Search results for: ultrasonic machining

Authors: Jatinder Kumar

Abstract:

Ultrasonic machining is one of the most widely used non-traditional machining processes for machining of materials that are relatively brittle, hard and fragile such as advanced ceramics, refractories, crystals, quartz etc. There is a considerable lack of research on its application to the cost-effective machining of tough materials such as titanium. In this investigation, the application of USM process for machining of titanium (ASTM Grade-I) has been explored. Experiments have been conducted to assess the effect of different parameters of USM process on machining rate and tool wear rate as response characteristics. The process parameters that were included in this study are: abrasive grit size, tool material and power rating of the ultrasonic machine. It has been concluded that titanium is fairly machinable with USM process. Significant improvement in the machining rate can be realized by manipulating the process parameters and obtaining the optimum combination of these parameters.

Keywords: abrasive grit size, tool material, titanium, ultrasonic machining

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Authors: Ravinder Kataria, Jatinder Kumar, B. S. Pabla

Abstract:

Ultrasonic machining is one of the most widely used non-traditional machining processes for machining of materials that are relatively brittle, hard, and fragile such as advanced ceramics, refractories, crystals, quartz etc. Present article has been targeted at investigating the impact of different experimental conditions (power rating, cobalt content, tool material, thickness of work piece, tool geometry, and abrasive grit size) on over cut in ultrasonic drilling of WC-Co composite material. Taguchi’s L-36 orthogonal array has been employed for conducting the experiments. Significant factors have been identified using analysis of variance (ANOVA) test. The experimental results revealed that abrasive grit size and tool material are most significant factors for over cut.

Keywords: ANOVA, abrasive grit size, Taguchi, WC-Co, ultrasonic machining

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Authors: S. Y. Lin, C. H. Kuan, C. H. She, W. T. Wang

Abstract:

In this study, ultrasonic assisted machining (UAM) technique is applied in side-surface milling experiment for glass-ceramic workpiece material. The tungsten carbide cutting-tool with diamond coating is used in conjunction with two kinds of cooling/lubrication mediums such as water-soluble (WS) cutting fluid and minimum quantity lubricant (MQL). Full factorial process parameter combinations on the milling experiments are planned to investigate the effect of process parameters on cutting performance. From the experimental results, it tries to search for the better process parameter combination which the edge-indentation and the surface roughness are acceptable. In the machining experiments, ultrasonic oscillator was used to excite a cutting-tool along the radial direction producing a very small amplitude of vibration frequency of 20KHz to assist the machining process. After processing, toolmaker microscope was used to detect the side-surface morphology, edge-indentation and cutting tool wear under different combination of cutting parameters, and analysis and discussion were also conducted for experimental results. The results show that the main leading parameters to edge-indentation of glass ceramic are cutting depth and feed rate. In order to reduce edge-indentation, it needs to use lower cutting depth and feed rate. Water-soluble cutting fluid provides a better cooling effect in the primary cutting area; it may effectively reduce the edge-indentation and improve the surface morphology of the glass ceramic. The use of ultrasonic assisted technique can effectively enhance the surface finish cleanness and reduce cutting tool wear and edge-indentation.

Keywords: glass-ceramic, ultrasonic assisted machining, cutting performance, edge-indentation

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Authors: M. A. Moghaddas, M. Short, N. Wiley, A. Y. Yi, K. F. Graff

Abstract:

The application of ultrasonic vibrations to machining processes has a long history, ranging from slurry-based systems able to drill brittle materials, to more recent developments involving low power ultrasonics for high precision machining, with many of these at the research and laboratory stages. The focus of this development is the application of high levels of ultrasonic power (1,000’s of watts) to standard, heavy duty machine tools – drilling being the immediate focus, with developments in milling in progress – with the objective of dramatically increasing system productivity through faster feed rates, this benefit arising from the thrust force reductions obtained by power ultrasonic vibrations. The presentation will describe development of an advanced drilling system based on a special, acoustically designed, rugged drill module capable of functioning under heavy duty production conditions, and making use of standard tool holder means, and able to obtain thrust force reductions while maintaining or improving surface finish and drilling accuracy. The characterization of the system performance will be described, and results obtained in drilling several materials (Aluminum, Stainless steel, Titanium) presented.

Keywords: dimensional accuracy, machine tool, productivity, surface roughness, thrust force, ultrasonic vibrations, ultrasonic-assisted drilling

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Authors: Philipp Zopf, Franz Haas

Abstract:

Manufacturing of very hard and refractory materials like ceramics, glass or carbide poses particular challenges on tools and machines. The company Sauer GmbH developed especially for this application area ultrasonic tool holders working in a frequency range from 15 to 60 kHz and superimpose the common tool movement in the vertical axis. This technique causes a structural weakening in the contact area and facilitates the machining. The possibility of the force reduction for these special materials especially in drilling of carbide with diamond tools up to 30 percent made the authors try to expand the application range of this method. To make the results evaluable, the authors decide to start with existing processes in which the positive influence of the ultrasonic assistance is proven to understand the mechanism. The comparison of a grinding process the Institute use to machine materials mentioned in the beginning and steel could not be more different. In the first case, the authors use tools with geometrically undefined edges. In the second case, the edges are geometrically defined. To get valid results of the tests, the authors decide to investigate two manufacturing methods, drilling and milling. The main target of the investigation is to reduce the cutting force measured with a force measurement platform underneath the workpiece. Concerning to the direction of the ultrasonic assistance, the authors expect lower cutting forces and longer endurance of the tool in the drilling process. To verify the frequencies and the amplitudes an FFT-analysis is performed. It shows the increasing damping depending on the infeed rate of the tool. The reducing of amplitude of the cutting force comes along.

Keywords: drilling, machining, milling, ultrasonic

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Authors: Dong-Keun Jeong, Jong-Hyun Kim, Woon-Ha Yoon, Hee-Je Kim

Abstract:

In order to automatically operate the ultrasonic transducer drive system for sonicating aluminum, this paper proposes the ultrasonic transducer sensorless control algorithm. The resonance frequency shift and electrical impedance change is a common phenomenon in the state of the ultrasonic transducer. The proposed control algorithm make use of the impedance change of ultrasonic transducer according to the environment between air state and aluminum alloy state, it controls the ultrasonic transducer drive system autonomous without a sensor. The proposed sensorless autonomous ultrasonic transducer control algorithm was experimentally verified using a 3kW prototype ultrasonic transducer drive system.

Keywords: ultrasonic transducer drive system, impedance change, sensorless, autonomous control algorithm

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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

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Authors: Herlina Abdul Rahim, Javad Abbaszadeh, Ruzairi Abdul Rahim

Abstract:

In this research, the non-invasive ultrasonic transmission tomography is investigated. In order to model the ultrasonic wave scattering for different thickness of metal pipes, two-dimensional (2D) finite element modeling (FEM) has been utilized. The wall thickness variation of the metal pipe and its influence on propagation of the ultrasonic pressure wave are explored in this paper, includes frequency analysing in order to find the maximum applicable frequency. The simulation results have been compared to experimental data and are shown to provide key insight for this well-defined experimental case by explaining the achieved reconstructed images from experimental setup. Finally, the experimental results which are useful for further investigation for the application of ultrasonic transmission tomography in industry are illustrated.

Keywords: ultrasonic transmission tomography, ultrasonic sensors, ultrasonic wave, non-invasive tomography, metal pipe

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Authors: Ricardo Torcato, Helder Morais

Abstract:

The manufacture of crystal glass parts is based on obtaining the rough geometry by blowing and/or injection, generally followed by a set of manual finishing operations using cutting and grinding tools. The forming techniques used do not allow the obtainment, with repeatability, of parts with complex shapes and the finishing operations use intensive specialized labor resulting in high cycle times and production costs. This work aims to explore the digital manufacture of crystal glass parts by investigating new subtractive techniques for the automated, flexible finishing of these parts. Finishing operations are essential to respond to customer demands in terms of crystal feel and shine. It is intended to investigate the applicability of different computerized finishing technologies, namely milling and grinding in a CNC machining center with or without ultrasonic assistance, to crystal processing. Research in the field of grinding hard and brittle materials, despite not being extensive, has increased in recent years, and scientific knowledge about the machinability of crystal glass is still very limited. However, it can be said that the unique properties of glass, such as high hardness and very low toughness, make any glass machining technology a very challenging process. This work will measure the performance improvement brought about by the use of ultrasound compared to conventional crystal grinding. This presentation is focused on the mechanical characterization and analysis of the cutting forces in CNC machining of superior crystal glass (Pb ≥ 30%). For the mechanical characterization, the Vickers hardness test provides an estimate of the material hardness (Hv) and the fracture toughness based on cracks that appear in the indentation. Mechanical impulse excitation test estimates the Young’s Modulus, shear modulus and Poisson ratio of the material. For the cutting forces, it a dynamometer was used to measure the forces in the face grinding process. The tests were made based on the Taguchi method to correlate the input parameters (feed rate, tool rotation speed and depth of cut) with the output parameters (surface roughness and cutting forces) to optimize the process (better roughness using the cutting forces that do not compromise the material structure and the tool life) using ANOVA. This study was conducted for conventional grinding and for the ultrasonic grinding process with the same cutting tools. It was possible to determine the optimum cutting parameters for minimum cutting forces and for minimum surface roughness in both grinding processes. Ultrasonic-assisted grinding provides a better surface roughness than conventional grinding.

Keywords: CNC machining, crystal glass, cutting forces, hardness

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Authors: T. Zlámal, J. Petrů, M. Pagáč, P. Krajkovič

Abstract:

For the required function of components with the thermal spray coating, it is necessary to perform additional machining of the coated surface. The paper deals with assessing the surface integrity of Metco 2042, a plasma sprayed coating, after its machining. The selected plasma sprayed coating serves as an abradable sealing coating in a jet engine. Therefore, the spray and its surface must meet high quality and functional requirements. Plasma sprayed coatings are characterized by lamellar structure, which requires a special approach to their machining. Therefore, the experimental part involves the set-up of special cutting tools and cutting parameters under which the applied coating was machined. For the assessment of suitably set machining parameters, selected parameters of surface integrity were measured and evaluated during the experiment. To determine the size of surface irregularities and the effect of the selected machining technology on the sprayed coating surface, the surface roughness parameters Ra and Rz were measured. Furthermore, the measurement of sprayed coating surface hardness by the HR 15 Y method before and after machining process was used to determine the surface strengthening. The changes of strengthening were detected after the machining. The impact of chosen cutting parameters on the surface roughness after the machining was not proven.

Keywords: machining, plasma sprayed coating, surface integrity, strengthening

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Authors: Alan C. Lin, Tsong Der Lin

Abstract:

This study proposes a deviation control method to add interpolation points to numerical control (NC) codes of five-axis machining in order to achieve the required machining accuracy. Specific research issues include: (1) converting machining data between the CL (cutter location) domain and the NC domain, (2) calculating the deviation between the deviated path and the linear path, (3) finding interpolation points, and (4) determining tool orientations for the interpolation points. System implementation with practical examples will also be included to highlight the applicability of the proposed methodology.

Keywords: CAD/CAM, cutter path, five-axis machining, numerical control

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Authors: Yasuyuki Nabeshima

Abstract:

Many tunnels which have been constructed since more than 50 years were existing in Japan. Lining concrete in these tunnels have many problems such as crack, flacking and void. Inner void between lining concrete and rock was very hard to find by outside visual check and hammering test. In this paper, non-destructive inspection by using ultrasonic was applied to investigate inner void. A model concrete with inner void was used as specimen and ultrasonic inspection was applied to specify the location and the size of void. As a result, ultrasonic inspection could accurately find the inner void.

Keywords: tunnel, lining concrete, void, non-destructive inspection, ultrasonic

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Authors: Pedro Acevedo, Carlos Díaz, Mónica Vázquez, Joel Durán

Abstract:

This paper describes the design of a pulse generator based on the Programmable System-on-Chip (PSoC) module. In this module, using programmable logic is possible to implement different pulses which are required for ultrasonic applications, either in a single channel or multiple channels. This module can operate with programmable frequencies from 3-74 MHz; its programming may be versatile covering a wide range of ultrasonic applications. It is ideal for low-power ultrasonic applications where PZT or PVDF transducers are used.

Keywords: PSoC, pulse generator, PVDF, ultrasonic transducer

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Authors: Kiraz Esmeli, Alper Ozkan

Abstract:

In this study, firstly, the effect of ultrasonic treatment on the stability of celestite suspension was investigated. In this context, the variations of the suspension stability with ultrasonic power, treatment time, immersion depth of ultrasonic probe, and treatment regime (batch and continuous) were determined. The experimental results showed that the suspension stability and zeta potential of celestite decreased with ultrasonic treatment. Also, the treatment time, immersion depth of probe, and treatment regime affected the stability of celestite suspension. Secondly, the effect of pre-treatment of the suspension with the ultrasonic process on the shear flocculation of celestite using sodium dodecyl sulfate (SDS) was studied and the variations of the flocculation, zeta potential, and contact angle of the mineral with SDS concentration were presented. It was found that the ultrasonic pre-treatment slightly improved the shear flocculation of celestite particles in accordance with the increase in the contact angles. In addition, the ultrasonic process again relatively reduced the magnitude of the negative potential of celestite particles in the presence of SDS.

Keywords: celestite, contact angle, suspension stability, ultrasonic treatment, zeta potential

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Authors: Szymon Wojciechowski, Damian Przestacki, Tadeusz Chwalczuk

Abstract:

The paper is focused on the evaluation of surface integrity formed during turning of Inconel 718 with the application of various laser assistance strategies. The primary objective of the work was to determine the relations between the applied machining strategy and the obtained surface integrity, in order to select the effective cutting conditions allowing the obtainment of high surface quality. The carried out experiment included the machining of Inconel 718 in the conventional turning conditions, as well as during the continuous laser assisted machining and sequential laser assistance. The surface integrity was evaluated by the measurements of machined surface topographies, microstructures and the microhardness. Results revealed that surface integrity of Inconel 718 is strongly affected by the selected machining strategy. The significant improvement of the surface roughness formed during machining of Inconel 718, can be reached by the application of simultaneous laser heating and cutting (LAM).

Keywords: Inconel 718, laser assisted machining, surface integrity, turning

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Authors: Jiri Brozovsky

Abstract:

Modulus of elasticity is one of the important parameters of construction materials, which considerably influence their deformation properties and which can also be determined by means of non-destructive test methods like ultrasonic pulse method. However, measurement results of ultrasonic pulse methods are influenced by various factors, one of which is the natural frequency of the transducers. The paper states knowledge about influence of natural frequency of the transducers (54; 82 and 150kHz) on ultrasonic pulse velocity and dynamic modulus of elasticity (Young's Dynamic modulus of elasticity). Differences between ultrasonic pulse velocity and dynamic modulus of elasticity were found with the same smallest dimension of test specimen in the direction of sounding and density their value decreases as the natural frequency of transducers grew.

Keywords: calcium silicate brick, ultrasonic pulse method, ultrasonic pulse velocity, dynamic modulus of elasticity

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Authors: Gyu-Jin Kim, Hyo-Gyoung Kwak

Abstract:

In this research, the effect of prestressing force on the nonlinearity of concrete was investigated by an experimental study. For the measurement of ultrasonic nonlinearity, a prestressed concrete beam was prepared and a nonlinear resonant ultrasound method was adopted. When the prestressing force changes, the stress state of the concrete inside the beam is affected, which leads to the occurrence of micro-cracks and changes in mechanical properties. Therefore, it is necessary to introduce nonlinear ultrasonic technology which sensitively reflects microstructural changes. Repetitive prestressing load history, including maximum levels of 45%, 60% and 75%, depending on the compressive strength, is designed to evaluate the impact of loading levels on the nonlinearity. With the experimental results, the possibility of ultrasonic nonlinearity as a trial indicator of stress was evaluated.

Keywords: micro crack, nonlinear ultrasonic resonant spectroscopy, prestressed concrete beam, prestressing force, ultrasonic nonlinearity

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Authors: Ziad. Sh. Al Sarraf

Abstract:

Ultrasonic metal welding has been the subject of ongoing research and development, most recently concentrating on metal joining in miniature devices, for example to allow solder-free wire bonding. As well as at the small scale, there are also opportunities to research the joining of thicker sheet metals and to widen the range of similar and dissimilar materials that can be successfully joined using this technology. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal spot welding device. The ultrasonic metal spot welding horn is modelled using finite element analysis (FEA) and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered effectively to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. The results show how the weld strength is particularly sensitive to the combination of clamping force and ultrasonic vibration amplitude of the welding tip, but there are optimal combinations of these and also limits that must be clearly identified.

Keywords: ultrasonic welding, vibration amplitude, welding force, weld strength

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Authors: Jui-Pin Hung, Qiao-Wen Chang, Kung-Da Wu, Yong-Run Chen

Abstract:

This study was aimed to investigate the machining stability of a spindle tool with different preloaded amount. To this end, the vibration tests were conducted on the spindle unit with different preload to assess the dynamic characteristics and machining stability of the spindle unit. Current results demonstrate that the tool tip frequency response characteristics and the machining stabilities in X and Y direction are affected to change for spindle with different preload. As can be found from the results, a high preloaded spindle tool shows higher limited cutting depth at mid position, while a spindle with low preload shows a higher limited depth. This implies that the machining stability of spindle tool system is affected to vary by the machine frame structure. Besides, such an effect is quite different and varied with the preload of the spindle.

Keywords: bearing preload, dynamic compliance, machining stability, spindle

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Authors: Deepak

Abstract:

WEDM is an amazingly potential electro-wire process for machining of hard metal compounds and metal grid composites without making contact. Wire electrical machining is a developing noncustomary machining process for machining hard to machine materials that are electrically conductive. It is an exceptionally exact, precise, and one of the most famous machining forms in nontraditional machining. WEDM has turned into the fundamental piece of many assembling process ventures, which require precision, variety, and accuracy. In the present examination, AA-6063 is utilized as a workpiece, and execution investigation is done to discover the critical control factors. Impact of different parameters like a pulse on time, pulse off time, servo voltage, peak current, water pressure, wire tension, wire feed upon surface hardness has been researched while machining on AA-6063. RSM has been utilized to advance the yield variable. A variety of execution measures with input factors was demonstrated by utilizing the response surface methodology.

Keywords: AA-6063, response surface methodology, WEDM, surface roughness

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Authors: Nikhil Deshpande, Rahul Mahajan

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Laser Beam Machining (LBM) is a non-traditional machining process that has inherent problems like dross, striation, and Heat Affected Zone (HAZ) which reduce the quality of machining. In the present day scenario, these problems are controlled only by iteratively adjusting a large number of process parameters. This paper applies Axiomatic Design principles to design LBM process so as to eliminate the problem of dross and striation and minimize the effect of HAZ. Process parameters and their ranges are proposed to set-up the LBM process, execute the cut and finish the workpiece so as to obtain the best quality cut.

Keywords: laser beam machining, dross, striation, heat affected zone, axiomatic design

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Authors: Sun Tao, Lou Liang, Tan Xing Haw Marvin, Gu Yuandong Alex

Abstract:

Patients with blood clots in their brains can experience problems with their vision or speech, seizures and general weakness. To treat blood clots, clinicians presently have two options. The first involves drug therapy to thin the blood and thus reduce the clot. The second choice is to invasively remove the clot using a plastic tube called a catheter. Both approaches carry a high risk of bleeding, and invasive procedures, such as catheter intervention, can also damage the blood vessel wall and cause infection. Ultrasonic treatment as a potential alternative therapy to break down clots is attracting growing interests due to the reduced adverse effects. To demonstrate the concept, in this investigation a microfabricated ultrasonic device was electrically packaged with printed circuit board to treat healthy human blood. The red blood cells could be broken down after 3-hour ultrasonic treatment.

Keywords: microfabrication, blood clot, ultrasonic thrombolysis device, ultrasonic device

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Authors: K. N. Umesh

Abstract:

Wood Polymer Composites (WPC) were synthesized artificially by combining polypropylene, wood and resin. It is difficult to obtain a good surface finish by conventional machining on WPC because of material degradation due to excessive heat generated during the process. In order to preserve the material property and deliver a better surface finish and accuracy, a proper solution is devised for the machining of wood composites at low temperature. This research focuses on studying the effects of parameters of cryogenic machining on sawdust incorporated polypropylene composite material, in view of evolving the most suitable composition and an appropriate combination of process parameters. The machining characteristics of the six different compositions of WPC were evaluated by analyzing the trend. An attempt is made to determine proper combinations material composition and process control parameters, through process capability studies. A WPC of 80%-wood (saw dust particles), 20%-polypropylene and 0%-resin was found to be the best alternative for obtaining the best surface finish under cryogenic machining conditions.

Keywords: Cryogenic Machining, Process Capability, Surface Finish, Wood Polymer Composites

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Authors: Hadi Rezghimaleki, Masatoshi Kubouchi, Yoshihiko Arao

Abstract:

The use of natural fiber composites (NFCs) is growing at a fast rate regarding industrial applications and principle researches due to their eco-friendly, renewable nature, and low density/costs. Drilling is one of the most important machining operations that are carried out on natural fiber composites. Delamination is a major concern in the drilling process of NFCs that affects the structural integrity and long-term reliability of the machined components. Flax fiber reinforced epoxy composite laminates were prepared by hot press technique. In this research, we evaluated drilling-induced delamination of flax/epoxy composites by X-ray computed tomography (CT), ultrasonic testing (UT), and optical methods and compared the results.

Keywords: natural fiber composites, flax/epoxy, X-ray CT, ultrasonic testing

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Authors: Sandeep Singh Sandhu, Karanvir Singh Ghuman, Parminder Singh Saini

Abstract:

The aim of the present investigation was to study the effect of ultrasonic vibration on the cladding of the AISI 308 on the mild steel plates using the shielded metal arc welding (SMAW). Ultrasonic vibrations were applied to molten austenitic stainless steel during the welding process. Due to acoustically induced cavitations and streaming there is a complete mixture of the clad metal and the base metal. It was revealed that cladding of AISI 308 over mild steel along with ultrasonic vibrations result in uniform and finer grain structures. The effect of the vibration on the dilution, mechanical properties and metallographic studies were also studied. It was found that the welding done using the ultrasonic vibration has the less dilution and CVN value for the vibrated sample was also high.

Keywords: surfacing, ultrasonic vibrations, mechanical properties, shielded metal arc welding

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Authors: Radhey Sham Rajoria

Abstract:

Pressure to increase the competitiveness in the manufacturing sector and for the survival in the market has led to the development of machining centres, which enhance productivity, improve quality, shorten the lead time, and reduce the manufacturing cost. With the innovation of machining centres in the manufacturing sector the production lines have been replaced by these machining centers, having the ability to machine various processes and multiple tooling with automatic tool changer (ATC) for the same part. Also the process plans can be easily generated for complex components. Some means are required to utilize the machining center at its best. The present work is concentrated on the automated part program generation, and in turn automated process plan generation for the turned components on Denford “MIRAC” 8 stations ATC lathe machining centre. A package in C++ on DOS platform is developed which generates the complete CNC part program, process plan and process sequence for the turned components. The input to this system is in the form of a blueprint in graphical format with machining parameters and variables, and the output is the CNC part program which is stored in a .mir file, ready for execution on the machining centre.

Keywords: CNC, MIRAC, ATC, process planning

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Authors: Jenq-Shyong Chen, Ben-Fong Yu

Abstract:

CNC(computer numerical control) machining centers have been widely used for machining different metal components for various industries. For a specific CNC machine, its everyday job is assigned to cut different products with quite different attributes such as material type, workpiece weight, geometry, tooling, and cutting conditions. Theoretically, the dynamic characteristics of the CNC machine should be properly tuned match each machining job in order to get the optimal machining performance. However, most of the CNC machines are set with only a standard set of CNC parameters. In this study, we have developed an auto-tuning system which can automatically change the CNC parameters and in hence change the machine dynamic characteristics according to the selection of machining modes which are set by the mixed combination of three machine performance indexes: the HO (high surface quality) index, HP (high precision) index and HS (high speed) index. The acceleration, jerk, corner error tolerance, oscillation and dynamic bandwidth of machine’s feed axes have been changed according to the selection of the machine performance indexes. The proposed auto-tuning system of the CNC parameters has been implemented on a PC-based CNC controller and a three-axis machining center. The measured experimental result have shown the promising of our proposed auto-tuning system.

Keywords: auto-tuning, CNC parameters, machining mode, high speed, high accuracy, high surface quality

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Authors: Ajay Kumar Sarathe, Abhinay Kumar

Abstract:

Production of quality products required for specific engineering applications is an important issue. The roughness of the surface plays an important role in the quality of the product by using appropriate machining parameters to eliminate wastage due to over machining. To increase the quality of the surface, the optimum machining parameter setting is crucial during the machining operation. The effect of key machining parameters- spindle speed, feed rate, and depth of cut on surface roughness has been evaluated. Experimental work was carried out using High Speed Steel tool and AlSI 1018 as workpiece material. In this study, the predictive model has been developed using Box-Behnken Design. An experimental investigation has been carried out for this work using BBD for three factors and observed that the predictive model of Ra value is closed to predictive value with a marginal error of 2.8648 %. Developed model establishes a correlation between selected key machining parameters that influence the surface roughness in a AISI 1018. F

Keywords: ANOVA, BBD, optimisation, response surface methodology

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Authors: Seunghee Park, Junkyeong Kim, Eun-Seok Shin, Sang-Hun Han

Abstract:

In this study, two kinds of nondestructive evaluation (NDE) techniques (rebound hardness and ultrasonic pulse velocity methods) are investigated for the effective maintenance of underwater concrete structures. A new methodology to estimate the underwater concrete strengths more effectively, named “artificial neural network (ANN) – based concrete strength estimation with the combination of rebound hardness and ultrasonic pulse velocity methods” is proposed and verified throughout a series of experimental works.

Keywords: underwater concrete, rebound hardness, Schmidt hammer, ultrasonic pulse velocity, ultrasonic sensor, artificial neural networks, ANN

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Authors: Majid Zargar, Frank Bullen, Ron Ayers

Abstract:

One of the important factors in the design of asphalt concrete mixes is the accurate measurement of air voids and their variable distribution. Both can have significant impact on long and short term fatigue and creep behaviour under traffic. While some simple methods exist for overall evaluation of air voids, measuring air void distribution in asphalt concrete is very complex, involving expensive techniques such as X-ray methodologies. The research reported in the paper investigated the use of non-destructive ultrasonic techniques as an alternative to estimate the amount of air voids and their distribution within asphalt samples. Seventy-four Standard AC–14 asphalt samples made with three types of bitumen; Multigrade, PMB and C320 were analysed using ultrasonic techniques. The results have illustrated that ultrasonic testing has the potential of being a rapid, accurate and cost-effective method of estimating air void distribution in asphalt.

Keywords: asphalt concrete, air voids, ultrasonic, mechanical behaviour

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