and the Carbide inserts cutting tool are used. Three machining parameters; speed, feed rate and depth of cut are investigated along three levels; low, medium and high of each parameter (Taguchi Orthogonal Arrays). The setting of machining parameters were determined by using Taguchi Method and the Signal-to-Noise (S/N) ratio are assessed to define the optimal levels and to predict the effect of surface roughness with assigned parameters based on L9. The final experimental outcomes are presented to prove the optimization parameters recommended by manufacturer are accurate.

Keywords: inserts, milling process, signal-to-noise (S/N) ratio, surface roughness, Taguchi Optimization Method

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Authors: Mohieddine Benghersallah, Lakhdar Boulanouar, Salim Belhadi

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Currently, higher production rate with required quality and low cost is the basic principle in the competitive manufacturing industry. This is mainly achieved by using high cutting speed and feed rates. Elevated temperatures in the cutting zone under these conditions shorten tool life and adversely affect the dimensional accuracy and surface integrity of component. Thus it is necessary to find optimum cutting conditions (cutting speed, feed rate, machining environment, tool material and geometry) that can produce components in accordance with the project and having a relatively high production rate. Response surface methodology is a collection of mathematical and statistical techniques that are useful for modelling and analysis of problems in which a response of interest is influenced by several variables and the objective is to optimize this response. The work presented in this paper examines the effects of cutting parameters (cutting speed, feed rate and depth of cut) on to the surface roughness through the mathematical model developed by using the data gathered from a series of milling experiments performed.

Keywords: Statistical analysis (RSM), Bearing steel, Coating inserts, Tool life, Surface Roughness, End milling.

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Authors: Opeyemi Atiba-Oyewo, Maurice S. Onyango, Christian Wolkersdorfer

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Characterization and nanostructure formation of banana peels as sorbent material are described in this paper. The transformation of this agricultural waste via mechanical milling to enhance its properties such as changed in microstructure and surface area for water pollution control and other applications were studied. Mechanical milling was employed using planetary continuous milling machine with ethanol as a milling solvent and the samples were taken at time intervals between 10 h to 30 h to examine the structural changes. The samples were characterised by X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infra-red (FTIR), Transmission electron microscopy (TEM) and Brunauer Emmett and teller (BET). Results revealed three typical structures with different deformation mechanisms and the grain-sizes within the range of (71-12 nm), nanostructure of the particles and fibres. The particle size decreased from 65µm to 15 nm as the milling progressed for a period of 30 h. The morphological properties of the materials indicated that the particle shapes becomes regular and uniform as the milling progresses. Furthermore, particles fracturing resulted in surface area increment from 1.0694-4.5547 m2/g. The functional groups responsible for the banana peels capacity to coordinate and remove metal ions, such as the carboxylic and amine groups were identified at absorption bands of 1730 and 889 cm-1, respectively. However, the choice of this sorbent material for the sorption or any application will depend on the composition of the pollutant to be eradicated.

Keywords: characterization, nanostructure, nanosorbent, eco-friendly, banana peels, mechanical milling, water quality

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Authors: Daniel Karthik, Vijay Baheti, Jiri Militky, Sundaramurthy Palanisamy

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Fibre based nano particles are presently considered as one of the potential filler materials for the improvement of mechanical and physical properties of polymer composites. Due to high matrix-filler interfacial area there will be uniform and homogeneous dispersion of nanoparticles. In micro/nano filler reinforced composites, resin material is usually tailored by organic or inorganic nanoparticles to have improved matrix properties. The objective of this study was to compare the potential of reinforcement of different organic and inorganic micro/nano fillers in epoxy composites. Industrial and agricultural waste of fibres like Agave Americana, cornhusk, jute, basalt, carbon, glass and fly ash was utilized to prepare micro/nano particles. Micro/nano particles were obtained using high energy planetary ball milling process in dry condition. Milling time and ball size were kept constant throughout the ball milling process. Composites were fabricated by hand lay method. Particle loading was kept constant to 3% wt. for all composites. In present study, loading of fillers was selected as 3 wt. % for all composites. Dynamic mechanical properties of the nanocomposite films were performed in three-point bending mode with gauge length and sample width of 50 mm and 10 mm respectively. The samples were subjected to an oscillating frequency of 1 Hz, 5 Hz and 10 Hz and 100 % oscillating amplitude in the temperature ranges of 30°C to 150°C at the heating rate of 3°C/min. Damping was found to be higher with the jute composites. Amongst organic fillers lowest damping factor was observed with Agave Americana particles, this means that Agave americana fibre particles have betters interface adhesion with epoxy resin. Basalt, fly ash and glass particles have almost similar damping factors confirming better interface adhesion with epoxy.

Keywords: ball milling, damping factor, matrix-filler interface, particle reinforcements

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Authors: Amir Mahyar Khorasani, Ian Gibson, Moshe Goldberg, Mohammad Masoud Movahedi, Guy Littlefair

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One of the important factors in manufacturing processes especially machining operations is surface quality. Improving this parameter results in improving fatigue strength, corrosion resistance, creep life and surface friction. The reliability and clearance of removable joints such as thread and nuts are highly related to the surface roughness. In this work, the effect of different cutting parameters such as cutting fluid pressure, feed rate and cutting speed on the surface quality of the crest of thread in the high-speed milling of Brass C3600 have been determined. Two popular neural networks containing MLP and RBF coupling with Taguchi L32 have been used to model surface roughness which was shown to be highly adept for such tasks. The contribution of this work is modelling surface roughness on the crest of the thread by using precise profilometer with nanoscale resolution. Experimental tests have been carried out for validation and approved suitable accuracy of the proposed model. Also analysing the interaction of parameters two by two showed that the most effective cutting parameter on the surface value is feed rate followed by cutting speed and cutting fluid pressure.

Keywords: artificial neural networks, cutting conditions, high-speed machining, surface roughness, thread milling

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Authors: Khaled M. Youssef, Sara I. Ahmed

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In this study, artifacts-free bulk nanocrystalline pure aluminum alloy samples were prepared through mechanical milling under ultra-high purity argon and at both liquid nitrogen and room temperatures. The nanostructure evolution during milling was examined using X-ray diffraction and transmission electron microscope techniques. The in-situ consolidated samples after milling exhibited an average grain size of 18 nm. The tensile properties of this novel material are reported in comparison with coarse-grained aluminum alloys. The 0.2% offset yield strength of the nanocrystalline aluminum was found to be 340 MPa. This value is at least one order of magnitude higher than that of the coarse-grained aluminum alloy. In addition to this extraordinarily high strength, the nanocrystalline aluminum showed a significant tensile ductility, with 6% uniform elongation and 11% elongation-to-failure. The transmission electron microscope observations in this study provide evidence of deformation twinning in the plastically deformed nanocrystalline aluminum. These results highlight a change of the deformation mechanism from a typical dislocation slip to twinning deformation induced by partial dislocation activities.

Keywords: nanocrystalline, aluminum, strength, ductility

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Authors: Christoph Ramsauer, Jaydeep Karandikar, Tony Schmitz, Friedrich Bleicher

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Machining stability is an important limitation to discrete part machining. In this work, a networked implementation of milling stability optimization with Bayesian learning is presented. The milling process was monitored with a wireless sensory tool holder instrumented with an accelerometer at the Vienna University of Technology, Vienna, Austria. The recorded data from a milling test cut is used to classify the cut as stable or unstable based on the frequency analysis. The test cut result is fed to a Bayesian stability learning algorithm at the University of Tennessee, Knoxville, Tennessee, USA. The algorithm calculates the probability of stability as a function of axial depth of cut and spindle speed and recommends the parameters for the next test cut. The iterative process between two transatlantic locations repeats until convergence to a stable optimal process parameter set is achieved.

Keywords: machining stability, machine learning, sensor, optimization

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Authors: Asif Mahmood, Yousef Alzeghayer

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The size effects of a precursor Y2BaCuO5 (Y211) powder on the microstructure and critical current density (Jc) of liquid infiltration growth (LIG)-processed YBa2Cu3O7-y (Y123) bulk superconductors were investigated in terms of milling time (t). YBCO bulk samples having high Jc values have been selected for the flywheel energy storage system. Y211 powders were attrition-milled for 0-10 h in 2 h increments at a fixed rotation speed of 400 RPM. Y211 pre-forms were made by pelletizing the milled Y211 powders followed by subsequent sintering, after which an LIG process with top seeding was applied to the Y211/Ba3Cu5O8 (Y035) pre-forms. Spherical pores were observed in all LIG-processed Y123 samples, and the pore density gradually decreased as t increased from 0 h to 8 h. In addition to the reduced pore density, the Y211 particle size in the final Y123 products also decreased with increasing t. As t increased further to 10 h, unexpected Y211 coarsening and large pore evolutions were observed. The magnetic susceptibility-temperature curves showed that the onset superconducting transition temperature (Tc, onset) of all samples was the same (91.5 K), but the transition width became greater as t increased. The Jc of the Y123 bulk superconductors fabricated in this study was observed to correlate well with t of the Y211 precursor powder. The maximum Jc of 1.0×105 A cm-2 (at 77 K, 0 T) was achieved at t = 8 h, which is attributed to the reduction in pore density and Y211 particle size. The prolonged milling time of t = 10 h decreased the Jc of the LIG-processed Y123 superconductor owing to the evolution of large pores and exaggerated Y211 growth. YBCO bulk samples having high Jc (samples prepared using 8 h milled powders) have been used for the energy storage system in flywheel energy storage system.

Keywords: critical current, bulk superconductor, liquid infiltration, bioinformatics

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Authors: Kious Mecheri, Hadjadj Abdechafik, Ameur Aissa

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The wear of cutting tool degrades the quality of the product in the manufacturing processes. The online monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear online. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.

Keywords: flank wear, cutting forces, high speed milling, signal processing, neural network

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Authors: Preeti Makkar, R. C. Agarwala, Vijaya Agarwala

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The present study focuses on the preparation of Al2O3 nanoparticles by top down approach i.e. mechanical milling using high energy planetary ball mill at 250 rpm for 40h. The milled Al2O3 nanoparticles are then used as the second phase to develop electroless (EL) Ni-P- Al2O3 nanocomposite coatings on mild steel substrate. An alkaline bath was used with a suspension of Al2O3 particles (4 g/L) for the synthesis of Ni-P-Al2O3 nanocomposite coating. The surface morphology, size range and phase analysis of as-prepared Al2O3 particles and the coatings were characterized using X-ray diffraction (XRD) and field emission scanning electron microscopy (FESEM). The coatings were heat treated at 400°C for 1h in argon atmosphere and the hardness of the nanocomposite coatings was investigated with respect to Ni-P before and after heat treatment. The results showed that as milled Al2O3 nanoparticles exhibit irregular shaped and size ranges around 40-45 nm. The Al2O3 particles are uniformly distributed in Ni-P matrix. The microhardness of the coatings is found to be significantly improved after heat treatment (1126 VHN).

Keywords: Electroless (EL), Ni-P-Al2O3, nanocomposite, mechanical milling, microhardness

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Authors: B. J. Babalola, M. B. Shongwe

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Spark Plasma Sintering technique is a novel processing method that produces limited grain growth and highly dense variety of materials; alloys, superalloys, and carbides just to mention a few. However, initial particle size and spark plasma sintering parameters are factors which influence the grain growth and mechanical properties of sintered materials. Ni-Cr alloys are regarded as the most promising alloys for aerospace turbine blades, owing to the fact that they meet the basic requirements of desirable mechanical strength at high temperatures and good resistance to oxidation. The conventional method of producing this alloy often results in excessive grain growth and porosity levels that are detrimental to its mechanical properties. The effect of sintering temperature was evaluated on the microstructure and mechanical properties of the nanostructured Ni-17Cr alloy. Nickel and chromium powder were milled using high energy ball milling independently for 30 hours, milling speed of 400 revs/min and ball to powder ratio (BPR) of 10:1. The milled powders were mixed in the composition of Nickel having 83 wt % and chromium, 17 wt %. This was sintered at varied temperatures from 800°C, 900°C, 1000°C, 1100°C and 1200°C. The structural characteristics such as porosity, grain size, fracture surface and hardness were analyzed by scan electron microscopy and X-ray diffraction, Archimedes densitometry, micro-hardness tester. The corresponding results indicated an increase in the densification and hardness property of the alloy as the temperature increases. The residual porosity of the alloy reduces with respect to the sintering temperature and in contrast, the grain size was enhanced. The study of the mechanical properties, including hardness, densification shows that optimum properties were obtained for the sintering temperature of 1100°C. The advantages of high sinterability of Ni-17Cr alloy using milled powders and microstructural details were discussed.

Keywords: densification, grain growth, milling, nanostructured materials, sintering temperature

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Authors: B. Voucko, M. Benkovic, N. Cukelj, S. Drakula, D. Novotni, S. Balbino, D. Curic

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Oxidative stress is considered as one of the causes leading to metabolic disorders in humans. Therefore, the ability of antioxidants to inhibit free radical production is their primary role in the human organism. Antioxidants originating from cereals, especially flavonoids and polyphenols, are mostly bound and indigestible. Micronization damages the cell wall which consecutively results in bioactive material to be more accessible in vivo. In order to ensure complete fragmentation, micronization is often combined with high temperatures (e.g., for bran 200°C) which can lead to degradation of bioactive compounds. The innovative non-thermal technology of cryo-milling is an ultra-fine micronization method that uses liquid nitrogen (LN2) at a temperature of 195°C to freeze and cool the sample during milling. Freezing at such low temperatures causes the material to become brittle which ensures the generation of fine particles while preserving the bioactive content of the material. The aim of this research was to determine if production of ultra-fine material with cryo-milling will result in the augmentation of available bioactive compounds of buckwheat and pumpkin seed cake. For that reason, buckwheat and pumpkin seed cake were ground in a ball mill (CryoMill, Retch, Germany) with and without the use of LN2 for 8 minutes, in a 50 mL stainless steel jar containing one grinding ball (Ø 25 mm) at an oscillation frequency of 30 Hz. The cryo-milled samples were cooled with LN2 for 2 minutes prior to milling, followed by the first cycle of milling (4 minutes), intermediary cooling (2 minutes), and finally the second cycle of milling (further 4 minutes). A continuous process of milling was applied to the samples ground without freezing with LN2. Particle size distribution was determined using the Scirocco 2000 dry dispersion unit (Malvern Instruments, UK). Antioxidant activity was determined by 2,2-Diphenyl-1-picrylhydrazyl (DPPH) test and ferric reducing antioxidant power (FRAP) assay, while the total phenol content was determined using the Folin Ciocalteu method, using the ultraviolet-visible spectrophotometer (Specord 50 Plus, Germany). The content of the free phenolic acids, rutin in buckwheat, tyrosol in pumpkin seed cake, was determined with an HPLC-PDA method (Agilent 1200 series, Germany). Cryo-milling resulted in 11 times smaller size of buckwheat particles, and 3 times smaller size of pumpkin seed particles than milling without the use of LN2, but also, a lower uniformity of the particle size distribution. Lack of freezing during milling of pumpkin seed cake caused a formation of agglomerates due to its high-fat content (21 %). Cryo-milling caused augmentation of buckwheat flour antioxidant activity measured by DPPH test (23,9%) and an increase in available rutin content (14,5%). Also, it resulted in an augmentation of the total phenol content (36,9%) and available tyrosol content (12,5%) of pumpkin seed cake. Antioxidant activity measured with the FRAP test, as well as the content of phenolic acids remained unchanged independent of the milling process. The results of this study showed the potential of cryo-milling for complete raw material utilization in the food industry, as well as a tool for extraction of aimed bioactive components.

Keywords: bioactive, ball-mill, buckwheat, cryo-milling, pumpkin seed cake

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Authors: Saad Nawaz, Yu Gang, Miao Haibin

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Titanium alloys are attractive materials for aerospace industry due to their exceptional strength to weight ratio that is maintained at elevated temperatures and their good corrosion resistance. Major applications of titanium alloys were military aerospace industry, but since last decade the trend has now shifted towards commercial industry. On the other hand, titanium alloys are notorious for being poor thermal conductor that leads to them being difficult materials for machining. In this experimental study, Stellram Indexable milling cutter XDLT09-D41 is used for rough down milling of Ti6Al4V for small depth of cut under different combinations of parameters and application of high-pressure coolant. The machining performance was evaluated in terms of tool wear, tool life, and thermal crack. The tool wear was mostly observed at the tool tip and at bottom part of tool thermal deformations were observed which propagated with respect to time. Flank wear due to scratching of the cutting chips and diffusion wear because of high thermal stresses were observed specially at the bottom of the cutting tool. It was found that maximum tool life was obtained at the speed of 40m/min, feed rate of 358mm/min and depth of cut of 0.8mm. In the end, it was concluded that machining of Ti6Al4V is a thermally dominant process which leads to high thermal stresses in machining zone that results in increasing tool wear rate and deformation propagation.

Keywords: tool wear, cutting speed, flank wear , tool life

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Authors: Laslouni Warda, M. Azzaz

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The intermetallic-based on transition metal compounds present interesting magnetic properties for the technological applications (permanent magnets, magnetic recording…). Cu70 Fe18Co12 and Cu70 Fe30 nanostructured with crystallite size vary from 10 a 12 nanometers have been developed by a mechanical milling method. For Cu-Fe samples, the iron and copper distribution was clear. The distribution showed a homogeneous distribution of iron and copper in a Cu-Fe obtained after 36 h milling. The structural properties have been performed with X-ray diffraction. With increasing milling times, Fe and Co diffuse into the Cu matrix, which accelerates the formation of the magnetic nanostructure Cu- Fe-Co and Cu-Fe alloys. The magnetic behavior is investigated using Vibrating Sample Magnetometer (VSM). The two alloys nanocrystals possess ferromagnetic character at room temperature

Keywords: Cu-Fe-Co, Cu-Fe, nanocrystals, SEM, hysteresis loops, VSM, anisotropy theory

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Authors: Vineeth G. Kuriakose, Joseph C. Chen, Ye Li

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The research follows a systematic approach to optimize the parameters for parts machined by turning and milling processes. The quality characteristic chosen is surface roughness since the surface finish plays an important role for parts that require surface contact. A tapered cylindrical surface is designed as a test specimen for the research. The material chosen for machining is aluminum alloy 6061 due to its wide variety of industrial and engineering applications. HAAS VF-2 TR computer numerical control (CNC) vertical machining center is used for milling and HAAS ST-20 CNC machine is used for turning in this research. Taguchi analysis is used to optimize the surface roughness of the machined parts. The L₉ Orthogonal Array is designed for four controllable factors with three different levels each, resulting in 18 experimental runs. Signal to Noise (S/N) Ratio is calculated for achieving the specific target value of 75 ± 15 µin. The controllable parameters chosen for turning process are feed rate, depth of cut, coolant flow and finish cut and for milling process are feed rate, spindle speed, step over and coolant flow. The uncontrollable factors are tool geometry for turning process and tool material for milling process. Hypothesis testing is conducted to study the significance of different uncontrollable factors on the surface roughnesses. The optimal parameter settings were identified from the Taguchi analysis and the process capability C_p and the process capability index C_pk were improved from 1.76 and 0.02 to 3.70 and 2.10 respectively for turning process and from 0.87 and 0.19 to 3.85 and 2.70 respectively for the milling process. The surface roughnesses were improved from 60.17 µin to 68.50 µin, reducing the defect rate from 52.39% to 0% for the turning process and from 93.18 µin to 79.49 µin, reducing the defect rate from 71.23% to 0% for the milling process. The purpose of this study is to efficiently utilize the Taguchi design analysis to improve the surface roughness.

Keywords: surface roughness, Taguchi parameter design, CNC turning, CNC milling

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Authors: Joseph Chen, N. Hundal

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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: T. V. K. Gupta, J. Ramkumar, Puneet Tandon, N. S. Vyas

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Abrasive Water Jet Machining (AWJM) is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application i.e. abrasive size, flow rate, standoff distance, and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate, and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.

Keywords: abrasive flow rate, surface finish, abrasive size, standoff distance, traverse speed

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Authors: Opeyemi Atiba-Oyewo, Maurice S. Onya, Christian Wolkersdorfer

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Nanostructure formation and characterization of eco-friendly banana peels nanosorbent are thoroughly described in this paper. The transformation of material during mechanical milling to enhance certain properties such as changes in microstructure and surface area to solve the current problems involving water pollution and water quality were studied. The mechanical milling was employed using planetary continuous milling machine and ethanol as process control agent, the sample were taken at time interval between 10 h to 30 h to examine the structural changes. The samples were characterised by X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infra-red (FTIR), Transmission electron microscopy (TEM) and Brunauer Emmett and teller (BET). Results revealed that the three typical structures with different grain-size, lattice strain and shapes were observed, and the deformation mechanisms in these structures were found to be different, further particles fracturing results to surface area increment which was confirmed by Brunauer Emmett and teller (BET) analysis. X-ray diffraction (XRD) shows high densities of dislocations in large crystallites, implying that dislocation slip is the dominant deformation mechanism. Scanning electron microscopy revealed the morphological properties of the materials at different milling time, nanostructure of the particles and fibres were confirmed by Transmission electron microscopy and FT-IR identified the functional groups responsible for its capacity to coordinate and remove metal ions, such as the carboxylic and amine groups at absorption bands of 1730 and 889 cm-1, respectively. However, the choice of this sorbent material for the sorption of any contaminants will depend on the composition of the effluent to be treated.

Keywords: banana peels, eco-friendly, mechanical milling, nanosorbent, nanostructure water quality

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Authors: Ahmad Alazemi, M. Sherif El-Eskandrany, Mohamad Kishk, Thanyan AlOnaizi, Ahmad Alduweesh, Shorouq Abdullaleel

Abstract:

Arc melting technique followed by top-down approach, using a high-energy ball milling technique were employed to synthesize nanocrystalline of Cu50(Zr50-xNix)50 (x = 0, 10, 20 and 30 at.%) powder particles. The end-products of the alloy powders obtained after 50 h of the ball milling time were uniform in composition and had spherical-like morphology with an average particle size of 0.75 µm in diameter. The powders, which consisted of nanocrystalline grains with an average grain size of 10 nm in diameter, were used as feedstock materials for double face coating of stainless (SUS304) sheets, using cold spraying process. The coating materials enjoyed nanocrystalline structure and uniform composition. Biofilms were grown on 20-mm2 SUS304 sheets coated coupons inoculated with 1.5 × 108 CFU ml−1 E. coli. Significant biofilm inhibition was recorded in the nanoparticles coated coupons in comparison to non-coated SUS304 coupon. In conclusion, this study demonstrates that formation of biofilms can be significantly inhibited by Cu-based alloys especially in case of high (Ni) content. The inhibition of biofilm formation by nanocrystalline powders of Cu-based provides a practical approach to achieve the inhibition of biofilms formed by an emerging pathogen.

Keywords: biofilm, Cu, E.coli, FE-HRTEM/EDS, nanomaterials, nanocrystalline

Procedia PDF Downloads 395

Authors: Zihua Wu, Yueming He, Xiaoxiao Yu, Yuanyuan Wang, Huaqing Xie

Abstract:

The match of Solar thermoelectric generator (STEG) and phase change materials (PCM) can enhance the solar energy storage and reduce environmental impact from the day-and-night transformation and weather changes. This work utilizes D-mannitol (DM) matrix as the suitable PCM for coupling with thermoelectric generator to achieve the middle-temperature solar energy storage performance at 165℃-167℃. DM/MWCNT composite phase change materials prepared by ball milling not only can keep a high phase change enthalpy of DM material but also have great photo-thermal conversion efficiency of 82%. Based on the self-made storage device container, the effect of PCM thickness on the solar energy storage performance is further discussed and analyzed. The experimental results prove that PCM-STEG coupling system can output more electric energy than pure STEG system because PCM can decline the heat transfer and storage thermal energy to further generate the electric energy through thermal-to-electric conversion when the light is removed. The increase of PCM thickness can reduce the heat transfer and enhance thermal storage, and then the power generation performance of PCM-STEG coupling system can be improved. As the increase of light intensity, the output electric energy of the coupling system rises accordingly, and the maximum amount of electrical energy can reach by 113.85 J at 1.6 W/cm2. The study of the PCM-STEG coupling system has certain reference for the development of solar energy storage and application.

Keywords: solar energy, solar thermoelectric generator, phase change materials, solar-to-electric energy, DM/MWCNT

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Authors: Daniela Evtimovska, Ivana Srbinovska, Padraig O’Rourke

Abstract:

Kostal Macedonia has the challenge to mill a rigid-flex printed circuit board (PCB). The PCB elaborated in this paper is made of FR4 material covered with polyimide through the whole surface on the one side, including the tabs where PCBs need to be separated. After milling only 1.44 meters, the updraft routing tool isn’t effective and causes polyimide debris on all PCB cuts if it continues to mill with the same tool. Updraft routing tool is used for all another product in Kostal Macedonia, and it is changing after milling 60 meters. Changing the tool adds 80 seconds to the cycle time. One solution is using a laser-cut machine. Buying a laser-cut machine for cutting only one product doesn’t make financial sense. The focus is given to find an internal solution among the options under review to solve the issue with polyimide debris. In the paper, the design of the rigid-flex panel is described deeply. It is evaluated downdraft routing tool as a possible solution which could be used for the flex rigid panel as a specific product. It is done a comparison between updraft and down draft routing tools from a technical and financial aspect of view, taking into consideration the customer requirements for the rigid-flex PCB. The results show that using the downdraft routing tool is the best solution in this case. This tool is more expensive for 0.62 euros per piece than updraft. The downdraft routing tool needs to be changed after milling 43.44 meters in comparison with the updraft tool, which needs to be changed after milling only 1.44 meters. It is done analysis which actions should be taken in order further improvements and the possibility of maximum serving of downdraft routing tool.

Keywords: Kostal Macedonia, rigid flex PCB, polyimide, debris, milling process, up/down draft routing tool

Procedia PDF Downloads 159

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 78