Search results for: cutting process
5469 Real Time Compensation of Machining Errors for Machine Tools NC based on Systematic Dispersion
Authors: M. Rahou, A. Cheikh, F. Sebaa
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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. In this paper, an experimental study on the influence of the wear of the cutting tool (systematic dispersions) is explored. This study was carried out on three stages .The first stage allows machining without elimination of dispersions (random, systematic) so the tolerances of manufacture according to total dispersions. In the second stage, the results of the first stage are filtered in such way to obtain the tolerances according to random dispersions. Finally, from the two previous stages, the systematic dispersions are generated. The objective of this study is to model by the least squares method the error of manufacture based on systematic dispersion. Finally, an approach of optimization of the manufacturing tolerances was developed for machining on a CNC machine toolKeywords: Dispersions, Compensation, modeling, manufacturing Tolerance, machine tool.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 23285468 Design Optimization of Cutting Parameters when Turning Inconel 718 with Cermet Inserts
Authors: M. Aruna, V. Dhanalaksmi
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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
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 28285467 Prediction of Tool and Nozzle Flow Behavior in Ultrasonic Machining Process
Authors: Vinod Kumar, Jatinder Kumar
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The use of hard and brittle material has become increasingly more extensive in recent years. Therefore processing of these materials for the parts fabrication has become a challenging problem. However, it is time-consuming to machine the hard brittle materials with the traditional metal-cutting technique that uses abrasive wheels. In addition, the tool would suffer excessive wear as well. However, if ultrasonic energy is applied to the machining process and coupled with the use of hard abrasive grits, hard and brittle materials can be effectively machined. Ultrasonic machining process is mostly used for the brittle materials. The present research work has developed models using finite element approach to predict the mechanical stresses sand strains produced in the tool during ultrasonic machining process. Also the flow behavior of abrasive slurry coming out of the nozzle has been studied for simulation using ANSYS CFX module. The different abrasives of different grit sizes have been used for the experimentation work.Keywords: Stress, MRR, Flow, Ultrasonic Machining
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 27975466 Microstructure Changes of Machined Surfaceson Austenitic 304 Stainless Steel
Authors: Lin. Yan, Wenyu. Yang, Hongping. Jin, Zhiguang Wang
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This paper presents a experiment to estimate the influences of cutting conditions in microstructure changes of machining austenitic 304 stainless steel, especially for wear insert. The wear insert were prefabricated with a width of 0.5 mm. And the forces, temperature distribution, RS, and microstructure changes were measured by force dynamometer, infrared thermal camera, X-ray diffraction, XRD, SEM, respectively. The results told that the different combinations of machining condition have a significant influence on machined surface microstructure changes. In addition to that, the ANOVA and AOMwere used to tell the different influences of cutting speed, feed rate, and wear insert.Keywords: Microstructure Changes, Wear width, Stainless steel
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 23205465 ANN Based Model Development for Material Removal Rate in Dry Turning in Indian Context
Authors: Mangesh R. Phate, V. H. Tatwawadi
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This paper is intended to develop an artificial neural network (ANN) based model of material removal rate (MRR) in the turning of ferrous and nonferrous material in a Indian small-scale industry. MRR of the formulated model was proved with the testing data and artificial neural network (ANN) model was developed for the analysis and prediction of the relationship between inputs and output parameters during the turning of ferrous and nonferrous materials. The input parameters of this model are operator, work-piece, cutting process, cutting tool, machine and the environment.
The ANN model consists of a three layered feedforward back propagation neural network. The network is trained with pairs of independent/dependent datasets generated when machining ferrous and nonferrous material. A very good performance of the neural network, in terms of contract with experimental data, was achieved. The model may be used for the testing and forecast of the complex relationship between dependent and the independent parameters in turning operations.
Keywords: Field data based model, Artificial neural network, Simulation, Convectional Turning, Material removal rate.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 19595464 Multi Response Optimization in Drilling Al6063/SiC/15% Metal Matrix Composite
Authors: Hari Singh, Abhishek Kamboj, Sudhir Kumar
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This investigation proposes a grey-based Taguchi method to solve the multi-response problems. The grey-based Taguchi method is based on the Taguchi’s design of experimental method, and adopts grey relational analysis (GRA) to transfer multi-response problems into single-response problems. In this investigation, an attempt has been made to optimize the drilling process parameters considering weighted output response characteristics using grey relational analysis. The output response characteristics considered are surface roughness, burr height and hole diameter error under the experimental conditions of cutting speed, feed rate, step angle, and cutting environment. The drilling experiments were conducted using L27 orthogonal array. A combination of orthogonal array, design of experiments and grey relational analysis was used to ascertain best possible drilling process parameters that give minimum surface roughness, burr height and hole diameter error. The results reveal that combination of Taguchi design of experiment and grey relational analysis improves surface quality of drilled hole.
Keywords: Metal matrix composite, Drilling, Optimization, step drill, Surface roughness, burr height, hole diameter error.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 32425463 Optimization of Surface Roughness in Turning Process Utilizing Live Tooling via Taguchi Methodology
Authors: Weinian Wang, Joseph C. Chen
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The objective of this research is to optimize the process of cutting cylindrical workpieces utilizing live tooling on a HAAS ST-20 lathe. Surface roughness (Ra) has been investigated as the indicator of quality characteristics for machining process. Aluminum alloy was used to conduct experiments due to its wide range usages in engineering structures and components where light weight or corrosion resistance is required. In this study, Taguchi methodology is utilized to determine the effects that each of the parameters has on surface roughness (Ra). A total of 18 experiments of each process were designed according to Taguchi’s L9 orthogonal array (OA) with four control factors at three levels of each and signal-to-noise ratios (S/N) were computed with Smaller the better equation for minimizing the system. The optimal parameters identified for the surface roughness of the turning operation utilizing live tooling were a feed rate of 3 inches/min(A3); a spindle speed of 1300 rpm(B3); a 2-flute titanium nitrite coated 3/8” endmill (C1); and a depth of cut of 0.025 inches (D2). The mean surface roughness of the confirmation runs in turning operation was 8.22 micro inches. The final results demonstrate that Taguchi methodology is a sufficient way of process improvement in turning process on surface roughness.
Keywords: Live tooling, surface roughness, Taguchi Parameter Design, CNC turning operation.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 7915462 Role of Process Parameters on Pocket Milling with Abrasive Water Jet Machining Technique
Authors: T. V. K. Gupta, J. Ramkumar, Puneet Tandon, N. S. Vyas
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Abrasive Water Jet Machining is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application, i.e., abrasive size, flow rate, standoff distance and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.
Keywords: Abrasive flow rate, surface finish, abrasive size, standoff distance, traverse speed.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 42195461 Response Surface Methodology for Optimum Hardness of TiN on Steel Substrate
Authors: R. Joseph Raviselvan, K. Ramanathan, P. Perumal, M. R. Thansekhar
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Hard coatings are widely used in cutting and forming tool industries. Titanium Nitride (TiN) possesses good hardness, strength, and corrosion resistance. The coating properties are influenced by many process parameters. The coatings were deposited on steel substrate by changing the process parameters such as substrate temperature, nitrogen flow rate and target power in a D.C planer magnetron sputtering. The structure of coatings were analysed using XRD. The hardness of coatings was found using Micro hardness tester. From the experimental data, a regression model was developed and the optimum response was determined using Response Surface Methodology (RSM).Keywords: Hardness, RSM, sputtering, TiN XRD.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 15745460 Application of Nano Cutting Fluid under Minimum Quantity Lubrication (MQL) Technique to Improve Grinding of Ti – 6Al – 4V Alloy
Authors: Dinesh Setti, Sudarasan Ghosh, P. Venkateswara Rao
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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.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 40125459 Tool Path Generation and Manufacturing Process for Blades of a Compressor Rotor
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This paper presents a complete procedure for tool path planning and blade machining in 5-axis manufacturing. The actual cutting contact and cutter locations can be determined by lead and tilt angles. The tool path generation is implemented by piecewise curved approximation and chordal deviation detection. An application about drive surface method promotes flexibility of tool control and stability of machine motion. A real manufacturing process is proposed to separate the operation into three regions with five stages and to modify the local tool orientation with an interactive algorithm.Keywords: 5-axis machining, tool orientation, lead and tilt angles, tool path generation.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 22535458 Performance Evaluation of Minimum Quantity Lubrication on EN3 Mild Steel Turning
Authors: Swapnil Rajan Jadhav, Ajay Vasantrao Kashikar
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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
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 4645457 Performance Evaluation of Minimum Quantity Lubrication on EN3 Mild Steel Turning
Authors: Swapnil Rajan Jadhav, Ajay Vasantrao Kashikar
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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
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3615456 A Framework for SQL Learning: Linking Learning Taxonomy, Cognitive Model and Cross Cutting Factors
Authors: Huda Al Shuaily, Karen Renaud
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Databases comprise the foundation of most software systems. System developers inevitably write code to query these databases. The de facto language for querying is SQL and this, consequently, is the default language taught by higher education institutions. There is evidence that learners find it hard to master SQL, harder than mastering other programming languages such as Java. Educators do not agree about explanations for this seeming anomaly. Further investigation may well reveal the reasons. In this paper, we report on our investigations into how novices learn SQL, the actual problems they experience when writing SQL, as well as the differences between expert and novice SQL query writers. We conclude by presenting a model of SQL learning that should inform the instructional material design process better to support the SQL learning process.
Keywords: Pattern, SQL, learning, model.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 13265455 CAD Based Predictive Models of the Undeformed Chip Geometry in Drilling
Authors: Panagiotis Kyratsis, Dr. Ing. Nikolaos Bilalis, Dr. Ing. Aristomenis Antoniadis
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Twist drills are geometrical complex tools and thus various researchers have adopted different mathematical and experimental approaches for their simulation. The present paper acknowledges the increasing use of modern CAD systems and using the API (Application Programming Interface) of a CAD system, drilling simulations are carried out. The developed DRILL3D software routine, creates parametrically controlled tool geometries and using different cutting conditions, achieves the generation of solid models for all the relevant data involved (drilling tool, cut workpiece, undeformed chip). The final data derived, consist a platform for further direct simulations regarding the determination of cutting forces, tool wear, drilling optimizations etc.Keywords: Drilling, CAD based simulation, 3D-modelling.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 18775454 Milling Simulations with a 3-DOF Flexible Planar Robot
Authors: Hoai Nam Huynh, Edouard Rivière-Lorphèvre, Olivier Verlinden
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Manufacturing technologies are becoming continuously more diversified over the years. The increasing use of robots for various applications such as assembling, painting, welding has also affected the field of machining. Machining robots can deal with larger workspaces than conventional machine-tools at a lower cost and thus represent a very promising alternative for machining applications. Furthermore, their inherent structure ensures them a great flexibility of motion to reach any location on the workpiece with the desired orientation. Nevertheless, machining robots suffer from a lack of stiffness at their joints restricting their use to applications involving low cutting forces especially finishing operations. Vibratory instabilities may also happen while machining and deteriorate the precision leading to scrap parts. Some researchers are therefore concerned with the identification of optimal parameters in robotic machining. This paper continues the development of a virtual robotic machining simulator in order to find optimized cutting parameters in terms of depth of cut or feed per tooth for example. The simulation environment combines an in-house milling routine (DyStaMill) achieving the computation of cutting forces and material removal with an in-house multibody library (EasyDyn) which is used to build a dynamic model of a 3-DOF planar robot with flexible links. The position of the robot end-effector submitted to milling forces is controlled through an inverse kinematics scheme while controlling the position of its joints separately. Each joint is actuated through a servomotor for which the transfer function has been computed in order to tune the corresponding controller. The output results feature the evolution of the cutting forces when the robot structure is deformable or not and the tracking errors of the end-effector. Illustrations of the resulting machined surfaces are also presented. The consideration of the links flexibility has highlighted an increase of the cutting forces magnitude. This proof of concept will aim to enrich the database of results in robotic machining for potential improvements in production.Keywords: Control, machining, multibody, robotic, simulation.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 13555453 Efficient CNC Milling by Adjusting Material Removal Rate
Authors: Majid Tolouei-Rad
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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.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 34665452 Milling Chatter Prevention by Adaptive Spindle Speed Tuning
Authors: Nan-Chyuan Tsai, Din-Chang Chen, Rong-Mao Lee, Bai-Lu Wang
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This paper presents how the real-time chatter prevention can be realized by feedback of acoustic cutting signal, and the efficacy of the proposed adaptive spindle speed tuning algorithm is verified by intensive experimental simulations. A pair of microphones, perpendicular to each other, is used to acquire the acoustic cutting signal resulting from milling chatter. A real-time feedback control loop is constructed for spindle speed compensation so that the milling process can be ensured to be within the stability zone of stability lobe diagram. Acoustic Chatter Signal Index (ACSI) and Spindle Speed Compensation Strategy (SSCS) are proposed to quantify the acoustic signal and actively tune the spindle speed respectively. By converting the acoustic feedback signal into ACSI, an appropriate Spindle Speed Compensation Rate (SSCR) can be determined by SSCS based on real-time chatter level or ACSI. Accordingly, the compensation command, referred to as Added-On Voltage (AOV), is applied to increase/decrease the spindle motor speed. By inspection on the precision and quality of the workpiece surface after milling, the efficacy of the real-time chatter prevention strategy via acoustic signal feedback is further assured.Keywords: Chatter compensation, Stability lobes, Non-invasivemeasurement.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 17025451 Improvement Plant Layout Using Systematic Layout Planning (SLP) for Increased Productivity
Authors: W. Wiyaratn, A. Watanapa
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The objective of this research is to study plant layout of iron manufacturing based on the systematic layout planning pattern theory (SLP) for increased productivity. In this case study, amount of equipments and tools in iron production are studied. The detailed study of the plant layout such as operation process chart, flow of material and activity relationship chart has been investigated. The new plant layout has been designed and compared with the present plant layout. The SLP method showed that new plant layout significantly decrease the distance of material flow from billet cutting process until keeping in ware house.Keywords: Plant layout, Systematic Layout Planning, Flowanalysis, Activity relationship chart
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 138455450 Multi-Objective Optimization of Electric Discharge Machining for Inconel 718
Authors: Pushpendra S. Bharti, S. Maheshwari
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Electric discharge machining (EDM) is one of the most widely used non-conventional manufacturing process to shape difficult-to-cut materials. The process yield, in terms of material removal rate, surface roughness and tool wear rate, of EDM may considerably be improved by selecting the optimal combination(s) of process parameters. This paper employs Multi-response signal-to-noise (MRSN) ratio technique to find the optimal combination(s) of the process parameters during EDM of Inconel 718. Three cases v.i.z. high cutting efficiency, high surface finish, and normal machining have been taken and the optimal combinations of input parameters have been obtained for each case. Analysis of variance (ANOVA) has been employed to find the dominant parameter(s) in all three cases. The experimental verification of the obtained results has also been made. MRSN ratio technique found to be a simple and effective multi-objective optimization technique.
Keywords: EDM, material removal rate, multi-response signal-to-noise ratio, optimization, surface roughness.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 11875449 The Effect of the Disc Coulters Forms on Cutting of Spring Barley Residues in No-Tillage
Authors: E. Šarauskis, L. Masilionytė, K. Romaneckas, Z. Kriaučiūnienė, A. Jasinskas
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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
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 19675448 Crafting of Paper Cutting Techniques for Embellishment of Fashion Textiles
Authors: A. Vaidya-Soocheta, K. M. Wong-Hon-Lang
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Craft and fashion have always been interlinked. The combination of both often gives stunning results. The present study introduces ‘Paper Cutting Craft Techniques’ like the Japanese –Kirigami, Mexican –PapelPicado, German –Scherenschnitte, Polish –Wycinankito in textiles to develop innovative and novel design structures as embellishments and ornamentation. The project studies various ways of using these paper cutting techniques to obtain interesting features and delicate design patterns on fabrics. While paper has its advantages and related uses, it is fragile rigid and thus not appropriate for clothing. Fabric is sturdy, flexible, dimensionally stable and washable. In the present study, the cut out techniques develop creative design motifs and patterns to give an inventive and unique appeal to the fabrics. The beauty and fascination of lace in garments have always given them a nostalgic charm. Laces with their intricate and delicate complexity in combination with other materials add a feminine touch to a garment and give it a romantic, mysterious appeal. Various textured and decorative effects through fabric manipulation are experimented along with the use of paper cutting craft skills as an innovative substitute for developing lace or “Broderie Anglaise” effects on textiles. A number of assorted fabric types with varied textures were selected for the study. Techniques to avoid fraying and unraveling of the design cut fabrics were introduced. Fabrics were further manipulated by use of interesting prints with embossed effects on cut outs. Fabric layering in combination with assorted techniques such as cutting of folded fabric, printing, appliqué, embroidery, crochet, braiding, weaving added a novel exclusivity to the fabrics. The fabrics developed by these innovative methods were then tailored into garments. The study thus tested the feasibility and practicability of using these fabrics by designing a collection of evening wear garments based on the theme ‘Nostalgia’. The prototypes developed were complemented by designing fashion accessories with the crafted fabrics. Prototypes of accessories add interesting features to the study. The adaptation and application of this novel technique of paper cutting craft on textiles can be an innovative start for a new trend in textile and fashion industry. The study anticipates that this technique will open new avenues in the world of fashion to incorporate its use commercially.Keywords: Collection, fabric cutouts, nostalgia, prototypes.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 25295447 Studies on the Characterization and Machinability of Duplex Stainless Steel 2205 during Dry Turning
Authors: Gaurav D. Sonawane, Vikas G. Sargade
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The present investigation is a study of the effect of advanced Physical Vapor Deposition (PVD) coatings on cutting temperature residual stresses and surface roughness during Duplex Stainless Steel (DSS) 2205 turning. Austenite stabilizers like nickel, manganese, and molybdenum reduced the cost of DSS. Surface Integrity (SI) plays an important role in determining corrosion resistance and fatigue life. Resistance to various types of corrosion makes DSS suitable for applications with critical environments like Heat exchangers, Desalination plants, Seawater pipes and Marine components. However, lower thermal conductivity, poor chip control and non-uniform tool wear make DSS very difficult to machine. Cemented carbide tools (M grade) were used to turn DSS in a dry environment. AlTiN and AlTiCrN coatings were deposited using advanced PVD High Pulse Impulse Magnetron Sputtering (HiPIMS) technique. Experiments were conducted with cutting speed of 100 m/min, 140 m/min and 180 m/min. A constant feed and depth of cut of 0.18 mm/rev and 0.8 mm were used, respectively. AlTiCrN coated tools followed by AlTiN coated tools outperformed uncoated tools due to properties like lower thermal conductivity, higher adhesion strength and hardness. Residual stresses were found to be compressive for all the tools used for dry turning, increasing the fatigue life of the machined component. Higher cutting temperatures were observed for coated tools due to its lower thermal conductivity, which results in very less tool wear than uncoated tools. Surface roughness with uncoated tools was found to be three times higher than coated tools due to lower coefficient of friction of coating used.Keywords: Cutting temperatures, DSS2205, dry turning, HiPIMS, surface integrity.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 8765446 Effects of Canned Cycles and Cutting Parameters on Hole Quality in Cryogenic Drilling of Aluminum 6061-6T
Authors: M. N. Islam, B. Boswell, Y. R. Ginting
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The influence of canned cycles and cutting parameters on hole quality in cryogenic drilling has been investigated experimentally and analytically. A three-level, three-parameter experiment was conducted by using the design-of-experiment methodology. The three levels of independent input parameters were the following: for canned cycles—a chip-breaking canned cycle (G73), a spot drilling canned cycle (G81), and a deep hole canned cycle (G83); for feed rates—0.2, 0.3, and 0.4 mm/rev; and for cutting speeds—60, 75, and 100 m/min. The selected work and tool materials were aluminum 6061-6T and high-speed steel (HSS), respectively. For cryogenic cooling, liquid nitrogen (LN2) was used and was applied externally. The measured output parameters were the three widely used quality characteristics of drilled holes—diameter error, circularity, and surface roughness. Pareto ANOVA was applied for analyzing the results. The findings revealed that the canned cycle has a significant effect on diameter error (contribution ratio 44.09%) and small effects on circularity and surface finish (contribution ratio 7.25% and 6.60%, respectively). The best results for the dimensional accuracy and surface roughness were achieved by G81. G73 produced the best circularity results; however, for dimensional accuracy, it was the worst level.Keywords: Circularity, diameter error, drilling canned cycle, Pareto ANOVA, surface roughness.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 11345445 Minimizing the Drilling-Induced Damage in Fiber Reinforced Polymeric Composites
Authors: S. D. El Wakil, M. Pladsen
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Fiber reinforced polymeric (FRP) composites are finding wide-spread industrial applications because of their exceptionally high specific strength and specific modulus of elasticity. Nevertheless, it is very seldom to get ready-for-use components or products made of FRP composites. Secondary processing by machining, particularly drilling, is almost always required to make holes for fastening components together to produce assemblies. That creates problems since the FRP composites are neither homogeneous nor isotropic. Some of the problems that are encountered include the subsequent damage in the region around the drilled hole and the drilling – induced delamination of the layer of ply, that occurs both at the entrance and the exit planes of the work piece. Evidently, the functionality of the work piece would be detrimentally affected. The current work was carried out with the aim of eliminating or at least minimizing the work piece damage associated with drilling of FPR composites. Each test specimen involves a woven reinforced graphite fiber/epoxy composite having a thickness of 12.5 mm (0.5 inch). A large number of test specimens were subjected to drilling operations with different combinations of feed rates and cutting speeds. The drilling induced damage was taken as the absolute value of the difference between the drilled hole diameter and the nominal one taken as a percentage of the nominal diameter. The later was determined for each combination of feed rate and cutting speed, and a matrix comprising those values was established, where the columns indicate varying feed rate while and rows indicate varying cutting speeds. Next, the analysis of variance (ANOVA) approach was employed using Minitab software, in order to obtain the combination that would improve the drilling induced damage. Experimental results show that low feed rates coupled with low cutting speeds yielded the best results.
Keywords: Drilling of Composites, dimensional accuracy of holes drilled in composites, delamination and charring, graphite-epoxy composites.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 7995444 Influence of Composition and Austempering Temperature on Machinability of Austempered Ductile Iron
Authors: Jagmohan Datt, Uma Batra
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Present investigations involve a systematic study on the machinability of austempered ductile irons (ADI) developed from four commercially viable ductile irons alloyed with different contents of 0, 0.1, 0.3 and 0.6 wt.% of Ni. The influence of Ni content, amount of retained austenite and hardness of ADI on machining behavior has been conducted systematically. Austempering heat treatment was carried out for 120 minutes at four temperatures- 270oC, 320oC, 370oC or 420oC, after austenitization at 900oC for 120 min. Milling tests were performed and machinability index, cutting forces and surface roughness measurements were used to evaluate the machinability. Higher cutting forces, lower machinability index and the poorer surface roughness of the samples austempered at lower temperatures indicated that austempering at higher temperatures resulted in better machinability. The machinability of samples austempered at 420oC, which contained higher fractions of retained austenite, was superior to that of samples austempered at lower temperatures, indicating that hardness is an important factor in assessing machinability in addition to high carbon austenite content. The ADI with 0.6% Ni, austempered at 420°C for 120 minutes, demonstrated best machinability.
Keywords: Austempering, machinability, machining index, cutting force, surface finish.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 23725443 Influence of High Speed Parameters on the Quality of Machined Surface
Authors: Jana Novakova, Lenka Petrkovska, Josef Brychta, Robert Cep, Lenka Ocenasova
Abstract:
The contribution is dealing with the influence of high speed parameters on the quality of machined surface. In general the principle of high speed cutting lies in achieving faster machine times with concurrent increase in accuracy and quality of the machined areas in largely irregular, mathematically hard to define shapes. High speed machining is a highly effective method of machining with the following goals: increasing of machining productivity, increasing of quality of the machined surface, improving of machining economy, improving of ecological aspects of machining. This article is based on an experiment performed by the Department of Machining and Assembly of the Faculty of Mechanical Engineering of VŠBTechnical University of Ostrava.
Keywords: High speed cutting, measurement, surface integrity, surface roughness, residual stress/
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 17975442 Mathematical Modeling to Predict Surface Roughness in CNC Milling
Authors: Ab. Rashid M.F.F., Gan S.Y., Muhammad N.Y.
Abstract:
Surface roughness (Ra) is one of the most important requirements in machining process. In order to obtain better surface roughness, the proper setting of cutting parameters is crucial before the process take place. This research presents the development of mathematical model for surface roughness prediction before milling process in order to evaluate the fitness of machining parameters; spindle speed, feed rate and depth of cut. 84 samples were run in this study by using FANUC CNC Milling α-Τ14ιE. Those samples were randomly divided into two data sets- the training sets (m=60) and testing sets(m=24). ANOVA analysis showed that at least one of the population regression coefficients was not zero. Multiple Regression Method was used to determine the correlation between a criterion variable and a combination of predictor variables. It was established that the surface roughness is most influenced by the feed rate. By using Multiple Regression Method equation, the average percentage deviation of the testing set was 9.8% and 9.7% for training data set. This showed that the statistical model could predict the surface roughness with about 90.2% accuracy of the testing data set and 90.3% accuracy of the training data set.
Keywords: Surface roughness, regression analysis.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 21175441 Effect of the Workpiece Position on the Manufacturing Tolerances
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.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 20885440 Study of Mechanical Properties of Aluminium Alloys on Normal Friction Stir Welding and Underwater Friction Stir Welding for Structural Applications
Authors: Lingaraju Dumpala, Laxmi Mohan Kumar Chintada, Devadas Deepu, Pravin Kumar Yadav
Abstract:
Friction stir welding is the new-fangled and cutting-edge technique in welding applications; it is widely used in the fields of transportation, aerospace, defense, etc. For thriving significant welding joints and properties of friction stir welded components, it is essential to carry out this advanced process in a prescribed systematic procedure. At this moment, Underwater Friction Stir Welding (UFSW) Process is the field of interest to do research work. In the continuous assessment, the study of UFSW process is to comprehend problems occurred in the past and the structure through which the mechanical properties of the welded joints can be value-added and contributes to conclude results an acceptable and resourceful joint. A meticulous criticism is given on how to modify the experimental setup from NFSW to UFSW. It can discern the influence of tool materials, feeds, spindle angle, load, rotational speeds and mechanical properties. By expending the DEFORM-3D simulation software, the achieved outcomes are validated.
Keywords: Underwater friction stir welding, al alloys, mechanical properties, normal friction stir welding.
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1086