Search results for: Dimensional accuracy-PMMA-CNTs-laser cutting.

Authors: Vasanta Duggirala, Y. Viswanatha Naidu

Abstract:

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: Abdulhamit Donder, Erhan Ilhan Konukseven

Abstract:

Grinding operation is performed in order to obtain desired surfaces precisely in machining process. The needed relative motion between the cutting tool and the workpiece is generally created either by the movement of the cutting tool or by the movement of the workpiece or by the movement of both of them as in our case. For all these cases, the coherence level between the movements and the interaction forces is a key influential parameter for efficient grinding. Therefore, in this work, spectral coherence analysis has been performed to investigate the coherence level between grinding interaction forces and the movement of the workpiece on our robotic-grinding experimental setup in METU Mechatronics Laboratory.

Keywords: Coherence analysis, correlation, FFT, grinding, Hanning window, machining, Piezo actuator, reverse arrangements test, spectral analysis.

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

Abstract:

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: M. Rahou, F. Sebaa, A. Cheikh

Abstract:

Manufacturing tolerancing is intended to determine the intermediate geometrical and dimensional states of the part during its manufacturing process. These manufacturing dimensions also serve to satisfy not only the functional requirements given in the definition drawing, but also the manufacturing constraints, for example geometrical defects of the machine, vibration and the wear of the cutting tool. The choice of positioning has an important influence on the cost and quality of manufacture. To avoid this problem, a two-step approach has been developed. The first step is dedicated to the determination of the optimum position. As for the second step, a study was carried out for the tightening effect on the tolerance interval.

Keywords: Dispersion, tolerance, manufacturing, position.

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

Abstract:

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: 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: Mohammad Taghi Darvishi, Maliheh Najafi, Mohammad Najafi

Abstract:

In this work, we obtain some analytic solutions for the (3+1)-dimensional breaking soliton after obtaining its Hirota-s bilinear form. Our calculations show that, three-wave method is very easy and straightforward to solve nonlinear partial differential equations.

Keywords: (3+1)-dimensional breaking soliton equation, Hirota'sbilinear form.

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Authors: Dharmveer Singh Rajput , P. K. Singh, Mahua Bhattacharya

Abstract:

Clustering in high dimensional space is a difficult problem which is recurrent in many fields of science and engineering, e.g., bioinformatics, image processing, pattern reorganization and data mining. In high dimensional space some of the dimensions are likely to be irrelevant, thus hiding the possible clustering. In very high dimensions it is common for all the objects in a dataset to be nearly equidistant from each other, completely masking the clusters. Hence, performance of the clustering algorithm decreases. In this paper, we propose an algorithmic framework which combines the (reduct) concept of rough set theory with the k-means algorithm to remove the irrelevant dimensions in a high dimensional space and obtain appropriate clusters. Our experiment on test data shows that this framework increases efficiency of the clustering process and accuracy of the results.

Keywords: High dimensional clustering, sub-space, k-means, rough set, discernibility matrix.

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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: 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: Dalvir Singh, Somnath Chattopadhyaya

Abstract:

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: Charles D. Otine, Samuel B. Kucel, Lena Trojer

Abstract:

Selecting the data modeling technique for an information system is determined by the objective of the resultant data model. Dimensional modeling is the preferred modeling technique for data destined for data warehouses and data mining, presenting data models that ease analysis and queries which are in contrast with entity relationship modeling. The establishment of data warehouses as components of information system landscapes in many organizations has subsequently led to the development of dimensional modeling. This has been significantly more developed and reported for the commercial database management systems as compared to the open sources thereby making it less affordable for those in resource constrained settings. This paper presents dimensional modeling of HIV patient information using open source modeling tools. It aims to take advantage of the fact that the most affected regions by the HIV virus are also heavily resource constrained (sub-Saharan Africa) whereas having large quantities of HIV data. Two HIV data source systems were studied to identify appropriate dimensions and facts these were then modeled using two open source dimensional modeling tools. Use of open source would reduce the software costs for dimensional modeling and in turn make data warehousing and data mining more feasible even for those in resource constrained settings but with data available.

Keywords: About Database, Data Mining, Data warehouse, Dimensional Modeling, Open Source.

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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: Tao Nie, Weiqiang Liu

Abstract:

In order to obtain an accurate result of the heat transfer of the rib in the internal cooling Rectangular channel, using separation of variables, analytical solutions of three dimensional steady-state heat conduction in rectangular ribs are given by solving three dimensional steady-state function of the rectangular ribs. Therefore, we can get solution of three dimensional temperature field in the rib. Based on the solution, we can get how the Bi number affected on heat transfer. Furthermore, comparisons of the analytical and numerical results indicate agreement on temperature field in the rib.

Keywords: variable separation method, analytical solution, rib, heat transfer

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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

Abstract:

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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