Search results for: hybrid machining

Authors: B. Varaprasad, C. Srinivasa Rao

Abstract:

In the manufacturing sector, hard turning has emerged as vital machining process for cutting hardened steels. Besides many advantages of hard turning operation, one has to implement to achieve close tolerances in terms of surface finish, high product quality, reduced machining time, low operating cost and environmentally friendly characteristics. In the present study, three-dimensional CAE (Computer Aided Engineering) based simulation of  hard turning by using commercial software DEFORM 3D has been compared to experimental results of  stresses, temperatures and tool forces in machining of AISI D3 steel using mixed Ceramic inserts (CC6050). In the present analysis, orthogonal cutting models are proposed, considering several processing parameters such as cutting speed, feed, and depth of cut. An exhaustive friction modeling at the tool-work interfaces is carried out. Work material flow around the cutting edge is carefully modeled with adaptive re-meshing simulation capability. In process simulations, feed rate and cutting speed are constant (i.e.,. 0.075 mm/rev and 155 m/min), and analysis is focused on stresses, forces, and temperatures during machining. Close agreement is observed between CAE simulation and experimental values.

Keywords: hard turning, computer aided engineering, computational machining, finite element method

Procedia PDF Downloads 433

Authors: Theena Thayalan, K. N. Ramesh Babu

Abstract:

Machining induced residual stress (RS) is one of the most important surface integrity parameters that characterize the near surface layer of a mechanical component, which plays a crucial role in controlling the performance, especially its fatigue life. Since experimental determination of RS is expensive and time consuming, it would be of great benefit if they could be predicted. In such case, it would be possible to select the cutting parameters required to produce a favorable RS profile. In the present study, an effort has been made to develop a 'two dimensional finite element model (FEM)' to simulate orthogonal cutting process and to predict surface and sub-surface RS using the commercial FEA software DEFORM-2D. The developed finite element model has been validated through experimental investigation of RS. In the experimentation, the orthogonal cutting tests were carried out on AISI 4340 by varying the cutting speed (VC) and uncut chip thickness (f) at three levels and the surface & sub-surface RS has been measured using XRD and Electro polishing techniques. The comparison showed that the RS obtained using developed numerical model is in reasonable agreement with that of experimental data.

Keywords: FEM, machining, residual stress, XRF

Procedia PDF Downloads 315

Authors: Abdallah M. Abdelkawy, Tarek M. El Hossainya, I. El Mahallawib

Abstract:

Recently, significant achievements have been made in development and manufacturing of nano-dispersed metal matrix nanocomposites (MMNCs). They gain their importance due to their high strength to weight ratio. The machining problems of these new materials are less widely investigated, thus this work focuses on machining of them. Aluminum-Silicon (A356)/ MMNC dispersed with alumina (Al2O3) is important in many applications include engine blocks. The final finish process of this application depends heavily on machining. The most important machining parameter studied includes: cutting force and surface roughness. Experimental trails are performed on the number of special samples of MMNC (with different Al2O3%) where the relation between Al2O3% and cutting speed, feed rate and cutting depth with cutting force and surface roughness were studied. The data obtained were statistically analyzed using Analysis of variance (ANOVA) to define the significant factors on both cutting force and surface roughness and their level of confident. Response Surface Methodology (RSM) is used to build a model relating cutting conditions and Al2O3% to the cutting force and surface roughness. The results have shown that feed and depth of cut have the major contribution on the cutting force and the surface roughness followed by cutting speed and nano-percent in MMNCs.

Keywords: machinability, cutting force, surface roughness, Ra, RSM, ANOVA, MMNCs

Procedia PDF Downloads 345

Authors: Javier A. Dominguez Caballero, Graeme A. Manson, Matthew B. Marshall

Abstract:

Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.

Keywords: ceramic cutting tools, high speed machining, image processing, tool condition monitoring, tool wear

Procedia PDF Downloads 267

Authors: Ahmed A. D. Sarhan, M. Sayuti, M. Hamdi

Abstract:

Due to rapid consumption of world's fossil fuel resources and impracticality of large-scale application and production of renewable energy, the significance of energy efficiency improvement of current available energy modes has been widely realized by both industry and academia. In the CNC machining field, the key solution for this issue is by increasing the effectiveness of the existing lubrication systems as it could reduce the power required to overcome the friction component in machining process. For more improvement, introducing the nanolubrication could produce much less power consumption as the rolling action of billions units of nanoparticle in the tool chip interface could reduce the cutting forces significantly. In this research, the possibility of using carbon onion nanolubrication with DLC cutting tool is investigated to reduce the machining power consumption. Carbon onion nanolubrication has been successfully developed with high tribology performance and mixed with ordinary mineral oil. The proper sonification method is used to provide a way to mix and suspend the particles thoroughly and efficiently. Furthermore, Diamond-Like Carbon (DLC) cutting tool is used and expected to play significant role in reducing friction and cutting forces and increasing abrasion resistance. The results showed significant reduction of the cutting force and the working power compared with the other conditions of using carbon black and normal lubrication systems.

Keywords: carbon onion, nanolubrication, machining power consumption, DLC cutting tool

Procedia PDF Downloads 404

Authors: Joseph Chen, N. Hundal

Abstract:

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

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

Procedia PDF Downloads 298

Authors: Hoai Nam Huynh, Edouard Rivière-Lorphèvre, Olivier Verlinden

Abstract:

Manufacturing technologies are becoming continuously more diversified over the years. The increasing use of robots for various applications such as assembling, painting, welding has also affected the field of machining. Machining robots can deal with larger workspaces than conventional machine-tools at a lower cost and thus represent a very promising alternative for machining applications. Furthermore, their inherent structure ensures them a great flexibility of motion to reach any location on the workpiece with the desired orientation. Nevertheless, machining robots suffer from a lack of stiffness at their joints restricting their use to applications involving low cutting forces especially finishing operations. Vibratory instabilities may also happen while machining and deteriorate the precision leading to scrap parts. Some researchers are therefore concerned with the identification of optimal parameters in robotic machining. This paper continues the development of a virtual robotic machining simulator in order to find optimized cutting parameters in terms of depth of cut or feed per tooth for example. The simulation environment combines an in-house milling routine (DyStaMill) achieving the computation of cutting forces and material removal with an in-house multibody library (EasyDyn) which is used to build a dynamic model of a 3-DOF planar robot with flexible links. The position of the robot end-effector submitted to milling forces is controlled through an inverse kinematics scheme while controlling the position of its joints separately. Each joint is actuated through a servomotor for which the transfer function has been computed in order to tune the corresponding controller. The output results feature the evolution of the cutting forces when the robot structure is deformable or not and the tracking errors of the end-effector. Illustrations of the resulting machined surfaces are also presented. The consideration of the links flexibility has highlighted an increase of the cutting forces magnitude. This proof of concept will aim to enrich the database of results in robotic machining for potential improvements in production.

Keywords: control, milling, multibody, robotic, simulation

Procedia PDF Downloads 223

Authors: M. Mourad, K. Mahmoud

Abstract:

Recently hybrid vehicles have become a major concern as one alternative vehicles. This type of hybrid vehicle contributes greatly to reducing pollution. Therefore, this work studies the influence of electrification phase of hybrid electric vehicle on emission of vehicle at different road conditions. To accomplish this investigation, a simulation model was used to evaluate the external characteristics of the hybrid electric vehicle according to variant conditions of road resistances. Therefore, this paper reports a methodology to decrease the vehicle emission especially greenhouse gas emission inside cities. The results show the effect of electrification on vehicle performance characteristics. The results show that CO₂ emission of vehicle decreases up to 50.6% according to an urban driving cycle due to applying the electrification strategy for hybrid electric vehicle.

Keywords: electrification strategy, hybrid electric vehicle, driving cycle, CO2 emission

Procedia PDF Downloads 407

Authors: Muhammad Bello Ibrahim, M. Auwal Zakari, Aliyu Usman

Abstract:

Hybrid concrete construction (HCC) combines all the benefits of pre-casting with the advantages of cast in-situ construction. Merging the two, as a hybrid structure, results in even greater construction speed, value, and the overall economy. Its variety of uses has gained popularity in the United States and in Europe due to its distinctive benefits. However, the increase of its application in some countries (including Nigeria) has been relatively slow. Several researches have shown that hybrid construction offers an ultra-high performance concrete that offers superior strength, durability and aesthetics with design flexibility and within sustainability credentials, based on the available and economically visible technologies. This paper examines and documents the criterion that will help inform the process of deciding whether or not to adopt hybrid concrete construction (HCC) technology rather than more traditional alternatives. It also the present situation of design, construction and research on hybrid structures.

Keywords: hybrid concrete construction, Nigeria, sustainable infrastructure development, design flexibility

Procedia PDF Downloads 520

Authors: Qiming Zhang, Youda Ye, Qinxue Jiang

Abstract:

Accurate prediction of external flowfield and aero-heating at the wall of hypersonic vehicle is very crucial for the design of aircrafts. Unstructured/hybrid meshes have more powerful advantages than structured meshes in terms of pre-processing, parallel computing and mesh adaptation, so it is imperative to develop high-resolution numerical methods for the calculation of aerothermal environment on unstructured/hybrid meshes. The inviscid flux scheme is one of the most important factors affecting the accuracy of unstructured/ hybrid mesh heat flux calculation. Here, a new hybrid flux scheme is developed and the approach of interface type selection is proposed: i.e. 1) using the exact Riemann scheme solution to calculate the flux on the faces parallel to the wall; 2) employing Sterger-Warming (S-W) scheme to improve the stability of the numerical scheme in other interfaces. The results of the heat flux fit the one observed experimentally and have little dependence on grids, which show great application prospect in unstructured/ hybrid mesh.

Keywords: aero-heating prediction, computational fluid dynamics, hybrid meshes, hybrid schemes

Procedia PDF Downloads 201

Authors: P. Hari Krishna, V. Ramana Murty

Abstract:

Different types of foundations are subjected to pullout or tensile loads depending on the soil in which they are embedded or due to the structural loads coming on them. In those circumstances, anchors were generally used to resist these loads. This paper presents the field pullout studies on hybrid anchor piles embedded in different types of soils. The pullout capacity and resistance of the hybrid granular anchor piles installed in the native expansive soil which is available in the campus are compared with similar hybrid concrete anchor piles which were installed in similar field conditions.

Keywords: expansive soil, hybrid concrete anchor piles, hybrid granular anchor piles, pullout tests

Procedia PDF Downloads 375

Authors: Vinay Patil, Swapnil Kekade, Ashish Supare, Vinayak Pawar, Shital Jadhav, Rajkumar Singh

Abstract:

In recent days, bainitic steel is used in automobile and non-automobile sectors due to its high strength. Bainitic steel is difficult to machine because of its high hardness, hence in this paper machinability of bainitic steel is studied by using Taguchi design of experiments (DOE) approach. Convectional turning experiments were done by using L16 orthogonal array for three input parameters viz. cutting speed, depth of cut and feed. The Taguchi method is applied to study the performance characteristics of machining parameters with surface roughness (Ra), cutting force and tool wear rate. By using Taguchi analysis, optimized process parameters for best surface finish and minimum cutting forces were analyzed.

Keywords: conventional turning, Taguchi method, S/N ratio, bainitic steel machining

Procedia PDF Downloads 303

Authors: Tetsuya Yabuki, Yasunori Arizumi, Tetsuhiro Shimozato, Samy Guezouli, Hiroaki Matsusita, Masayuki Tai

Abstract:

The main object of this paper is to present the research results of the development of a hybrid stainless steel girder system for bridge construction undertaken at University of Ryukyu. In order to prevent the corrosion damage and reduce the fabrication costs, a hybrid stainless steel girder in bridge construction is developed, the stainless steel girder of which is stiffened and braced by structural carbon steel materials. It is verified analytically and experimentally that the ultimate strength of the hybrid stainless steel girder is equal to or greater than that of conventional carbon steel girder. The benefit of the life-cycle cost of the hybrid stainless steel girder is also shown.

Keywords: smart structure, hybrid stainless steel members, ultimate strength, steel bridge, corrosion prevention

Procedia PDF Downloads 338

Authors: J. Satya Eswari, J. Sekhar Babub, Meena Murmu, Govardhan Bhat

Abstract:

Electrical Discharge Machining (EDM) is an unconventional manufacturing process based on removal of material from a part by means of a series of repeated electrical sparks created by electric pulse generators at short intervals between a electrode tool and the part to be machined emmersed in dielectric fluid. In this paper, a study will be performed on the influence of the factors of peak current, pulse on time, interval time and power supply voltage. The output responses measured were material removal rate (MRR) and surface roughness. Finally, the parameters were optimized for maximum MRR with the desired surface roughness. RSM involves establishing mathematical relations between the design variables and the resulting responses and optimizing the process conditions. RSM is not free from problems when it is applied to multi-factor and multi-response situations. Design of experiments (DOE) technique to select the optimum machining conditions for machining AISI 4140 using EDM. The purpose of this paper is to determine the optimal factors of the electro-discharge machining (EDM) process investigate feasibility of design of experiment techniques. The work pieces used were rectangular plates of AISI 4140 grade steel alloy. The study of optimized settings of key machining factors like pulse on time, gap voltage, flushing pressure, input current and duty cycle on the material removal, surface roughness is been carried out using central composite design. The objective is to maximize the Material removal rate (MRR). Central composite design data is used to develop second order polynomial models with interaction terms. The insignificant coefficients’ are eliminated with these models by using student t test and F test for the goodness of fit. CCD is first used to establish the determine the optimal factors of the electro-discharge machining (EDM) for maximizing the MRR. The responses are further treated through a objective function to establish the same set of key machining factors to satisfy the optimization problem of the electro-discharge machining (EDM) process. The results demonstrate the better performance of CCD data based RSM for optimizing the electro-discharge machining (EDM) process.

Keywords: electric discharge machining (EDM), modeling, optimization, CCRD

Procedia PDF Downloads 315

Authors: Adam Janásek, Marek Pagáč

Abstract:

The article is looking for an experimental determination of tool life tests for ceramic cutting inserts. Mentioned experimental determination should provide an added information about cutting process. The mechanism of tool wear, cutting temperature in machining, quality machined surface and machining process itself is the information, which are important for whole manufacturing process. Mainly, the roughness plays very important role in determining how a real object will interact with its environment. The main aim was to determine the number of machined inserts, tool life and micro-geometry, as well. On the basis of previous tests the tool-wear was measured at constant cutting parameter which is more typical for high volume manufacturing processes.

Keywords: ceramic, insert, machining, surface roughness, tool-life, tool-wear

Procedia PDF Downloads 462

Authors: Saad Nawaz, Yu Gang, Miao Haibin

Abstract:

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

Procedia PDF Downloads 291

Authors: Nabila Louai, Fouad Khaldi, Houria Benharchache

Abstract:

In this paper, the case of meeting a household’s electrical energy demand with hybrid systems has been examined. The objective is to study technological feasibility and economic viability of the electrification project by a hybrid system (PV/ wind) of a residential home located in Batna-Algeria and to reduce the emissions from traditional power by using renewable energy. An autonomous hybrid wind/photovoltaic (PV)/battery power system and a PV/Wind grid connected system, has been carried out using Hybrid Optimization Model for Electric Renewable (HOMER) simulation software. As a result, it has been found that electricity from the grid can be supplied at a lower price than electricity from renewable energy at this moment.

Keywords: batna, household, hybrid system, renewable energy, techno-economy

Procedia PDF Downloads 560

Authors: Moudar H. A. Zgoul, Amin Al Zamer

Abstract:

Adhesive materials and adhesion have been the focal point of multiple research works related to numerous applications, particularly, aerospace, and aviation industries. To enhance the properties of conventional adhesive materials, additives have been introduced to the mix in order to enhance their mechanical and physical properties by creating a hybrid adhesive material. The evaluation of the mechanical properties of such hybrid adhesive materials is thus of an essential requirement for the purpose of properly modeling their behavior accurately. This paper presents an approach/tool to simulate the behavior such hybrid adhesives in a way that will allow researchers to better understand their behavior while in service.

Keywords: adhesive materials, analysis, hybrid adhesives, mechanical properties, simulation

Procedia PDF Downloads 384

Authors: A. Meydanlioglu, F. Arikan

Abstract:

In recent years, thanks to the development of information and communication technologies, the computer and internet have been used widely in higher education. Internet-based education is impacting traditional higher education as online components increasingly become integrated into face-to-face (FTF) courses. The goal of combined internet-based and traditional education is to take full advantage of the benefits of each platform in order to provide an educational opportunity that can promote student learning better than can either platform alone. Research results show that the use of hybrid learning is more effective than online or FTF models in higher education. Due to the potential benefits, an increasing number of institutions are interested in developing hybrid courses, programs, and degrees. Future research should evaluate the effectiveness of hybrid learning. This paper is designed to determine the impact of hybrid learning on higher education.

Keywords: e-learning, higher education, hybrid learning, online education

Procedia PDF Downloads 856

Authors: Dylan Santos De Pinho, Nabil Ouerhani

Abstract:

Energy consumption of machine-tools is becoming critical for machine-tool builders and end-users because of economic, ecological and legislation-related reasons. Many machine-tool builders are seeking for solutions that allow the reduction of energy consumption of machine-tools while preserving the same productivity rate and the same quality of machined parts. In this paper, we present the first results of a project conducted jointly by academic and industrial partners to reduce the energy consumption of a Swiss-Type lathe. We employ genetic algorithms to find optimal machining parameters – the set of parameters that lead to the best trade-off between energy consumption, part quality and tool lifetime. Three main machining process parameters are considered in our optimization technique, namely depth of cut, spindle rotation speed and material feed rate. These machining process parameters have been identified as the most influential ones in the configuration of the Swiss-type machining process. A state-of-the-art multi-objective genetic algorithm has been used. The algorithm combines three fitness functions, which are objective functions that permit to evaluate a set of parameters against the three objectives: energy consumption, quality of the machined parts, and tool lifetime. In this paper, we focus on the investigation of the fitness function related to energy consumption. Four different energy consumption related fitness functions have been investigated and compared. The first fitness function refers to the Kienzle cutting force model. The second fitness function uses the Material Removal Rate (RMM) as an indicator of energy consumption. The two other fitness functions are non-deterministic, learning-based functions. One fitness function uses a simple Neural Network to learn the relation between the process parameters and the energy consumption from experimental data. Another fitness function uses Lasso regression to determine the same relation. The goal is, then, to find out which fitness functions predict best the energy consumption of a Swiss-Type machining process for the given set of machining process parameters. Once determined, these functions may be used for optimization purposes – determine the optimal machining process parameters leading to minimum energy consumption. The performance of the four fitness functions has been evaluated. The Tornos DT13 Swiss-Type Lathe has been used to carry out the experiments. A mechanical part including various Swiss-Type machining operations has been selected for the experiments. The evaluation process starts with generating a set of CNC (Computer Numerical Control) programs for machining the part at hand. Each CNC program considers a different set of machining process parameters. During the machining process, the power consumption of the spindle is measured. All collected data are assigned to the appropriate CNC program and thus to the set of machining process parameters. The evaluation approach consists in calculating the correlation between the normalized measured power consumption and the normalized power consumption prediction for each of the four fitness functions. The evaluation shows that the Lasso and Neural Network fitness functions have the highest correlation coefficient with 97%. The fitness function “Material Removal Rate” (MRR) has a correlation coefficient of 90%, whereas the Kienzle-based fitness function has a correlation coefficient of 80%.

Keywords: adaptive machining, genetic algorithms, smart manufacturing, parameters optimization

Procedia PDF Downloads 119

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

Abstract:

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

Procedia PDF Downloads 259

Authors: Xiaolin Tang, Wei Yang, Xiaoan Chen

Abstract:

The research described in this paper was aimed at exploring the torsional vibration characteristics of a power-split hybrid powertrain equipped with a dual mass flywheel. The dynamic equations of governing torsional vibration for this hybrid driveline are presented, and the multi-body dynamic model for the powertrain is established with the software of ADAMS. Accordingly, different parameters of dual mass flywheel are investigated by forced vibration to reduce the torsional vibration of hybrid drive train. The analysis shows that the implementation of a dual mass flywheel is an effective way to decrease the torsional vibration of the hybrid powertrain. At last, the optimal combination of parameters yielding the lowest vibration is provided.

Keywords: dual mass flywheel, hybrid electric vehicle, torsional vibration, powertrain, dynamics

Procedia PDF Downloads 377

Authors: Hong Lu, Yongquan Zhang, Wei Fan, Xiangang Su

Abstract:

Bent mandrel has been widely used as precise mould in automobile industry, shipping industry and aviation industry. To improve the versatility and efficiency of turning method of bent mandrel with fixed rotational center, an instantaneous machining model based on cutting parameters and machine dimension is prospered in this paper. The spiral-like tool path generation approach in non-axisymmetric turning process of bent mandrel is developed as well to deal with the error of part-to-part repeatability in existed turning model. The actual cutter-location points are calculated by cutter-contact points, which are obtained from the approach of spiral sweep process using equal-arc-length segment principle in polar coordinate system. The tool offset is set to avoid the interference between tool and work piece is also considered in the machining model. Depend on the spindle rotational angle, synchronization control of X-axis, Z-axis and C-axis is adopted to generate the tool-path of the turning process. The simulation method is developed to generate NC program according to the presented model, which includes calculation of cutter-location points and generation of tool-path of cutting process. With the approach of a bent mandrel taken as an example, the maximum offset of center axis is 4mm in the 3D space. Experiment results verify that the machining model and turning method are appropriate for the characteristics of bent mandrel.

Keywords: bent mandrel, instantaneous machining model, simulation method, tool-path generation

Procedia PDF Downloads 313

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

Abstract:

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

Procedia PDF Downloads 179

Authors: Pushpendra S. Bharti, S. Maheshwari

Abstract:

Electric discharge machining (EDM) is one of the most widely used non-conventional manufacturing process to shape difficult-to-cut materials. The process yield, in terms of material removal rate, surface roughness and tool wear rate, of EDM may considerably be improved by selecting the optimal combination(s) of process parameters. This paper employs Multi-response signal-to-noise (MRSN) ratio technique to find the optimal combination(s) of the process parameters during EDM of Inconel 718. Three cases v.i.z. high cutting efficiency, high surface finish, and normal machining have been taken and the optimal combinations of input parameters have been obtained for each case. Analysis of variance (ANOVA) has been employed to find the dominant parameter(s) in all three cases. The experimental verification of the obtained results has also been made. MRSN ratio technique found to be a simple and effective multi-objective optimization technique.

Keywords: electric discharge machining, material removal rate, surface roughness, too wear rate, multi-response signal-to-noise ratio, multi response signal-to-noise ratio, optimization

Procedia PDF Downloads 325

Authors: D. R. T. N. K. Dissanayake, H. M. S. K. Herath, H. K. S. G. Gunadasa, P. Weerasinghe

Abstract:

Luffa is a tropical and subtropical vegetable, belongs to family Cucurbiteceae. It is predominantly monoecious in sex expression and provides an ample scope for utilization of hybrid vigor. Hybrid varieties develop through open pollination, produce higher yields due to its hybrid vigor. Naga F1 hybrid variety consists number of desirable traits other than higher yield such as strong and vigorous plants, fruits with long deep ridges, attractive green color fruits ,better fruit weight, length and early maturity compared to the local Luffa cultivars. Unavailability of fertilizer recommendations for hybrid cucurbit vegetables leads to an excess fertilizer application causing a vital environmental issue that creates undesirable impacts on nature and the human health. Main Objective of this research is to determine effect of different nitrogen and potassium fertilizer rates on growth and yield of Naga F1 Variety. Other objectives are, to evaluate specific growth parameters and yield, to identify the optimum nitrogen and potassium fertilizer levels based on growth and yield of hybrid Luffa variety. As well as to formulate the general fertilizer recommendation for hybrid Luffa -Naga F1 variety.

Keywords: hybrid, nitrogen, phosphorous, potassium

Procedia PDF Downloads 557

Authors: Dejan Tanikić, Jelena Đoković, Saša Kalinović, Miodrag Manić, Saša Ranđelović

Abstract:

This paper deals with measuring and modelling of the quality of the machined surface of the metal machining process. The average surface roughness (R_a) which represents the quality of the machined part was measured during the dry turning of the AISI 4140 steel. A large number of factors with the unknown relations among them influences this parameter, and that is why mathematical modelling is extremely complicated. Different values of cutting speed, feed rate, depth of cut (cutting regime) and workpiece hardness causes different surface roughness values. Modelling with soft computing techniques may be very useful in such cases. This paper presents the usage of the fuzzy logic-based system for determining metal machining process parameter in order to find the proper values of cutting regimes.

Keywords: fuzzy logic, metal machining, process modeling, surface roughness

Procedia PDF Downloads 134

Authors: Atul K. Desai, Hemal J. Shah

Abstract:

The tall windmill towers are designed as monopole tower or lattice tower. In the present research, a 125-meter high hybrid tower which is a combination of lattice and monopole type is proposed. The response of hybrid tower is compared with conventional monopole tower. The towers were analyzed in finite element method software considering nonlinear seismic time history load. The synthetic seismic time history for different soil is derived using the SeismoARTIF software. From the present research, it is concluded that, in the hybrid tower, we are not getting resonance condition. The base shear is less in hybrid tower compared to monopole tower for different soil conditions.

Keywords: dynamic analysis, hybrid wind mill tower, resonance condition, synthetic time history

Procedia PDF Downloads 119

Authors: Murat Sarıkaya, Abdulkadir Güllü

Abstract:

Haynes 25 alloy (also known as L-605 alloy) is cobalt based super alloy which has widely applications such as aerospace industry, turbine and furnace parts, power generators and heat exchangers and petroleum refining components due to its excellent characteristics. However, the workability of this alloy is more difficult compared to normal steels or even stainless. In present work, an experimental investigation was performed under cryogenic cooling to determine cutting tool wear patterns and obtain optimal cutting parameters in turning of cobalt based superalloy Haynes 25. In experiments, uncoated carbide tool was used and cutting speed (V) and feed rate (f) were considered as test parameters. Tool wear (VBmax) were measured for process performance indicators. Analysis of variance (ANOVA) was performed to determine the importance of machining parameters.

Keywords: cryogenic machining, difficult-to-cut alloy, tool wear, turning

Procedia PDF Downloads 558

Authors: Ahmed A. D. Sarhan, S. R. Besharaty, Javad Akbaria, M. Hamdi

Abstract:

The capability of CNC gantry milling machines in manufacturing long components has caused the expanded use of such machines. On the other hand, the machines’ gantry rigidity can reduce under severe loads or vibration during operation. Indeed, the quality of machining is dependent on the machine’s dynamic behavior throughout the operating process. For this reason, this type of machines has always been used prudently and are non efficient. Therefore, they can usually be employed for rough machining and may not produce adequate surface finishing. In this paper, a CNC gantry milling machine with the potential to produce good surface finish has been designed and analyzed. The lowest natural frequency of this machine is 202 Hz at all motion amplitudes with a full range of suitable frequency responses. Meanwhile, the maximum deformation under dead loads for the gantry machine is 0.565µm, indicating that this machine tool is capable of producing higher product quality.

Keywords: frequency response, finite element, gantry machine, gantry design, static and dynamic analysis

Procedia PDF Downloads 323