Search results for: Abrasive water jet machining

Authors: Afzeri, A.G.E Sujtipto, R. Muhida, M. Konneh, Darmawan

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Increasing the demand for effectively use of the production facility requires the tools for sharing the manufacturing facility through remote operation of the machining process. This research introduces the methodology of machining technology for direct remote operation of networked milling machine. The integrated tools with virtual simulation, remote desktop protocol and Setup Free Attachment for remote operation of milling process are proposed. Accessing and monitoring of machining operation is performed by remote desktop interface and 3D virtual simulations. Capability of remote operation is supported by an auto setup attachment with a reconfigurable pin type setup free technology installed on the table of CNC milling machine to perform unattended machining process. The system is designed using a computer server and connected to a PC based controlled CNC machine for real time monitoring. A client will access the server through internet communication and virtually simulate the machine activity. The result has been presented that combination between real time virtual simulation and remote desktop tool is enabling to operate all machine tool functions and as well as workpiece setup..

Keywords: Remote Desktop, PC Based CNC, Remote Machining.

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Authors: Naveen Beri, S. Maheshwari, C. Sharma, Anil Kumar

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In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.

Keywords: Electrical discharge machining (EDM), Powder Metallurgy (PM), Taguchi method, Material Removal Rate (MRR), Surface Roughness (SR).

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

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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: Ergin Kosa, Ali Göksenli

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Erosion and abrasion are wear mechanisms reducing the lifetime of machine elements like valves, pump and pipe systems. Both wear mechanisms are acting at the same time, causing a “Synergy” effect, which leads to a rapid damage of the surface. Different parameters are effective on erosive abrasive wear rate. In this study effect of particle impact angle on wear rate and wear mechanism of ductile and brittle materials was investigated. A new slurry pot was designed for experimental investigation. As abrasive particle, silica sand was used. Particle size was ranking between 200- 500 μm. All tests were carried out in a sand-water mixture of 20% concentration for four hours. Impact velocities of the particles were 4.76 m/s. As ductile material steel St 37 with Vickers Hardness Number (VHN) of 245 and quenched St 37 with 510 VHN was used as brittle material. After wear tests, morphology of the eroded surfaces were investigated for better understanding of the wear mechanisms acting at different impact angles by using Scanning Electron Microscope. The results indicated that wear rate of ductile material was higher than brittle material. Maximum wear rate was observed by ductile material at a particle impact angle of 300 and decreased further by an increase in attack angle. Maximum wear rate by brittle materials was by impact angle of 450 and decreased further up to 900. Ploughing was the dominant wear mechanism by ductile material. Microcracks on the surface were detected by ductile materials, which are nucleation centers for crater formation. Number of craters decreased and depth of craters increased by ductile materials by attack angle higher than 300. Deformation wear mechanism was observed by brittle materials. Number and depth of pits decreased by brittle materials by impact angles higher than 450. At the end it is concluded that wear rate could not be directly related to impact angle of particles due to the different reaction of ductile and brittle materials.

Keywords: Erosive wear, particle impact angle, silica sand, wear rate, ductile-brittle material.

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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.

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Authors: J. C. T. Benavente, J. C. E. Ferreira

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The rapid development of manufacturing and information systems has caused significant changes in manufacturing environments in recent decades. Mass production has given way to flexible manufacturing systems, in which an important characteristic is customized or "on demand" production. In this scenario, the seamless and without gaps information flow becomes a key factor for success of enterprises. In this paper we present a framework to support the mapping of features into machining workingsteps compliant with the ISO 14649 standard (known as STEP-NC). The system determines how the features can be made with the available manufacturing resources. Examples of the mapping method are presented for features such as a pocket with a general surface.

Keywords: Features, ISO 14649 standard, STEP-NC, mapping, machining workingsteps.

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Authors: Mandeep Kumar, Hari Singh

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The effective optimization of machining process parameters affects dramatically the cost and production time of machined components as well as the quality of the final products. This paper presents the optimization aspects of a Wire Electrical Discharge Machining operation using Inconel X-750 as work material. The objective considered in this study is minimization of the dimensional deviation. Six input process parameters of WEDM namely spark gap voltage, pulse-on time, pulse-off time, wire feed rate, peak current and wire tension, were chosen as variables to study the process performance. Taguchi's design of experiments methodology has been used for planning and designing the experiments. The analysis of variance was carried out for raw data as well as for signal to noise ratio. Four input parameters and one two-factor interaction have been found to be statistically significant for their effects on the response of interest. The confirmation experiments were also performed for validating the predicted results.

Keywords: ANOVA, DOE, inconel, machining, optimization.

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Authors: Himanshu Payal, Sachin Maheshwari, Pushpendra S. Bharti

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Electrical discharge machining (EDM), a non-conventional machining process, finds wide applications for shaping difficult-to-cut alloys. Process modeling of EDM is required to exploit the process to the fullest. Process modeling of EDM is a challenging task owing to involvement of so many electrical and non-electrical parameters. This work is an attempt to model the EDM process using artificial neural network (ANN). Experiments were carried out on die-sinking EDM taking Inconel 825 as work material. ANN modeling has been performed using experimental data. The prediction ability of trained network has been verified experimentally. Results indicate that ANN can predict the values of performance measures of EDM satisfactorily.

Keywords: Artificial neural network, EDM, metal removal rate, modeling, surface roughness.

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Authors: Mohammad A. Khasawneh

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The design of high pressure water jet based polishing equipment and its fabrication conducted in this study is reported herein, together with some preliminary test results for assessing its applicability for HMA surface polishing. This study also provides preliminary findings concerning the test variables, such as the rotational speed, the water jet pressure, the abrasive agent used, and the impact angel that were experimentally investigated in this study. The preliminary findings based on four trial tests (two on large slab specimens and two on small size gyratory compacted specimens), however, indicate that both friction and texture values tend to increase with the polishing durations for two combinations of pressure and rotation speed of the rotary deck. It seems that the more polishing action the specimen is subjected to; the aggregate edges are created such that the surface texture values are increased with the accompanied increase in friction values. It may be of interest (but which is outside the scope of this study) to investigate if the similar trend exist for HMA prepared with aggregate source that is sand and gravel.

Keywords: High-pressure, water jet, Friction, Texture, Polishing, Statistical Analysis.

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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

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Authors: Jana Petrů, Tomáš Zlámal, Robert Čep, Lenka Čepová

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This article is focused on the thermal spray coating machining issue. Those are irreplaceable in many areas of nowadays industrial branches such as aerospace industry, mostly thanks to their excellent qualities in production and also in renovation of machinery parts. The principals of thermal spraying and elementary diversification are described in introduction. Plasma coating method of composite materials – cermets – is described more thoroughly. The second part describes thermal spray coating machining and grinding in detail. This part contains suggestion of appropriate grinding tool and assessment of cutting conditions used for grinding a given part. Conclusion describes a problem which occurred while grinding a cermet thermal spray coating with a specially designed grindstone and a way to solve this problem.

Keywords: Coating, aerospace, plasma, grinding.

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Authors: M. N. Osman Zahid, K. Case, D. Watts

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This paper reports an advanced approach in the application of CNC machining for rapid manufacturing processes (CNC-RM). The aim of this study is to improve the quality of machined parts by introducing different cutting tools during finishing operations. As the cutting is performed in different directions, the surfaces presented on part can be classified into several categories. Therefore, suitable cutting tools are assigned to machine particular surfaces and to improve the quality. Experimental studies have been carried out by fabricating several parts based on the suggested approach. The results provide further support for implementing this approach in rapid machining processes.

Keywords: CNC machining, End mill tool, Finishing operation, Rapid manufacturing.

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Authors: Rakesh Prajapati, Purvik Patel, Hardik Patel

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Productivity and quality are two important aspects that have become great concerns in today’s competitive global market. Every production/manufacturing unit mainly focuses on these areas in relation to the process, as well as the product developed. The electrical discharge machining (EDM) process, even now it is an experience process, wherein the selected parameters are still often far from the maximum, and at the same time selecting optimization parameters is costly and time consuming. Material Removal Rate (MRR) during the process has been considered as a productivity estimate with the aim to maximize it, with an intention of minimizing surface roughness taken as most important output parameter. These two opposites in nature requirements have been simultaneously satisfied by selecting an optimal process environment (optimal parameter setting). Objective function is obtained by Regression Analysis and Analysis of Variance. Then objective function is optimized using Genetic Algorithm technique. The model is shown to be effective; MRR and Surface Roughness improved using optimized machining parameters.

Keywords: Material removal rate, TWR, OC, DOE, ANOVA, MINITAB.

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Authors: B. Varaprasad, C. Srinivasa Rao

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In the manufacturing sector, hard turning has emerged as vital machining process for cutting hardened steels. Besides many advantages of hard turning operation, one has to implement to achieve close tolerances in terms of surface finish, high product quality, reduced machining time, low operating cost and environmentally friendly characteristics. In the present study, three-dimensional CAE (Computer Aided Engineering) based simulation of  hard turning by using commercial software DEFORM 3D has been compared to experimental results of  stresses, temperatures and tool forces in machining of AISI D3 steel using mixed Ceramic inserts (CC6050). In the present analysis, orthogonal cutting models are proposed, considering several processing parameters such as cutting speed, feed, and depth of cut. An exhaustive friction modeling at the tool-work interfaces is carried out. Work material flow around the cutting edge is carefully modeled with adaptive re-meshing simulation capability. In process simulations, feed rate and cutting speed are constant (i.e.,. 0.075 mm/rev and 155 m/min), and analysis is focused on stresses, forces, and temperatures during machining. Close agreement is observed between CAE simulation and experimental values.

Keywords: Hard-turning, computer-aided engineering, computational machining, finite element method.

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Authors: K. Broniszewski, J. Woźniak, K. Czechowski, P. Orłowski, A. Olszyna

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Alumina matrix composites with addition of hexagonal boron nitride (hBN), acting as solid lubricant, were produced. Main purpose of solid lubricants is to dispose the necessity of using cooling lubricants in machining process. Hot pressing was used as a consolidating process for Al2O3-x%wt.hBN (x=1/ 2,5/ 5 /7,5 /10) composites. Properties of sinters such as relative density, hardness, Young-s modulus and fracture toughness were examined. Obtained samples characterize by high relative density. Hardness and fracture toughness values allow the use of alumina – hBN composites for machining steels even in hardened condition. However it was observed that high weight content of hBN can negatively influence the mechanical properties of composites.

Keywords: Alumina. Composites, Hexagonal boron nitride, Machining

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Authors: F. Tafnout, E. Belut, B. Oesterlé, J.R. Fontaine

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As a part of the development of a numerical method of close capture exhausts systems for machining devices, a test rig recreating a situation similar to a grinding operation, but in a perfectly controlled environment, is used. The properties of the obtained spray of solid particles are initially characterized using particle tracking velocimetry (PTV), in order to obtain input and validation parameters for numerical simulations. The dispersion of a tracer gas (SF6) emitted simultaneously with the particle jet is then studied experimentally, as the dispersion of such a gas is representative of that of finer particles, whose aerodynamic response time is negligible. Finally, complete modeling of the test rig is achieved to allow comparison with experimental results and thus to progress towards validation of the models used to describe a twophase flow generated by machining operation.

Keywords: Pollutants, capture, tracer gas, SF6, PTV, numericalmodeling.

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Authors: Javier A. Dominguez Caballero, Graeme A. Manson, Matthew B. Marshall

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Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.

Keywords: Ceramic cutting tools, high speed machining, image processing, tool condition monitoring, tool wear.

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Authors: J. Chen, N. Hundal

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Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.

Keywords: Surface roughness, taguchi parameter design, turning center, turn-milling operations, vertical machining center.

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Authors: Lorenzo Daghini, Andreas Archenti, Cornel Mihai Nicolescu

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This paper introduces a novel design for boring bar with enhanced damping capability. The principle followed in the design phase was to enhance the damping capability minimizing the loss in static stiffness through implementation of composite material interfaces. The newly designed tool has been compared to a conventional tool. The evaluation criteria were the dynamic characteristics, frequency and damping ratio, of the machining system, as well as the surface roughness of the machined workpieces. The use of composite material in the design of damped tool has been demonstrated effective. Furthermore, the autoregressive moving average (ARMA) models presented in this paper take into consideration the interaction between the elastic structure of the machine tool and the cutting process and can therefore be used to characterize the machining system in operational conditions.

Keywords: ARMA, cutting stability, damped tool, machining.

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Authors: Zs. Kovács, Zs. J. Viharos, J. Kodácsy

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As a well-known conventional finishing process, the grinding is commonly used to manufacture seal mating surfaces and bearing surfaces, but is also creates twisted surfaces. The machined surfaces by turning or grinding usually have twist structure on the surfaces, which can convey lubricants such as conveyor screw. To avoid this phenomenon, have to use special techniques or machines, for example start-stop turning, tangential turning, ultrasonic protection or special toll geometries. All of these solutions have high cost and difficult usability. In this paper, we describe a system and summarize the results of the experimental research carried out mainly in the field of Magnetic Abrasive Polishing (MAP) and Magnetic Roller Burnishing (MRB). These technologies are simple and also green while able to produce twist-free surfaces. During the tests, C45 normalized steel was used as workpiece material which was machined by simple and Wiper geometrical turning inserts in a CNC turning lathe. After the turning, the MAP and MRB technologies can be used directly to reduce the twist of surfaces. The evaluation was completed by advanced measuring and IT equipment.

Keywords: Magnetism, finishing, polishing, roller burnishing, twist-free.

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Authors: Chia-Jung Chen, Rong-Shine Lin, Rong-Guey Chang

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As networking has become popular, Web-learning tends to be a trend while designing a tool. Moreover, five-axis machining has been widely used in industry recently; however, it has potential axial table colliding problems. Thus this paper aims at proposing an efficient web-learning collision detection tool on five-axis machining. However, collision detection consumes heavy resource that few devices can support, thus this research uses a systematic approach based on web knowledge to detect collision. The methodologies include the kinematics analyses for five-axis motions, separating axis method for collision detection, and computer simulation for verification. The machine structure is modeled as STL format in CAD software. The input to the detection system is the g-code part program, which describes the tool motions to produce the part surface. This research produced a simulation program with C programming language and demonstrated a five-axis machining example with collision detection on web site. The system simulates the five-axis CNC motion for tool trajectory and detects for any collisions according to the input g-codes and also supports high-performance web service benefiting from C. The result shows that our method improves 4.5 time of computational efficiency, comparing to the conventional detection method.

Keywords: Collision detection, Five-axis machining, Separating axis.

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Authors: S.I.Nikolaeva, Yu.V. Petrov, L.Ye.Skipnikova

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It has been shown that the solution of water shortage problem in Central Asia closely connected with inclusion of atmosphere water vapour into the system of response and water resources management. Some methods of water extraction from atmosphere have been discussed.

Keywords: potable water, water resources, water problems, water scarcity.

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Authors: Dejan Tanikić, Jelena Đoković, Saša Kalinović, Miodrag Manić, Saša Ranđelović

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This paper deals with measuring and modelling of the quality of the machined surface of the metal machining process. The average surface roughness (R_a) which represents the quality of the machined part was measured during the dry turning of the AISI 4140 steel. A large number of factors with the unknown relations among them influences this parameter, and that is why mathematical modelling is extremely complicated. Different values of cutting speed, feed rate, depth of cut (cutting regime) and workpiece hardness causes different surface roughness values. Modelling with soft computing techniques may be very useful in such cases. This paper presents the usage of the fuzzy logic-based system for determining metal machining process parameter in order to find the proper values of cutting regimes.

Keywords: Metal machining, surface roughness, fuzzy logic, process modelling.

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Authors: M.Davami, M.Zadshakoyan

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Production of hard-to-cut materials with uncoated carbide cutting tools in turning, not only cause tool life reduction but also, impairs the product surface roughness. In this paper, influence of hot machining method were studied and presented in two cases. Case1-Workpiece surface roughness quality with constant cutting parameter and 300 ºC initial workpiece surface temperature. Case 2- Tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min). The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10(SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300 ºC, causing reduction of yield stress about 15%. Results obtained experimentally, show that the method used can considerably improved surface quality of the workpiece.

Keywords: Hard-to-cut material, Hot machining, Surfaceroughness, Tool Temperature

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Authors: Murat Sarıkaya, Abdulkadir Güllü

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Haynes 25 alloy (also known as L-605 alloy) is cobalt based super alloy which has widely applications such as aerospace industry, turbine and furnace parts, power generators and heat exchangers and petroleum refining components due to its excellent characteristics. However, the workability of this alloy is more difficult compared to normal steels or even stainless. In present work, an experimental investigation was performed under cryogenic cooling to determine cutting tool wear patterns and obtain optimal cutting parameters in turning of cobalt based superalloy Haynes 25. In experiments, uncoated carbide tool was used and cutting speed (V) and feed rate (f) were considered as test parameters. Tool wear (VBmax) were measured for process performance indicators. Analysis of variance (ANOVA) was performed to determine the importance of machining parameters.

Keywords: Cryogenic machining, difficult-to-cut alloy, tool wear, turning.

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Authors: Thella Babu Rao, A. Gopala Krishna

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This investigation presents the formulation of kerf (width of slit) and optimal control parameter settings of wire electrochemical discharge machining which results minimum possible kerf while machining Al7075/SiCp MMCs. WEDM is proved its efficiency and effectiveness to cut the hard ceramic reinforced MMCs within the permissible budget. Among the distinct performance measures of WEDM process, kerf is an important performance characteristic which determines the dimensional accuracy of the machined component while producing high precision components. The lack of available of the machinability information such advanced MMCs result the more experimentation in the manufacturing industries. Therefore, extensive experimental investigations are essential to provide the database of effect of various control parameters on the kerf while machining such advanced MMCs in WEDM. Literature reviled the significance some of the electrical parameters which are prominent on kerf for machining distinct conventional materials. However, the significance of reinforced particulate size and volume fraction on kerf is highlighted in this work while machining MMCs along with the machining parameters of pulse-on time, pulse-off time and wire tension. Usually, the dimensional tolerances of machined components are decided at the design stage and a machinist pay attention to produce the required dimensional tolerances by setting appropriate machining control variables. However, it is highly difficult to determine the optimal machining settings for such advanced materials on the shop floor. Therefore, in the view of precision of cut, kerf (cutting width) is considered as the measure of performance for the model. It was found from the literature that, the machining conditions of higher fractions of large size SiCp resulting less kerf where as high values of pulse-on time result in a high kerf. A response surface model is used to predict the relative significance of various control variables on kerf. Consequently, a powerful artificial intelligence called genetic algorithms (GA) is used to determine the best combination of the control variable settings. In the next step the conformation test was conducted for the optimal parameter settings and found good agreement between the GA kerf and measured kerf. Hence, it is clearly reveal that the effectiveness and accuracy of the developed model and program to analyze the kerf and to determine its optimal process parameters. The results obtained in this work states that, the resulted optimized parameters are capable of machining the Al7075/SiCp MMCs more efficiently and with better dimensional accuracy.

Keywords: Al7075SiCP MMC, kerf, WEDM, optimization.

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Authors: Ahmed A. D. Sarhan, M. Sayuti, M. Hamdi

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Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters set-up, making the machining process on the glass excellent in manufacturing complicated special products compared to other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness. These parameters include the lubrication pressure, spindle speed, feed rate and depth of cut. In this research work, a fuzzy logic model is offered to predict the surface roughness of a machined surface in glass milling operation using CBN grinding tool. Four membership functions are allocated to be connected with each input of the model. The predicted results achieved via fuzzy logic model are compared to the experimental result. The result demonstrated settlement between the fuzzy model and experimental results with the 93.103% accuracy.

Keywords: CNC-machine, Glass milling, Grinding, Surface roughness, Cutting force, Fuzzy logic model.

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Authors: M. K. Pradhan, C. K. Biswas,

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In the current research, neuro-fuzzy model and regression model was developed to predict Material Removal Rate in Electrical Discharge Machining process for AISI D2 tool steel with copper electrode. Extensive experiments were conducted with various levels of discharge current, pulse duration and duty cycle. The experimental data are split into two sets, one for training and the other for validation of the model. The training data were used to develop the above models and the test data, which was not used earlier to develop these models were used for validation the models. Subsequently, the models are compared. It was found that the predicted and experimental results were in good agreement and the coefficients of correlation were found to be 0.999 and 0.974 for neuro fuzzy and regression model respectively

Keywords: Electrical discharge machining, material removal rate, neuro-fuzzy model, regression model, mountain clustering.

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Authors: C. Ramsauer, J. Karandikar, D. Leitner, T. Schmitz, F. Bleicher

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Machining instability, or chatter, can impose an important limitation to discrete part machining. In this work, a networked implementation of milling stability optimization with Bayesian learning is presented. The milling process was monitored with a wireless sensory tool holder instrumented with an accelerometer at the TU Wien, Vienna, Austria. The recorded data from a milling test cut were used to classify the cut as stable or unstable based on a frequency analysis. The test cut result was used in a Bayesian stability learning algorithm at the University of Tennessee, Knoxville, Tennessee, USA. The algorithm calculated the probability of stability as a function of axial depth of cut and spindle speed based on the test result and recommended parameters for the next test cut. The iterative process between two transatlantic locations was repeated until convergence to a stable optimal process parameter set was achieved.

Keywords: Bayesian learning, instrumented tool holder, machining stability, optimization strategy.

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Authors: Ahmed A. D. Sarhan, S. R. Besharaty, Javad Akbaria, M. Hamdi

Abstract:

The capability of CNC gantry milling machines in manufacturing long components has caused the expanded use of such machines. On the other hand, the machines’ gantry rigidity can reduce under severe loads or vibration during operation. Indeed, the quality of machining is dependent on the machine’s dynamic behavior throughout the operating process. For this reason, these types of machines have always been used widely and are not efficient. Therefore, they can usually be employed for rough machining and may not produce adequate surface finishing. In this paper, a CNC gantry milling machine with the potential to produce good surface finish has been designed and analyzed. The lowest natural frequency of this machine is 202 Hz corresponding to 12000 rpm at all motion amplitudes with a full range of suitable frequency responses. Meanwhile, the maximum deformation under dead loads for the gantry machine is 0.565*m, indicating that this machine tool is capable of producing higher product quality.

Keywords: Finite element, frequency response, gantry design, gantry machine, static and dynamic analysis.

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