Search results for: milling

Authors: Brou K., Guéhi T., Konan A. G., Gbakayoro J. B., Gnakri D.

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Two types of crushing were applied to grains of red sorghum: manual crushing using a mortar and pestle of kitchen and mechanical crushing using a hammer mill. The flours obtained at the end of these various crushing were filtered and subdivided in different fractions according to the diameters of the mesh of the sieves (0.16mm; 0.25mm; 0.315mm; 0.4mm, and 0.63mm…). Some physical, chemical and nutritional traits of these flours were evaluated using Association of Official Analytical Chemists (AOAC). In vitro digestibility of these flours was also studied with freezing of flour 1% like substrate and α-amylase from B. licheniformis (E.C.3.2.1.1; Megazyme, Wicklow, Ireland). The results revealed that the batches of flours which have the finest diameters as 0.16mm; 0.25mm are the richest one in nutrients and are also the most digestible. Also mechanical crushing is the best mean to obtain significant amount of flours. In conclusion, the type of crushing and the size of the particles have an impact on the final concentration of some nutrients of the flours obtained. Indeed, the finest particles (0.16mm – 0.25mm 0.315mm) obtained after sifting of the flours are more nutritive and have a better digestibility than others size. So the finest particles could be advised for management of cereals namely the sorghum for the production of the infantile foods.

Keywords: Nutrients, digestibility, crush, flour, milling, granulometry.

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Authors: Salah Gariani, Islam Shyha, Fawad Inam, Dehong Huo

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A controlled cutting fluid impinging supply system (CUT-LIST) was developed to deliver an accurate amount of cutting fluid into the machining zone via well-positioned coherent nozzles based on a calculation of the heat generated. The performance of the CUT-LIST was evaluated against a conventional flood cutting fluid supply system during step shoulder milling of Ti-6Al-4V using vegetable oil-based cutting fluid. In this paper, the micro-hardness of the machined surface was used as the main criterion to compare the two systems. CUT-LIST provided significant reductions in cutting fluid consumption (up to 42%). Both systems caused increased micro-hardness value at 100 µm from the machined surface, whereas a slight reduction in micro-hardness of 4.5% was measured when using CUL-LIST. It was noted that the first 50 µm is the soft sub-surface promoted by thermal softening, whereas down to 100 µm is the hard sub-surface caused by the cyclic internal work hardening and then gradually decreased until it reached the base material nominal hardness. It can be concluded that the CUT-LIST has always given lower micro-hardness values near the machined surfaces in all conditions investigated.

Keywords: Impinging supply system, micro-hardness, shoulder milling, Ti-6Al-4V, vegetable oil-based cutting fluid.

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

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

Keywords: Control, machining, multibody, robotic, simulation.

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Authors: Behrooz Movahedi

Abstract:

Fe-based amorphous feedstock powders are used as the matrix into which various ratios of hard B4C nanoparticles (0, 5, 10, 15, 20 vol.%) as reinforcing agents were prepared using a planetary high-energy mechanical milling. The ball-milled nanocomposite feedstock powders were also sprayed by means of high-velocity oxygen fuel (HVOF) technique. The characteristics of the powder particles and the prepared coating depending on their microstructures and nanohardness were examined in detail using nanoindentation tester. The results showed that the formation of the Fe-based amorphous phase was noticed over the course of high-energy ball milling. It is interesting to note that the nanocomposite coating is divided into two regions, namely, a full amorphous phase region and homogeneous dispersion of B4C nanoparticles with a scale of 10–50 nm in a residual amorphous matrix. As the B4C content increases, the nanohardness of the composite coatings increases, but the fracture toughness begins to decrease at the B4C content higher than 20 vol.%. The optimal mechanical properties are obtained with 15 vol.% B4C due to the suitable content and uniform distribution of nanoparticles. Consequently, the changes in mechanical properties of the coatings were attributed to the changes in the brittle to ductile transition by adding B4C nanoparticles.

Keywords: Fe-based amorphous, B4C nanoparticles, nanocomposite coating, HVOF.

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Authors: Sangamesh G. Sakri, Akash N. Patil, Sadashivappa M. Kotli

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Agro based industries in India are considered as the micro, small and medium enterprises (MSME). In India, MSMEs contribute approximately 8 percent of the country’s GDP, 42 percent of the manufacturing output and 40 percent of exports. The toor dal (scientific name Cajanus cajan, commonly known as yellow gram, pigeon pea) is the second largest pulse crop in India accounting for about 20% of total pulse production. The toor dal milling industry in India is one of the major agro-processing industries in the country. Most of the dal mills are concentrated in pulse producing areas, which are spread all over the country. In Karnataka state, Gulbarga is a district, where toor dal is the main crop and is grown extensively. There are more than 500 dal mills in and around the Gulbarga district to process dal. However, the majority of these dal milling units use traditional methods of processing which are energy and capital intensive. There exists a huge energy saving potential in these mills. An energy audit is conducted on a dal mill in Gulbarga to understand the energy consumption pattern to assess the energy saving potential, and an economic analysis is conducted to identify energy conservation opportunities.

Keywords: Conservation, demand side management, load curve, toor dal.

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Authors: J. Hajnys, M. Pagac, J. Petru, P. Stefek, J. Mesicek, J. Kratochvil

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The new progressive method of 3D metal printing SLM (Selective Laser Melting) is increasingly expanded into the normal operation. As a result, greater demands are placed on the surface quality of the parts produced in this way. The article deals with research of selected finishing methods (tumbling, face milling, sandblasting, shot peening and brushing) and their impact on the final surface roughness. The 20 x 20 x 7 mm produced specimens using SLM additive technology on the Renishaw AM400 were subjected to testing of these finishing methods by adjusting various parameters. Surface parameters of roughness Sa, Sz were chosen as the evaluation criteria and profile parameters Ra, Rz were used as additional measurements. Optical measurement of surface roughness was performed on Alicona Infinite Focus 5. An experiment conducted to optimize the surface roughness revealed, as expected, that the best roughness parameters were achieved through a face milling operation. Tumbling is particularly suitable for 3D printing components, as tumbling media are able to reach even complex shapes and, after changing to polishing bodies, achieve a high surface gloss. Surface quality after tumbling depends on the process time. Other methods with satisfactory results are shot peening and tumbling, which should be the focus of further research.

Keywords: Additive manufacturing, selective laser melting, surface roughness, stainless steel.

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Authors: M. S. Said, J. A. Ghani, Che Hassan C. H., N. N. Wan, M. A. Selamat, R. Othman

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Metal matrix composites (MMCs) attract considerable attention as a result from its ability in providing a high strength, high modulus, high toughness, high impact properties, improving wear resistance and providing good corrosion resistance compared to unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been widely used in various industrial sectors such as in transportation, domestic equipment, aerospace, military, construction, etc. Aluminium silicon alloy is an MMC that had been reinforced with aluminium nitrate (AlN) particle and become a new generation material use in automotive and aerospace sector. The AlN is one of the advance material that have a bright prospect in future since it has features such as lightweight, high strength, high hardness and stiffness quality. However, the high degree of ceramic particle reinforcement and the irregular nature of the particles along the matrix material that contribute to its low density is the main problem which leads to difficulties in machining process. This paper examined the tool wear when milling AlSi/AlN Metal Matrix Composite using a TiB2 (Titanium diboride) coated carbide cutting tool. The volume of the AlN reinforced particle was 10% and milling process was carried out under dry cutting condition. The TiB2 coated carbide insert parameters used were at the cutting speed of (230, 300 and 370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The Sometech SV-35 video microscope system used to quantify of the tool wear. The result shown that tool life span increasing with the cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at 0.4mm) which constituted an optimum condition for longer tool life lasted until 123.2 mins. Meanwhile, at medium cutting speed which at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we found that tool life span lasted until 119.86 mins while at low cutting speed it lasted in 119.66 mins. High cutting speed will give the best parameter in cutting AlSi/AlN MMCs material. The result will help manufacturers in machining process of AlSi/AlN MMCs materials.

Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, TiB2 coated cemented carbide tool.

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Authors: Tadahiro Wada, Koji Iwamoto

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In turning hardened steel, polycrystalline cubic boron nitride (cBN) compacts are widely used, due to their higher hardness and higher thermal conductivity. However, in milling hardened steel, fracture of cBN cutting tools readily occurs because they have poor fracture toughness. Therefore, coated cemented carbide tools, which have good fracture toughness and wear resistance, are generally widely used. In this study, hardened steel (ASTM D2, JIS SKD11, 60HRC) was milled with three physical vapor deposition (PVD)-coated cemented carbide end mill cutters in order to determine effective tool materials for cutting hardened steel at high cutting speeds. The coating films used were (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating films. (Ti,W,Si,Al)N is a new type of coating film. The inner layer of the (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating system is (Ti,W)N coating film, and the outer layer is (Ti,W,Si)N and (Ti,W,Si,Al)N coating films, respectively. Furthermore, commercial (Ti,Al)N-based coating film was also used. The following results were obtained: (1) In milling hardened steel at a cutting speed of 3.33 m/s, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,W)N/(Ti,W,Si)N-coated tool. And, compared with the commercial (Ti,Al)N, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,Al)N-coated tool. (2) The tool wear of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool increased with an increase in cutting speed. (3) The (Ti,W)N/(Ti,W,Si,Al)N-coated cemented carbide was an effective tool material for high-speed cutting below a cutting speed of 3.33 m/s.

Keywords: cutting, physical vapor deposition (PVD) coating system, hardened steel, tool wear

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Authors: Satish Kumar, Arun Kumar Gupta, Pankaj Chandna

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In the modern manufacturing systems, the use of thermal cutting techniques using oxyfuel, plasma and laser have become indispensable for the shape forming of high quality complex components; however, the conventional chip removal production techniques still have its widespread space in the manufacturing industry. Both these types of machining operations require the positioning of end effector tool at the edge where the cutting process commences. This repositioning of the cutting tool in every machining operation is repeated several times and is termed as non-productive time or airtime motion. Minimization of this non-productive machining time plays an important role in mass production with high speed machining. As, the tool moves from one region to the other by rapid movement and visits a meticulous region once in the whole operation, hence the non-productive time can be minimized by synchronizing the tool movements. In this work, this problem is being formulated as a general travelling salesman problem (TSP) and a genetic algorithm approach has been applied to solve the same. For improving the efficiency of the algorithm, the GA has been hybridized with a noble special heuristic and simulating annealing (SA). In the present work a novel heuristic in the combination of GA has been developed for synchronization of toolpath movements during repositioning of the tool. A comparative analysis of new Meta heuristic techniques with simple genetic algorithm has been performed. The proposed metaheuristic approach shows better performance than simple genetic algorithm for minimization of nonproductive toolpath length. Also, the results obtained with the help of hybrid simulated annealing genetic algorithm (HSAGA) are also found better than the results using simple genetic algorithm only.

Keywords: Non-productive time, Airtime, 2.5 D milling, Laser cutting, Metaheuristic, Genetic Algorithm, Simulated Annealing.

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Authors: Geun-Il Park, Jae-Won Lee, Dou-Youn Lee, Jung-Won Lee, Kwang-Wook Kim, Kee-Chan Song

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Thermochemcial characteristics of powder fabricated using oxidation treatment of spent PWR fuel and SIMFUEL were evaluated for recycling of spent fuel such as DUPIC process. Especially, the influence of spent fuel burn-ups on the powder fabrication characteristics was experimentally evaluated, ranging from 27,300 to 65,000 MWd/tU. Densities of powder manufactured from an oxidation, OREOX and the milling processes at the same process conditions were compared as a function of the fuel burn-ups respectively. Also, based on chemical analysis results, homogeneity of fissile elements in oxidized powder was confirmed.

Keywords: Spent PWR fuel, DUPIC, Oxidation, OREOX, Powder, Chemical analysis

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Authors: Patcharin Worathanakul, Wisaroot Payubnop, Akhapon Muangpet

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Utilization of bagasse ash for silica sources is one of the most common application for agricultural wastes and valuable biomass byproducts in sugar milling. The high percentage silica content from bagasse ash was used as silica source for sodium silicate solution. Different heating temperature, time and acid treatment were studies for silica extraction. The silica was characterized using various techniques including X-ray fluorescence, X-ray diffraction, Scanning electron microscopy, and Fourier Transform Infrared Spectroscopy method,. The synthesis conditions were optimized to obtain the bagasse ash with the maximum silica content. The silica content of 91.57 percent was achieved from heating of bagasse ash at 600°C for 3 hours under oxygen feeding and HCl treatment. The result can be used as value added for bagasse ash utilization and minimize the environmental impact of disposal problems.

Keywords: Bagasse ash, synthesis, silica, extraction, posttreatment

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Authors: Bogdan Bogdanov, Irena Markovska, Yancho Hristov, Dimitar Georgiev

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Lightweight ceramic materials in the form of bricks and blocks are widely used in modern construction. They may be obtained by adding of rice husk, rye straw, etc, as porous forming materials. Rice husk is a major by-product of the rice milling industry. Its utilization as a valuable product has always been a problem. Various technologies for utilization of rice husk through biological and thermochemical conversion are being developed. The purpose of this work is to develop lightweight ceramic materials with clay matrix and filler of rice husk and examine their main physicomechanical properties. The results obtained allow to suppose that the materials synthesized on the basis of waste materials can be used as lightweight materials for construction purpose.

Keywords: lightweight ceramic materials, properties, agro-waste

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Authors: Sasho Guergov

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The purpose of the paper is to develop an informationcontrol environment for overall management and self-reconfiguration of the reconfigurable multifunctional machine tool for machining both rotation and prismatic parts and high concentration of different technological operations - turning, milling, drilling, grinding, etc. For the realization of this purpose on the basis of defined sub-processes for the implementation of the technological process, architecture of the information-search system for machine control is suggested. By using the object-oriented method, a structure and organization of the search system based on agents and manager with central control are developed. Thus conditions for identification of available information in DBs, self-reconfiguration of technological system and entire control of the reconfigurable multifunctional machine tool are created.

Keywords: Information system, multifunctional machine tool, reconfigurable machine tool, search system.

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Authors: Wipada Ploysuksai, Pramoch Rangsunvigit, Santi Kulprathipanja

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In this work, effects of catalysts (TiO2, and Nb2O5) were investigated on the hydrogen desorption of Mg(BH4)2. LiBH4 and MgCl2 with 2:1 molar ratio were mixed by using ball milling to prepare Mg(BH4)2. The desorption behaviors were measured by thermo-volumetric apparatus. The hydrogen desorption capacity of the mixed sample milled for 2 h was 4.78 wt% with a 2-step released. The first step occurred at 214 °C and the second step appeared at 374 °C. The addition of 16 wt% Nb2O5 decreased the desorption temperature in the second step about 66 °C and increased the hydrogen desorption capacity to 4.86 wt% hydrogen. The addition of TiO2 also improved the desorption temperature in the second step and the hydrogen desorption capacity. It decreased the desorption temperature about 71°C and showed a high amount of hydrogen, 5.27 wt%, released from the mixed sample. The hydrogen absorption after desorption of Mg(BH4)2 was also studied under 9.5 MPa and 350 °C for 12 h.

Keywords: hydrogen storage, LiBH4, metal hydride, Mg(BH4)2

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Authors: A. Shishkin, V. Mironovs, D. Goljandin, A. Korjakins

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The goal of this work is to develop sustainable and durable ceramic cellular structures using widely available natural resources- clay and milled waste glass. Present paper describes method of obtaining clay ceramic foam (CCF) with addition of milled waste glass in 5, 7 and 10 wt% by direct foaming with high speed mixer-disperser (HSMD). For more efficient clay and waste glass milling and mixing, the high velocity disintegrator was used. The CCF with 5, 7, and 10 wt% were obtained at 900, 950, 1000 and 1050 °C firing temperature and they have demonstrated mechanical compressive strength for all 12 samples ranging from 3.8 to 14.3 MPa and porosity 76-65%. Obtained CCF has compressive strength 14.3 MPa and porosity 65.3%.

Keywords: Ceramic foam, waste glass, clay foam, glass foam, open cell, direct foaming.

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Authors: R. Alipour, F. Nadjarian, A. Alinaghizade

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Considering complexity of products, new geometrical design and investment tolerances that are necessary, measuring and dimensional controlling involve modern and more precise methods. Photo digitizing method using two cameras to record pictures and utilization of conventional method named “cloud points" and data analysis by the use of ATOUS software, is known as modern and efficient in mentioned context. In this paper, benefits of photo digitizing method in evaluating sampling of machining processes have been put forward. For example, assessment of geometrical integrity surface in 5-axis milling process and measurement of carbide tool wear in turning process, can be can be brought forward. Advantages of this method comparing to conventional methods have been expressed.

Keywords: photo digitizing, tool wear, geometrical integrity, cloud points

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Authors: D. Karimi, M.J. Nategh

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One of the main concerns about parallel mechanisms is the presence of singular points within their workspaces. In singular positions the mechanism gains or loses one or several degrees of freedom. It is impossible to control the mechanism in singular positions. Therefore, these positions have to be avoided. This is a vital need especially in computer controlled machine tools designed and manufactured on the basis of parallel mechanisms. This need has to be taken into consideration when selecting design parameters. A prerequisite to this is a thorough knowledge about the effect of design parameters and constraints on singularity. In this paper, quality condition index was introduced as a criterion for evaluating singularities of different configurations of a hexapod mechanism obtainable by different design parameters. It was illustrated that this method can effectively be employed to obtain the optimum configuration of hexapod mechanism with the aim of avoiding singularity within the workspace. This method was then employed to design the hexapod table of a CNC milling machine.

Keywords: Hexapod, Machine Tool, Singularity, Workspace.

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Authors: Orose Rugchati, Khumthong Mahawongwiriya, Kanita Thanacharoenchanaphas

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Yam starch obtained from the water yam (munlued) by the wet milling process was studied for some physicochemical properties. Yam starch film was prepared by casting using glycerol as a plasticizer. The effect of different glycerol (1.30, 1.65 and 2.00g/100g of filmogenic solution) and starch concentrations (3.30, 3.65 and 4.00g /100g of filmogenic solution) were evaluated on some characteristics of the film. The temperature for obtaining the gelatinized starch solution was 70-80°C and then dried at 45°C for 4 hours. The resulting starch from munlued granular morphology was triangular and the average size of the granule was 26.68 μm. The amylose content by colorimetric method was 26 % and the gelatinize temperature was 70-80°C. The appearance of the film was smooth, transparent, and glossy with average moisture content of 25.96% and thickness of 0.01mm. Puncture deformation and flexibility increased with glycerol content. The starch and glycerol concentration were a significant factor of the yam starch film characteristics. Yam starch film can be described as a biofilm providing many applications and developments with the advantage of biodegradability.

Keywords: Characteristics of Biodegradable film, yam starch, Dioscoreaalata, substitute, Thailand.

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Authors: M. Bittencourt, E. K. Yanful, D. Velasquez, A. E. Jungles

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The CMLP building was developed to be a model for sustainability with strategies to reduce water, energy and pollution, and to provide a healthy environment for the building occupants. The aim of this paper is to investigate the environmental effects of energy used by this building. A LCA (life cycle analysis) was led to measure the real environmental effects produced by the use of energy. The impact categories most affected by the energy use were found to be the human health effects, as well as ecotoxicity. Natural gas extraction, uranium milling for nuclear energy production, and the blasting for mining and infrastructure construction are the processes contributing the most to emissions in the human health effect. Data comparing LCA results of CMLP building with a conventional building results showed that energy used by the CMLP building has less damage for the environment and human health than a conventional building.

Keywords: Environmental Impacts, Green buildings, Life CycleAnalysis, Sustainability

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Authors: V. J. Pillewan, D. N. Raut, K. N. Patil, D. K. Shinde

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Forging, milling, turning, grinding and shaping etc. are the various industrial manufacturing processes which generate the metal waste. Grinding is extensively used in the finishing operation. The waste generated contains significant impurities apart from the metal particles. Due to these significant impurities, it becomes difficult to process and gets usually dumped in the landfills which create environmental problems. Therefore, it becomes essential to reuse metal waste to create value added products. Powder injection molding process is used for producing the porous metal matrix framework. This paper discusses the presented design of the porous framework to be used for the liquid filter application. Different parameters are optimized to obtain the better strength framework with variable porosity. Carbon nanotubes are used as reinforcing materials to enhance the strength of the metal matrix framework.

Keywords: Grinding waste, powder injection molding, carbon nanotubes, metal matrix composites.

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Authors: Kaliyaperumal Anandavel, Raghu V. Prakash, Antonio Davis

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This paper presents the influence of preloading on a) the contact tractions, b) slip levels and c) stresses at the dovetail blade-disc interface of an aero-engine through a three-dimensional (3D) finite element (FE) modeling and analysis. The preloading is applied by an interference fit at the dovetail interface and the bulk loading is applied through the rotational speed of rotor. Preloading at the dovetail interface reduces the peak contact pressure developed due to bulk loading up to 35%, and reduces the peak contact pressure and stress difference between top and bottom contact edges. Increasing the level of preloading reduces the cyclic stress amplitude at the interface up to certain values of preload and as a consequence, an improvement in fatigue life could be expected. Fretting damage, due to vibration and wind milling effect during engine ground condition, can be minimized by preloading the dovetail interface.

Keywords: Dovetail interface, Preload, Interference fit, ContactStress, Fretting Fatigue.

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Authors: Smriti H. Bhandari, S. M. Deshpande

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Surface metrology with image processing is a challenging task having wide applications in industry. Surface roughness can be evaluated using texture classification approach. Important aspect here is appropriate selection of features that characterize the surface. We propose an effective combination of features for multi-scale and multi-directional analysis of engineering surfaces. The features include standard deviation, kurtosis and the Canny edge detector. We apply the method by analyzing the surfaces with Discrete Wavelet Transform (DWT) and Dual-Tree Complex Wavelet Transform (DT-CWT). We used Canberra distance metric for similarity comparison between the surface classes. Our database includes the surface textures manufactured by three machining processes namely Milling, Casting and Shaping. The comparative study shows that DT-CWT outperforms DWT giving correct classification performance of 91.27% with Canberra distance metric.

Keywords: Dual-tree complex wavelet transform, surface metrology, surface roughness, texture classification.

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Authors: Louis Denis Kevin Catherine, Raja Aziz Raja Ma’arof, Azrina Arshad, Sangeeth Suresh

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Machining parameters are very important in determining the surface quality of any material. In the past decade, some new engineering materials were developed for the manufacturing industry which created a need to conduct an investigation on the impact of the said parameters on their surface roughness. Polyurethane (PU) block is widely used in the automotive industry to manufacture parts such as checking fixtures that are used to verify the dimensional accuracy of automotive parts. In this paper, the design of experiment (DOE) was used to investigate on the effect of the milling parameters on the PU block. Furthermore, an analysis of the machined surface chemical composition was done using scanning electron microscope (SEM). It was found that the surface roughness of the PU block is severely affected when PU undergoes a flood machining process instead of a dry condition. In addition the stepover and the silicon content were found to be the most significant parameters that influence the surface quality of the PU block.

Keywords: Polyurethane (PU), design of experiment (DOE), scanning electron microscope (SEM), surface roughness.

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Authors: Abdullah Yassin, Takashi Ueda, Syed Tarmizi Syed Shazali

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This paper presents an experimental investigation on the machinability of laser-sintered material using small ball end mill focusing on wear mechanisms. Laser-sintered material was produced by irradiating a laser beam on a layer of loose fine SCM-Ni-Cu powder. Bulk carbon steel JIS S55C was selected as a reference steel. The effects of powder consolidation mechanisms and unsintered powder on the tool life and wear mechanisms were carried out. Results indicated that tool life in cutting laser-sintered material is lower than that in cutting JIS S55C. Adhesion of the work material and chipping were the main wear mechanisms of the ball end mill in cutting laser-sintered material. Cutting with the unsintered powder surrounding the tool and laser-sintered material had caused major fracture on the cutting edge.

Keywords: Laser-sintered material, tool life, wear mechanism.

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Authors: Anders Berglund, Cornel Mihai Nicolescu, Henrik Svensson

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Swedish truck industry is investigating the possibility for implementing the use of Compacted Graphite Iron (CGI) in their heavy duty diesel engines. Compared to the alloyed gray iron used today, CGI has superior mechanical properties but not as good machinability. Another issue that needs to be addressed when implementing CGI is the inhomogeneous microstructure when the cast component has different section thicknesses, as in cylinder blocks. Thinner sections results in finer pearlite, in the material, with higher strength. Therefore an investigation on its influence on machinability was needed. This paper focuses on the effect that interlamellar distance in pearlite has on CGI machinability and material physical properties. The effect of pearlite content and nodularity is also examined. The results showed that interlamellar distance in pearlite did not have as large effect on the material physical properties or machinability as pearlite content. The paper also shows the difficulties of obtaining a homogeneous microstructure in inhomogeneous workpieces.

Keywords: Compacted graphite iron (CGI), machinability, microstructure, milling, interlamellar distance in pearlite.

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Authors: M.C.S. Ribeiro, J.P. Meixedo, A. Fiúza, M.L. Dinis, Ana C. Meira Castro, F.J.G. Silva, C. Costa, F. Ferreira, M.R. Alvim

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In this study the effect of incorporation of recycled glass-fibre reinforced polymer (GFRP) waste materials, obtained by means of milling processes, on mechanical behaviour of polyester polymer mortars was assessed. For this purpose, different contents of recycled GFRP waste powder and fibres, with distinct size gradings, were incorporated into polyester based mortars as sand aggregates and filler replacements. Flexural and compressive loading capacities were evaluated and found better than unmodified polymer mortars. GFRP modified polyester based mortars also show a less brittle behaviour, with retention of some loading capacity after peak load. Obtained results highlight the high potential of recycled GFRP waste materials as efficient and sustainable reinforcement and admixture for polymer concrete and mortars composites, constituting an emergent waste management solution.

Keywords: GFRP waste, Mechanical behaviour, Polymer mortars, Recyclability.

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Authors: Mónika Bartalné-Berceli, Eszter Izsó, Szilveszter Gergely, András Salgó

Abstract:

Presently a significant portion of the Earth's population does not have access to healthy food. Either because they cannot afford it or because they do not know which one are they. The aim of the VII th Framework Chance project (Nr. 266331) supported by the European Union has been to develop relatively cheap food with favourable nutritional value and it should have acceptable quality for consumers. As one task of the project we manufactured bread products as a basic food. We examined the enrichment of bread products with four kinds of bran, with a special milling product of grain industry (aleurone-rich flour) and with a soy-based sprouted additive. The applied concentration of the six mentioned additives has been optimized and the physical properties of the bread products were monitored. The weight/density of the enriched breads increased a bit, however the volume and height decreased slightly compared to the corresponding data of the control bread. The optimized composition of the final product is favourably affected by these additives having highly preferred composition from nutritional point of view.

Keywords: Aleurone-rich flour, Brans, Bread products, Sprouted soybean, YASO.

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Authors: Afzeri, R. Muhida, Darmawan, A. N. Berahim

Abstract:

Sharing the manufacturing facility through remote operation and monitoring of a machining process is challenge for effective use the production facility. Several automation tools in term of hardware and software are necessary for successfully remote operation of a machine. This paper presents a prototype of workpiece holding attachment for remote operation of milling process by self configuration the workpiece setup. The prototype is designed with mechanism to reorient the work surface into machining spindle direction with high positioning accuracy. Variety of parts geometry is hold by attachment to perform single setup machining. Pin type with array pattern additionally clamps the workpiece surface from two opposite directions for increasing the machining rigidity. Optimum pins configuration for conforming the workpiece geometry with minimum deformation is determined through hybrid algorithms, Genetic Algorithms (GA) and Particle Swarm Optimization (PSO). Prototype with intelligent optimization technique enables to hold several variety of workpiece geometry which is suitable for machining low of repetitive production in remote operation.

Keywords: Optimization, Remote machining, GeneticAlgorithms, Machining Fixture.

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Authors: Rajashekar Patil, S. Mohan Kumar, Shreya Ajmera

Abstract:

To understand complex living system an effort has made by mechanical engineers and dentists to deliver prompt products and services to patients concerned about their aesthetic look. Since two decades various bracket systems have designed involving techniques like milling, injection molding which are technically not flexible for the customized dental product development. The aim of this paper to design, develop a customized system which is economical and mainly emphasizes the expertise design and integration of engineering and dental fields. A custom made selfadjustable lingual bracket and customized implants are designed and developed using computer aided design (CAD) and rapid prototyping technology (RPT) to improve the smiles and to overcome the difficulties associated with conventional ones. Lengthy orthodontic treatment usually not accepted by the patients because the patient compliance is lost. Patient-s compliance can be improved by facilitating faster tooth movements by designing a localized dental vibrator using advanced engineering principles.

Keywords: Orthodontics, Prosthodontics, Lingual bracket, Implants, Dental vibrator, Computer aided design, Rapid prototyping technology.

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Authors: Robert Cep, Lenka Ocenasova, Jana Novakova, Karel Kouril, Jan Valicek, Branimir Barisic

Abstract:

This paper deals with the problem of thermal and mechanical shocks, which rising during operation, mostly at interrupted cut. Here will be solved their impact on the cutting edge tool life, the impact of coating technology on resistance to shocks and experimental determination of tool life in heating flame. Resistance of removable cutting edges against thermal and mechanical shock is an important indicator of quality as well as its abrasion resistance. Breach of the edge or its crumble may occur due to cyclic loading. We can observe it not only during the interrupted cutting (milling, turning areas abandoned hole or slot), but also in continuous cutting. This is due to the volatility of cutting force on cutting. Frequency of the volatility in this case depends on the type of rising chips (chip size element). For difficult-to-machine materials such as austenitic steel particularly happened at higher cutting speeds for the localization of plastic deformation in the shear plane and for the inception of separate elements substantially continuous chips. This leads to variations of cutting forces substantially greater than for other types of steel.

Keywords: Cutting Tool Life, Heating, Mechanical Shocks, Thermal Shocks

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