Search results for: Cutting conditions

Authors: A. P. Kulkarni, P. Randive, A. R. Mache

Abstract:

In today-s era of plasma and laser cutting, machines using oxy-acetylene flame are also meritorious due to their simplicity and cost effectiveness. The objective to devise a Computer controlled Oxy-Fuel profile cutting machine arose from the increasing demand for metal cutting with respect to edge quality, circularity and lesser formation of redeposit material. The System has an 8 bit micro controller based embedded system, which assures stipulated time response. A new window based Application software was devised which takes a standard CAD file .DXF as input and converts it into numerical data required for the controller. It uses VB6 as a front end whereas MS-ACCESS and AutoCAD as back end. The system is designed around AT89C51RD2, powerful 8 bit, ISP micro controller from Atmel and is optimized to achieve cost effectiveness and also maintains the required accuracy and reliability for complex shapes. The backbone of the system is a cleverly designed mechanical assembly along with the embedded system resulting in an accuracy of about 10 microns while maintaining perfect linearity in the cut. This results in substantial increase in productivity. The observed results also indicate reduced inter laminar spacing of pearlite with an increase in the hardness of the edge region.

Keywords: Computer-Control, Profile, Oxy-Fuel.

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Authors: T. Inada, M. Kanzaki, W. Ano, S. Hardiwinoto, R. Sadono

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In a lowland dipterocarp forest, we assessed the impact of canopy openness (CO) and the resultant changes under different logging systems using hemispherical photography. CO was assessed in a primary forest and two forests logged selectively  using reduced impact logging. At one site, 3-m-wide strip cutting was conducted for line planting. From the comparison of CO among the three sites, we found significant changes caused by logging. However, no significant difference was observed between the two logged sites. Strip cutting treatment did not affect CO. One year after, significant canopy closure occurred in both of the logged sites. Canopy closure was significant regardless of the disturbance element, logging gap, skid trail, or strip cutting line. Significant establishment of seedlings within a year was observed in the strip cutting line. Seedling establishment seemed to contribute to rapid canopy closure and prospected to affect to the survival and growth of planted trees.

Keywords: Hemispherical photography, light condition, lowland dipterocarp forest, selective logging.

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Authors: Zone-Ching Lin, Meng-Hua Lin, Ying-Chih Hsu

Abstract:

This paper uses quasi-steady molecular statics model and diamond tool to carry out simulation temperature rise of nanoscale orthogonal cutting single-crystal silicon. It further qualitatively analyzes temperature field of silicon workpiece without considering heat transfer and considering heat transfer. This paper supposes that the temperature rise of workpiece is mainly caused by two heat sources: plastic deformation heat and friction heat. Then, this paper develops a theoretical model about production of the plastic deformation heat and friction heat during nanoscale orthogonal cutting. After the increased temperature produced by these two heat sources are added up, the acquired total temperature rise at each atom of the workpiece is substituted in heat transfer finite difference equation to carry out heat transfer and calculates the temperature field in each step and makes related analysis.

Keywords: Quasi-steady molecular statics, Nanoscale orthogonal cutting, Finite difference, Temperature.

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Authors: Nilrudra Mandal, B Doloi, B Mondal

Abstract:

An attempt has been made to investigate the machinability of zirconia toughened alumina (ZTA) inserts while turning AISI 4340 steel. The insert was prepared by powder metallurgy process route and the machining experiments were performed based on Response Surface Methodology (RSM) design called Central Composite Design (CCD). The mathematical model of flank wear, cutting force and surface roughness have been developed using second order regression analysis. The adequacy of model has been carried out based on Analysis of variance (ANOVA) techniques. It can be concluded that cutting speed and feed rate are the two most influential factor for flank wear and cutting force prediction. For surface roughness determination, the cutting speed & depth of cut both have significant contribution. Key parameters effect on each response has also been presented in graphical contours for choosing the operating parameter preciously. 83% desirability level has been achieved using this optimized condition.

Keywords: Analysis of variance (ANOVA), Central Composite Design (CCD), Response Surface Methodology (RSM), Zirconia Toughened Alumina (ZTA).

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

Abstract:

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

Keywords: Metal machining, surface roughness, fuzzy logic, process modelling.

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Authors: M.Davami, M.Zadshakoyan

Abstract:

Production of hard-to-cut materials with uncoated carbide cutting tools in turning, not only cause tool life reduction but also, impairs the product surface roughness. In this paper, influence of hot machining method were studied and presented in two cases. Case1-Workpiece surface roughness quality with constant cutting parameter and 300 ºC initial workpiece surface temperature. Case 2- Tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min). The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10(SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300 ºC, causing reduction of yield stress about 15%. Results obtained experimentally, show that the method used can considerably improved surface quality of the workpiece.

Keywords: Hard-to-cut material, Hot machining, Surfaceroughness, Tool Temperature

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Authors: P. Painmanakul, T. Chintateerachai, S. Lertlapwasin, N. Rojvilavan, T. Chalermsinsuwan, N. Chawaloesphonsiya, O. Larpparisudthi

Abstract:

Conventional coagulation, advance oxidation process (AOPs), and the combined process were evaluated and compared for its suitability to treat the stabilized cutting-oil wastewater. The 90% efficiency was obtained from the coagulation at Al₂(SO₄)₃ dosage of 150 mg/L and pH 7. On the other hands, efficiencies of AOPs for 30 minutes oxidation time were 10% for acoustic oxidation, 12% for acoustic oxidation with hydrogen peroxide, 76% for Fenton, and 92% sono-Fenton processes. The highest efficiency for effective oil removal of AOPs required large amount of chemical. Therefore, AOPs were studied as a post-treatment after conventional separation process. The efficiency was considerable as the effluent COD can pass the standard required for industrial wastewater discharge with less chemical and energy consumption.

 

Keywords: Cutting oily-wastewater, Advance oxidation process, Sono-Fenton, Combined process.

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Authors: David Downey

Abstract:

With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical, aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: Additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear.

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Authors: Murat Sarıkaya, Abdulkadir Güllü

Abstract:

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

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

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Authors: M. Sadilek, L. Petrkovska, J. Kratochvil

Abstract:

The article deals with the possibilities of increasing the efficiency of turning thin-walled workpieces. It proposes a new strategy for turning and it proposes new implementation of roughing cycles where a variable depth of cut is applied. Proposed roughing cycles are created in the CAD/CAM system. These roughing cycles are described in relation to their further use in practice.

The experimental research has focused on monitoring the durability of cutting tool and increases its tool life. It compares the turning where the standard roughing cycle is used and the turning where the proposed roughing cycle with variable depth of cut is applied. In article are monitored tool wear during cutting with the sintered carbide cutting edge. The result verifies theoretical prerequisites of tool wear.

Keywords: Variable depth of cut, CAD-CAM system, turning, durability.

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Authors: Chana Raksiri, Pornchai Chatchaikulsiri

Abstract:

The objective of this research is parameters optimized of the stair shape workpiece which is cut by CNC Wire-Cut EDM (WEDW). The experiment material is SKD-11 steel of stair-shaped with variable height workpiece 10, 20, 30 and 40 mm. with the same 10 mm. thickness are cut by Sodick's CNC Wire-Cut EDM model AD325L. The experiments are designed by 3k full factorial experimental design at 3 level 2 factors and 9 experiments with 2 replicate. The selected two factor are servo voltage (SV) and servo feed rate (SF) and the response is cutting thickness error. The experiment is divided in two experiments. The first experiment determines the significant effective factor at confidential interval 95%. The SV factor is the significant effective factor from first result. In order to result smallest cutting thickness error of workpieces is 17 micron with the SV value is 46 volt. Also show that the lower SV value, the smaller different thickness error of workpiece. Then the second experiment is done to reduce different cutting thickness error of workpiece as small as possible by lower SV. The second experiment result show the significant effective factor at confidential interval 95% is the SV factor and the smallest cutting thickness error of workpieces reduce to 11 micron with the experiment SV value is 36 volt.

Keywords: CNC Wire-Cut, Variable Thickness Workpiece, Design of Experiments, Full Factorial Design

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Authors: Joseph C. Chen, Venkata Mohan Kudapa

Abstract:

Development of two real-time surface roughness (Ra) prediction systems for milling operations was attempted. The systems used not only cutting parameters, such as feed rate and spindle speed, but also the cutting current generated and corrected by a clamp type energy sensor. Two different approaches were developed. First, a fuzzy inference system (FIS), in which the fuzzy logic rules are generated by experts in the milling processes, was used to conduct prediction modeling using current cutting data. Second, a neuro-fuzzy system (ANFIS) was explored. Neuro-fuzzy systems are adaptive techniques in which data are collected on the network, processed, and rules are generated by the system. The inference system then uses these rules to predict Ra as the output. Experimental results showed that the parameters of spindle speed, feed rate, depth of cut, and input current variation could predict Ra. These two systems enable the prediction of Ra during the milling operation with an average of 91.83% and 94.48% accuracy by FIS and ANFIS systems, respectively. Statistically, the ANFIS system provided better prediction accuracy than that of the FIS system.

Keywords: Surface roughness, input current, fuzzy logic, neuro-fuzzy, milling operations.

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Authors: Tadahiro Wada, Shinichi Enoki, Hiroyuki Hanyu

Abstract:

In this study, WC-Ni-based cemented carbides having different nickel contents were used as the substrate for cutting tool materials. Hardened steel was turned by a (Ti,W,Si)N-coated WC-Ni-based cemented carbide tool, and the tool wear was experimentally investigated. The following results were obtained: (1) In the (Ti,W,Si)N-coated WC-Ni-based cemented carbide, the hardness of the coating film was not much different from the content of the binding material, Ni, and the adhesion strength increased with a decrease in Ni content. (2) There is little difference between the wear progress of the (Ti,W,Si)N-coated WC-7%Ni-based cemented carbide tool and that of the (Ti,W,Si)N-coated WC-6%Co-based cemented carbide tool. (3) The wear progress of the (Ti,W,Si)N-coated WC-Ni-based cemented carbide became slower with a decrease in Ni content.

From the above, it is has become clear that WC-Ni-based cemented carbide can be used as a substrate for cutting tool materials.

Keywords: Rare metals, turning, WC-Ni-based cemented carbide, (Ti, W, Si)N coating film, hardened steel.

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Authors: V.Sivaraman, S. Sankaran, L. Vijayaraghavan

Abstract:

Machining through turning was carried out in a lathe to study the chip formation of Multiphase Ferrite (F-B-M) microalloyed steel. Taguchi orthogonal array was employed to perform the machining. Continuous and discontinuous chips were formed for different cutting parameters like speed, feed and depth of cut. Optical and scanning electron microscope was employed to identify the chip morphology.

Keywords: Multiphase microalloyed steel, chip formation, Taguchi technique, turning, cutting parameters

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Authors: J. Chatthong, W. Boonchouytan, R. Burapa

Abstract:

The purpose of study was to design and construction the semi-automatic sliced ginger machine for reduce production times in sheet and slice ginger procedure furthermore, reduced amount of labor of slides and cutting method. Take consider into clean and safety of workers and consumers. The principle of machines, used 1 horsepower motor, rotation speed of sliced blade 967 rpm, the diameter of sliced dish 310 mm, consists of 2 blades for sheet cutting ginger and the power from motor which transfer to rotate the sliced blade roller, rotation speed 440 rpm. The slice cutter roller was sliced ginger from sheet ginger to line ginger. The conveyer could adjustment level of motors, used to the beginning area that sheet ginger was transference to the roller for sheet and sliced cutting in next process. The cover of sliced cutting had channel for 1 tuber of ginger. The semi-automatic sliced ginger machine could produced sheet ginger 81.8 kg/h (6.2 times of labor) and line ginger 17.9 kg/h (2.5 times of labor) compare with, labor work could produced sheet ginger 13.2 kg/h and line ginger 7.1 kg/h, and when timekeeper, the total times of semi auto machine 30.86 kg/h and labor 4.6 kg/h, there for the semi auto machine was 6.7 times of labor. The semiautomatic sliced ginger machine convenient, easy for use and maintain, in addition to reduce fatigue of body and seriousness from works; must be used high skill, and protection accident in slicing procedure. Beside, machine could used with other vegetables for example potato, carrot .etc

Keywords: Sliced Machine, Sliced Ginger, Line Ginger

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Authors: S. Srinivas, N. Ramesh Babu

Abstract:

This paper presents a model to predict the depth of penetration in polycrystalline ceramic material cut by abrasive waterjet. The proposed model considered the interaction of cylindrical jet with target material in upper region and neglected the role of threshold velocity in lower region. The results predicted with the proposed model are validated with the experimental results obtained with Silicon Carbide (SiC) blocks.

Keywords: Abrasive waterjet cutting, analytical modeling, ceramics, microcutting and intergranular cracking.

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Authors: Tadahiro Wada, Hiroyuki Hanyu

Abstract:

In this study, to clarify the effectiveness of an aluminum/chromium/tungsten-based-coated tool for cutting sintered steel, tool wear was experimentally investigated. The sintered steel was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and (Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the physical vapor deposition (PVD) method. Moreover, the tool wear of the aluminum/chromium/tungsten-based-coated item was compared with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool wear mechanism of the aluminum/chromium/tungsten-coating film for cutting sintered steel, Scanning Electron Microscope observation and Energy Dispersive x-ray Spectroscopy mapping analysis were conducted on the abraded surface. The following results were obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated tool was the slowest among that of the five coated tools. (2) Adding carbon (C) to the aluminum/chromium/tungsten-based-coating film was effective for improving the wear-resistance. (3) The main wear mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)- and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.

Keywords: Cutting, physical vapor deposition coating method, tool wear, tool wear mechanism, sintered steel.

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Authors: Samy E. Oraby, Ayman M. Alaskari

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The importance of machining process in today-s industry requires the establishment of more practical approaches to clearly represent the intimate and severe contact on the tool-chipworkpiece interfaces. Mathematical models are developed using the measured force signals to relate each of the tool-chip friction components on the rake face to the operating cutting parameters in rough turning operation using multilayers coated carbide inserts. Nonlinear modeling proved to have high capability to detect the nonlinear functional variability embedded in the experimental data. While feedrate is found to be the most influential parameter on the friction coefficient and its related force components, both cutting speed and depth of cut are found to have slight influence. Greater deformed chip thickness is found to lower the value of friction coefficient as the sliding length on the tool-chip interface is reduced.

Keywords: Mathematical modeling, Cutting forces, Frictionforces, Friction coefficient and Chip ratio.

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Authors: A. M. Alaskari, S. E. Oraby

Abstract:

The quality of a machined surface is becoming more and more important to justify the increasing demands of sophisticated component performance, longevity, and reliability. Usually, any machining operation leaves its own characteristic evidence on the machined surface in the form of finely spaced micro irregularities (surface roughness) left by the associated indeterministic characteristics of the different elements of the system: tool-machineworkpart- cutting parameters. However, one of the most influential sources in machining affecting surface roughness is the instantaneous state of tool edge. The main objective of the current work is to relate the in-process immeasurable cutting edge deformation and surface roughness to a more reliable easy-to-measure force signals using a robust non-linear time-dependent modeling regression techniques. Time-dependent modeling is beneficial when modern machining systems, such as adaptive control techniques are considered, where the state of the machined surface and the health of the cutting edge are monitored, assessed and controlled online using realtime information provided by the variability encountered in the measured force signals. Correlation between wear propagation and roughness variation is developed throughout the different edge lifetimes. The surface roughness is further evaluated in the light of the variation in both the static and the dynamic force signals. Consistent correlation is found between surface roughness variation and tool wear progress within its initial and constant regions. At the first few seconds of cutting, expected and well known trend of the effect of the cutting parameters is observed. Surface roughness is positively influenced by the level of the feed rate and negatively by the cutting speed. As cutting continues, roughness is affected, to different extents, by the rather localized wear modes either on the tool nose or on its flank areas. Moreover, it seems that roughness varies as wear attitude transfers from one mode to another and, in general, it is shown that it is improved as wear increases but with possible corresponding workpart dimensional inaccuracy. The dynamic force signals are found reasonably sensitive to simulate either the progressive or the random modes of tool edge deformation. While the frictional force components, feeding and radial, are found informative regarding progressive wear modes, the vertical (power) components is found more representative carrier to system instability resulting from the edge-s random deformation.

Keywords: Dynamic force signals, surface roughness (finish), tool wear and deformation, tool wear modes (nose, flank)

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Authors: Rajaram Kr. Gupta, Bhupendra Kumar, T. V. K. Gupta, D. S. Ramteke

Abstract:

Machining of hard materials is a recent technology for direct production of work-pieces. The primary challenge in machining these materials is selection of cutting tool inserts which facilitates an extended tool life and high-precision machining of the component. These materials are widely for making precision parts for the aerospace industry. Nickel-based alloys are typically used in extreme environment applications where a combination of strength, corrosion resistance and oxidation resistance material characteristics are required. The present paper reports the theoretical and experimental investigations carried out to understand the influence of machining parameters on the response parameters. Considering the basic machining parameters (speed, feed and depth of cut) a study has been conducted to observe their influence on material removal rate, surface roughness, cutting forces and corresponding tool wear. Experiments are designed and conducted with the help of Central Composite Rotatable Design technique. The results reveals that for a given range of process parameters, material removal rate is favorable for higher depths of cut and low feed rate for cutting forces. Low feed rates and high values of rotational speeds are suitable for better finish and higher tool life.

Keywords: Speed, feed, depth of cut, roughness, cutting force, flank wear.

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Authors: M. Aruna, V. Dhanalaksmi

Abstract:

Inconel 718, a nickel based super-alloy is an extensively used alloy, accounting for about 50% by weight of materials used in an aerospace engine, mainly in the gas turbine compartment. This is owing to their outstanding strength and oxidation resistance at elevated temperatures in excess of 5500 C. Machining is a requisite operation in the aircraft industries for the manufacture of the components especially for gas turbines. This paper is concerned with optimization of the surface roughness when turning Inconel 718 with cermet inserts. Optimization of turning operation is very useful to reduce cost and time for machining. The approach is based on Response Surface Method (RSM). In this work, second-order quadratic models are developed for surface roughness, considering the cutting speed, feed rate and depth of cut as the cutting parameters, using central composite design. The developed models are used to determine the optimum machining parameters. These optimized machining parameters are validated experimentally, and it is observed that the response values are in reasonable agreement with the predicted values.

Keywords: Inconel 718, Optimization, Response Surface Methodology (RSM), Surface roughness

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Authors: Jehnming Lin

Abstract:

The effects of the contact ball-lens on the soda lime glass in laser thermal cleavage with a cw Nd-YAG laser were investigated in this study. A contact ball-lens was adopted to generate a bending force on the crack formation of the soda-lime glass in the laser cutting process. The Nd-YAG laser beam (wavelength of 1064 nm) was focused through the ball-lens and transmitted to the soda-lime glass, which was coated with a carbon film on the surface with a bending force from a ball-lens to generate a tensile stress state on the surface cracking. The fracture was controlled by the contact ball-lens and a straight cutting was tested to demonstrate the feasibility. Experimental observations on the crack propagation from the leading edge, main section and trailing edge of the glass sheet were compared with various mechanical and thermal loadings. Further analyses on the stress under various laser powers and contact ball loadings were made to characterize the innovative technology. The results show that the distributions of the side crack at the leading and trailing edges are mainly dependent on the boundary condition, contact force, cutting speed and laser power. With the increase of the mechanical and thermal loadings, the region of the side cracks might be dramatically reduced with proper selection of the geometrical constrains. Therefore the application of the contact ball-lens is a possible way to control the fracture in laser cleavage with improved cutting qualities.

Keywords: Laser cleavage, controlled fracture, contact ball lens.

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

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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: 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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Authors: Swapnil Rajan Jadhav, Ajay Vasantrao Kashikar

Abstract:

Lubrication, cooling and chip removal are the desired functions of any cutting fluid. Conventional or flood lubrication requires high volume flow rate and cost associated with this is higher. In addition, flood lubrication possesses health risks to machine operator. To avoid these consequences, dry machining and minimum quantity are two alternatives. Dry machining cannot be a suited alternative as it can generate greater heat and poor surface finish. Here, turning work is carried out on a Lathe machine using EN3 Mild steel. Variable cutting speeds and depth of cuts are provided and corresponding temperatures and surface roughness values were recorded. Experimental results are analyzed by Minitab software. Regression analysis, main effect plot, and interaction plot conclusion are drawn by using ANOVA. There is a 95.83% reduction in the use of cutting fluid. MQL gives a 9.88% reduction in tool temperature, this will improve tool life. MQL produced a 17.64% improved surface finish. MQL appears to be an economical and environmentally compatible lubrication technique for sustainable manufacturing.

Keywords: ANOVA, MQL, regression analysis, surface roughness

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Authors: Swapnil Rajan Jadhav, Ajay Vasantrao Kashikar

Abstract:

Lubrication, cooling and chip removal are the desired functions of any cutting fluid. Conventional or flood lubrication requires high volume flow rate and cost associated with this is higher. In addition, flood lubrication possesses health risks to machine operator. To avoid these consequences, dry machining and minimum quantity are two alternatives. Dry machining cannot be a suited alternative as it can generate greater heat and poor surface finish. Here, turning work is carried out on a Lathe machine using EN3 Mild steel. Variable cutting speeds and depth of cuts are provided and corresponding temperatures and surface roughness values were recorded. Experimental results are analyzed by Minitab software. Regression analysis, main effect plot, and interaction plot conclusion are drawn by using ANOVA. There is a 95.83% reduction in the use of cutting fluid. MQL gives a 9.88% reduction in tool temperature, this will improve tool life. MQL produced a 17.64% improved surface finish. MQL appears to be an economical and environmentally compatible lubrication technique for sustainable manufacturing.

Keywords: ANOVA, MQL, regression analysis, surface roughness

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Authors: Jui P. Hung, Yuan L. Lai, Hui T. You

Abstract:

Chatter vibration has been a troublesome problem for a machine tool toward the high precision and high speed machining. Essentially, the machining performance is determined by the dynamic characteristics of the machine tool structure and dynamics of cutting process, which can further be identified in terms of the stability lobe diagram. Therefore, realization on the machine tool dynamic behavior can help to enhance the cutting stability. To assess the dynamic characteristics and machining stability of a vertical milling system under the influence of a linear guide, this study developed a finite element model integrated the modeling of linear components with the implementation of contact stiffness at the rolling interface. Both the finite element simulations and experimental measurements reveal that the linear guide with different preload greatly affects the vibration behavior and milling stability of the vertical column spindle head system, which also clearly indicate that the predictions of the machining stability agree well with the cutting tests. It is believed that the proposed model can be successfully applied to evaluate the dynamics performance of machine tool systems of various configurations.

Keywords: Machining stability, Vertical milling machine, Linearguide, Contact stiffness.

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

Abstract:

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

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

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Authors: Majid Tolouei-Rad

Abstract:

This paper describes a combined mathematicalgraphical approach for optimum tool path planning in order to improve machining efficiency. A methodology has been used that stabilizes machining operations by adjusting material removal rate in pocket milling operations while keeping cutting forces within limits. This increases the life of cutting tool and reduces the risk of tool breakage, machining vibration, and chatter. Case studies reveal the fact that application of this approach could result in a slight increase of machining time, however, a considerable reduction of tooling cost, machining vibration, noise and chatter can be achieved in addition to producing a better surface finish.

Keywords: CNC machines, milling, optimization, removal rate.

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Authors: E. Šarauskis, L. Masilionytė, K. Romaneckas, Z. Kriaučiūnienė, A. Jasinskas

Abstract:

The introduction of sowing technologies into minimum- or no-tillage soil has a number of economical and environmental virtues, such as improving soil properties, decreasing soil erosion and degradation, and saving working time and fuel. However, the main disadvantage of these technologies is that plant residues on the soil surface reduce the quality of the planted crop seeds, thus requiring plant residues to be removed or cut. This paper presents a analysis of disc coulter parameters and an experimental investigation of cutting spring barley straw containing various amounts of moisture with different disc coulters (smooth and notched).

Keywords: Disc coulter, Spring barley residue, No-till, Straw moisture

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