Search results for: ultrasonic assisted machining
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 513

Search results for: ultrasonic assisted machining

153 Localizing and Experiencing Electronic Questionnaires in an Educational Web Site

Authors: Theodore H. Kaskalis

Abstract:

One of the main research methods in humanistic studies is the collection and process of data through questionnaires. This paper reports our experiences of localizing and adapting the phpESP package of electronic surveys, which led to a friendly on-line questionnaire environment offered through our department web site. After presenting the characteristics of this environment, we identify the expected benefits and present a questionnaire carried out through both the traditional and electronic way. We present the respondents' feedback and then we report the researchers' opinions.Finally, we propose ideas we intend to implement in order to further assist and enhance the research based on this web accessed,electronic questionnaire environment.

Keywords: Electronic questionnaires, Computer assisted webinterviewing, Survey data collection, Survey data visualization.

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152 Control of Thermal Flow in Machine Tools Using Shape Memory Alloys

Authors: Reimund Neugebauer, Welf-Guntram Drossel, Andre Bucht, Christoph Ohsenbrügge

Abstract:

In this paper the authors propose and verify an approach to control heat flow in machine tool components. Thermal deformations are a main aspect that affects the accuracy of machining. Due to goals of energy efficiency, thermal basic loads should be reduced. This leads to inhomogeneous and time variant temperature profiles. To counteract these negative consequences, material with high melting enthalpy is used as a method for thermal stabilization. The increased thermal capacity slows down the transient thermal behavior. To account for the delayed thermal equilibrium, a control mechanism for thermal flow is introduced. By varying a gap in a heat flow path the thermal resistance of an assembly can be controlled. This mechanism is evaluated in two experimental setups. First to validate the ability to control the thermal resistance and second to prove the possibility of a self-sufficient option based on the selfsensing abilities of thermal shape memory alloys.

Keywords: energy-efficiency, heat transfer path, MT thermal stability, thermal shape memory alloy

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151 Study on Discontinuity Properties of Phased-Array Ultrasound Transducer Affecting to Sound Pressure Fields Pattern

Authors: Tran Trong Thang, Nguyen Phan Kien, Trinh Quang Duc

Abstract:

The phased-array ultrasound transducer types are utilities for medical ultrasonography as well as optical imaging. However, their discontinuity characteristic limits the applications due to the artifacts contaminated into the reconstructed images. Because of the effects of the ultrasound pressure field pattern to the echo ultrasonic waves as well as the optical modulated signal, the side lobes of the focused ultrasound beam induced by discontinuity of the phased-array ultrasound transducer might the reason of the artifacts. In this paper, a simple method in approach of numerical simulation was used to investigate the limitation of discontinuity of the elements in phased-array ultrasound transducer and their effects to the ultrasound pressure field. Take into account the change of ultrasound pressure field patterns in the conditions of variation of the pitches between elements of the phased-array ultrasound transducer, the appropriated parameters for phased-array ultrasound transducer design were asserted quantitatively.

Keywords: Phased-array ultrasound transducer, sound pressure pattern, discontinuous sound field, numerical visualization.

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150 An Evaluation of the Oxide Layers in Machining Swarfs to Improve Recycling

Authors: J. Uka, B. McKay, T. Minton, O. Adole, R. Lewis, S. J. Glanvill, L. Anguilano

Abstract:

Effective heat treatment conditions to obtain maximum aluminium swarf recycling are investigated in this work. Aluminium swarf briquettes underwent treatments at different temperatures and cooling times to investigate the improvements obtained in the recovery of aluminium metal. The main issue for the recovery of the metal from swarfs is to overcome the constraints due to the oxide layers present in high concentration in the swarfs since they have a high surface area. Briquettes supplied by Renishaw were heat treated at 650, 700, 750, 800 and 850 ℃ for 1-hour and then cooled at 2.3, 3.5 and 5 ℃/min. The resulting material was analysed using SEM EDX to observe the oxygen diffusion and aluminium coalescence at the boundary between adjacent swarfs. Preliminary results show that, swarf needs to be heat treated at a temperature of 850 ℃ and cooled down slowly at 2.3 ℃/min to have thin and discontinuous alumina layers between the adjacent swarf and consequently allowing aluminium coalescence. This has the potential to save energy and provide maximum financial profit in preparation of swarf briquettes for recycling.

Keywords: Aluminium, swarf, oxide layers, recycle, reuse.

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149 Process Optimisation for Internal Cylindrical Rough Turning of Nickel Alloy 625 Weld Overlay

Authors: Lydia Chan, Islam Shyha, Dale Dreyer, John Hamilton, Phil Hackney

Abstract:

Nickel-based superalloys are generally known to be difficult to cut due to their strength, low thermal conductivity, and high work hardening tendency. Superalloy such as alloy 625 is often used in the oil and gas industry as a surfacing material to provide wear and corrosion resistance to components. The material is typically applied onto a metallic substrate through weld overlay cladding, an arc welding technique. Cladded surfaces are always rugged and carry a tough skin; this creates further difficulties to the machining process. The present work utilised design of experiment to optimise the internal cylindrical rough turning for weld overlay surfaces. An L27 orthogonal array was used to assess effects of the four selected key process variables: cutting insert, depth of cut, feed rate, and cutting speed. The optimal cutting conditions were determined based on productivity and the level of tool wear.

Keywords: Cylindrical turning, nickel superalloy, turning of overlay, weld overlay.

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148 Surface Roughness and MRR Effect on Manual Plasma Arc Cutting Machining

Authors: R. Bhuvenesh, M.H. Norizaman, M.S. Abdul Manan

Abstract:

Industrial surveys shows that manufacturing companies define the qualities of thermal removing process based on the dimension and physical appearance of the cutting material surface. Therefore, the roughness of the surface area of the material cut by the plasma arc cutting process and the rate of the removed material by the manual plasma arc cutting machine was importantly considered. Plasma arc cutter Selco Genesis 90 was used to cut Standard AISI 1017 Steel of 200 mm x100 mm x 6 mm manually based on the selected parameters setting. The material removal rate (MRR) was measured by determining the weight of the specimens before and after the cutting process. The surface roughness (SR) analysis was conducted using Mitutoyo CS-3100 to determine the average roughness value (Ra). Taguchi method was utilized to achieve optimum condition for both outputs studied. The microstructure analysis in the region of the cutting surface is performed using SEM. The results reveal that the SR values are inversely proportional to the MRR values. The quality of the surface roughness depends on the dross peak that occurred after the cutting process.

Keywords: Material removal rate, plasma arc cutting, surface roughness, Taguchi method

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147 Vibration, Lubrication and Machinery Consideration for a Mixer Gearbox Related to Iran Oil Industries

Authors: Omid A. Zargar

Abstract:

In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.

Keywords: Gear box, condition monitoring, time wave form (TWF), fast Fourier transform (FFT), gear mesh frequency (GMF), Shock Pulse measurement (SPM), bearing condition unit (BCU), pinion, bevel gear, micro pitting, surface fatigue.

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146 Geographic Profiling Based on Multi-point Centrography with K-means Clustering

Authors: Jiaji Zhou, Le Liang, Long Chen

Abstract:

Geographic Profiling has successfully assisted investigations for serial crimes. Considering the multi-cluster feature of serial criminal spots, we propose a Multi-point Centrography model as a natural extension of Single-point Centrography for geographic profiling. K-means clustering is first performed on the data samples and then Single-point Centrography is adopted to derive a probability distribution on each cluster. Finally, a weighted combinations of each distribution is formed to make next-crime spot prediction. Experimental study on real cases demonstrates the effectiveness of our proposed model.

Keywords: Geographic profiling, Centrography model, K-means algorithm

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145 Design of Air Conditioning Automation for Patisserie Shopwindow

Authors: Kemal Tutuncu, Recai Ozcan

Abstract:

Having done in this study, air-conditioning automation for patisserie shopwindow was designed. In the cooling sector it is quite important to cooling up the air temperature in the shopwindow within short time interval. Otherwise the patisseries inside of the shopwindow will be spoilt in a few days. Additionally the humidity is other important parameter for the patisseries kept in shopwindow. It must be raised up to desired level in a quite short time. Traditional patisserie shopwindows only allow controlling temperature manually. There is no humidity control and humidity is supplied by fans that are directed to the water at the bottom of the shopwindows. In this study, humidity and temperature sensors (SHT11), PIC, AC motor controller, DC motor controller, ultrasonic nebulizer and other electronic circuit members were used to simulate air conditioning automation for patisserie shopwindow in proteus software package. The simulation results showed that temperature and humidity values are adjusted in desired time duration by openloop control technique. Outer and inner temperature and humidity values were used for control mechanism.

Keywords: Air conditioning automation, temperature and humidity, SHT11, AC motor controller, open-loop control.

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144 A DOE Study of Ultrasound Intensified Removal of Phenol

Authors: P. R. Rahul, A. Kannan

Abstract:

Ultrasound-aided adsorption of phenol by Granular Activated Carbon (GAC) was investigated at different frequencies ranging from 35 kHz, 58 kHz, and 192 kHz. Other factors influencing adsorption such as Adsorbent dosage (g/L), the initial concentration of the phenol solution (ppm) and RPM was also considered along with the frequency variable. However, this study involved calorimetric measurements which helped is determining the effect of frequency on the % removal of phenol from the power dissipated to the system was normalized. It was found that low frequency (35 kHz) cavitation effects had a profound influence on the % removal of phenol per unit power. This study also had cavitation mapping of the ultrasonic baths, and it showed that the effect of cavitation on the adsorption system is irrespective of the position of the vessel. Hence, the vessel was placed at the center of the bath. In this study, novel temperature control and monitoring system to make sure that the system is under proper condition while operations. From the BET studies, it was found that there was only 5% increase in the surface area and hence it was concluded that ultrasound doesn’t profoundly alter the equilibrium value of the adsorption system. DOE studies indicated that adsorbent dosage has a higher influence on the % removal in comparison with other factors.

Keywords: Ultrasound, adsorption, granulated activated carbon, phenol.

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143 Experimental Determination of Large Strain Localization in Cut Steel Chips

Authors: A. Simoneau

Abstract:

Metal cutting is a severe plastic deformation process involving large strains, high strain rates, and high temperatures. Conventional analysis of the chip formation process is based on bulk material deformation disregarding the inhomogeneous nature of the material microstructure. A series of orthogonal cutting tests of AISI 1045 and 1144 steel were conducted which yielded similar process characteristics and chip formations. With similar shear angles and cut chip thicknesses, shear strains for both chips were found to range from 2.0 up to 2.8. The manganese-sulfide (MnS) precipitate in the 1144 steel has a very distinct and uniform shape which allows for comparison before and after chip formation. From close observations of MnS precipitates in the cut chips it is shown that the conventional approach underestimates plastic strains in metal cutting. Experimental findings revealed local shear strains around a value of 6. These findings and their implications are presented and discussed.

Keywords: Machining, metal cutting, microstructure, plastic strains, local strain.

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142 Construction of Large Scale UAVs Using Homebuilt Composite Techniques

Authors: Brian J. Kozak, Joshua D. Shipman, Peng Hao Wang, Blake Shipp

Abstract:

The unmanned aerial system (UAS) industry is growing at a rapid pace. This growth has increased the demand for low cost, custom made and high strength unmanned aerial vehicles (UAV). The area of most growth is in the area of 25 kg to 200 kg vehicles. Vehicles this size are beyond the size and scope of simple wood and fabric designs commonly found in hobbyist aircraft. These high end vehicles require stronger materials to complete their mission. Traditional aircraft construction materials such as aluminum are difficult to use without machining or advanced computer controlled tooling. However, by using general aviation composite aircraft homebuilding techniques and materials, a large scale UAV can be constructed cheaply and easily. Furthermore, these techniques could be used to easily manufacture cost made composite shapes and airfoils that would be cost prohibitive when using metals. These homebuilt aircraft techniques are being demonstrated by the researchers in the construction of a 75 kg aircraft.

Keywords: Composite aircraft, homebuilding, unmanned aerial system, unmanned aerial vehicles.

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141 Ultrasonic Evaluation of Bone Callus Growth in a Rabbit Tibial Distraction Model

Authors: H.K. Luk, Y.M. Lai, L. Qin, C.W. Chan, Z. Liu, Y.P. Huang, Y.P. Zheng

Abstract:

Ultrasound is useful in demonstrating bone mineral density of regenerating osseous tissue as well as structural alterations. A proposed ultrasound method, which included ultrasonography and acoustic parameters measurement, was employed to evaluate its efficacy in monitoring the bone callus changes in a rabbit tibial distraction osteogenesis (DO) model. The findings demonstrated that ultrasonographic images depicted characteristic changes of the bone callus, typical of histology findings, during the distraction phase. Follow-up acoustic parameters measurement of the bone callus, including speed of sound, reflection and attenuation, showed significant linear changes over time during the distraction phase. The acoustic parameters obtained during the distraction phase also showed moderate to strong correlation with consolidated bone callus density and micro-architecture measured by micro-computed tomography at the end of the consolidation phase. The results support the preferred use of ultrasound imaging in the early monitoring of bone callus changes during DO treatment.

Keywords: Bone Callus Growth, Rabbit Tibial DistractionOsteogenesis, Ultrasonography, Ultrasonometry

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140 The Feasibility of Using Milled Glass Wastes in Concrete to Resist Freezing-Thawing Action

Authors: Raed Abendeh, Mousa Bani Baker, Zaydoun Abu Salem, Heham Ahmad

Abstract:

The using of waste materials in the construction industry can reduce the dependence on the natural aggregates which are going at the end to deplete. The glass waste is generated in a huge amount which can make one of its disposals in concrete industry effective not only as a green solution but also as an advantage to enhance the performance of mechanical properties and durability of concrete. This article reports the performance of concrete specimens containing different percentages of milled glass waste as a partial replacement of cement (Powder), when they are subject to cycles of freezing and thawing. The tests were conducted on 75-mm cubes and 75 x 75 x 300-mm prisms. Compressive strength based on laboratory testing and non-destructive ultrasonic pulse velocity test were performed during the action of freezing-thawing cycles (F/T). The results revealed that the incorporation of glass waste in concrete mixtures is not only feasible but also showed generally better strength and durability performance than control concrete mixture. It may be said that the recycling of waste glass in concrete mixes is not only a disposal way, but also it can be an exploitation in concrete industry.

Keywords: Durability, glass waste, freeze-thaw cycles, nondestructive test.

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139 Nano Effects of Nitrogen Ion Implantation on TiN Hard Coatings Deposited by PVD and IBAD

Authors: Branko Skoric, Aleksandar Miletic, Pal Terek, Lazar Kovacevic, Milan Kukuruzovic

Abstract:

In this paper, we present the results of a study of TiN thin films which are deposited by a Physical Vapour Deposition (PVD) and Ion Beam Assisted Deposition (IBAD). In the present investigation the subsequent ion implantation was provided with N5+ ions. The ion implantation was applied to enhance the mechanical properties of surface. The thin film deposition process exerts a number of effects such as crystallographic orientation, morphology, topography, densification of the films. A variety of analytic techniques were used for characterization, such as scratch test, calo test, Scanning electron microscopy (SEM), Atomic Force Microscope (AFM), X-ray diffraction (XRD) and Energy Dispersive X-ray analysis (EDAX).

Keywords: Steel, coating, super hard, ion implantation, nanohardness.

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138 An Experimental Study on the Mechanical Performance of Concrete Enhanced with Graphene Nanoplatelets

Authors: Johana Jaramillo, Robin Kalfat, Dmitriy A. Dikin

Abstract:

The cement production process is one of the major sources of carbon dioxide (CO2), a potent greenhouse gas. Indeed, as a result of its cement manufacturing process, concrete contributes approximately 8% of global greenhouse gas emissions. In addition to environmental concerns, concrete also has a low tensile and ductility strength, which can lead to cracks. Graphene Nanoplatelets (GNPs) have proven to be an eco-friendly solution for improving the mechanical and durability properties of concrete. The current research investigates the effects of preparing concrete enhanced with GNPs by using different wet dispersions techniques and mixing methods on its mechanical properties. Concrete specimens were prepared with 0.00 wt%, 0.10 wt%, 0.20 wt%, 0.30 wt% and wt% GNPs. Compressive and flexural strength of concrete at age 7 days were determined. The results showed that the maximum improvement in mechanical properties was observed when GNPs content was 0.20 wt%. The compressive and flexural strength were improved by up to 17.5% and 8.6%, respectively. When GNP dispersions were prepared by the combination of a drill and an ultrasonic probe, mechanical properties experienced maximum improvement.

Keywords: Concrete, dispersion techniques, graphene nanoplatelets, mechanical properties, mixing methods.

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137 Electronic and Computer-Assisted Refreshable Braille Display Developed for Visually Impaired Individuals

Authors: Ayşe Eldem, Fatih Başçiftçi

Abstract:

Braille alphabet is an important tool that enables visually impaired individuals to have a comfortable life like those who have normal vision. For this reason, new applications related to the Braille alphabet are being developed. In this study, a new Refreshable Braille Display was developed to help visually impaired individuals learn the Braille alphabet easier. By means of this system, any text downloaded on a computer can be read by the visually impaired individual at that moment by feeling it by his/her hands. Through this electronic device, it was aimed to make learning the Braille alphabet easier for visually impaired individuals with whom the necessary tests were conducted.

Keywords: Visually Impaired Individual, Braille, Braille Display, Refreshable Braille Display, USB.

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136 Fabrication and Characterization of CdS Nanoparticles Annealed by using Different Radiations

Authors: Aneeqa Sabah, Saadat Anwar Siddiqi, Salamat Ali

Abstract:

The systematic manipulations of shapes and sizes of inorganic compounds greatly benefit the various application fields including optics, magnetic, electronics, catalysis and medicine. However shape control has been much more difficult to achieve. Hence exploration of novel method for the preparation of differently shaped nanoparticles is challenging research area. II-VI group of semiconductor cadmium sulphide (CdS) nanostructure with different morphologies (such as, acicular like, mesoporous, spherical shapes) and of crystallite sizes vary from 11 to 16 nm were successfully synthesized by chemical aqueous precipitation of Cd2+ ions with homogeneously released S2- ions from decomposition of cadmium sulphate (CdSO4) and thioacetamide (CH3CSNH2) by annealing at different radiations (microwave, ultrasonic and sunlight) with matter and systematic research has been done for various factors affecting the controlled growth rate of CdS nanoparticles. The obtained nanomaterials have been characterized by X-ray Diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR), Thermogravometric (DSC-TGA) analysis and Scanning Electron Microscopy (SEM). The result indicates that on increasing the reaction time particle size increases but on increasing the molar ratios grain size decreases.

Keywords: CdS nanoparticles, Morphology, Oxidation, Radiations

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135 Effect of Composite Material on Damping Capacity Improvement of Cutting Tool in Machining Operation Using Taguchi Approach

Authors: S. Ghorbani, N. I. 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.

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134 An Active Mixer with Vertical Flow Placement via a Series of Inlets for Micromixing

Authors: Pil Woo Heo, In Sub Park

Abstract:

Flows in a microchannel are laminar, which means that mixing depends on only inter-diffusion. A micromixer plays an important role in obtaining fast diagnosis results in the fields of m-TAS (total analysis system), Bio-MEMS and LOC (lab-on-a-chip).

In this paper, we propose a new active mixer with vertical flow placement via a series of inlets for micromixing. This has two inlets on the same axis, one of which is located before the other. The sample input by the first inlet flows into the down-position, while the other sample by the second inlet flows into the up-position. In the experiment, the samples were located vertically in up-down positions in a micro chamber. PZT was attached below a chamber, and ultrasonic waves were radiated in the down to up direction towards the samples in the micro chamber in order to accelerate the mixing. The mixing process was measured by the change of color in a micro chamber using phenolphthalein and NaOH. The results of the experiment showed that the samples in the microchamber were efficiently mixed and that our new active mixer was superior to the horizontal type of active mixers in view of the grey levels and the standard deviation.

Keywords: Active mixer, vertical flow placement, microchannel, bio-MEMS, LOC.

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133 ANN Based Model Development for Material Removal Rate in Dry Turning in Indian Context

Authors: Mangesh R. Phate, V. H. Tatwawadi

Abstract:

This paper is intended to develop an artificial neural network (ANN) based model of material removal rate (MRR) in the turning of ferrous and nonferrous material in a Indian small-scale industry. MRR of the formulated model was proved with the testing data and artificial neural network (ANN) model was developed for the analysis and prediction of the relationship between inputs and output parameters during the turning of ferrous and nonferrous materials. The input parameters of this model are operator, work-piece, cutting process, cutting tool, machine and the environment.

The ANN model consists of a three layered feedforward back propagation neural network. The network is trained with pairs of independent/dependent datasets generated when machining ferrous and nonferrous material. A very good performance of the neural network, in terms of contract with experimental data, was achieved. The model may be used for the testing and forecast of the complex relationship between dependent and the independent parameters in turning operations.

Keywords: Field data based model, Artificial neural network, Simulation, Convectional Turning, Material removal rate.

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132 Designing of Multi-Agent Rescue Robot: Development and Basic Experiments of Master-Slave Type Rescue Robots

Authors: J. Lin, T. C. Kuo, C. -Y. Gau, K. C. Liu, Y. J. Huang, J. D. Yu, Y. W. Lin

Abstract:

A multi-agent type robot for disaster response in calamity scene is proposed in this paper. The proposed grouped rescue robots can perform cooperative reconnaissance and surveillance to achieve a given rescue mission. The multi-agent rescue of dual set robot consists of one master set and three slave units. The research for this rescue robot system is going to detect at harmful environment where human is unreachable, such as the building is infected with virus or the factory has hazardous liquid in effluent. As a dual set robot, with Bluetooth and communication network, the master set can connect with slave units and send information back to computer by wireless and monitor. Therefore, rescuer can be informed the real-time information in a calamity area. Furthermore, each slave robot is able to obstacle avoidance by ultrasonic sensors, and encodes distance and location by compass. The master robot can integrate every devices information to increase the efficiency of prospected and research unknown area.

Keywords: Designing of multi-agent rescue robot, development and basic experiments of master-slave type rescue robots.

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131 Optimization of Surface Roughness and Vibration in Turning of Aluminum Alloy AA2024 Using Taguchi Technique

Authors: Vladimir Aleksandrovich Rogov, Ghorbani Siamak

Abstract:

Determination of optimal conditions of machining parameters is important to reduce the production cost and achieve the desired surface quality. This paper investigates the influence of cutting parameters on surface roughness and natural frequency in turning of aluminum alloy AA2024. The experiments were performed at the lathe machine using two different cutting tools made of AISI 5140 and carbide cutting insert coated with TiC. Turning experiments were planned by Taguchi method L9 orthogonal array.Three levels for spindle speed, feed rate, depth of cut and tool overhang were chosen as cutting variables. The obtained experimental data has been analyzed using signal to noise ratio and analysis of variance. The main effects have been discussed and percentage contributions of various parameters affecting surface roughness and natural frequency, and optimal cutting conditions have been determined. Finally, optimization of the cutting parameters using Taguchi method was verified by confirmation experiments.

Keywords: Turning, Cutting conditions, Surface roughness, Natural frequency, Taguchi method, ANOVA, S/N ratio.

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130 Application of Nano Cutting Fluid under Minimum Quantity Lubrication (MQL) Technique to Improve Grinding of Ti – 6Al – 4V Alloy

Authors: Dinesh Setti, Sudarasan Ghosh, P. Venkateswara Rao

Abstract:

Minimum Quantity Lubrication (MQL) technique obtained a significant attention in machining processes to reduce environmental loads caused by usage of conventional cutting fluids. Recently nanofluids are finding an extensive application in the field of mechanical engineering because of their superior lubrication and heat dissipation characteristics. This paper investigates the use of a nanofluid under MQL mode to improve grinding characteristics of Ti-6Al-4V alloy. Taguchi-s experimental design technique has been used in the present investigation and a second order model has been established to predict grinding forces and surface roughness. Different concentrations of water based Al2O3 nanofluids were applied in the grinding operation through MQL setup developed in house and the results have been compared with those of conventional coolant and pure water. Experimental results showed that grinding forces reduced significantly when nano cutting fluid was used even at low concentration of the nano particles and surface finish has been found to improve with higher concentration of the nano particles.

Keywords: MQL, Nanofluid, Taguchi method, Ti-6Al-4V.

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129 Optimization of Surface Finish in Milling Operation Using Live Tooling via Taguchi Method

Authors: Harish Kumar Ponnappan, Joseph C. Chen

Abstract:

The main objective of this research is to optimize the surface roughness of a milling operation on AISI 1018 steel using live tooling on a HAAS ST-20 lathe. In this study, Taguchi analysis is used to optimize the milling process by investigating the effect of different machining parameters on surface roughness. The L9 orthogonal array is designed with four controllable factors with three different levels each and an uncontrollable factor, resulting in 18 experimental runs. The optimal parameters determined from Taguchi analysis were feed rate – 76.2 mm/min, spindle speed 1150 rpm, depth of cut – 0.762 mm and 2-flute TiN coated high-speed steel as tool material. The process capability Cp and process capability index Cpk values were improved from 0.62 and -0.44 to 1.39 and 1.24 respectively. The average surface roughness values from the confirmation runs were 1.30 µ, decreasing the defect rate from 87.72% to 0.01%. The purpose of this study is to efficiently utilize the Taguchi design to optimize the surface roughness in a milling operation using live tooling.

Keywords: Live tooling, surface roughness, Taguchi analysis, Computer Numerical Control (CNC) milling operation, CNC turning operation.

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128 Analytical Cutting Forces Model of Helical Milling Operations

Authors: Changyi Liu, Gui Wang, Matthew Dargusch

Abstract:

Helical milling operations are used to generate or enlarge boreholes by means of a milling tool. The bore diameter can be adjusted through the diameter of the helical path. The kinematics of helical milling on a three axis machine tool is analysed firstly. The relationships between processing parameters, cutting tool geometry characters with machined hole feature are formulated. The feed motion of the cutting tool has been decomposed to plane circular feed and axial linear motion. In this paper, the time varying cutting forces acted on the side cutting edges and end cutting edges of the flat end cylinder miller is analysed using a discrete method separately. These two components then are combined to produce the cutting force model considering the complicated interaction between the cutters and workpiece. The time varying cutting force model describes the instantaneous cutting force during processing. This model could be used to predict cutting force, calculate statics deflection of cutter and workpiece, and also could be the foundation of dynamics model and predicting chatter limitation of the helical milling operations.

Keywords: Helical milling, Hole machining, Cutting force, Analytical model, Time domain

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127 Multi-Walled Carbon Nanotubes/Polyacrylonitrile Composite as Novel Semi-Permeable Mixed Matrix Membrane in Reverse Osmosis Water Treatment Process

Authors: M. M. Doroodmand, Z.Tahvildar, M. H.Sheikhi

Abstract:

novel and simple method is introduced for rapid and highly efficient water treatment by reverse osmosis (RO) method using multi-walled carbon nanotubes (MWCNTs) / polyacrylonitrile (PAN) polymer as a flexible, highly efficient, reusable and semi-permeable mixed matrix membrane (MMM). For this purpose, MWCNTs were directly synthesized and on-line purified by chemical vapor deposition (CVD) process, followed by directing the MWCNT bundles towards an ultrasonic bath, in which PAN polymer was simultaneously suspended inside a solid porous silica support in water at temperature to ~70 οC. Fabrication process of MMM was finally completed by hot isostatic pressing (HIP) process. In accordance with the analytical figures of merit, the efficiency of fabricated MMM was ~97%. The rate of water treatment process was also evaluated to 6.35 L min-1. The results reveal that, the CNT-based MMM is suitable for rapid treatment of different forms of industrial, sea, drinking and well water samples.

Keywords: Mixed Matrix Membrane, Carbon Nanostructures, Chemical Vapour Deposition, Hot Isostatic Pressing

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126 Application of Pearson Parametric Distribution Model in Fatigue Life Reliability Evaluation

Authors: E. A. Azrulhisham, Y. M. Asri, A. W. Dzuraidah, A. H. Hairul Fahmi

Abstract:

The aim of this paper is to introduce a parametric distribution model in fatigue life reliability analysis dealing with variation in material properties. Service loads in terms of responsetime history signal of Belgian pave were replicated on a multi-axial spindle coupled road simulator and stress-life method was used to estimate the fatigue life of automotive stub axle. A PSN curve was obtained by monotonic tension test and two-parameter Weibull distribution function was used to acquire the mean life of the component. A Pearson system was developed to evaluate the fatigue life reliability by considering stress range intercept and slope of the PSN curve as random variables. Considering normal distribution of fatigue strength, it is found that the fatigue life of the stub axle to have the highest reliability between 10000 – 15000 cycles. Taking into account the variation of material properties associated with the size effect, machining and manufacturing conditions, the method described in this study can be effectively applied in determination of probability of failure of mass-produced parts.

Keywords: Stub axle, Fatigue life reliability, Stress-life, PSN curve, Weibull distribution, Pearson system

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125 Cognition of Driving Context for Driving Assistance

Authors: Manolo Dulva Hina, Clement Thierry, Assia Soukane, Amar Ramdane-Cherif

Abstract:

In this paper, we presented our innovative way of determining the driving context for a driving assistance system. We invoke the fusion of all parameters that describe the context of the environment, the vehicle and the driver to obtain the driving context. We created a training set that stores driving situation patterns and from which the system consults to determine the driving situation. A machine-learning algorithm predicts the driving situation. The driving situation is an input to the fission process that yields the action that must be implemented when the driver needs to be informed or assisted from the given the driving situation. The action may be directed towards the driver, the vehicle or both. This is an ongoing work whose goal is to offer an alternative driving assistance system for safe driving, green driving and comfortable driving. Here, ontologies are used for knowledge representation.

Keywords: Cognitive driving, intelligent transportation system, multimodal system, ontology, machine learning.

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124 Stress Corrosion Crack Identification with Direct Assessment Method in Pipeline Downstream from a Compressor Station

Authors: H. Gholami, M. Jalali Azizpour

Abstract:

Stress Corrosion Crack (SCC) in pipeline is a type of environmentally assisted cracking (EAC), since its discovery in 1965 as a possible cause of failure in pipeline, SCC has caused, on average, one of two failures per year in the U.S, According to the NACE SCC DA a pipe line segment is considered susceptible to SCC if all of the following factors are met: The operating stress exceeds 60% of specified minimum yield strength (SMYS), the operating temperature exceeds 38°C, the segment is less than 32 km downstream from a compressor station, the age of the pipeline is greater than 10 years and the coating type is other than Fusion Bonded Epoxy(FBE). In this paper as a practical experience in NISOC, Direct Assessment (DA) Method is used for identification SCC defect in unpiggable pipeline located downstream of compressor station.

Keywords: Stress Corrosion Crack, Direct Assessment, Disbondment, Transgranular SCC, Compressor Station.

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