Search results for: high speed machining

Authors: Mengjun Zhang, Yuli Sun, Dunwen Zuo, Chunxiang Xie, Chunming Zhang

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Experimental study on slicing of sapphire with fixed abrasive diamond wire saw was conducted in this paper. The process parameters were optimized through orthogonal experiment of three factors and four levels. The effects of wire speed, feed speed and tension pressure on the surface roughness were analyzed. Surface roughness in cutting direction and feed direction were both detected. The results show that feed speed plays the most significant role on the surface roughness of sliced sapphire followed by wire speed and tension pressure. The optimized process parameters are as follows: wire speed 1.9 m/s, feed speed 0.187 mm/min and tension pressure 0.18 MPa. In the end, the results were verified by analysis of variance.

Keywords: fixed abrasive, diamond wire saw, slicing, sapphire, orthogonal experiment

Procedia PDF Downloads 426

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

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

Keywords: boring, chatter, mass damping, passive damping

Procedia PDF Downloads 335

Authors: Siddegowda, Y. A. Sathish, G. Krishnegowda, T. M. Mohan Kumar

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Road accidents are a human tragedy. They involve high human suffering and monetary costs in terms of untimely death, injuries and social problems. India had earned the dubious distinction of having more number of fatalities due to road accidents in the world. Road safety is emerging as a major social concern around the world especially in India because of infrastructure project works. A case study was taken on NH – 07 which connects to various major cities and industries. The study shows that major cases of fatalities are due to bus, trucks and high speed vehicles. The main causes of accidents are due to high density, non-restriction of speed, use of mobile phones, lack of board signs on road parking, visibility restriction, improper geometric design, road use characteristics, environmental aspects, social aspects etc. Data analysis and preventive measures are enlightened in this paper.

Keywords: accidents, environmental aspects, fatalities, geometric design, road user characteristics

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Authors: Min-Shiuan Liou, Yi Shan Yang, Yang-Zhan Huang, Chia-Wen Hsieh

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A high speed growing and butanol-tolerant Clostridium acetobutylicum HOL1 mutant was screened throughout continuous adaption culture with C. acetobutylicum ATCC 824. The HOL1 strain can grow well in 10 g/L butanol contained CGM medium and can produce about 12.8 g /L butanol during 24 hrs. The C. acetobutylicum HOL1 strain was able to produce 166 mM butanol with 21 mM acetone at pH 4.8, resulting in a butanol selectivity (a molar ratio of butanol to total solvents) of 0.79, which is much higher than that (0.6) of the wild-type strain C. acetobutylicum ATCC 824. The acetate and butyrate accumulation were not observed during fermentation of the HOL1 strain. A hyper-butanol producing C. acetobutylicum HOL1 (pBPHS-3), which was created to overexpress the Bacillus psychrosaccharolyticus originated specific heat-shock protein gene, hspX, from a clostridial phosphotransbutyrylase promoter, was studied for its potential to produce a high titer of butanol. Overexpression of hspX resulted in increased final butanol yield 47% and 30% higher than those of the the ATCC824 and the HOL1 strains, respectively. The remarkable high-speed growth and butanol tolerance of strain HOL1 (pBPHS-3) demonstrates that overexpression of heterogeneous stress protein-encoding gene, hspX, could help C. acetobutylicum to effectively produce a high concentration of butanol.

Keywords: Clostridium acetobutylicum, butanol, heat-shock protein, resistance

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Authors: Min Chang Shin, Byung Hun Jeong, Jeong Sik Han, Jung Hoon Park

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In modern times, as flight speeds have increased due to improvements in aircraft and missile engine performance, thermal loads have also increased. Because of the friction heat of air flow with high speed on the surface of the vehicle, it is not easy to cool the superheat of the vehicle by the simple air cooling method. For this reason, a cooling method through endothermic heat is attracting attention by using a fuel that causes an endothermic reaction in a high-speed vehicle. There are two main ways of cooling the fuel through the endothermic reaction. The first is physical heat absorption. When the temperature rises, there is a sensible heat that accompanies it. The second is the heat of reaction corresponding to the chemical heat absorption, which absorbs heat during the fuel decomposes. Generally, since the decomposition reaction of the fuel proceeds at a high temperature, it does not achieve a great efficiency in cooling the high-speed flight body. However, when the catalyst is used, decomposition proceeds at a low temperature thereby increasing the cooling efficiency. However, when the catalyst is used as a powder, the catalyst enters the engine and damages the engine or the catalyst can deteriorate the performance due to the sintering. On the other hand, when used in the form of pellets, catalyst loss can be prevented. However, since the specific surface of pellet is small, the efficiency of the catalyst is low. And it can interfere with the flow of fuel, resulting in pressure loss and problems with fuel injection. In this study, we tried to maximize the performance of the catalyst by preparing a hollow fiber type pellet for zeolite ZSM-5, which has a higher amount of heat absorption, than other conventional pellets. The hollow fiber type pellet was prepared by phase inversion method. The hollow fiber type pellet has a finger-like pore and sponge-like pore. So it has a higher specific surface area than conventional pellets. The crystal structure of the prepared ZSM-5 catalyst was confirmed by XRD, and the characteristics of the catalyst were analyzed by TPD/TPR device. This study was conducted as part of the Basic Research Project (Pure-17-20) of Defense Acquisition Program Administration.

Keywords: catalyst, endothermic reaction, high-speed vehicle cooling, zeolite, ZSM-5

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Authors: Simon Guerin-Marthe, Marie Violay

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Thermal Pressurization (TP) has been proposed as a key mechanism involved in the weakening of faults during dynamic ruptures. Theoretical and numerical studies clearly show how frictional heating can lead to an increase in pore fluid pressure due to the rapid slip along faults occurring during earthquakes. In addition, recent laboratory studies have evidenced local pore pressure or local temperature variation during rotary shear tests, which are consistent with TP theoretical and numerical models. The aim of this study is to complement previous ones by measuring both local pore pressure and local temperature variations in the vicinity of a water-saturated calcite gouge layer subjected to a controlled slip velocity in direct double shear configuration. Laboratory investigation of TP process is crucial in order to understand the conditions at which it is likely to become a dominant mechanism controlling dynamic friction. It is also important in order to understand the timing and magnitude of temperature and pore pressure variations, to help understanding when it is negligible, and how it competes with other rather strengthening-mechanisms such as dilatancy, which can occur during rock failure. Here we present unique direct measurements of temperature and pressure variations during high-speed friction experiments under various load point velocities and show the timing of these variations relatively to the slip event.

Keywords: thermal pressurization, double-shear test, high-speed friction, dilatancy

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Authors: Satyanarayana Kosaraju, Venu Gopal Anne, Sateesh Nagari

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

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

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Authors: Zbigniew Wochynski, Justyna Skrzynska, Robert Jedrys, Zdzislaw Kobos

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The aim of the study is to determine the types of motor skills and their impact on achieving results while undergoing Aviation Synthetic Efficiency Test (ASET). The study involved 59 cadets, 21 years-old on average, who are studying on first year for a pilot. The average weight of the respondents is 73.8 kg. The subjects were divided into two groups by weight: up to 73.8 kg -group A (n-30) and above 73,8kg -group B (n-29). All subjects underwent the following tests: running at 40m, 100m, 1000m, 2000m, pull-ups, ASET. In both groups, the cadets were divided into two motor skills types taking into advance 40 m running, pull-ups, 2000 meters running and then subjected to do ASET. There has been shown statistically significant increase in group B in body height, weight and BMI with p <0.0003, p <0.0001, p <0.0001 compared to group A. The results indicate that the dominant motor type in all subjects is the endurance-strength model, which reached the speed V = 1,42m/s in overcoming ASET. This is confirmed by the correlation between 2000m and pull-ups r = 0.37 (p <0.05). In group A, the results indicate that the dominant type of motor is a high-speed-endurance model (26.6%), which reached speed V = 1,42m/s in overcoming ASET. In Group B, there was type of motor speed-strength (20.6%), which reached speed of V = 1.45m/s in overcoming ASET. This confirms the correlation between ASET and pull-ups r = 0.56 (p <0.005). Examined cadets who were having one dominant characteristic achieved worse results is ASET. The best results from all examined cadets in overcoming ASET had the type of motor endurance-strength, in group A endurance-speed model and in group B type of speed-strength

Keywords: ASET, Aviation Synthetic Efficiency Test, motor skills, physical tests, pilot-cadets

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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: M. T. Ahn, J. H. Park, S. H. Park, S. H. Ha

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Diffusion bonding has been continuously studied. Temperature and pressure are the most important factors to increase the strength between diffusion bonded interfaces. Diffusion bonding is an important factor affecting the bonding strength of the lined pipe. The increase of the diffusion bonding force results in a high formability clad pipe. However, in the case of drawing, it is difficult to obtain a high pressure between materials due to a relatively small reduction in cross-section, and it is difficult to prevent elongation or to tear of material in hot drawing even if the reduction in the section is increased. In this paper, to increase the diffusion bonding force, we derive optimal temperature and pressure to suppress material stretching and realize precise thickness precision.

Keywords: diffusion bonding, temperature, pressure, drawing speed

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Authors: Upal Barua

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The risk of severe crashes at high-speed right-turns at intersections is a major safety concern these days. The application of a smart right-turn at an intersection is increasing day by day to address is an issue. The design, ‘Smart Right-turn’ consists of a narrow-angle of channelization at approximately 70°. This design increases the cone of vision of the right-tuning drivers towards the crossing pedestrians as well as traffic on the cross-road. As part of the Safety Improvement Program in Austin Transportation Department, several smart right-turns were constructed at high crash intersections where high-speed right-turns were found to be a contributing factor. This paper features the state of the art techniques applied in planning, engineering, designing and construction of this smart right-turn, key factors driving the success, and lessons learned in the process. This paper also presents the significant crash reductions achieved from the application of this smart right-turn design using Empirical Bayes method. The result showed that smart right-turns can reduce overall right-turn crashes by 43% and severe right-turn crashes by 70%.

Keywords: smart right-turn, intersection, cone of vision, empirical Bayes method

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Authors: Ravi Vishwanath, Saumya Kumaar, S. N. Omkar

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Brain-computer interfacing (BCI) is a technology that is almost four decades old, and it was developed solely for the purpose of developing and enhancing the impact of neuroprosthetics. However, in the recent times, with the commercialization of non-invasive electroencephalogram (EEG) headsets, the technology has seen a wide variety of applications like home automation, wheelchair control, vehicle steering, etc. One of the latest developed applications is the mind-controlled quadrotor unmanned aerial vehicle. These applications, however, do not require a very high-speed response and give satisfactory results when standard classification methods like Support Vector Machine (SVM) and Multi-Layer Perceptron (MLPC). Issues are faced when there is a requirement for high-speed control in the case of fixed-wing unmanned aerial vehicles where such methods are rendered unreliable due to the low speed of classification. Such an application requires the system to classify data at high speeds in order to retain the controllability of the vehicle. This paper proposes a novel method of classification which uses a combination of Common Spatial Paradigm and Linear Discriminant Analysis that provides an improved classification accuracy in real time. A non-linear SVM based classification technique has also been discussed. Further, this paper discusses the implementation of the proposed method on a fixed-wing and VTOL unmanned aerial vehicles.

Keywords: brain-computer interface, classification, machine learning, unmanned aerial vehicles

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Authors: Janaki Rama Raju Patchamatla, Emani Pavan Kumar

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The idea of increasing the existing train speeds and introduction of the high-speed trains in India as a part of Vision-2020 is really challenging from both economic viability and technical feasibility. More than economic viability, technical feasibility has to be thoroughly checked for safe operation and execution. Trains moving at high speeds need a well-established firm and safe track thoroughly tested against vibration effects. With increased speeds of trains, the track structure and layered soil-structure interaction have to be critically assessed for vibration and displacements. Physical establishment of track, testing and experimentation is a costly and time taking process. Software-based modelling and simulation give relatively reliable, cost-effective means of testing effects of critical parameters like sleeper design and density, properties of track and sub-grade, etc. The present paper reports the applicability of infinite elements in reducing the unrealistic stress-wave reflections from so-called soil-structure interface. The influence of the infinite elements is quantified in terms of the displacement time histories of adjoining soil and the deformation pattern in general. In addition, the railhead response histories at various locations show that the numerical model is realistic without any aberrations at the boundaries. The numerical model is quite promising in its ability to simulate the critical parameters of track design.

Keywords: high speed railway track, finite element method, Infinite elements, vibration analysis, soil-structure interface

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Authors: W. Hasan, H. Farhat, A. Alhilo, L. Tamimi

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Oil in water (O/W) emulsions are utilized extensively for cooling and lubricating cutting tools during parts machining. A robust Lattice Boltzmann (LBM) thermal-surfactants model, which provides a useful platform for exploring complex emulsions’ characteristics under variety of flow conditions, is used here for the study of the fluid behavior during conventional tools cooling. The transient thermal capabilities of the model are employed for simulating the effects of the flow conditions of O/W emulsions on the cooling of cutting tools. The model results show that the temperature outcome is slightly affected by reversing the direction of upper plate (workpiece). On the other hand, an important increase in effective viscosity is seen which supports better lubrication during the work.

Keywords: hybrid lattice Boltzmann method, Gunstensen model, thermal, surfactant-covered droplet, Marangoni stress

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Authors: Aydin Teymourifar, Gurkan Ozturk

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In this paper, a hybrid distributed algorithm has been suggested for the multi-objective job shop scheduling problem. Many new approaches are used at design steps of the distributed algorithm. Co-evolutionary structure of the algorithm and competition between different communicated hybrid algorithms, which are executed simultaneously, causes to efficient search. Using several machines for distributing the algorithms, at the iteration and solution levels, increases computational speed. The proposed algorithm is able to find the Pareto solutions of the big problems in shorter time than other algorithm in the literature. Apache Spark and Hadoop platforms have been used for the distribution of the algorithm. The suggested algorithm and implementations have been compared with results of the successful algorithms in the literature. Results prove the efficiency and high speed of the algorithm.

Keywords: distributed algorithms, Apache Spark, Hadoop, job shop scheduling, multi-objective optimization

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Authors: Ahmed Bakry, Moustafa Ahmed

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We model and simulate the combined effect of fiber dispersion and frequency chirp of a directly modulated high-speed laser diode on the figures of merit of a non-amplified 40-Gbps optical fiber link. We consider both the return to zero (RZ) and non-return to zero (NRZ) patterns of the pseudorandom modulation bits. The performance of the fiber communication system is assessed by the fiber-length limitation due to the fiber dispersion. We study the influence of replacing standard single-mode fibers by non-zero dispersion-shifted fibers on the maximum fiber length and evaluate the associated power penalty. We introduce new dispersion tolerances for 1-dB power penalty of the RZ and NRZ 40-Gbps optical fiber links.

Keywords: bit error rate, dispersion, frequency chirp, fiber communications, semiconductor laser

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Authors: Marlone D. Severo

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A pre- and post-test quasi-experimental design was used to test the intervention of Trachtenberg Speed Math on the mathematical competency of sixty (60) matched-paired students with a poor performing grade in Mathematics from one of the biggest public national high school at the South of Metro Manila. Both control and experimental group were administered with the Attitude Towards Mathematics Inventory (ATMI) before the pretest were given and both group showed high dislike for Mathematics. Pretest showed a 53 percent accuracy for the control group and 51 percent for the experimental group using a 15-item long multiplication test without any aid of a computing device. The experimental group were taught how to use the Trachtenberg number-keys and techniques in multiplication between October 2014 to March 2015. Post-test showed an improvement in the experimental group with 96 percent accuracy for the control group and a dismal 57 percent for the control group in long-multiplication. Post-test ATMI were administered. The control group showed a great dislike towards Mathematics, while the experimental group showed a positive attitude towards the subject.

Keywords: attitude towards mathematics, mathematical competency, number-keys, trachtenberg speed math

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Authors: J. Kundrák, I. Sztankovics, K. Gyáni

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In addition to the increase of the material removal rate or surface rate, or the improvement of the surface quality, which are the main aims of the development of manufacturing technology, a growing number of other manufacturing requirements have appeared in the machining of workpiece surfaces. Among these, it is becoming increasingly dominant to generate a surface topography in finishing operations which meet more closely the needs of operational requirements. These include the examination of the surface periodicity and/or ensuring that the twist structure values are within the limits (or even preventing its occurrence) in specified cases such as on the sealing surfaces of rotating shafts or on the inside working surfaces of needle roller bearings. In the view of the measurement, the twist has different parameters from surface roughness, which must be determined for the machining procedures. Therefore in this paper the alteration of the theoretical values of the parameters determining twist structure are studied as a function of the kinematic properties.

Keywords: kinematic parameters, rotational turning, surface topography, twist structure

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Authors: Ying-Pin Chang

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This paper presents a method for combining a particle swarm optimization with nonlinear time-varying evolution and orthogonal arrays (PSO-NTVEOA) in the planning of harmonic filters for the high speed railway traction system with specially connected transformers in unbalanced three-phase power systems. The objective is to minimize the cost of the filter, the filters loss, the total harmonic distortion of currents and voltages at each bus simultaneously. An orthogonal array is first conducted to obtain the initial solution set. The set is then treated as the initial training sample. Next, the PSO-NTVEOA method parameters are determined by using matrix experiments with an orthogonal array, in which a minimal number of experiments would have an effect that approximates the full factorial experiments. This PSO-NTVEOA method is then applied to design optimal harmonic filters in Taiwan High Speed Rail (THSR) traction system, where both rectifiers and inverters with IGBT are used. From the results of the illustrative examples, the feasibility of the PSO-NTVEOA to design an optimal passive harmonic filter of THSR system is verified and the design approach can greatly reduce the harmonic distortion. Three design schemes are compared that V-V connection suppressing the 3rd order harmonic, and Scott and Le Blanc connection for the harmonic improvement is better than the V-V connection.

Keywords: harmonic filters, particle swarm optimization, nonlinear time-varying evolution, orthogonal arrays, specially connected transformers

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Authors: Fayssal Amrane, Azeddine Chaiba, Bruno Francois

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In this paper, design and experimental study based on Direct Power Control (DPC) of DFIG is proposed for Stand-alone mode in Variable Speed Wind Energy Conversion System (VS-WECS). The proposed IDPC method based on robust IP (Integral-Proportional) controllers in order to control the Rotor Side Converter (RSC) by the means of the rotor current d-q axes components (Ird* and Irq*) of Doubly Fed Induction Generator (DFIG) through AC-DC-AC converter. The implementation is realized using dSPACE dS1103 card under Sub and Super-synchronous operations (means < and > of the synchronous speed “1500 rpm”). Finally, experimental results demonstrate that the proposed control using IP provides improved dynamic responses, and decoupled control of the wind turbine has driven DFIG with high performances (good reference tracking, short response time and low power error) despite for sudden variation of wind speed and rotor references currents.

Keywords: Direct Power Control (DPC), Doubly fed induction generator (DFIG), Wind Energy Conversion System (WECS), Experimental study.

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Authors: Maria Tsompanoglou, Dimitris Armenis

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Vessel behavior in different operational and weather conditions constitutes the main area of interest for the ship operator. Ship speed and fuel consumption are the most decisive parameters in this respect, as their correlation provides information about the economic and environmental efficiency of the vessel, becoming the basis of decision making in terms of maintenance and trading. In the analysis of vessel operational profile for the evaluation of fuel consumption and the equivalent CO2 emissions footprint, the indications of Speed Through Water are widely used. The seasonal and regional variations in seawater characteristics, which are available nowadays, can provide the basis for accurate estimation of the errors in Speed Through Water indications at any time. Accuracy in the speed value on a route basis can enable operator identify the ship fuel and propulsion efficiency and proceed with improvements. This paper discusses case studies, where the actual vessel speed was corrected by a post-processing algorithm. The effects of the vessel correction to standard Key Performance Indicators, as well as operational findings not identified earlier, are also discussed.

Keywords: data analytics, MATLAB, vessel performance monitoring, speed through water

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Authors: Juan C. Sanchez, Jose L. Endrino, Alejandro Toro, Hugo A. Estupinan, Glenn Leighton

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For years, the reduction of friction and wear has been a matter of interest in the engineering field. Several solutions have been proposed to address this issue, including the use of lubricants and coatings to reduce the frictional forces and to increase the surface wear resistance. Alternatively, texturing processes have been used in a wide variety of materials, in many cases inspired in natural surfaces. Nature has shown how species adapt to the environment and the engineers try to understand natural surfaces for particular applications by analyzing outstanding species such as gecko for high adhesion, lotus leaves for hydrophobicity, sharks for reduced flow resistance and snakes for optimized frictional response. Texturized surfaces have shown a superior performance in terms of the frictional response in many situations, and the control of its behavior greatly depends on the manufacturing process. The focus of this work is to evaluate the tribological behavior of AISI 52100 steel samples texturized by Photochemical Machining (PCM). The surface texture was inspired by several features of the snakeskin such as aspect ratio of fibrils and mean fibril spacing. Two coatings were applied on the texturized surface, namely Diamond-like Carbon (DLC) and Molybdenum Disulphide (MoS₂), and their tribological behavior after pin-on-disk tests were compared with that of the non-texturized and uncovered surfaces. The samples were characterised through Stereoscopic Microscope (SM), Scanning Electron Microscope (SEM), Optical Microscope (OM), Profilometer, Raman Spectrometer (RS) and X-Ray Diffractometer (XRD). The Coefficient of Friction (COF) measured in pin-on-disk tests showed correlations with the sliding direction (relative to the texture features) and the aspect ratio of the texture features. Regarding the coated surfaces, the DLC and MoS₂ coating had a good performance in terms of wear rate and coefficient of friction compared with the uncoated and non-texturized surfaces. On the other hand, for the uncoated surfaces, the texture showed an influence in the tribological performance with respect to the non-texturized surface.

Keywords: coating, coefficient of friction, deterministic surface, photochemical machining

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Authors: Song Zhiyong, Zhao Bo, Du Li, Wang Wei

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Aircraft structures generally have complex surface. Because of constantly switching postures of motion axis, five-axis CNC machine’s composite stiffness changes during CNC machining. It gives rise to different amplitude of vibration of processing system, which further leads to the different effects on surface waviness. In order to provide a solution for this problem, we take the “S” shape test specimen’s CNC machining for the object, through calculate the five axis CNC machine’s composite stiffness and establish vibration model, we analysis of the influence mechanism between vibration amplitude and surface waviness. Through carry out the surface quality measurement experiments, verify the validity and accuracy of the theoretical analysis. This paper’s research results provide a theoretical basis for surface waviness control.

Keywords: five axis CNC machine, “S” shape test specimen, composite stiffness, surface waviness

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Authors: S. Sulaiman, M. A. Razak, M. R. Ibrahim, A. A. Khan

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An experimental work on the effect of different current and pulse duration on performance of EDM process of Allegheny Ludlum D2 Tool Steel (UNS T30402). The effect of varying the machining parameters on the machining responses such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness (Ra) have been investigated. In this study, triangular shape and circular shape of copper was used as an electrode with surface area of 100 mm². The experiments were repeated for three different values of pulse duration (100 µs, 200 µs and 400 µs) with combination of three different values of discharge current (12 A, 16 A and 24 A). It was found that the pulse duration and current have significant effect on MRR, EWR and Ra. An increase in the pulse durations causes an increase in the MRR and Ra, but a decrease in the EWR. Meanwhile, the effect of currents on EDM performance shows that the increasing currents lead to an increase in the MRR, EWR and Ra.

Keywords: allegheny ludlum D2 tool steel, current, EDM, surface roughness, pulse duration

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Authors: Yingyi Zhou, Tohru Kawabe

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With the spread of EVs (electric Vehicles), the ride comfort has been gaining a lot of attention. The influence of the lateral acceleration is important for the improvement of ride comfort of EVs as well as the longitudinal acceleration, especially upon turning of the vehicle. Therefore, this paper proposes a practical optimal speed control method to greatly improve the ride comfort in the vehicle turning situation. For consturcting this method, effective criteria that can appropriately evaluate deterioration of ride comfort is derived. The method can reduce the influence of both the longitudinal and the lateral speed changes for providing a confortable ride. From several simulation results, we can see the fact that the method can prevent aggravation of the ride comfort by suppressing the influence of longitudinal speed change in the turning situation. Hence, the effectiveness of the method is recognized.

Keywords: electric vehicle, speed control, ride comfort, optimal control theory, driving support system

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Authors: Jui-Pui Hung, Yu-Sheng Lai, Tzuo-Liang Luo, Kung-Da Wu, Yun-Ji Zhan

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This study presented the investigation of the influence of the tool holder interface stiffness on the dynamic characteristics of a spindle tool system. The interface stiffness was produced by drawbar force on the tool holder, which tends to affect the spindle dynamics. In order to assess the influence of interface stiffness on the vibration characteristic of spindle unit, we first created a three dimensional finite element model of a high speed spindle system integrated with tool holder. The key point for the creation of FEM model is the modeling of the rolling interface within the angular contact bearings and the tool holder interface. The former can be simulated by a introducing a series of spring elements between inner and outer rings. The contact stiffness was calculated according to Hertz contact theory and the preload applied on the bearings. The interface stiffness of the tool holder was identified through the experimental measurement and finite element modal analysis. Current results show that the dynamic stiffness was greatly influenced by the tool holder system. In addition, variations of modal damping, static stiffness and dynamic stiffness of the spindle tool system were greatly determined by the interface stiffness of the tool holder which was in turn dependent on the draw bar force applied on the tool holder. Overall, this study demonstrates that identification of the interface characteristics of spindle tool holder is of very importance for the refinement of the spindle tooling system to achieve the optimum machining performance.

Keywords: dynamic stiffness, spindle-tool holder, interface stiffness, drawbar force

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Authors: Mohammad Goli, Akram Sharifi, Mohammad Yousefi Jozdani, Seyed Ali Mortazavi

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An industrial spray dryer was used, and the effects of atomizer speed on the physicochemical properties of milk powder, the textural and sensory characteristics of white cheese made from this milk powder, were evaluated. For this purpose, whole milk was converted into powder by using three different speeds (10,000, 11,000, and 12,000 rpm). Results showed that with increasing atomizer speed in the spray dryer, the average size of casein micelle is significantly decreased (p < 0.05), whereas no significant effect is observed on the chemical properties of milk powder. White cheese characteristics indicated that with increasing atomizer speed, texture parameters, such as hardness, mastication, and gumminess, were significantly reduced (p < 0.05). Sensory evaluation also revealed that cheese samples prepared with dried milk produced at 12,000 rpm were highly accepted by panelists. Overall, the findings suggested that 12,000 rpm is the optimal atomizer speed for milk powder production.

Keywords: spray drying, powder technology, atomizer speed, particle size, white cheese physical properties

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Authors: Riccardo Angiuli, Michele Giannuzzi, Rodolfo Franchi, Gabriele Papadia

Abstract:

Temperature knowledge in machining is fundamental to improve the numerical and FEM models used for the study of some critical process aspects, such as the behavior of the worked material and tool. The extreme conditions in which they operate make it impossible to use traditional measuring instruments; infrared thermography can be used as a valid measuring instrument for temperature measurement during metal cutting. In the study, a large experimental program on superduplex steel (ASTM A995 gr. 5A) cutting was carried out, the relevant cutting temperatures were measured by infrared thermography when certain cutting parameters changed, from traditional values to extreme ones. The values identified were used to calibrate a FEM model for the prediction of residual life of the tools. During the study, the problems related to the detection of cutting temperatures by infrared thermography were analyzed, and a dedicated procedure was developed that could be used during similar processing.

Keywords: machining, infrared thermography, FEM, temperature measurement

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Authors: Sachin Pawar, Suman Patra, Goutam Mukhopadhyay

Abstract:

The primary function of a shaft is to transfer power. The shaft can be cast or forged and then machined to the final shape. Manufacturing of ~5 m length and 0.6 m diameter shaft is very critical. More difficult is to maintain its straightness during heat treatment and machining operations, which involve thermal and mechanical loads, respectively. During the machining operation of a such forged mandrel shaft, a deflection of 3-4mm was observed. To remove this deflection shaft was pressed at both ends which led to the development of cracks in it. To investigate the root cause of the deflection and cracking, the sample was cut from the failed shaft. Possible causes were identified with the help of a cause and effect diagram. Chemical composition analysis, microstructural analysis, and hardness measurement were done to confirm whether the shaft meets the required specifications or not. Chemical composition analysis confirmed that the material grade was 42CrMo4. Microstructural analysis revealed the presence of untempered martensite, indicating improper heat treatment. Due to this, ductility and impact toughness values were considerably lower than the specification of the mentioned grade. Residual stress measurement of one more bent shaft manufactured by a similar route was done by portable X-ray diffraction(XRD) technique. For better understanding, measurements were done at twelve different locations along the length of the shaft. The occurrence of a high amount of undesirable tensile residual stresses close to the Ultimate Tensile Strength(UTS) of the material was observed. Untempered martensitic structure, lower ductility, lower impact strength, and presence of a high amount of residual stresses all confirmed the improper tempering heat treatment of the shaft. Tempering relieves the residual stresses. Based on the findings of this study, stress-relieving heat treatment was done to remove the residual stresses and deflection in the shaft successfully.

Keywords: residual stress, mandrel shaft, untempered martensite, portable XRD

Procedia PDF Downloads 85

Authors: Ming-Yen Chang, Sheng-Hung Ke

Abstract:

This research focuses on the development of a speed bump identification system for real-time control of adjustable shock absorbers in vehicular suspension systems. The study initially involved the collection of images of various speed bumps, and rubber speed bump profiles found on roadways. These images were utilized for training and recognition purposes through the deep learning object detection algorithm YOLOv5. Subsequently, the trained speed bump identification program was integrated with an in-vehicle camera system for live image capture during driving. These images were instantly transmitted to a computer for processing. Using the principles of monocular vision ranging, the distance between the vehicle and an approaching speed bump was determined. The appropriate control distance was established through both practical vehicle measurements and theoretical calculations. Collaboratively, with the electronically adjustable shock absorbers equipped in the vehicle, a shock absorber control system was devised to dynamically adapt the damping force just prior to encountering a speed bump. This system effectively mitigates passenger discomfort and enhances ride quality.

Keywords: adjustable shock absorbers, image recognition, monocular vision ranging, ride

Procedia PDF Downloads 36