Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 3694

Search results for: tool

3694 Study of Tool Shape during Electrical Discharge Machining of AISI 52100 Steel

Authors: Arminder Singh Walia, Vineet Srivastava, Vivek Jain

Abstract:

In Electrical Discharge Machining (EDM) operations, the workpiece confers to the shape of the tool. Further, the cost of the tool contributes the maximum effect on total operation cost. Therefore, the shape and profile of the tool become highly significant. Thus, in this work, an attempt has been made to study the effect of process parameters on the shape of the tool. Copper has been used as the tool material for the machining of AISI 52100 die steel. The shape of the tool has been evaluated by determining the difference in out of roundness of tool before and after machining. Statistical model has been developed and significant process parameters have been identified which affect the shape of the tool. Optimum process parameters have been identified which minimizes the shape distortion.

Keywords: discharge current, flushing pressure, pulse-on time, pulse-off time, out of roundness, electrical discharge machining

Procedia PDF Downloads 157
3693 Comparative Assessment of MRR, TWR, and Surface Integrity in Rotary and Stationary Tool EDM for Machining AISI D3 Tool Steel

Authors: Anand Prakash Dwivedi, Sounak Kumar Choudhury

Abstract:

Electric Discharge Machining (EDM) is a well-established and one of the most primitive unconventional manufacturing processes, that is used world-wide for the machining of geometrically complex or hard and electrically conductive materials which are extremely difficult to cut by any other conventional machining process. One of the major flaws, over all its advantages, is its very slow Material Removal Rate (MRR). In order to eradicate this slow machining rate, various researchers have proposed various methods like; providing rotational motion to the tool or work-piece or to both, mixing of conducting additives (such as SiC, Cr, Al, graphite etc) powders in the dielectric, providing vibrations to the tool or work-piece or to both etc. Present work is a comparative study of Rotational and Stationary Tool EDM, which deals with providing rotational motion to the copper tool for the machining of AISI D3 Tool Steel and the results have been compared with stationary tool EDM. It has been found that the tool rotation substantially increases the MRR up to 28%. The average surface finish increases around 9-10% by using the rotational tool EDM. The average tool wear increment is observed to be around 19% due to the tool rotation. Apart from this, the present work also focusses on the recast layer analysis, which are being re-deposited on the work-piece surface during the operation. The recast layer thickness is less in case of Rotational EDM and more for Stationary Tool EDM. Moreover, the cracking on the re-casted surface is also more for stationary tool EDM as compared with the rotational EDM.

Keywords: EDM, MRR, Ra, TWR

Procedia PDF Downloads 207
3692 Using Single Decision Tree to Assess the Impact of Cutting Conditions on Vibration

Authors: S. Ghorbani, N. I. Polushin

Abstract:

Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.

Keywords: cutting condition, vibration, natural frequency, decision tree, CART algorithm

Procedia PDF Downloads 228
3691 Life Prediction of Cutting Tool by the Workpiece Cutting Condition

Authors: Noemia Gomes de Mattos de Mesquita, José Eduardo Ferreira de Oliveira, Arimatea Quaresma Ferraz

Abstract:

Stops to exchange cutting tool, to set up again the tool in a turning operation with CNC or to measure the workpiece dimensions have a direct influence on production. The premature removal of the cutting tool results in high cost of machining since the parcel relating to the cost of the cutting tool increases. On the other hand, the late exchange of cutting tool also increases the cost of production because getting parts out of the preset tolerances may require rework for its use when it does not cause bigger problems such as breaking of cutting tools or the loss of the part. Therefore, the right time to exchange the tool should be well defined when wanted to minimize production costs. When the flank wear is the limiting tool life, the time predetermination that a cutting tool must be used for the machining occurs within the limits of tolerance can be done without difficulty. This paper aims to show how the life of the cutting tool can be calculated taking into account the cutting parameters (cutting speed, feed and depth of cut), workpiece material, power of the machine, the dimensional tolerance of the part, the finishing surface, the geometry of the cutting tool and operating conditions of the machine tool, once known the parameters of Taylor algebraic structure. These parameters were raised for the ABNT 1038 steel machined with cutting tools of hard metal.

Keywords: machining, productions, cutting condition, design, manufacturing, measurement

Procedia PDF Downloads 516
3690 Tool Damage and Adhesion Effects in Turning and Drilling of Hardened Steels

Authors: Chris M. Taylor, Ian Cook, Raul Alegre, Pedro Arrazola, Phil Spiers

Abstract:

Noteworthy results have been obtained in the turning and drilling of hardened high-strength steels using tungsten carbide based cutting tools. In a finish turning process, it was seen that surface roughness and tool flank wear followed very different trends against cutting time. The suggested explanation for this behaviour is that the profile cut into the workpiece surface is determined by the tool’s cutting edge profile. It is shown that the profile appearing on the cut surface changes rapidly over time, so the profile of the tool cutting edge should also be changing rapidly. Workpiece material adhered onto the cutting tool, which is also known as a built-up edge, is a phenomenon which could explain the observations made. In terms of tool damage modes, workpiece material adhesion is believed to have contributed to tool wear in examples provided from finish turning, thread turning and drilling. Additionally, evidence of tool fracture and tool abrasion were recorded.

Keywords: turning, drilling, adhesion, wear, hard steels

Procedia PDF Downloads 214
3689 Effect of the Drawbar Force on the Dynamic Characteristics of a Spindle-Tool Holder System

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

Abstract:

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

Procedia PDF Downloads 271
3688 Cutting Tool-Life Test of Ceramic Insert for Engine Sleeve

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 350
3687 Simulation of Particle Damping in Boring Tool Using Combined Particles

Authors: S. Chockalingam, U. Natarajan, D. M. Santhoshsarang

Abstract:

Particle damping is a promising vibration attenuating technique in boring tool than other type of damping with minimal effect on the strength, rigidity and stiffness ratio of the machine tool structure. Due to the cantilever nature of boring tool holder in operations, it suffers chatter when the slenderness ratio of the tool gets increased. In this study, Copper-Stainless steel (SS) particles were packed inside the boring tool which acts as a damper. Damper suppresses chatter generated during machining and also improves the machining efficiency of the tool with better slenderness ratio. In the first approach of particle damping, combined Cu-SS particles were packed inside the vibrating tool, whereas Copper and Stainless steel particles were selected separately and packed inside another tool and their effectiveness was analysed in this simulation. This study reveals that the efficiency of finite element simulation of the boring tools when equipped with particles such as copper, stainless steel and a combination of both. In this study, the newly modified boring tool holder with particle damping was simulated using ANSYS12.0 with and without particles. The aim of this study is to enhance the structural rigidity through particle damping thus avoiding the occurrence of resonance in the boring tool during machining.

Keywords: boring bar, copper-stainless steel, chatter, particle damping

Procedia PDF Downloads 327
3686 Designing a Tool for Software Maintenance

Authors: Amir Ngah, Masita Abdul Jalil, Zailani Abdullah

Abstract:

The aim of software maintenance is to maintain the software system in accordance with advancement in software and hardware technology. One of the early works on software maintenance is to extract information at higher level of abstraction. In this paper, we present the process of how to design an information extraction tool for software maintenance. The tool can extract the basic information from old program such as about variables, based classes, derived classes, objects of classes, and functions. The tool have two main part; the lexical analyzer module that can read the input file character by character, and the searching module which is user can get the basic information from existing program. We implemented this tool for a patterned sub-C++ language as an input file.

Keywords: extraction tool, software maintenance, reverse engineering, C++

Procedia PDF Downloads 372
3685 A Neural Network System for Predicting the Hardness of Titanium Aluminum Nitrite (TiAlN) Coatings

Authors: Omar M. Elmabrouk

Abstract:

The cutting tool, in the high-speed machining process, is consistently dealing with high localized stress at the tool tip, tip temperature exceeds 800°C and the chip slides along the rake face. These conditions are affecting the tool wear, the cutting tool performances, the quality of the produced parts and the tool life. Therefore, a thin film coating on the cutting tool should be considered to improve the tool surface properties while maintaining its bulks properties. One of the general coating processes in applying thin film for hard coating purpose is PVD magnetron sputtering. In this paper, the prediction of the effects of PVD magnetron sputtering coating process parameters, sputter power in the range of (4.81-7.19 kW), bias voltage in the range of (50.00-300.00 Volts) and substrate temperature in the range of (281.08-600.00 °C), were studied using artificial neural network (ANN). The results were compared with previously published results using RSM model. It was found that the ANN is more accurate in prediction of tool hardness, and hence, it will not only improve the tool life of the tool but also significantly enhances the efficiency of the machining processes.

Keywords: artificial neural network, hardness, prediction, titanium aluminium nitrate coating

Procedia PDF Downloads 459
3684 Prediction of Cutting Tool Life in Drilling of Reinforced Aluminum Alloy Composite Using a Fuzzy Method

Authors: Mohammed T. Hayajneh

Abstract:

Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al2O3 particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.

Keywords: composite, fuzzy, tool life, wear

Procedia PDF Downloads 189
3683 Tool for Determining the Similarity between Two Web Applications

Authors: Doru Anastasiu Popescu, Raducanu Dragos Ionut

Abstract:

In this paper the presentation of a tool which measures the similarity between two websites is made. The websites are compound only from webpages created with HTML. The tool uses three ways of calculating the similarity between two websites based on certain results already published. The first way compares all the webpages within a website, the second way compares a webpage with all the pages within the second website and the third way compares two webpages. Java programming language and technologies such as spring, Jsoup, log4j were used for the implementation of the tool.

Keywords: Java, Jsoup, HTM, spring

Procedia PDF Downloads 263
3682 Optimization of Process Parameters for Rotary Electro Discharge Machining Using EN31 Tool Steel: Present and Future Scope

Authors: Goutam Dubey, Varun Dutta

Abstract:

In the present study, rotary-electro discharge machining of EN31 tool steel has been carried out using a pure copper electrode. Various response variables such as Material Removal Rate (MRR), Tool Wear Rate (TWR), and Machining Rate (MR) have been studied against the selected process variables. The selected process variables were peak current (I), voltage (V), duty cycle, and electrode rotation (N). EN31 Tool Steel is hardened, high carbon steel which increases its hardness and reduces its machinability. Reduced machinability means it not economical to use conventional methods to machine EN31 Tool Steel. So, non-conventional methods play an important role in machining of such materials.

Keywords: electric discharge machining, EDM, tool steel, tool wear rate, optimization techniques

Procedia PDF Downloads 74
3681 Development of a Green Star Certification Tool for Existing Buildings in South Africa

Authors: Bouwer Kleynhans

Abstract:

The built environment is responsible for about 40% of the world’s energy consumption and generates one third of global carbon dioxide emissions. The Green Building Council of South Africa’s (GBCSA) current rating tools are all for new buildings. By far the largest portion of buildings exist stock and therefore the need to develop a certification tool for existing buildings. Direct energy measurement comprises 27% of the total available points in this tool. The aim of this paper is to describe the development process of a green star certification tool for existing buildings in South Africa with specific emphasis on the energy measurement criteria. Successful implementation of this tool within the property market will ensure a reduced carbon footprint of buildings.

Keywords: certification tool, development process, energy consumption, green buildings

Procedia PDF Downloads 219
3680 Intelligent Tooling Embedded Sensors for Monitoring the Wear of Cutting Tools in Turning Applications

Authors: Hatim Laalej, Jon Stammers

Abstract:

In machining, monitoring of tool wear is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Currently, the task of monitoring the wear on the cutting tool is carried out by the operator who performs manual inspections of the cutting tool, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from loss of productivity. The cutting tool consumable costs may also be higher than necessary when tools are changed before the end of their useful life. Furthermore, damage can be caused to the workpiece when tools are not changed soon enough leading to a significant increase in the costs of manufacturing. The present study is concerned with the development of break sensor printed on the flank surface of poly-crystalline diamond (PCD) cutting to perform on-line condition monitoring of the cutting tool used to machine Titanium Ti-6al-4v bar. The results clearly show that there is a strong correlation between the break sensor measurements and the amount of wear in the cutting tool. These findings are significant in that they help the user/operator of the machine tool to determine the condition of the cutting tool without the need of performing manual inspection, thereby reducing the manufacturing costs such as the machine down time.

Keywords: machining, manufacturing, tool wear, signal processing

Procedia PDF Downloads 129
3679 Ginger Washer Tool Using Pedal to Increase the Quality of Herbal Medicine

Authors: Finda A. Mahardika, Niken Aristyawati, Retno W. Damayanti

Abstract:

Improvement technology needed to increase productivity of home industry that make herbal medicine is ginger washer tool. To solve this case, the writers develop existing technologies to create a tool that serves as a wash of ginger. This washer uses pedal tools to help the brush washer move. This tool is expected to produce ginger with good quality. In addition, this tool is also expected to be able to save time as well as water used when conducting the process of leaching. This tool is based on the size of the anthropometri people of Indonesia for the results of an ergonomic. The activities carried out by conducting a study of theory, experiment based on existing theories and make modifications based on the results obtained.

Keywords: ginger, ginger washer, technology, pedal

Procedia PDF Downloads 138
3678 Experimental Studies on the Effect of Rake Angle on Turning Ti-6Al-4V with TiAlN Coated Carbides

Authors: Satyanarayana Kosaraju, Venu Gopal Anne, Sateesh Nagari

Abstract:

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

Procedia PDF Downloads 379
3677 An Investigation of Machinability of Inconel 718 in EDM Using Different Cryogenic Treated Tools

Authors: Pradeep Joshi, Prashant Dhiman, Shiv Dayal Dhakad

Abstract:

Inconel 718 is a family if Nickel-Chromium based Superalloy; it has very high oxidation and corrosion resistance. Inconel 718 is widely being used in aerospace, engine, turbine etc. due to its high mechanical strength and creep resistance. Being widely used, its machining should be easy but in real its machining is very difficult, especially by using traditional machining methods. It becomes easy to machine only by using non Traditional machining such as EDM. During EDM machining there is wear of both tool and workpiece, the tool wear is undesired because it changes tool shape, geometry. To reduce the tool wear rate (TWR) cryogenic treatment is performed on tool before the machining operation. The machining performances of the process are to be evaluated in terms of MRR, TWR which are functions of Discharge current, Pulse on-time, Pulse Off-time.

Keywords: EDM, cyrogenic, TWR, MRR

Procedia PDF Downloads 331
3676 A Tool to Measure the Usability Guidelines for Arab E-Government Websites

Authors: Omyma Alosaimi, Asma Alsumait

Abstract:

The website developer and designer should follow usability guidelines to provide a user-friendly interface. Using tools to measure usability, the evaluator can evaluate automatically hundreds of links within few minutes. It has the advantage of detecting some violations that only machines can detect. For that using usability evaluating tool is important to find as many violations as possible. There are many websites usability testing tools, but none is developed to measure the usability of e-government website nor Arabic e-government websites. To measure the usability of the Arabic e-government websites, a tool is developed and tested in this paper. A comparison of using a tool specifically developed for e-government websites and general usability testing tool is presented.

Keywords: e-government, human computer interaction, usability evaluation, usability guidelines

Procedia PDF Downloads 319
3675 Investigation of Stellram Indexable Milling Cutter XDLT09-D41 Tool Wear for Machining of Ti6Al4V

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 195
3674 Study of Machinability for Titanium Alloy Ti-6Al-4V through Chip Formation in Milling Process

Authors: Moaz H. Ali, Ahmed H. Al-Saadi

Abstract:

Most of the materials used in the industry of aero-engine components generally consist of titanium alloys. Advanced materials, because of their excellent combination of high specific strength, lightweight, and general corrosion resistance. In fact, chemical wear resistance of aero-engine alloy provide a serious challenge for cutting tool material during the machining process. The reduction in cutting temperature distributions leads to an increase in tool life and a decrease in wear rate. Hence, the chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The result of low thermal conductivity and diffusivity of this alloy in the concentration of high temperatures at the tool-work-piece and tool-chip interface. Consequently, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. Otherwise, the result will be accelerating tool wear, increasing manufacturing cost and time consuming.

Keywords: machinability, titanium alloy (ti-6al-4v), chip formation, milling process

Procedia PDF Downloads 346
3673 Effect of Post Hardening on PVD Coated Tools

Authors: Manjinder Bajwa, Mahipal Singh, Ashish Tulli

Abstract:

In the research, the effect of varying cutting parameters, design parameters and heat treatment processes were studied on the cutting performance (Tool life) of a PVD coated tool. Thus, in a quest for these phenomenon comparison, a single coated tool and a multicoated tool were analyzed after suitable heat treatment process. TNMG shaped insert with single coating of TiCN and multi-coating of TiAlN/TiN were developed on tungsten carbide substrate. These coated inserts were then successfully annealed and normalized for a temperature of 350°C for 30 minutes and their cutting performance was evaluated as per the flank wear obtained after turning of mild steel. The results showed that heat treatment had a suitable impact on the tool life of the coated insert and also led to increase in the micro-hardness of the tool coatings and decrease in the wear rate.

Keywords: PVD coatings, flank wear, micro-hardness, annealing, normalizing

Procedia PDF Downloads 247
3672 Arabic Quran Search Tool Based on Ontology

Authors: Mohammad Alqahtani, Eric Atwell

Abstract:

This paper reviews and classifies most of the important types of search techniques that have been applied on the holy Quran. Then, it addresses the limitations in these techniques. Additionally, this paper surveys most existing Quranic ontologies and what are their deficiencies. Finally, it explains a new search tool called: A semantic search tool for Al Quran based on Qur’anic ontologies. This tool will overcome all limitations in the existing Quranic search applications.

Keywords: holy Quran, natural language processing (NLP), semantic search, information retrieval (IR), ontology

Procedia PDF Downloads 436
3671 A Simulation Tool for Projection Mapping Based on Mapbox and Unity

Authors: Noriko Hanakawa, Masaki Obana

Abstract:

A simulation tool has been proposed for big-scale projection mapping events. The tool has four main functions based on Mapbox and Unity utilities. The first function is building a 3D model of real cities by MapBox. The second function is a movie projection to some buildings in real cities by Unity. The third function is a movie sending function from a PC to a virtual projector. The fourth function is mapping movies with fitting buildings. The simulation tool was adapted to a real projection mapping event that was held in 2019. The event has been finished. The event had a serious problem in the movie projection to the target building. The extra tents were set in front of the target building. The tents became the obstacles to the movie projection. The simulation tool can be reappeared the problems of the event. Therefore, if the simulation tool was developed before the 2019 projection mapping event, the problem of the tents’ obstacles could be avoided with the simulation tool. In addition, we confirmed that the simulation tool is useful to make a plan of future projection mapping events in order to avoid obstacles of various extra equipment such as utility poles, planting trees, monument towers.

Keywords: projection mapping, projector position, real 3D map, avoiding obstacles

Procedia PDF Downloads 56
3670 Performance Assessment of Carbon Nano Tube Based Cutting Fluid in Machining Process

Authors: Alluru Gopala Krishna, Thella Babu Rao

Abstract:

In machining, there is always a problem with heat generation and friction produced during the process as they consequently affect tool wear and surface finish. An instant heat transfer mechanism could protect the cutting tool edge and enhance the tool life by cooling the cutting edge of the tool. In the present work, carbon nanotube (CNT) based nano-cutting fluid is proposed for machining a hard-to-cut material. Tool wear and surface roughness are considered for the evaluation of the nano-cutting fluid in turning process. The performance of nanocoolant is assessed against the conventional coolant and dry machining conditions and it is observed that the proposed nanocoolant has produced better performance than the conventional coolant.

Keywords: CNT based nano cutting fluid, tool wear, turning, surface roughness

Procedia PDF Downloads 162
3669 Heuristic Evaluation of Children’s Authoring Tool for Game Making

Authors: Laili Farhana Md Ibharim, Maizatul Hayati Mohamad Yatim

Abstract:

The main purpose of this study is to evaluate the heuristic inspection of children’s authoring tools to develop games. The researcher has selected 15 authoring tools for making games specifically for educational purposes. Nine students from Diploma of Game Design and Development course and four lecturers from the computing department involved in this evaluation. A set of usability heuristic checklist used as a guideline for the students and lecturers to observe and test the authoring tools selected. The study found that there are just a few authoring tools that fulfill most of the heuristic requirement and suitable to apply to children. In this evaluation, only six out of fifteen authoring tools have passed above than five elements in the heuristic inspection checklist. The researcher identified that in order to develop a usable authoring tool developer has to emphasis children acceptance and interaction of the authoring tool. Furthermore, the authoring tool can be a tool to enhance their mental development especially in creativity and skill.

Keywords: authoring tool, children, game making, heuristic

Procedia PDF Downloads 228
3668 Reusing of HSS Hacksaw Blades as Rough Machining Tool

Authors: Raja V., Chokkalingam B.

Abstract:

For rough cutting, in many industries and educational institutions using carbon steels or HSS single point cutting tools in center lathe machine. In power hacksaw blades, only the cutter teeth region used to parting off the given material. The portions other than the teeth can be used as a single point cutting tool for rough turning and facing on soft materials. The hardness and Tensile strength of this used Power hacksaw blade is almost same as conventional cutting tools. In this paper, the effect of power hacksaw blades over conventional tool has been compared. Thickness of the blade (1.6 mm) is very small compared to its length and width. Hence, a special tool holding device is designed to hold the tool.

Keywords: hardness, high speed steels, power hacksaw blade, tensile strength

Procedia PDF Downloads 345
3667 Acoustic Emission for Tool-Chip Interface Monitoring during Orthogonal Cutting

Authors: D. O. Ramadan, R. S. Dwyer-Joyce

Abstract:

The measurement of the interface conditions in a cutting tool contact is essential information for performance monitoring and control. This interface provides the path for the heat flux to the cutting tool. This elevate in the cutting tool temperature leads to motivate the mechanism of tool wear, thus affect the life of the cutting tool and the productivity. This zone is representative by the tool-chip interface. Therefore, understanding and monitoring this interface is considered an important issue in machining. In this paper, an acoustic emission (AE) technique was used to find the correlation between AE parameters and the tool-chip interface. For this reason, a response surface design (RSD) has been used to analyse and optimize the machining parameters. The experiment design was based on the face centered, central composite design (CCD) in the Minitab environment. According to this design, a series of orthogonal cutting experiments for different cutting conditions were conducted on a Triumph 2500 lathe machine to study the sensitivity of the acoustic emission (AE) signal to change in tool-chip contact length. The cutting parameters investigated were the cutting speed, depth of cut, and feed and the experiments were performed for 6082-T6 aluminium tube. All the orthogonal cutting experiments were conducted unlubricated. The tool-chip contact area was investigated using a scanning electron microscope (SEM). The results obtained in this paper indicate that there is a strong dependence of the root mean square (RMS) on the cutting speed, where the RMS increases with increasing the cutting speed. A dependence on the tool-chip contact length has been also observed. However there was no effect observed of changing the cutting depth and feed on the RMS. These dependencies have been clarified in terms of the strain and temperature in the primary and secondary shear zones, also the tool-chip sticking and sliding phenomenon and the effect of these mechanical variables on dislocation activity at high strain rates. In conclusion, the acoustic emission technique has the potential to monitor in situ the tool-chip interface in turning and consequently could indicate the approaching end of life of a cutting tool.

Keywords: Acoustic emission, tool-chip interface, orthogonal cutting, monitoring

Procedia PDF Downloads 394
3666 Effect of Composite Material on Damping Capacity Improvement of Cutting Tool in Machining Operation Using Taguchi Approach

Authors: Siamak Ghorbani, Nikolay Ivanovich Polushin

Abstract:

Chatter vibrations, occurring during cutting process, cause vibration between the cutting tool and workpiece, which deteriorates surface roughness and reduces tool life. The purpose of this study is to investigate the influence of cutting parameters and tool construction on surface roughness and vibration in turning of aluminum alloy AA2024. A new design of cutting tool is proposed, which is filled up with epoxy granite in order to improve damping capacity of the tool. Experiments were performed at the lathe using carbide cutting insert coated with TiC and two different cutting tools made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to design of experiment and to optimize cutting conditions. By the help of signal-to-noise ratio and analysis of variance the optimal cutting condition and the effect of the cutting parameters on surface roughness and vibration were determined. Effectiveness of Taguchi method was verified by confirmation test. It was revealed that new cutting tool with epoxy granite has reduced vibration and surface roughness due to high damping properties of epoxy granite in toolholder.

Keywords: ANOVA, damping capacity, surface roughness, Taguchi method, vibration

Procedia PDF Downloads 205
3665 Computational Tool for Surface Electromyography Analysis; an Easy Way for Non-Engineers

Authors: Fabiano Araujo Soares, Sauro Emerick Salomoni, Joao Paulo Lima da Silva, Igor Luiz Moura, Adson Ferreira da Rocha

Abstract:

This paper presents a tool developed in the Matlab platform. It was developed to simplify the analysis of surface electromyography signals (S-EMG) in a way accessible to users that are not familiarized with signal processing procedures. The tool receives data by commands in window fields and generates results as graphics and excel tables. The underlying math of each S-EMG estimator is presented. Setup window and result graphics are presented. The tool was presented to four non-engineer users and all of them managed to appropriately use it after a 5 minutes instruction period.

Keywords: S-EMG estimators, electromyography, surface electromyography, ARV, RMS, MDF, MNF, CV

Procedia PDF Downloads 354