Search results for: high speed cutting

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: Do Chi Thanh, Dang Ngoc Huy

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Nowadays, there are more and more variable speed drive systems in small-scale and large-scale applications such as the electric vehicle industry, household appliances, medical equipment, and other industrial fields led to the development of BLDC (Brushless DC) motors. BLDC drive has many advantages, such as higher efficiency, better speed torque characteristics, high power density, and low maintenance cost compared to other conventional motors. Most BLDC motors use a proportional-integral (PI) controller and a pulse width modulation (PWM) scheme for speed control. This article describes the simulation model of BLDC motor drive control with the help of MATLAB - SIMULINK simulation software. The built simulation model includes a BLDC motor dynamic block, Hall sensor signal generation block, inverter converter block, and PI controller.

Keywords: brushless DC motor, BLDC, six-step inverter, PI speed

Procedia PDF Downloads 45

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

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

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

Procedia PDF Downloads 101

Authors: Phatthara Surachon, Tosaphol Ratniyomchai, Thanatchai Kulworawanichpong

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This paper presents an aerodynamic brake study of reducing braking distance for high-speed trains (HST) using aerodynamic brakes as inspiration from the applications on the commercial aircraft wings. In case of emergency, both braking distance and stopping time are longer than the usual situation. Therefore, the passenger safety and the HST driving control management are definitely obtained by reducing the time and distance of train braking during emergency situation. Due to the limited study and implementation of the aerodynamic brake in HST, the possibility in use and the effectiveness of the aerodynamic brake to the train dynamic movement during braking are analyzed and considered. Regarding the aircraft’s flaps that applied in the HST, the areas of the aerodynamic brake acted as an additional drag force during train braking are able to vary depending on the operating angle and the required dynamic braking force. The HST with a varying speed of 200 km/h to 350 km/h is taken as a case study of this paper. The results show that the stopping time and the brake distance are effectively reduced by the aerodynamic brakes. The mechanical brake and its maintenance are effectively getting this benefit by extending its lifetime for longer use.

Keywords: high-speed train, aerodynamic brake, brake distance, drag force

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Authors: Khashayar Kazemzadeh, Mohammad Hanif Dasoomi

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According to the increasing travel demand in cities, bridges and tunnels are viewed as one of the fundamental components of cities transportation systems. Normally, due to geometric constraints forms in the tunnels, the considered speed in the tunnels is lower than the speed in connected highways. Therefore, drivers tend to reduce the speed near the entrance of the tunnels. In this paper, the effect of speed reduction on accident happened in the entrance of the tunnels has been discussed. The relation between accidents frequency and the parameters of speed, traffic volume and time of the accident in the mentioned tunnel has been analyzed and the mathematical model has been proposed.

Keywords: urban highway, accident, tunnel, mathematical model

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Authors: Chaitanya Varma, Arpan Mehar

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The present study demonstrates the procedure to analyse speed data collected on various four-lane divided sections in India. Field data for the study was collected at different straight and curved sections on rural highways with the help of radar speed gun and video camera. The data collected at the sections were analysed and parameters pertain to speed distributions were estimated. The different statistical distribution was analysed on vehicle type speed data and for mixed traffic speed data. It was found that vehicle type speed data was either follows the normal distribution or Log-normal distribution, whereas the mixed traffic speed data follows more than one type of statistical distribution. The most common fit observed on mixed traffic speed data were Beta distribution and Weibull distribution. The separate operating speed model based on traffic and roadway geometric parameters were proposed in the present study. The operating speed model with traffic parameters and curve geometry parameters were established. Two different operating speed models were proposed with variables 1/R and Ln(R) and were found to be realistic with a different range of curve radius. The models developed in the present study are simple and realistic and can be used for forecasting operating speed on four-lane highways.

Keywords: highway, mixed traffic flow, modeling, operating speed

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Authors: Chandra Gupt Porwal

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Excessive vibration means increased wear, increased repair efforts, bad product selection & quality and high energy consumption. This may be sometimes experienced by cavitation or suction/discharge re-circulation which could occur only when net positive suction head available NPSHA drops below the net positive suction head required NPSHR. Cavitation can cause axial surging if it is excessive, will damage mechanical seals, bearings, possibly other pump components frequently and shorten the life of the impeller. Efforts have been made to explain Suction Energy (SE), Specific Speed (Ns), Suction Specific Speed (Nss), NPSHA, NPSHR & their significance, possible reasons of cavitation /internal re-circulation, its diagnostics and remedial measures to arrest and prevent cavitation in this paper. A case study is presented by the author highlighting that the root cause of unwanted noise and vibration is due to cavitation, caused by high specific speeds or inadequate net- positive suction head available which results in damages to material surfaces of impeller & suction bells and degradation of machine performance, its capacity and efficiency too. The author strongly recommends revisiting the technical specifications of CW pumps to provide sufficient NPSH margin ratios > 1.5, for future projects and Nss be limited to 8500 -9000 for cavitation free operation.

Keywords: best efficiency point (BEP), net positive suction head NPSHA, NPSHR, specific speed NS, suction specific speed NSS

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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: M. Towhidur Rahman, Nasim Zaman Piyas, M. Sadiqul Baree, Shahnewaz Ahmed

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The design of high-speed craft has recently become one of the most active areas of naval architecture. Speed increase makes these vehicles more efficient and useful for military, economic or leisure purpose. The planing hull is designed specifically to achieve relatively high speed on the surface of the water. Speed on the water surface is closely related to the size of the vessel and the installed power. The Savitsky method was first presented in 1964 for application to non-monohedric hulls and for application to stepped hulls. This method is well known as a reliable comparative to CFD analysis of hull resistance. A computer program based on Savitsky’s method has been developed using MATLAB. The power of high-speed vessels has been computed in this research. At first, the program reads some principal parameters such as displacement, LCG, Speed, Deadrise angle, inclination of thrust line with respect to keel line etc. and calculates the resistance of the hull using empirical planning equations of Savitsky. However, some functions used in the empirical equations are available only in the graphical form, which is not suitable for the automatic computation. We use digital plotting system to extract data from nomogram. As a result, value of wetted length-beam ratio and trim angle can be determined directly from the input of initial variables, which makes the power calculation automated without manually plotting of secondary variables such as p/b and other coefficients and the regression equations of those functions are derived by using data from different charts. Finally, the trim angle, mean wetted length-beam ratio, frictional coefficient, resistance, and power are computed and compared with the results of Savitsky and good agreement has been observed.

Keywords: nomogram, planing hull, principal parameters, regression

Procedia PDF Downloads 376

Authors: Hyun-Koo Kim, Yong-Hun Kim, Soo-Young Suk, Ju H. Park, Ho-Youl Jung

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This paper presents an effective speed hump detection process at the day-time. we focus only on round types of speed humps in the day-time dynamic road environment. The proposed speed hump detection scheme consists mainly of two process as stereo matching and speed hump detection process. Our proposed process focuses to speed hump detection process. Speed hump detection process consist of noise reduction step, data fusion step, and speed hemp detection step. The proposed system is tested on Intel Core CPU with 2.80 GHz and 4 GB RAM tested in the urban road environments. The frame rate of test videos is 30 frames per second and the size of each frame of grabbed image sequences is 1280 pixels by 670 pixels. Using object-marked sequences acquired with an on-vehicle camera, we recorded speed humps and non-speed humps samples. Result of the tests, our proposed method can be applied in real-time systems by computation time is 13 ms. For instance; our proposed method reaches 96.1 %.

Keywords: data fusion, round types speed hump, speed hump detection, surface filter

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Authors: Lin Lu, Qiang Li, Tao Cai, Pengjun Zhang

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In this study, a detailed analysis of trajectory stability and flow characteristics of a high-speed projectile during the water-entry and water-exit process has been investigated numerically. The Zwart-Gerber-Belamri (Z-G-B) cavitation model and the SST k-ω turbulence model based on the Reynolds Averaged Navier-Stokes (RANS) method are employed. The numerical methodology is validated by comparing the experimental photograph of cavitation shape and the experimental underwater velocity with the numerical simulation results. Based on the numerical methodology, the influences of rotational speed, water-entry and water-exit angle of the projectile on the trajectory stability and flow characteristics have been carried out in detail. The variation features of projectile trajectory and total resistance have been conducted, respectively. In addition, the cavitation characteristics of water-entry and water-exit have been presented and analyzed. Results show that it may not be applicable for the water-entry and water-exit to achieve the projectile stability through the rotation of projectile. Furthermore, there ought to be a critical water-entry angle for the water-entry stability of practical projectile. The impact of water-exit angle on the trajectory stability and cavity phenomenon is not as remarkable as that of the water-entry angle.

Keywords: cavitation characteristics, high-speed projectile, numerical predictions, trajectory stability, water-entry, water-exit

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Authors: Ali Javaid, Rizwan Latif, Syed Adnan Qasim, Imran Shafi

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To control combustion inside a direct injection diesel engine, fuel atomization is the best tool. Controlling combustion helps in reducing emissions and improves efficiency. Cavitation is one of the most important factors that significantly affect the nature of spray before it injects into combustion chamber. Typical fuel injector nozzles are small and operate at a very high pressure, which limits the study of internal nozzle behavior especially in case of diesel engine. Simulating cavitation in a fuel injector will help in understanding the phenomenon and will assist in further development. There is a parametric variation between high speed and high torque low speed diesel engines. The objective of this study is to simulate internal spray characteristics for a low speed high torque diesel engine. In-nozzle cavitation has strong effects on the parameters e.g. mass flow rate, fuel velocity, and momentum flux of fuel that is to be injected into the combustion chamber. The external spray dynamics and subsequently the air – fuel mixing depends on a lot of the parameters of fuel injecting the nozzle. The approach used to model turbulence induced in – nozzle cavitation for high-torque low-speed diesel engine, is homogeneous equilibrium model. The governing equations were modeled using Matlab. Complete Model in question was extensively evaluated by performing 3-D time-dependent simulations on Open FOAM, which is an open source flow solver and implemented in CFD (Computational Fluid Dynamics). Results thus obtained will be analyzed for better evaporation in the near-nozzle region. The proposed analyses will further help in better engine efficiency, low emission, and improved fuel economy.

Keywords: cavitation, HEM model, nozzle flow, open foam, turbulence

Procedia PDF Downloads 245

Authors: Adnan Mazari, Engin Akcagun, Antonin Havelka, Funda Buyuk Mazari, Pavel Kejzlar

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This article experimentally investigates various physical properties of special fire retardant sewing threads under different sewing speeds. The aramid threads are common for sewing the fire-fighter clothing due to high strength and high melting temperature. 3 types of aramid threads with different linear densities are used for sewing at different speed of 2000 to 4000 r/min. The needle temperature is measured at different speeds of sewing and tensile properties of threads are measured before and after the sewing process respectively. The results shows that the friction and abrasion during the sewing process causes a significant loss to the tensile properties of the threads and needle temperature rises to nearly 300^oC at 4000 r/min of machine speed. The Scanning electron microscope images are taken before and after the sewing process and shows no melting spots but significant damage to the yarn. It is also found that machine speed of 2000r/min is ideal for sewing firefighter clothing for higher tensile properties and production.

Keywords: Kevlar, needle temperautre, nomex, sewing

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Authors: Vinayak Malaghan, Digvijay Pawar

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Speed is the independent parameter which plays a vital role in the highway design. Design consistency of the highways is checked based on the variation in the operating speed. Often the design consistency fails to meet the driver’s expectation which results in the difference between operating and design speed. Literature reviews have shown that significant crashes take place in horizontal curves due to lack of design consistency. The paper focuses on continuous speed profile study on tangent to curve transition for both day and night daytime. Data is collected using GPS device which gives continuous speed profile and other parameters such as acceleration, deceleration were analyzed along with Tangent to Curve Transition. In this present study, models were developed to predict operating speed on tangents and horizontal curves as well as model indicating the speed reduction from tangent to curve based on continuous speed profile data. It is observed from the study that vehicle tends to decelerate from approach tangent to between beginning of the curve and midpoint of the curve and then accelerates from curve to tangent transition. The models generated were compared for both day and night and can be used in the road safety improvement by evaluating the geometric design consistency.

Keywords: operating speed, design consistency, continuous speed profile data, day and night time

Procedia PDF Downloads 131

Authors: Guo-Ming Sung, Ramavath Naga Raju Naik

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This paper presents a low power, high speed, sense-amplifier based flip-flop (SAFF). The flip-flop’s power con-sumption and delay are greatly reduced by employing a new conditionally precharge sense-amplifier stage and a single-ended latch stage. Glitch-free and contention-free latch operation is achieved by using a conditional cut-off strategy. The design uses fewer transistors, has a lower clock load, and has a simple structure, all of which contribute to a near-zero setup time. When compared to previous flip-flop structures proposed for similar input/output conditions, this design’s performance and overall PDP have improved. The post layout simulation of the circuit uses 2.91µW of power and has a delay of 65.82 ps. Overall, the power-delay product has seen some enhancements. Cadence Virtuoso Designing tool with CMOS 90nm technology are used for all designs.

Keywords: high-speed, low-power, flip-flop, sense-amplifier

Procedia PDF Downloads 130

Authors: Lakdar Sadi-Haddad

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The past few years study of very high speed electrical drives have seen a resurgence of interest. An inventory of the number of scientific papers and patents dealing with the subject makes it relevant. In fact democratization of magnetic bearing technology is at the origin of recent developments in high speed applications. These machines have as main advantage a much higher power density than the state of the art. Nevertheless particular attention should be paid to the design of the inverter as well as control and command. Surface mounted permanent magnet synchronous machine is the most appropriate technology to address high speed issues. However, it has the drawback of using a carbon sleeve to contain magnets that could tear because of the centrifugal forces generated in rotor periphery. Carbon fiber is well known for its mechanical properties but it has poor heat conduction. It results in a very bad evacuation of eddy current losses induce in the magnets by time and space stator harmonics. The three-phase inverter is the main harmonic source causing eddy currents in the magnets. In high speed applications such harmonics are harmful because on the one hand the characteristic impedance is very low and on the other hand the ratio between the switching frequency and that of the fundamental is much lower than that of the state of the art. To minimize the impact of these harmonics a first lever is to use strategy of modulation producing low harmonic distortion while the second is to introduce a sinus filter between the inverter and the machine to smooth voltage and current waveforms applied to the machine. Nevertheless, in very high speed machine the interaction of the processes mentioned above may introduce particular harmonics that can irreversibly damage the system: harmonics at the resonant frequency, harmonics at the shaft mode frequency, subharmonics etc. Some studies address these issues but treat these phenomena with separate solutions (specific strategy of modulation, active damping methods ...). The purpose of this paper is to present a complete new active harmonic compensation algorithm based on an improvement of the standard vector control as a global solution to all these issues. This presentation will be based on a complete theoretical analysis of the processes leading to the generation of such undesired harmonics. Then a state of the art of available solutions will be provided before developing the content of a new active harmonic compensation algorithm. The study will be completed by a validation study using simulations and practical case on a high speed machine.

Keywords: active harmonic compensation, eddy current losses, high speed machine

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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

Procedia PDF Downloads 300

Authors: Ali Raza, Rizwan Latif, Syed Adnan Qasim, Imran Shafi

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Diesel engines are most efficient and reliable in terms of efficiency, reliability, and adaptability. Most of the research and development up till now have been directed towards High Speed Diesel Engine, for Commercial use. In these engines, objective is to optimize maximum acceleration by reducing exhaust emission to meet international standards. In high torque low speed engines, the requirement is altogether different. These types of engines are mostly used in Maritime Industry, Agriculture Industry, Static Engines Compressors Engines, etc. On the contrary, high torque low speed engines are neglected quite often and are eminent for low efficiency and high soot emissions. One of the most effective ways to overcome these issues is by efficient combustion in an engine cylinder. Fuel spray dynamics play a vital role in defining mixture formation, fuel consumption, combustion efficiency and soot emissions. Therefore, a comprehensive understanding of the fuel spray characteristics and atomization process in high torque low speed diesel engine is of great importance. Evaporation in the combustion chamber has a rigorous effect on the efficiency of the engine. In this paper, multiphase evaporation of fuel is modeled for high torque low speed engine using the CFD (computational fluid dynamics) codes. Two distinct phases of evaporation are modeled using modeling soft wares. The basic model equations are derived from the energy conservation equation and Naiver-Stokes equation. O’Rourke model is used to model the evaporation phases. The results obtained showed a generous effect on the efficiency of the engine. Evaporation rate of fuel droplet is increased with the increase in vapor pressure. An appreciable reduction in size of droplet is achieved by adding the convective heat effects in the combustion chamber. By and large, an overall increase in efficiency is observed by modeling distinct evaporation phases. This increase in efficiency is due to the fact that droplet size is reduced and vapor pressure is increased in the engine cylinder.

Keywords: diesel fuel, CFD, evaporation, multiphase

Procedia PDF Downloads 311

Authors: R. N. Karthik Babu, R. Sarvesh, A. Rajendra Prasad, G. Swaminathan

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M42 is a molybdenum-series high-speed alloy steel widely used because of its better hot-hardness and wear resistance. These steels are conventionally heat treated in a salt bath furnace with up to three stages of preheating with predetermined soaking and holding periods. Such methods often involve long periods of processing with a large amount of energy consumed. In this study, the M42 steel samples were heat-treated by rapidly heating the specimens to the austenising temperature of 1260 °C and cooled conventionally by quenching in a neutral salt bath at a temperature of 550 °C with the aid of a hybrid microwave furnace. As metals reflect microwaves, they cannot directly be heated up when placed in a microwave furnace. The technology used herein requires the specimens to be placed in a crucible lined with SiC which is a good absorber of microwaves and the SiC lining heats the metal through radiation which facilitates the volumetric heating of the metal. A sample of similar dimensions was heat treated conventionally and cooled in the same manner. Conventional tempering process was then carried out on both these samples and analysed for various parameters such as micro-hardness, processing time, etc. Microstructure analysis and scanning electron microscopy was also carried out. The objective of the study being that similar or better properties, with substantial time and energy saving and cost cutting are achievable by rapid heat treatment through hybrid microwave furnaces. It is observed that the heat treatment is done with substantial time and energy savings, and also with minute improvement in mechanical properties of the tool steel heat treated.

Keywords: rapid heating, heat treatment, metal processing, microwave heating

Procedia PDF Downloads 261

Authors: Agata Tomaszewska, Timothy Kamps, Stephan R. Turnock, Nicola Symonds

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Bob skeleton is a highly competitive sport in which an athlete reaches speeds up to 40 m/s sliding, head first, down an ice track. It is believed that the friction between the runners and ice significantly contributes to the amount of the total energy loss during a bob skeleton descent. There is only limited available experimental data regarding the friction of bob skeleton runners or indeed steel on the ice at high sliding speeds ( > 20 m/s). Testing methods used to investigate the friction of steel on ice in winter sports have been outlined, and their accuracy and repeatability discussed. A system thinking approach was used to investigate the runner-ice interaction during sliding and create concept designs of three ice tribometers. The operational envelope of the bob skeleton system has been defined through mathematical modelling. Designs of a drum, linear and inertia pin-on-disk tribometers were developed specifically for bob skeleton runner testing with the requirement of reaching up to 40 m/s speed and facilitate fresh ice sliding. The design constraints have been outline and the proposed solutions compared based on the ease of operation, accuracy and the development cost.

Keywords: bob skeleton, ice friction, high-speed tribometers, sliding friction

Procedia PDF Downloads 232

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

Procedia PDF Downloads 336

Authors: Shiva Abdoli, Daniel T.Semere

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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)

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Authors: Kyoung-Jin Joo, In-Gun Kim, Hyun-Seok Hong, Dong-Woo Kang, Ju Lee

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Recently, the permanent magnet-assisted synchronous reluctance motor (PMa-SynRM) that can be substituted for the induction motor has been studying because of the needs of the development of the premium high efficiency motor for the minimum energy performance standard (MEPS). PMa-SynRM is required to the speed and position information for motor speed and torque controls. However, to apply the sensors has many problems that are sensor mounting space shortage and additional cost, etc. Therefore, in this paper, speed-sensorless control based on model reference adaptive system (MRAS) is introduced to eliminate the sensor. The sensorless method is constructed in a reference model as standard and an adaptive model as the state observer. The proposed algorithm is verified by the simulation.

Keywords: PMa-SynRM, sensorless control, robust estimation, MRAS method

Procedia PDF Downloads 370

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

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

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

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Authors: Bruno S. Soria, Mauricio R. Policena, Andre J. Souza

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The state of the cutting tool is an important factor to consider during machining to achieve a good surface quality. The vibration generated during material cutting can also directly affect the surface quality and life of the cutting tool. In this work, the effect of mechanical broken failure (MBF) on carbide insert tools during face milling of AISI 304 stainless steel was evaluated using three levels of feed rate and two spindle speeds for each tool condition: three carbide inserts have perfect geometry, and three other carbide inserts have MBF. The axial and radial depths remained constant. The cutting forces were determined through a sensory system that consists of a piezoelectric dynamometer and data acquisition system. Discrete Wavelet Transform was used to separate the static part of the signals of force and vibration. The roughness of the machined surface was analyzed for each machining condition. The MBF of the tool increased the intensity and force of vibration and worsened the roughness factors.

Keywords: face milling, stainless steel, tool condition monitoring, wavelet discrete transform

Procedia PDF Downloads 117

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: Ayudhia P. Gusti, Semin

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It is known that total operating cost of a vessel is dominated by the cost of fuel consumption. How to reduce the fuel cost of ship so that the operational costs of fuel can be minimized is the question that arises. As the basis of these kinds of problem, sailing speed determination is an important factor to be considered by a shipping company. Optimal speed determination will give a significant influence on the route and berth schedule of ships, which also affect vessel operating costs. The purpose of this paper is to clarify some important issues about ship speed optimization. Sailing speed, displacement, sailing time, and specific fuel consumption were obtained from shipping log data to be further analyzed for modeling the speed optimization. The presented speed optimization model is expected to affect the fuel consumption and to reduce the cost of fuel consumption.

Keywords: maritime transportation, reducing fuel, shipping log data, speed optimization

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Authors: Hamed Rashid Sarand, Kemal Selçuk Öğüt

Abstract:

Speed is one of the fundamental variables of road traffic flow that stands as an important evaluation criterion for traffic analyses in several aspects. In particular, varieties of speed variable, such as average speed, free flow speed, optimum speed (capacity speed), acceleration/deceleration speed and so on, have been explicitly considered in the analysis of not only road safety but also road capacity. In the purpose of realizing 'road speed – maximum speed difference across lanes' and 'road flow rate – maximum speed difference across lanes' relations on freeway traffic, this study presents a case study conducted on a basic freeway segment of O-2 in Istanbul. The traffic data employed in this study have been obtained from 5 remote traffic microwave sensors operated by Istanbul Metropolitan Municipality. The study stretch is located between two successive freeway interchanges: Ümraniye and Kavacık. Daily traffic data of 4 years (2011-2014) summer months, July and August are used. The speed data are analyzed into two main flow areas such as uncongested and congested flows. In this study, the regression analyses were carried out in order to examine the relationship between maximum speed difference across lanes and road speed. These investigations were implemented at uncongested and congested flows, separately. Moreover, the relationship between maximum speed difference across lanes and road flow rate were evaluated by applying regression analyses for both uncongested and congested flows separately. It is concluded that there is the moderate relationship between maximum speed difference across lanes and road speed in 50% cases. Additionally, it is indicated that there is the moderate relationship between maximum speed difference across lanes and road flow rate in 30% cases. The maximum speed difference across lanes decreases as the road flow rate increases.

Keywords: maximum speed difference, regression analysis, remote traffic microwave sensor, speed differentiation, traffic flow

Procedia PDF Downloads 329

Authors: Varsha Singh, Kishan Fuse

Abstract:

This paper presents a study of the grey-Taguchi method to optimize CNC milling parameters of AA6061 T6 aluminium alloy. Grey-Taguchi method combines Taguchi method based design of experiments (DOE) with grey relational analysis (GRA). Multi-response optimization of different quality characteristics as surface roughness, material removal rate, cutting forces is done using grey relational analysis (GRA). The milling parameters considered for experiments include cutting speed, feed per tooth, and depth of cut. Each parameter with three levels is selected. A grey relational grade is used to estimate overall quality characteristics performance. The Taguchi’s L9 orthogonal array is used for design of experiments. MINITAB 17 software is used for optimization. Analysis of variance (ANOVA) is used to identify most influencing parameter. The experimental results show that grey relational analysis is effective method for optimizing multi-response characteristics. Optimum results are finally validated by performing confirmation test.

Keywords: ANOVA, CNC milling, grey relational analysis, multi-response optimization

Procedia PDF Downloads 285

Authors: Abdulhamit Donder, Erhan Ilhan Konukseven

Abstract:

Grinding operation is performed in order to obtain desired surfaces precisely in machining process. The needed relative motion between the cutting tool and the workpiece is generally created either by the movement of the cutting tool or by the movement of the workpiece or by the movement of both of them as in our case. For all these cases, the coherence level between the movements and the interaction forces is a key influential parameter for efficient grinding. Therefore, in this work, spectral coherence analysis has been performed to investigate the coherence level between grinding interaction forces and the movement of the workpiece on our robotic-grinding experimental setup in METU Mechatronics Laboratory.

Keywords: coherence analysis, correlation, FFT, grinding, hanning window, machining, Piezo actuator, reverse arrangements test, spectral analysis

Procedia PDF Downloads 374