Search results for: Work piece

Authors: A. Y. Bani Hashim, N. S. A. Ramdan

Abstract:

Inconsistency in manual inspection is real because humans get tired after some time. Recent trends show that automatic inspection is more appealing for mass production inspections. In such as a case, a robot manipulator seems the best candidate to run a dynamic visual inspection. The purpose of this work is to estimate the optimum workspace where a robot manipulator would perform a visual inspection process onto a work piece where a camera is attached to the end effector. The pseudo codes for the planned path are derived from the number of tool transit points, the delay time at the transit points, the process cycle time, and the configuration space that the distance between the tool and the work piece. It is observed that express start and swift end are acceptable in a robot program because applicable works usually in existence during these moments. However, during the mid-range cycle, there are always practical tasks programmed to be executed. For that reason, it is acceptable to program the robot such as that speedy alteration of actuator displacement is avoided. A dynamic visual inspection system using a robot manipulator seems practical for a work piece with a complex shape.

Keywords: Robot manipulator, Visual inspection, Work piece, Trajectory planning.

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Authors: Sadílek M., Čep R.

Abstract:

This work deals with problems of tool axis inclination angles in ball-end milling. Tool axis inclination angle contributes to improvement of functional surface properties (surface integrity - surface roughness, residual stress, micro hardness, etc.), decreasing cutting forces and improving production. By milling with ball-end milling tool, using standard way of cutting, when work piece and cutting tool contain right angle, we have zero cutting speed on edge. At this point cutting tool only pushes material into the work piece. Here we can observe the following undesirable effects - chip contraction, increasing of cutting temperature, increasing vibrations or creation of built-up edge. These effects have negative results – low quality of surface and decreasing of tool life (in the worse case even it is pinching out). These effects can be eliminated with the tilt of cutting tool or tilt of work piece.

Keywords: CAD/CAM system, tool axis inclination angle, ballend milling, surface roughness, cutting forces.

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Authors: Ali Reza Tahavvor, Saeed Hosseini, Nazli Jowkar, Afshin Karimzadeh Fard

Abstract:

Experimental & numeral study of temperature distribution during milling process, is important in milling quality and tools life aspects. In the present study the milling cross-section temperature is determined by using Artificial Neural Networks (ANN) according to the temperature of certain points of the work piece and the point specifications and the milling rotational speed of the blade. In the present work, at first three-dimensional model of the work piece is provided and then by using the Computational Heat Transfer (CHT) simulations, temperature in different nods of the work piece are specified in steady-state conditions. Results obtained from CHT are used for training and testing the ANN approach. Using reverse engineering and setting the desired x, y, z and the milling rotational speed of the blade as input data to the network, the milling surface temperature determined by neural network is presented as output data. The desired points temperature for different milling blade rotational speed are obtained experimentally and by extrapolation method for the milling surface temperature is obtained and a comparison is performed among the soft programming ANN, CHT results and experimental data and it is observed that ANN soft programming code can be used more efficiently to determine the temperature in a milling process.

Keywords: Milling process, rotational speed, Artificial Neural Networks, temperature.

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Authors: Panagiotis Kyratsis, Konstantinos Kakoulis

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Nowadays, the rapid development of CAD systems’ programming environments results in the creation of multiple downstream applications, which are developed and becoming increasingly available. CAD based manufacturing simulations is gradually following the same trend. Drilling is the most popular holemaking process used in a variety of industries. A specially built piece of software that deals with the drilling kinematics is presented. The cutting forces are calculated based on the tool geometry, the cutting conditions and the tool/work-piece materials. The results are verified by experimental work. Finally, the response surface methodology (RSM) is applied and mathematical models of the total thrust force and the thrust force developed because of the main cutting edges are proposed.

Keywords: Application programming interface, CAD, drilling, response surface methodology, RSM.

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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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Authors: S. D. El Wakil, M. Pladsen

Abstract:

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.

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Authors: P. R. Prabhu, S. M. Kulkarni, S. S. Sharma

Abstract:

Deep cold rolling (DCR) and low plasticity burnishing (LPB) process are cold working processes, which easily produce a smooth and work-hardened surface by plastic deformation of surface irregularities. The present study focuses on the surface roughness and surface hardness aspects of AISI 4140 work material, using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in order to identify the predominant factors amongst the selected parameters. They were then categorized in order of significance followed by setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. In the present work, the influence of main process parameters (force, feed rate, number of tool passes/overruns, initial roughness of the work piece, ball material, ball diameter and lubricant used) on the surface roughness and the hardness of AISI 4140 steel were studied for both LPB and DCR process and the results are compared. It was observed that by using LPB process surface hardness has been improved by 167% and in DCR process surface hardness has been improved by 442%. It was also found that the force, ball diameter, number of tool passes and initial roughness of the workpiece are the most pronounced parameters, which has a significant effect on the work piece-s surface during deep cold rolling and low plasticity burnishing process.

Keywords: Deep cold rolling, burnishing, surface roughness, surface hardness, design of experiments, AISI4140 steel.

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Authors: Alonggot Limcharoen, Jintana Wannarat, Vorawat Panich

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This study aims to investigate the balancing of the number of operators (Line Balancing technique) in the production line of hard disk drive components in order to increase efficiency. At present, the trend of using hard disk drives has continuously declined leading to limits in a company’s revenue potential. It is important to improve and develop the production process to create market share and to have the ability to compete with competitors with a higher value and quality. Therefore, an effective tool is needed to support such matters. In this research, the Arena program was applied to analyze the results both before and after the improvement. Finally, the precedent was used before proceeding with the real process. There were 14 work stations with 35 operators altogether in the RA production process where this study was conducted. In the actual process, the average production time was 84.03 seconds per product piece (by timing 30 times in each work station) along with a rating assessment by implementing the Westinghouse principles. This process showed that the rating was 123% underlying an assumption of 5% allowance time. Consequently, the standard time was 108.53 seconds per piece. The Takt time was calculated from customer needs divided by working duration in one day; 3.66 seconds per piece. Of these, the proper number of operators was 30 people. That meant five operators should be eliminated in order to increase the production process. After that, a production model was created from the actual process by using the Arena program to confirm model reliability; the outputs from imitation were compared with the original (actual process) and this comparison indicated that the same output meaning was reliable. Then, worker numbers and their job responsibilities were remodeled into the Arena program. Lastly, the efficiency of production process enhanced from 70.82% to 82.63% according to the target.

Keywords: Hard disk drive, line balancing, simulation, Arena program.

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Authors: A. Tellaeche, R. Arana, I.Maurtua

Abstract:

The exhaustive quality control is becoming more and more important when commercializing competitive products in the world's globalized market. Taken this affirmation as an undeniable truth, it becomes critical in certain sector markets that need to offer the highest restrictions in quality terms. One of these examples is the percussion cap mass production, a critical element assembled in firearm ammunition. These elements, built in great quantities at a very high speed, must achieve a minimum tolerance deviation in their fabrication, due to their vital importance in firing the piece of ammunition where they are built in. This paper outlines a machine vision development for the 100% inspection of percussion caps obtaining data from 2D and 3D simultaneous images. The acquisition speed and precision of these images from a metallic reflective piece as a percussion cap, the accuracy of the measures taken from these images and the multiple fabrication errors detected make the main findings of this work.

Keywords: critical tolerance, high speed decision makingsimultaneous 2D/3D machine vision.

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Authors: P. R. Prabhu, S. M. Kulkarni, S. S. Sharma

Abstract:

Deep cold rolling (DCR) is a cold working process, which easily produces a smooth and work-hardened surface by plastic deformation of surface irregularities. In the present study, the influence of main deep cold rolling process parameters on the surface roughness and the hardness of AISI 4140 steel were studied by using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in terms of identifying the predominant factor amongst the selected parameters, their order of significance and setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. It was found that the ball diameter, rolling force, initial surface roughness and number of tool passes are the most pronounced parameters, which have great effects on the work piece-s surface during the deep cold rolling process. A simple, inexpensive and newly developed DCR tool, with interchangeable collet for using different ball diameters, was used throughout the experimental work presented in this paper.

Keywords: Deep cold rolling, design of experiments, surface hardness, surface roughness

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Authors: M. A. Koroma, S. Widatalla, A. F. Kamara, C. Zhang

Abstract:

Our aim in this piece of work is to demonstrate the power of the Laplace Adomian decomposition method (LADM) in approximating the solutions of nonlinear differential equations governing the two-dimensional viscous flow induced by a shrinking sheet.

Keywords: Adomian polynomials, Laplace Adomian decomposition method, Padé Approximant, Shrinking sheet.

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Authors: D. V. Sreekanth, M. Sreenivasa Rao

Abstract:

Abrasive jet machining is one of the promising non-traditional machining processes which uses mechanical energy (pressure and velocity) for machining various materials. The process parameters that influence the metal removal rate are kerfs, surface finish, depth of cut, air pressure, and distance between nozzle and work piece, nozzle diameter, abrasive type, abrasive shape, and mass flow rate of abrasive particles. The abrasive particles coming out with high pressure not only hits work surface but also passes through the nozzle resulting in erosion. This paper focuses mainly on the effect of different parameters on the erosion of nozzle in Abrasive jet machining. Three different types of nozzles made of sapphire, tungsten carbide, and high carbon high chromium steel (HCHCS) are used for machining glass and the erosion of these nozzles are calculated. The results are shown in tabular form and graphical representation.

Keywords: AJM, nozzle, sapphire, tungsten carbide, chrome steel.

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Authors: W. Afef, A. Mohamed Ammar, G. Kamel, O. Ahmed

Abstract:

In the present study, a numerical approach to describe the pyrolysis of a single solid particle of wood is used to study the influence of various conditions such as particle size, heat transfer coefficient, reactor temperature and heating rate. The influence of these parameters in the change of the duration of the pyrolysis cycle was studied. Mathematical modeling was employed to simulate the heat, mass transfer, and kinetic processes inside the reactor. The evolutions of the mass loss as well as the evolution of temperature inside the thick piece are investigated numerically. The elaborated model was also employed to study the effect of the reactor temperature and the rate of heating on the change of the temperature and the local loss of the mass inside the piece of wood. The obtained results are in good agreement with the experimental data available in the literature.

Keywords: Wood, Pyrolysis, Modeling, Convective heat transfer, Kinetic.

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Authors: Vladimír Modrák

Abstract:

This paper offers a case study, in which methodological aspects of cell design for transformation the production process are applied. The cell redesign in this work is tightly focused to reach optimization of material flows under real manufacturing conditions. Accordingly, more individual techniques were aggregated into compact methodical procedure with aim to built one-piece flow production. Case study was concentrated on relatively typical situation of transformation from batch production to cellular manufacturing.

Keywords: Product/Quantity analysis, layout, design, manufacturing process.

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Authors: A. Chandrashekar, H. N. Reddappa, B. S. Ajaykumar

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A Friction stir welding tool is a critical component to the success of the process. The tool typically consists of a rotating round shoulder and a threaded cylindrical pin that heats the work piece, mostly by friction, and moves the softened alloy around it to form the joint. In this research work, an attempt has been made to investigate the relationship between FSW variables mainly tool profile, rotating speed, welding speed and the mechanical properties (tensile strength, yield strength, percentage elongation, and micro hardness) of friction stir welded aluminum alloy 5083 joints. From the experimental details, it can be assessed that the joint produced by using Triflute profile tool has contribute superior mechanical and structural properties as compared to Tapered unthreaded & Threaded tool for 1000rpm.

Keywords: Friction stir welding, Tool profile, Rotating speed, Strength, Speed ratio.

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Authors: Analise Borg, Paul Micallef

Abstract:

Over the past few years, the online multimedia collection has grown at a fast pace. Several companies showed interest to study the different ways to organise the amount of audio information without the need of human intervention to generate metadata. In the past few years, many applications have emerged on the market which are capable of identifying a piece of music in a short time. Different audio effects and degradation make it much harder to identify the unknown piece. In this paper, an audio fingerprinting system which makes use of a non-parametric based algorithm is presented. Parametric analysis is also performed using Gaussian Mixture Models (GMMs). The feature extraction methods employed are the Mel Spectrum Coefficients and the MPEG-7 basic descriptors. Bin numbers replaced the extracted feature coefficients during the non-parametric modelling. The results show that nonparametric analysis offer potential results as the ones mentioned in the literature.

Keywords: Audio fingerprinting, mapping algorithm, Gaussian Mixture Models, MFCC, MPEG-7.

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Authors: Amit Kohli, Aashim Wadhwa, Tapan Virmani, Ujjwal Jain

Abstract:

The objective of present work is to stimulate the machining of material by electrical discharge machining (EDM) to give effect of input parameters like discharge current (Ip), pulse on time (Ton), pulse off time (Toff) which can bring about changes in the output parameter, i.e. material removal rate. Experimental data was gathered from die sinking EDM process using copper electrode and Medium Carbon Steel (AISI 1040) as work-piece. The rules of membership function (MF) and the degree of closeness to the optimum value of the MMR are within the upper and lower range of the process parameters. It was found that proposed fuzzy model is in close agreement with the experimental results. By Intelligent, model based design and control of EDM process parameters in this study will help to enable dramatically decreased product and process development cycle times.

Keywords: Electrical discharge Machining (EDM), Fuzzy Logic, Material removal rate (MRR), Membership functions (MF).

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Authors: A. Samraj, S. Sayeed, J. E. Raja., J. Hossen, A. Rahman

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Monitoring the tool flank wear without affecting the throughput is considered as the prudent method in production technology. The examination has to be done without affecting the machining process. In this paper we proposed a novel work that is used to determine tool flank wear by observing the sound signals emitted during the turning process. The work-piece material we used here is steel and aluminum and the cutting insert was carbide material. Two different cutting speeds were used in this work. The feed rate and the cutting depth were constant whereas the flank wear was a variable. The emitted sound signal of a fresh tool (0 mm flank wear) a slightly worn tool (0.2 -0.25 mm flank wear) and a severely worn tool (0.4mm and above flank wear) during turning process were recorded separately using a high sensitive microphone. Analysis using Singular Value Decomposition was done on these sound signals to extract the feature sound components. Observation of the results showed that an increase in tool flank wear correlates with an increase in the values of SVD features produced out of the sound signals for both the materials. Hence it can be concluded that wear monitoring of tool flank during turning process using SVD features with the Fuzzy C means classification on the emitted sound signal is a potential and relatively simple method.

Keywords: Fuzzy c means, Microphone, Singular ValueDecomposition, Tool Flank Wear.

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Authors: Azhar Equbal, Anoop Kumar Sood, M. Asif Equbal, M. Israr Equbal

Abstract:

In the present work response surface methodology (RSM) based central composite design (CCD) is used for analyzing the electrical discharge machining (EDM) process. For experimentation, mild steel is selected as work piece and copper is used as electrode. Three machining parameters namely current (I), spark on time (T_on) and spark off time (T_off) are selected as the input variables. The output or response chosen is material removal rate (MRR) which is to be maximized. To reduce the number of runs face centered central composite design (FCCCD) was used. ANOVA was used to determine the significance of parameter and interactions. The suitability of model is tested using Anderson darling (AD) plot. The results conclude that different parameters considered i.e. current, pulse on and pulse off time; all have dominant effect on the MRR. At last, the optimized parameter setting for maximizing MRR is found through main effect plot analysis.

Keywords: Electrical discharge machining, electrode, MRR, RSM, ANOVA.

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Authors: Başak Uçanok

Abstract:

The aim of this study is to test the “work values" inventory developed by Tevruz and Turgut and to utilize the concept in a model, which aims to create a greater understanding of the work experience. In the study multiple effects of work values, work-value congruence and work centrality on organizational citizenship behavior are examined. In this respect, it is hypothesized that work values and work-value congruence predict organizational citizenship behavior through work centrality. Work-goal congruence test, Tevruz and Turgut-s work values inventory are administered along with Kanungo-s work centrality and Podsakoff et al.-s [47] organizational citizenship behavior test to employees working in Turkish SME-s. The study validated that Tevruz and Turgut-s work values inventory and the work-value congruence test were reliable and could be used for future research. The study revealed the mediating role of work centrality only for the relationship of work values and the responsibility dimension of citizenship behavior. Most important, this study brought in an important concept, work-value congruence, which enables a better understanding of work values and their relation to various attitudinal variables.

Keywords: Work values, work-value congruence, work centrality, organizational citizenship behavior.

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Authors: I. R. Kanu, T. J. Aspray, A. J. Adeloye

Abstract:

As a result of the ambiguity and complexity surrounding anaerobic digester foaming, efforts have been made by various researchers to understand the process of anaerobic digester foaming so as to proffer a solution that can be universally applied rather than site specific. All attempts ranging from experimental analysis to comparative review of other process has not fully explained the conditions and process of foaming in anaerobic digester. Studying the current available knowledge on foam formation and relating it to anaerobic digester process and operating condition, this piece of work presents a succinct and enhanced understanding of foaming in anaerobic digesters as well as introducing a simple method to identify the onset of anaerobic digester foaming based on analysis of historical data from a field scale system.

Keywords: Anaerobic digester, foam, biogas, surfactants, wastewater sludge.

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Authors: Bharatendra Rai

Abstract:

Cutting tools are widely used in manufacturing processes and drilling is the most commonly used machining process. Although drill-bits used in drilling may not be expensive, their breakage can cause damage to expensive work piece being drilled and at the same time has major impact on productivity. Predicting drill-bit breakage, therefore, is important in reducing cost and improving productivity. This study uses twenty features extracted from two degradation signals viz., thrust force and torque. The methodology used involves developing and comparing decision tree, random forest, and multinomial logistic regression models for classifying and predicting drill-bit breakage using degradation signals.

Keywords: Degradation signal, drill-bit breakage, random forest, multinomial logistic regression.

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Authors: Gizem Arslan Özgen, Kutay Yücetürk, Metin Tanoğlu, Engin Aktaş

Abstract:

Power transmitted from the engine to the final drive where useful work is applied through a system consisting of a gearbox, clutch, drive shaft and a differential in the rear-wheel-drive automobiles. It is well-known that the steel drive shaft is usually manufactured in two pieces to increase the fundamental bending natural frequency to ensure safe operation conditions. In this work, hybrid one-piece propeller shafts composed of carbon/epoxy and glass/epoxy composites have been designed for a rear wheel drive automobile satisfying three design specifications, such as static torque transmission capability, torsional buckling and the fundamental natural bending frequency. Hybridization of carbon and glass fibers is being studied to optimize the cost/performance requirements. Composites shaft materials with various fiber orientation angles and stacking sequences are being fabricated and analyzed using finite element analysis (FEA).

Keywords: Composite propeller shaft, hybridization, epoxy matrix, static torque transmission capability, torsional buckling strength, fundamental natural bending frequency.

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Authors: Ravinder Kataria, Jatinder Kumar, B. S. Pabla

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Ultrasonic machining is one of the most widely used non-traditional machining processes for machining of materials that are relatively brittle, hard, and fragile such as advanced ceramics, refractories, crystals, quartz etc. Present article has been targeted at investigating the impact of different experimental conditions (power rating, cobalt content, tool material, thickness of work piece, tool geometry, and abrasive grit size) on over cut in ultrasonic drilling of WC-Co composite material. Taguchi’s L-36 orthogonal array has been employed for conducting the experiments. Significant factors have been identified using analysis of variance (ANOVA) test. The experimental results revealed that abrasive grit size and tool material are most significant factors for over cut.

Keywords: ANOVA, Abrasive grit size, Taguchi, WC-Co, ultrasonic machining.

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Authors: Johan Fredin, Anders Jönsson

Abstract:

Abrasive waterjet cutting (AWJ) is a highly efficient method for cutting almost any type of material. When holes shall be cut the waterjet first needs to pierce the material.This paper presents a vast experimental analysis of piercing parameters effect on piercing time. Results from experimentation on feed rates, work piece thicknesses, abrasive flow rates, standoff distances and water pressure are also presented as well as studies on three methods for dynamic piercing. It is shown that a large amount of time and resources can be saved by choosing the piercing parameters in a correct way. The large number of experiments puts demands on the experimental setup. An automated experimental setup including piercing detection is presented to enable large series of experiments to be carried out efficiently.

Keywords: Waterjet cutting, Piercing, Experimentation

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Authors: R. Alipour, F. Nadjarian, A. Alinaghizade

Abstract:

Considering complexity of products, new geometrical design and investment tolerances that are necessary, measuring and dimensional controlling involve modern and more precise methods. Photo digitizing method using two cameras to record pictures and utilization of conventional method named “cloud points" and data analysis by the use of ATOUS software, is known as modern and efficient in mentioned context. In this paper, benefits of photo digitizing method in evaluating sampling of machining processes have been put forward. For example, assessment of geometrical integrity surface in 5-axis milling process and measurement of carbide tool wear in turning process, can be can be brought forward. Advantages of this method comparing to conventional methods have been expressed.

Keywords: photo digitizing, tool wear, geometrical integrity, cloud points

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Authors: Basavaraj V. Patil, Uday Chakkingal, T. S. Prasanna Kumar

Abstract:

Equal Channel Angular Pressing (ECAP) is currently being widely investigated because of its potential to produce ultrafine grained microstructures in metals and alloys. A sound knowledge of the plastic deformation and strain distribution is necessary for understanding the relationships between strain inhomogeneity and die geometry. Considerable research has been reported on finite element analysis of this process, assuming threedimensional plane strain condition. However, the two-dimensional models are not suitable due to the geometry of the dies, especially in cylindrical ones. In the present work, three-dimensional simulation of ECAP process was carried out for six outer corner radii (sharp to 10 mm in steps of 2 mm), with channel angle 105¶Çü▒, for strain hardening aluminium alloy (AA 6101) using ABAQUS/Standard software. Strain inhomogeneity is presented and discussed for all cases. Pattern of strain variation along selected radial lines in the body of the workpiece is presented. It is found from the results that the outer corner has a significant influence on the strain distribution in the body of work-piece. Based on inhomogeneity and average strain criteria, there is an optimum outer corner radius.

Keywords: Equal Channel Angular Pressing, Finite Element Analysis, strain inhomogeneity, plastic equivalent strain, ultra fine grain size, aluminium alloy 6101.

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Authors: Pavana Manvikar, G K Purohit

Abstract:

The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.

Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.

Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.

This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HR_C=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,

 

Ra= 0.305-0.005X₁ - 0.0175X₂ + 0.0525X₄ + 0.0125X₁X₄ -0.02X₂X₄ - 0.0375X₃X₄

 

Hv=160.625 -2.37 5X₁ + 5.125X₂ + 1.875X₃ + 4.375X₄ - 1.625X₁X₄ + 4.375X₂X₄ - 2.375X₃X₄

 

High surface microhardness (175H_V) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.

Keywords: Ball burnishing, surface roughness, micro-hardness.

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Authors: Hui Chen, Xiao Feng

Abstract:

Depressurization and pressurization streams in industrial systems constitute a work exchange network (WEN). In this paper, a novel graphical approach for targeting energy conservation potential of a WEN is proposed. Through constructing the composite work curves in the pressure-work diagram and assuming all of the mechanical energy of the depressurization streams is recovered by expanders, the maximum work target of a WEN can be determined via the proposed targeting steps. A WEN in an ammonia production process is used as a case study to illustrate the applicability of the proposed graphical approach.

Keywords: Expanders, Graphical approach, Pressure-work diagram, Work exchange network, Work target

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Authors: M. Padmavathi, R. M. Suresh

Abstract:

Every machine plays roles of client and server simultaneously in a peer-to-peer (P2P) network. Though a P2P network has many advantages over traditional client-server models regarding efficiency and fault-tolerance, it also faces additional security threats. Users/IT administrators should be aware of risks from malicious code propagation, downloaded content legality, and P2P software’s vulnerabilities. Security and preventative measures are a must to protect networks from potential sensitive information leakage and security breaches. Bit Torrent is a popular and scalable P2P file distribution mechanism which successfully distributes large files quickly and efficiently without problems for origin server. Bit Torrent achieved excellent upload utilization according to measurement studies, but it also raised many questions as regards utilization in settings, than those measuring, fairness, and Bit Torrent’s mechanisms choice. This work proposed a block selection technique using Fuzzy ACO with optimal rules selected using ACO.

Keywords: Ant Colony Optimization (ACO), Bit Torrent, Download time, Peer-to-Peer (P2P) network, Performance.

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