Search results for: Electrical Discharge Machining (EDM)
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 1202

Search results for: Electrical Discharge Machining (EDM)

1052 Stabilization of Angular-Shaped Riprap under Overtopping Flows

Authors: Dilavar Khan, Z. Ahmad

Abstract:

Riprap is mostly used to prevent erosion by flows down the steep slopes in river engineering. A total of 53 stability tests performed on angular riprap with a median stone size ranging from 15 to 278 mm and slope ranging from 1 to 40% are used in this study. The existing equations for the prediction of medium size of angular stones are checked for their accuracy using the available data. Predictions of median size using these equations are not satisfactory and results show deviation by more than ±20% from the observed values. A multivariable power regression analysis is performed to propose a new equation relating the median size with unit discharge, bed slope, riprap thickness and coefficient of uniformity. The proposed relationship satisfactorily predicts the median angular stone size with ±20% error. Further, the required size of the rounded stone is more than the angular stone for the same unit discharge and the ratio increases with unit discharge and also with embankment slope of the riprap.

Keywords: Angularity, Gradation, Riprap, Stabilization

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1051 Neural Network Monitoring Strategy of Cutting Tool Wear of Horizontal High Speed Milling

Authors: Kious Mecheri, Hadjadj Abdechafik, Ameur Aissa

Abstract:

The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc…. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.

Keywords: Flank wear, cutting forces, high speed milling, signal processing, neural network.

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1050 Intelligent Design of Reconfigurable Machines

Authors: Majid Tolouei-Rad

Abstract:

This paper presents methodologies for developing an intelligent CAD system assisting in analysis and design of reconfigurable special machines. It describes a procedure for determining feasibility of utilizing these machines for a given part and presents a model for developing an intelligent CAD system. The system analyzes geometrical and topological information of the given part to determine possibility of the part being produced by reconfigurable special machines from a technical point of view. Also feasibility of the process from a economical point of view is analyzed. Then the system determines proper positioning of the part considering details of machining features and operations needed. This involves determination of operation types, cutting tools and the number of working stations needed. Upon completion of this stage the overall layout of the machine and machining equipment required are determined.

Keywords: CAD, Knowledge based system, Reconfigurable

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1049 Integrating Process Planning and Scheduling for Prismatic Parts Regard to Due Date

Authors: M. Haddadzade, M. R. Razfar, M. Farahnakian

Abstract:

Integration of process planning and scheduling functions is necessary to achieve superior overall system performance. This paper proposes a methodology for integration of process planning and scheduling for prismatic component that can be implemented in a company with existing departments. The developed model considers technological constraints whereas available time for machining in shop floor is the limiting factor to produce multiple process plan (MPP). It takes advantage of MPP while guarantied the fulfillment of the due dates via using overtime. This study has been proposed to determinate machining parameters, tools, machine and amount of over time within the minimum cost objective while overtime is considered for this. At last the illustration shows that the system performance is improved by as measured by cost and compatible with due date.

Keywords: Due date, Integration, Multiple process plan, Process planning, Scheduling.

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1048 Pattern Recognition of Partial Discharge by Using Simplified Fuzzy ARTMAP

Authors: S. Boonpoke, B. Marungsri

Abstract:

This paper presents the effectiveness of artificial intelligent technique to apply for pattern recognition and classification of Partial Discharge (PD). Characteristics of PD signal for pattern recognition and classification are computed from the relation of the voltage phase angle, the discharge magnitude and the repeated existing of partial discharges by using statistical and fractal methods. The simplified fuzzy ARTMAP (SFAM) is used for pattern recognition and classification as artificial intelligent technique. PDs quantities, 13 parameters from statistical method and fractal method results, are inputted to Simplified Fuzzy ARTMAP to train system for pattern recognition and classification. The results confirm the effectiveness of purpose technique.

Keywords: Partial discharges, PD Pattern recognition, PDClassification, Artificial intelligent, Simplified Fuzzy ARTMAP

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1047 Open Channel Flow Measurement of Water by Using Width Contraction

Authors: Arun Goel, D. V. S. Verma, Sanjeev Sangwan

Abstract:

Present study was aimed to develop a discharge measuring device for irrigation and laboratory channels. Experiments were conducted on sharp edged constricted flow meters having four types of width constrictions namely 2:1, 1.5:1, 1:1 and 90o in the direction of flow. These devices were made of MS sheets and installed separately in a rectangular flume. All these four devices were tested under free and submerged flow conditions. Eight different discharges varying from 2 lit/sec to 30 lit/sec were passed through each device. In total around 500 observations of upstream and downstream depths were taken in the present work. For each discharge, free submerged and critical submergence under different flow conditions were noted and plotted. Once the upstream and downstream depths of flow over any of the device are known, the discharge can be easily calculated with the help of the curves developed for free and submerged flow conditions. The device having contraction 2:1 is the most efficient one as it allows maximum critical submergence.

Keywords: Flowrate, flowmeter, open channels, submergence.

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1046 Determining of Stage-Discharge Relationship for Meandering Compound Channels Using M5 Decision Tree Model

Authors: Mehdi Kheradmand, Mehdi Azhdary Moghaddam, Abdolreza Zahiri, Khalil Ghorbani

Abstract:

In modeling phenomena, the presence of local conditions may cause the use of a general relation not to produce good results and thus fail to demonstrate local changes. If possible, identifying homogenous limits and providing simple linear relations for each of these limits will increase the accuracy of models. Accordingly, the models are divided into simpler and smaller problems to solve complicated problems, and the obtained answers will be combined. This simple idea can be applied to decision tree models. For this aim, the input data values are divided into several sub-intervals or sub-regions, and an appropriate model is extracted for an appropriate model or equation. This research proposes the M5 decision tree method as a solution to accurately compute the flow discharge in meandering compound channels.

Keywords: Stage-discharge relationship, decision tree, M5 decision tree model, meandering compound channels.

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1045 Determination of Unsaturated Soil Permeability Based on Geometric Factor Development of Constant Discharge Model

Authors: A. Rifa’i, Y. Takeshita, M. Komatsu

Abstract:

After Yogyakarta earthquake in 2006, the main problem that occurred in the first yard of Prambanan Temple is ponding area that occurred after rainfall. Soil characterization needs to be determined by conducting several processes, especially permeability coefficient (k) in both saturated and unsaturated conditions to solve this problem. More accurate and efficient field testing procedure is required to obtain permeability data that present the field condition. One of the field permeability test equipment is Constant Discharge procedure to determine the permeability coefficient. Necessary adjustments of the Constant Discharge procedure are needed to be determined especially the value of geometric factor (F) to improve the corresponding value of permeability coefficient. The value of k will be correlated with the value of volumetric water content (θ) of an unsaturated condition until saturated condition. The principle procedure of Constant Discharge model provides a constant flow in permeameter tube that flows into the ground until the water level in the tube becomes constant. Constant water level in the tube is highly dependent on the tube dimension. Every tube dimension has a shape factor called the geometric factor that affects the result of the test. Geometric factor value is defined as the characteristic of shape and radius of the tube. This research has modified the geometric factor parameters by using empty material tube method so that the geometric factor will change. Saturation level is monitored by using soil moisture sensor. The field test results were compared with the results of laboratory tests to validate the results of the test. Field and laboratory test results of empty tube material method have an average difference of 3.33 x 10-4 cm/sec. The test results showed that modified geometric factor provides more accurate data. The improved methods of constant discharge procedure provide more relevant results.

Keywords: Constant discharge, geometric factor, permeability coefficient, unsaturated soils.

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1044 Development of Machinable Ellipses by NURBS Curves

Authors: Yuan L. Lai, Jian H. Chen, Jui P. Hung

Abstract:

Owning to the high-speed feed rate and ultra spindle speed have been used in modern machine tools, the tool-path generation plays a key role in the successful application of a High-Speed Machining (HSM) system. Because of its importance in both high-speed machining and tool-path generation, approximating a contour by NURBS format is a potential function in CAD/CAM/CNC systems. It is much more convenient to represent an ellipse by parametric form than to connect points laboriously determined in a CNC system. A new approximating method based on optimum processes and NURBS curves of any degree to the ellipses is presented in this study. Such operations can be the foundation of tool-radius compensation interpolator of NURBS curves in CNC system. All operating processes for a CAD tool is presented and demonstrated by practical models.

Keywords: Ellipse, Approximation, NURBS, Optimum.

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1043 Simulation of Die Casting Process in an Industrial Helical Gearbox Flange Die

Authors: Mehdi Modabberifar, Behrouz Raad, Bahman Mirzakhani

Abstract:

Flanges are widely used for connecting valves, pipes and other industrial devices such as gearboxes. Method of producing a flange has a considerable impact on the manner of their involvement with the industrial engines and gearboxes. By Using die casting instead of sand casting and machining for manufacturing flanges, production speed and dimensional accuracy of the parts increases. Also, in die casting, obtained dimensions are close to final dimensions and hence the need for machining flanges after die casting process decreases which makes a significant savings in raw materials and improves the mechanical properties of flanges. In this paper, a typical die of an industrial helical gearbox flange (size ISO 50) was designed and die casting process for producing this type of flange was simulated using ProCAST software. The results of simulation were used for optimizing die design. Finally, using the results of the analysis, optimized die was built.

Keywords: Die casting, finite element, flange.

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1042 Spectral Coherence Analysis between Grinding Interaction Forces and the Relative Motion of the Workpiece and the Cutting Tool

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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1041 Interaction Effect of Feed Rate and Cutting Speed in CNC-Turning on Chip Micro-Hardness of 304- Austenitic Stainless Steel

Authors: G. H. Senussi

Abstract:

The present work is concerned with the effect of turning process parameters (cutting speed, feed rate, and depth of cut) and distance from the center of work piece as input variables on the chip micro-hardness as response or output. Three experiments were conducted; they were used to investigate the chip micro-hardness behavior at diameter of work piece for 30[mm], 40[mm], and 50[mm]. Response surface methodology (R.S.M) is used to determine and present the cause and effect of the relationship between true mean response and input control variables influencing the response as a two or three dimensional hyper surface. R.S.M has been used for designing a three factor with five level central composite rotatable factors design in order to construct statistical models capable of accurate prediction of responses. The results obtained showed that the application of R.S.M can predict the effect of machining parameters on chip micro-hardness. The five level factorial designs can be employed easily for developing statistical models to predict chip micro-hardness by controllable machining parameters. Results obtained showed that the combined effect of cutting speed at it?s lower level, feed rate and depth of cut at their higher values, and larger work piece diameter can result increasing chi micro-hardness.

Keywords: Machining Parameters, Chip Micro-Hardness, CNCMachining, 304-Austenic Stainless Steel.

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1040 Tool Wear and Surface Roughness Prediction using an Artificial Neural Network (ANN) in Turning Steel under Minimum Quantity Lubrication (MQL)

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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1039 Using Single Decision Tree to Assess the Impact of Cutting Conditions on Vibration

Authors: S. Ghorbani, N. I. Polushin

Abstract:

Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.

Keywords: Cutting condition, vibration, natural frequency, decision tree, CART algorithm.

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1038 Modeling of Surface Roughness in Vibration Cutting by Artificial Neural Network

Authors: H. Soleimanimehr, M. J. Nategh , S. Amini

Abstract:

Development of artificial neural network (ANN) for prediction of aluminum workpieces' surface roughness in ultrasonicvibration assisted turning (UAT) has been the subject of the present study. Tool wear as the main cause of surface roughness was also investigated. ANN was trained through experimental data obtained on the basis of full factorial design of experiments. Various influential machining parameters were taken into consideration. It was illustrated that a multilayer perceptron neural network could efficiently model the surface roughness as the response of the network, with an error less than ten percent. The performance of the trained network was verified by further experiments. The results of UAT were compared with the results of conventional turning experiments carried out with similar machining parameters except for the vibration amplitude whence considerable reduction was observed in the built-up edge and the surface roughness.

Keywords: Aluminum, Artificial Neural Network (ANN), BuiltupEdge, Surface Roughness, Tool Wear, Ultrasonic VibrationAssisted Turning (UAT).

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1037 Effect of the Machine Frame Structures on the Frequency Responses of Spindle Tool

Authors: Yuan L. Lai, Yong R. Chen, Jui P. Hung, Tzuo L. Luo, Hsi H. Hsiao

Abstract:

Chatter vibration has been a troublesome problem for a machine tool toward the high precision and high speed machining. Essentially, the machining performance is determined by the dynamic characteristics of the machine tool structure and dynamics of cutting process. Therefore the dynamic vibration behavior of spindle tool system greatly determines the performance of machine tool. The purpose of this study is to investigate the influences of the machine frame structure on the dynamic frequency of spindle tool unit through finite element modeling approach. To this end, a realistic finite element model of the vertical milling system was created by incorporated the spindle-bearing model into the spindle head stock of the machine frame. Using this model, the dynamic characteristics of the milling machines with different structural designs of spindle head stock and identical spindle tool unit were demonstrated. The results of the finite element modeling reveal that the spindle tool unit behaves more compliant when the excited frequency approaches the natural mode of the spindle tool; while the spindle tool show a higher dynamic stiffness at lower frequency that may be initiated by the structural mode of milling head. Under this condition, it is concluded that the structural configuration of spindle head stock associated with the vertical column of milling machine plays an important role in determining the machining dynamics of the spindle unit.

Keywords: Machine tools, Compliance, Frequency response function, Machine frame structure, Spindle unit

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1036 Characteristics of Ozone Generated from Dielectric Barrier Discharge Plasma Actuators

Authors: R. Osada, S. Ogata, T. Segawa

Abstract:

Dielectric barrier discharge plasma actuators (DBD-PAs) have been developed for active flow control devices. However, it is necessary to reduce ozone produced by DBD toward practical applications using DBD-PAs. In this study, variations of ozone concentration, flow velocity, power consumption were investigated by changing exposed electrodes of DBD-PAs. Two exposed electrode prototypes were prepared: span-type with exposed electrode width of 0.1 mm, and normal-type with width of 5 mm. It was found that span-type shows lower power consumption and higher flow velocity than that of normal-type at Vp-p = 4.0-6.0 kV. Ozone concentration of span-type higher than normal-type at Vp-p = 4.0-8.0 kV. In addition, it was confirmed that catalyst located in downstream from the exposed electrode can reduce ozone concentration between 18 and 42% without affecting the induced flow.

Keywords: Dielectric barrier discharge plasma actuators, ozone diffusion, PIV measurement, power consumption.

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1035 Electrical and Magnetic Modelling of a Power Transformer: A Bond Graph Approach

Authors: Gilberto Gonzalez-A, Dunia Nuñez-P

Abstract:

Bond graph models of an electrical transformer including the nonlinear saturation are presented. The transformer using electrical and magnetic circuits are modelled. These models determine the relation between self and mutual inductances, and the leakage and magnetizing inductances of power transformers with two windings using the properties of a bond graph. The equivalence between electrical and magnetic variables is given. The modelling and analysis using this methodology to three phase power transformers can be extended.

Keywords: Bond graph, electrical transformer, magnetic circuits, nonlinear saturation.

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1034 A Statistical Approach for Predicting and Optimizing Depth of Cut in AWJ Machining for 6063-T6 Al Alloy

Authors: Farhad Kolahan, A. Hamid Khajavi

Abstract:

In this paper, a set of experimental data has been used to assess the influence of abrasive water jet (AWJ) process parameters in cutting 6063-T6 aluminum alloy. The process variables considered here include nozzle diameter, jet traverse rate, jet pressure and abrasive flow rate. The effects of these input parameters are studied on depth of cut (h); one of most important characteristics of AWJ. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. The adequacy of the model is evaluated using analysis of variance (ANOVA) technique. In the next stage, the proposed model is embedded into a Simulated Annealing (SA) algorithm to optimize the AWJ process parameters. The objective is to determine a suitable set of process parameters that can produce a desired depth of cut, considering the ranges of the process parameters. Computational results prove the effectiveness of the proposed model and optimization procedure.

Keywords: AWJ machining, Mathematical modeling, Simulated Annealing, Optimization

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1033 Hybrid Quasi-Steady Thermal Lattice Boltzmann Model for Studying the Behavior of Oil in Water Emulsions Used in Machining Tool Cooling and Lubrication

Authors: W. Hasan, H. Farhat, A. Alhilo, L. Tamimi

Abstract:

Oil in water (O/W) emulsions are utilized extensively for cooling and lubricating cutting tools during parts machining. A robust Lattice Boltzmann (LBM) thermal-surfactants model, which provides a useful platform for exploring complex emulsions’ characteristics under variety of flow conditions, is used here for the study of the fluid behavior during conventional tools cooling. The transient thermal capabilities of the model are employed for simulating the effects of the flow conditions of O/W emulsions on the cooling of cutting tools. The model results show that the temperature outcome is slightly affected by reversing the direction of upper plate (workpiece). On the other hand, an important increase in effective viscosity is seen which supports better lubrication during the work.

Keywords: Hybrid lattice Boltzmann method, Gunstensen model, thermal, surfactant-covered droplet, Marangoni stress.

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1032 Sustainable Use of Laura Lens during Drought

Authors: Kazuhisa Koda, Tsutomu Kobayashi

Abstract:

Laura Island, which is located about 50 km away from downtown, is a source of water supply in Majuro atoll, which is the capital of the Republic of the Marshall Islands. Low and flat Majuro atoll has neither river nor lake. It is very important for Majuro atoll to ensure the conservation of its water resources. However, upconing, which is the process of partial rising of the freshwater-saltwater boundary near the water-supply well, was caused by the excess pumping from it during the severe drought in 1998. Upconing will make the water usage of the freshwater lens difficult. Thus, appropriate water usage is required to prevent up coning in the freshwater lens because there is no other water source during drought. Numerical simulation of water usage applying SEAWAT model was conducted at the central part of Laura Island, including the water supply well, which was affected by upconing. The freshwater lens was created as a result of infiltration of consistent average rainfall. The lens shape was almost the same as the one in 1985. 0 of monthly rainfall and variable daily pump discharge were used to calculate the sustainable pump discharge from the water supply well. Consequently, the total amount of pump discharge was increased as the daily pump discharge was increased, indicating that it needs more time to recover from upconing. Thus, a pump standard to reduce the pump intensity is being proposed, which is based on numerical simulation concerning the occurrence of the up-coning phenomenon in Laura Island during the drought.

Keywords: Freshwater lens, islands, numerical simulation, sustainable water use.

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1031 On using PEMFC for Electrical Power Generation on More Electric Aircraft

Authors: Jenica Ileana Corcau, Liviu Dinca

Abstract:

The electrical power systems of aircrafts have made serious progress in recent years because the aircrafts depend more and more on the electricity. There is a trend in the aircraft industry to replace hydraulic and pneumatic systems with electrical systems, achieving more comfort and monitoring features and enlarging the energetic efficiency. Thus, was born the concept More Electric Aircraft. In this paper is analyzed the integration of a fuel cell into the existing electrical generation and distribution systems of an aircraft. The dynamic characteristics of fuel cell systems necessitate an adaptation of the electrical power system. The architecture studied in this paper consists of a 50kW fuel cell, a dc to dc converter and several loads. The dc to dc converter is used to step down the fuel cell voltage from about 625Vdc to 28Vdc.

Keywords: Electrical power system, More Electric Aircraft, Fuel Cell, dc to dc converter

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1030 Hydraulic Unbalance in Oil Injected Twin Rotary Screw Compressor Vibration Analysis (A Case History Related to Iran Oil Industries)

Authors: Omid A. Zargar

Abstract:

Vibration analysis of screw compressors is one of the most challenging cases in preventive maintenance. This kind of equipment considered as vibration bad actor facilities in industrial plants. On line condition monitoring systems developed too much in recent years. The high frequency vibration of ball bearings, gears, male and female caused complex fast Fourier transform (FFT) and time wave form (TWF) in screw compressors. The male and female randomly are sent to balance shop for balancing operation. This kind of operation usually caused some bending in rotors during the process that could cause further machining in such equipment. This kind of machining operation increased the vibration analysis complexity beside some process characteristic abnormality like inlet and out let pressure and temperature. In this paper mechanical principal and different type of screw compressors explained. Besides, some new condition monitoring systems and techniques for screw compressors discussed. Finally, one of the common behavior of oil injected twin rotary screw compressors called hydraulic unbalance that usually occurred after machining operation of male or female and have some specific characteristics in FFT and TWF discussed in details through a case history related to Iran oil industries.

Keywords: Vibration analysis, twin screw compressor, oil injected screw compressor, time wave form (TWF), fast Fourier transform (FFT), Hydraulic unbalance and rotor unbalance.

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1029 Analysis of the Theoretical Values of Several Characteristic Parameters of Surface Topography in Rotational Turning

Authors: J. Kundrák, I. Sztankovics, K. Gyáni

Abstract:

In addition to the increase of the material removal rate or surface rate, or the improvement of the surface quality, which are the main aims of the development of manufacturing technology, a growing number of other manufacturing requirements have appeared in the machining of workpiece surfaces. Among these it is becoming increasingly dominant to generate a surface topography in finishing operations which meets more closely the needs of operational requirements.

These include the examination of the surface periodicity and/or ensuring that the twist-structure values are within the limits (or even preventing its occurrence) in specified cases such as on the sealing surfaces of rotating shafts or on the inside working surfaces of needle roller bearings. In the view of the measurement the twist has different parameters from surface roughness, which must be determined for the machining procedures. Therefore in this paper the alteration of the theoretical values of the parameters determining twist structure are studied as a function of the kinematic properties.

Keywords: Kinematic parameters, rotational turning, surface topography, twist structure

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1028 A NonLinear Observer of an Electrical Transformer: A Bond Graph Approach

Authors: Gilberto Gonzalez-A , Israel Nuñez

Abstract:

A bond graph model of an electrical transformer including the nonlinear saturation is presented. A nonlinear observer for the transformer based on multivariable circle criterion in the physical domain is proposed. In order to show the saturation and hysteresis effects on the electrical transformer, simulation results are obtained. Finally, the paper describes that convergence of the estimates to the true states is achieved.

Keywords: Bond graph, nonlinear observer, electrical transformer, nonlinear saturation.

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1027 Finite Element Modeling to Predict the Effect of Nose Radius on the Equivalent Strain (PEEQ) for Titanium Alloy (Ti-6Al-4V)

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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1026 On-Line Geometrical Identification of Reconfigurable Machine Tool using Virtual Machining

Authors: Alexandru Epureanu, Virgil Teodor

Abstract:

One of the main research directions in CAD/CAM machining area is the reducing of machining time. The feedrate scheduling is one of the advanced techniques that allows keeping constant the uncut chip area and as sequel to keep constant the main cutting force. They are two main ways for feedrate optimization. The first consists in the cutting force monitoring, which presumes to use complex equipment for the force measurement and after this, to set the feedrate regarding the cutting force variation. The second way is to optimize the feedrate by keeping constant the material removal rate regarding the cutting conditions. In this paper there is proposed a new approach using an extended database that replaces the system model. The feedrate scheduling is determined based on the identification of the reconfigurable machine tool, and the feed value determination regarding the uncut chip section area, the contact length between tool and blank and also regarding the geometrical roughness. The first stage consists in the blank and tool monitoring for the determination of actual profiles. The next stage is the determination of programmed tool path that allows obtaining the piece target profile. The graphic representation environment models the tool and blank regions and, after this, the tool model is positioned regarding the blank model according to the programmed tool path. For each of these positions the geometrical roughness value, the uncut chip area and the contact length between tool and blank are calculated. Each of these parameters are compared with the admissible values and according to the result the feed value is established. We can consider that this approach has the following advantages: in case of complex cutting processes the prediction of cutting force is possible; there is considered the real cutting profile which has deviations from the theoretical profile; the blank-tool contact length limitation is possible; it is possible to correct the programmed tool path so that the target profile can be obtained. Applying this method, there are obtained data sets which allow the feedrate scheduling so that the uncut chip area is constant and, as a result, the cutting force is constant, which allows to use more efficiently the machine tool and to obtain the reduction of machining time.

Keywords: Reconfigurable machine tool, system identification, uncut chip area, cutting conditions scheduling.

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1025 Ethylene Epoxidation in a Low-Temperature Parallel Plate Dielectric Barrier Discharge System: Effects of Ethylene Feed Position and O2/C2H4 Feed Molar Ratio

Authors: Bunphot Paosombat, Thitiporn Suttikul, Sumaeth Chavadej

Abstract:

The effects of ethylene (C2H4) feed position and O2/C2H4 feed molar ratio on ethylene epoxidation in a parallel dielectric barrier discharge (DBD) were studied. The results showed that the ethylene feed position fraction of 0.5 and the feed molar ratio of O2/C2H4 of 0.2:1 gave the highest EO selectivity of 34.3% and the highest EO yield of 5.28% with low power consumptions of 2.11×10-16 Ws/molecule of ethylene converted and 6.34×10-16 Ws/molecule of EO produced when the DBD system was operated under the best conditions: an applied voltage of 19 kV, an input frequency of 500 Hz and a total feed flow rate of 50 cm3/min. The separate ethylene feed system provided much higher epoxidation activity as compared to the mixed feed system which gave EO selectivity of 15.5%, EO yield of 2.1% and the power consumption of EO produced of 7.7×10-16 Ws/molecule.

Keywords: Dielectric Barrier Discharge, C2H4 Feed Position, Epoxidation, Ethylene Oxide

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1024 An Investigation into Turbine Blade Tip Leakage Flows at High Speeds

Authors: Z. Saleh, E. J. Avital, T. Korakianitis

Abstract:

The effect of the blade tip geometry of a high pressure gas turbine is studied experimentally and computationally for high speed leakage flows. For this purpose two simplified models are constructed, one models a flat tip of the blade and the second models a cavity tip of the blade. Experimental results are obtained from a transonic wind tunnel to show the static pressure distribution along the tip wall and provide flow visualization. RANS computations were carried to provide further insight into the mean flow behavior and to calculate the discharge coefficient which is a measure of the flow leaking over the tip. It is shown that in both geometries of tip the flow separates over the tip to form a separation bubble. The bubble is higher for the cavity tip while a complete shock wave system of oblique waves ending with a normal wave can be seen for the flat tip. The discharge coefficient for the flat tip shows less dependence on the pressure ratio over the blade tip than the cavity tip. However, the discharge coefficient for the cavity tip is lower than that of the flat tip, showing a better ability to reduce the leakage flow and thus increase the turbine efficiency.

Keywords: Gas turbine, blade tip leakage flow, transonic flow.

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1023 Flow Discharge Determination in Straight Compound Channels Using ANNs

Authors: A. Zahiri, A. A. Dehghani

Abstract:

Although many researchers have studied the flow hydraulics in compound channels, there are still many complicated problems in determination of their flow rating curves. Many different methods have been presented for these channels but extending them for all types of compound channels with different geometrical and hydraulic conditions is certainly difficult. In this study, by aid of nearly 400 laboratory and field data sets of geometry and flow rating curves from 30 different straight compound sections and using artificial neural networks (ANNs), flow discharge in compound channels was estimated. 13 dimensionless input variables including relative depth, relative roughness, relative width, aspect ratio, bed slope, main channel side slopes, flood plains side slopes and berm inclination and one output variable (flow discharge), have been used in ANNs. Comparison of ANNs model and traditional method (divided channel method-DCM) shows high accuracy of ANNs model results. The results of Sensitivity analysis showed that the relative depth with 47.6 percent contribution, is the most effective input parameter for flow discharge prediction. Relative width and relative roughness have 19.3 and 12.2 percent of importance, respectively. On the other hand, shape parameter, main channel and flood plains side slopes with 2.1, 3.8 and 3.8 percent of contribution, have the least importance.

Keywords: ANN model, compound channels, divided channel method (DCM), flow rating curve

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