Search results for: Cutting forces

Authors: Salah Gariani, Islam Shyha, Osama Elgadi, Khaled Jegandi

Abstract:

In this work, a cooling coherent round nozzle was developed and the impact of nozzle placement (i.e. nozzle angle and stand-off/impinging distance) on the machinability of Ti-6Al-4V was evaluated. Key process measures were cutting force, workpiece temperature, tool wear, burr formation and average surface roughness (Ra). Experimental results showed that nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. A stand-off distance of 55 and 75 mm is also necessary to control burr formation, workpiece temperature and Ra, but coherent nozzle orientation has no statistically significant impact on the mean values of cutting force and tool wear. It can be concluded that stand-off distance is more substantially significant than nozzle angles when step shoulder milling Ti-6Al- 4V using vegetable oil-based cutting fluid.

Keywords: Coherent round nozzle, step shoulder milling, Ti-6Al-4V, vegetable oil-based cutting fluid.

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Authors: Weifeng Wang, Hengbin Zheng, Xianwei Zeng

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The launching nose plays an important role in the incremental launching construction. The parameters of the launching nose essentially affect the internal forces of the girder during the construction. The appropriate parameters can decrease the internal forces in the girder and save the material and reduce the cost. The simplified structural model, which is made with displacement method according to the characteristic of incremental launching construction and the variation rule of the internal forces, calculates and analyzes the effect of the length, the rigidity and weight of launch nose on the internal forces of girder during the incremental launching construction. The method, which can calculate the launching nose parameters for the optimum incremental launching construction, is achieved. This method is simple, reliable and easy for practical use.

Keywords: incremental launching, launching nose, optimumanalysis, displacement method

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Authors: Cem Karacal, Sohyung Cho, William Yu

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In metal cutting industries, mathematical/statistical models are typically used to predict tool replacement time. These off-line methods usually result in less than optimum replacement time thereby either wasting resources or causing quality problems. The few online real-time methods proposed use indirect measurement techniques and are prone to similar errors. Our idea is based on identifying the optimal replacement time using an electronic nose to detect the airborne compounds released when the tool wear reaches to a chemical substrate doped into tool material during the fabrication. The study investigates the feasibility of the idea, possible doping materials and methods along with data stream mining techniques for detection and monitoring different phases of tool wear.

Keywords: Tool condition monitoring, cutting tool replacement, data stream mining, e-Nose.

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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: Vasanta Duggirala, Y. Viswanatha Naidu

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This paper makes a contribution to the on-going debate on conceptualization and lexicalization of cutting and breaking (C&B) verbs by discussing data from Telugu, a language of India belonging to the Dravidian family. Five Telugu native speakers- verbalizations of agentive actions depicted in 43 short video-clips were analyzed. It was noted that verbalization of C&B events in Telugu requires formal units such as simple lexical verbs, explicator compound verbs, and other complex verb forms. The properties of the objects involved, the kind of instruments used, and the manner of action had differential influence on the lexicalization patterns. Further, it was noted that all the complex verb forms encode 'result' and 'cause' sub-events in that order. Due to the polysemy associated with some of the verb forms, our data does not support the straightforward bipartition of this semantic domain.

Keywords: Cluster analysis, Cutting and breaking events, Polysemy, Semantic extension, Telugu.

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Authors: Kooshyar Passbakhsh, Maryam Yazdi

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Geosynthetics have proved to be suitable for reinforced soil retaining walls. Based on the increasing uses of geosynthetic reinforced soil systems in the regions, which bear frequent earthquakes, the study of dynamic behavior of structures seems necessary. Determining the reinforcement forces is; therefore, one of the most important and main points of discussions in designing retaining walls, by which we prevent from conservative planning. Thus, this paper intended to investigate the effects of such parameters as wall height, acceleration type, vertical spacing of reinforcement, type of reinforcement and soil type on forces and deformation through numerical modeling of the geosynthetic reinforced soil retaining walls (GRSRW) under dynamic loading with finite difference method by using FLAC. The findings indicate rather positive results with each parameter.

Keywords: Geosynthetic Reinforced Soil Retaining Walls (GRSRW), dynamic analysis, Geosynthetic forces, Flac

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Authors: I. V. Kuzminov

Abstract:

The alternative hypothesis of the physics of gravitation is put forward in this paper. The hypothesis is constructed on the laws of classical physics. The process of expansion of the Universe explains the physics of gravity. The expansion of the Universe induces the resistance of gyroscopic forces of electron’s rotation. The second component of gravity forces is the resistance arising from the second derivative of linear expansion. This hypothesis does not reject the existing foundation of settlement, particularly as it is empirically constructed. The forces of gravitation and inertia share a common nature, which has been recognized before. The presented hypothesis does not criticize existing theories of gravitation; rather, it explores a separate theme. It is important to acknowledge that the expansion of the Universe exhibits isotropic characteristics. The proposed hypothesis provides a fundamental direction for further research. It is worth noting that this article does not aim to encompass all possible aspects of future investigations.

Keywords: Gyroscopic forces, the unity of the micro- and macrocosm, the expansion of the universe, the second derivative of expansion.

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Authors: S. M. Ali, N. R. Dhar

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Tool wear and surface roughness prediction plays a significant role in machining industry for proper planning and control of machining parameters and optimization of cutting conditions. This paper deals with developing an artificial neural network (ANN) model as a function of cutting parameters in turning steel under minimum quantity lubrication (MQL). A feed-forward backpropagation network with twenty five hidden neurons has been selected as the optimum network. The co-efficient of determination (R2) between model predictions and experimental values are 0.9915, 0.9906, 0.9761 and 0.9627 in terms of VB, VM, VS and Ra respectively. The results imply that the model can be used easily to forecast tool wear and surface roughness in response to cutting parameters.

Keywords: ANN, MQL, Surface Roughness, Tool Wear.

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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

Abstract:

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: H. Katkhuda

Abstract:

A time domain approach is used in this paper to identify unknown dynamic forces applied on two dimensional frames using the measured dynamic structural responses for a sub-structure in the two dimensional frame. In this paper a sub-structure finite element model with short length of measurement from only three or four accelerometers is required, and an iterative least-square algorithm is used to identify the unknown dynamic force applied on the structure. Validity of the method is demonstrated with numerical examples using noise-free and noise-contaminated structural responses. Both harmonic and impulsive forces are studied. The results show that the proposed approach can identify unknown dynamic forces within very limited iterations with high accuracy and shows its robustness even noise- polluted dynamic response measurements are utilized.

Keywords: Dynamic Force Identification, Dynamic Responses, Sub-structure and Time Domain.

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Authors: Ahmad Forouzan Tabar, Mohammad Azadi, Alireza Alesaadi

Abstract:

This paper describes a sliding mode controller for autonomous underwater vehicles (AUVs). The dynamic of AUV model is highly nonlinear because of many factors, such as hydrodynamic drag, damping, and lift forces, Coriolis and centripetal forces, gravity and buoyancy forces, as well as forces from thruster. To address these difficulties, a nonlinear sliding mode controller is designed to approximate the nonlinear dynamics of AUV and improve trajectory tracking. Moreover, the proposed controller can profoundly attenuate the effects of uncertainties and external disturbances in the closed-loop system. Using the Lyapunov theory the boundedness of AUV tracking errors and the stability of the proposed control system are also guaranteed. Numerical simulation studies of an AUV are included to illustrate the effectiveness of the presented approach.

Keywords: Lyapunov stability, autonomous underwater vehicle (AUV), sliding mode controller, electronics engineering.

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Authors: S. Hirokawa, M. Fukunaga, M. Mawatari

Abstract:

Knee joint forces are available by in vivo measurement using an instrumented knee prosthesis for small to moderate knee flexion but not for high flexion yet. We created a 2D mathematical model of the lower limb incorporating several new features such as a patello-femoral mechanism, a thigh-calf contact at high knee flexion and co-contracting muscles' force ratio, then used it to determine knee joint forces arising from high knee flexions in four kneeling conditions: rising with legs in parallel, with one foot forward, with or without arm use. With arms used, the maximum values of knee joint force decreased to about 60% of those with arms not used. When rising with one foot forward, if arms are not used, the forward leg sustains a force as large as that sustained when rising with legs parallel.

Keywords: Knee joint force, kneeling, mathematical model, biomechanics.

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Authors: S. Karabulut, A. Güllü, A. Güldas, R. Gürbüz

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This study investigates the effects of the lead angle and chip thickness variation on surface roughness during the machining of compacted graphite iron using ceramic cutting tools under dry cutting conditions. Analytical models were developed for predicting the surface roughness values of the specimens after the face milling process. Experimental data was collected and imported to the artificial neural network model. A multilayer perceptron model was used with the back propagation algorithm employing the input parameters of lead angle, cutting speed and feed rate in connection with chip thickness. Furthermore, analysis of variance was employed to determine the effects of the cutting parameters on surface roughness. Artificial neural network and regression analysis were used to predict surface roughness. The values thus predicted were compared with the collected experimental data, and the corresponding percentage error was computed. Analysis results revealed that the lead angle is the dominant factor affecting surface roughness. Experimental results indicated an improvement in the surface roughness value with decreasing lead angle value from 88° to 45°.

Keywords: CGI, milling, surface roughness, ANN, regression, modeling, analysis.

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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

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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: S. Ghorbani, N. I. Polushin

Abstract:

The machinability of workpieces (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron) in turning operation has been carried out using different types of cutting tool (conventional, cutting tool with holes in toolholder and cutting tool filled up with composite material) under dry conditions on a turning machine at different stages of spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). Experimentation was performed as per Taguchi’s orthogonal array. To evaluate the relative importance of factors affecting surface roughness the single decision tree (SDT), Decision tree forest (DTF) and Group method of data handling (GMDH) were applied.

Keywords: Decision Tree Forest, GMDH, surface roughness, taguchi method, turning process.

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Authors: Moaz H. Ali, M. N. M. Ansari, Pang Jing Shen

Abstract:

In present work, prediction the effect of nose radius, rz (mm) on the equivalent strain (PEEQ) and surface finish during the machining of titanium alloy (Ti-6Al-4V) through orthogonal cutting process. The results were performed at several of the nose radiuses, rz (mm) while the cutting speed, vc (m/min), feed rate, f (mm/tooth) and depth of cut, d (mm) were remained constant. The equivalent plastic strain (PEEQ) was estimated by using finite element modeling (FEM) and applied through ABAQUS/EXPLICIT software. The simulation results led to conclude that the equivalent plastic strain (PEEQ) was increased and surface roughness (Ra) decreased when increasing nose radius, rz (mm) during the machining of titanium alloy (Ti–6Al–4V) in dry cutting conditions.

Keywords: Finite element modeling (FEM), nose radius, plastic strain (PEEQ), titanium alloy (Ti-6Al-4V).

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Authors: I. V. Kuzminov

Abstract:

The proposed article is an analytical review of previously published articles in the series "Physics of Gravity", "The Picture of the World by Second Law of Thermodynamics" and others. The article shows the key role of the forces of gravity and the action of the second law of thermodynamics in shaping the picture of the world. In other words, the second law of thermodynamics can be called the law of matter cooling. The action in the compartment of the inverse temperature dependence of the forces of gravity and the second law of thermodynamics is carried out by the processes of separation, condensation, phase transitions, and transformation of matter. On the basis of the proposed concept, along the way, completely new versions of the development of events in the biography of the Earth are put forward. For example, new versions of the origin of planets, the origin of continents and others are being put forward. This article contains a list of articles and videos that are somehow related to the proposed topic. Articles and videos are presented in English and Russian.

Keywords: Gravity, the second law of thermodynamics, electron rotation, inverse temperature dependence, inertia forces, centrifugal forces.

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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: Iman Mazinani, Zubaidah Ismail, Ahmad Mustafa Hashim, Amirreza Saba

Abstract:

Two tragic tsunamis that devastated the west coast of Sumatra Island, Indonesia in 2004 and North East Japan in 2011 had damaged bridges to various extents. Tsunamis have resulted in the catastrophic deterioration of infrastructures i.e. coastal structures, utilities and transportation facilities. A bridge structure performs vital roles to enable people to perform activities related to their daily needs and for development. A damaged bridge needs to be repaired expeditiously. In order to understand the effects of tsunami forces on bridges, experimental tests are carried out to measure the characteristics of hydrodynamic force at various wave heights. Coastal bridge models designed at a 1:40 scale are used in a 24.0 m long hydraulic flume with a cross section of 1.5 m by 2.0 m. The horizontal forces and uplift forces in all cases show that forces increase nonlinearly with increasing wave amplitude.

Keywords: Tsunami, bridge, horizontal force, uplift force.

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

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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: Dalvir Singh, Somnath Chattopadhyaya

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During welding or flame cutting of metals, the prediction of heat affected zone (HAZ) is critical. There is need to develop a simple mathematical model to calculate the temperature variation in HAZ and derivative analysis can be used for this purpose. This study presents analytical solution for heat transfer through conduction in mild steel plate. The homogeneous and nonhomogeneous boundary conditions are single variables. The full field analytical solutions of temperature measurement, subjected to local heating source, are derived first by method of separation of variables followed with the experimental visualization using infrared imaging. Based on the present work, it is suggested that appropriate heat input characteristics controls the temperature distribution in and around HAZ.

Keywords: Conduction Heat Transfer, Heat Affected Zone (HAZ), Infra-Red Imaging, Numerical Method, Orthogonal Function, Plasma Arc Cutting, Separation of Variables, Temperature Measurement.

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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

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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

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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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