Search results for: Cryogenic machining

Authors: Samy E. Oraby, Ayman M. Alaskari

Abstract:

In recent years, scanning probe atomic force microscopy SPM AFM has gained acceptance over a wide spectrum of research and science applications. Most fields focuses on physical, chemical, biological while less attention is devoted to manufacturing and machining aspects. The purpose of the current study is to assess the possible implementation of the SPM AFM features and its NanoScope software in general machining applications with special attention to the tribological aspects of cutting tool. The surface morphology of coated and uncoated as-received carbide inserts is examined, analyzed, and characterized through the determination of the appropriate scanning setting, the suitable data type imaging techniques and the most representative data analysis parameters using the MultiMode SPM AFM in contact mode. The NanoScope operating software is used to capture realtime three data types images: “Height", “Deflection" and “Friction". Three scan sizes are independently performed: 2, 6, and 12 μm with a 2.5 μm vertical range (Z). Offline mode analysis includes the determination of three functional topographical parameters: surface “Roughness", power spectral density “PSD" and “Section". The 12 μm scan size in association with “Height" imaging is found efficient to capture every tiny features and tribological aspects of the examined surface. Also, “Friction" analysis is found to produce a comprehensive explanation about the lateral characteristics of the scanned surface. Configuration of many surface defects and drawbacks has been precisely detected and analyzed.

Keywords: SPM AFM contact mode, carbide inserts, scan size, surface defects, surface roughness, PSD.

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Authors: S. B. Alavi, G. Cerri, L. Chennaoui, A. Giovannelli, S. Mazzoni

Abstract:

Power Regeneration in Refrigeration Plant concept has been analyzed and has been shown to be capable of saving about 25% power in Cryogenic Plants with the Power Regeneration System (PRS) running under nominal conditions. The innovative component Compressor Expander Group (CEG) based on turbomachinery has been designed and built modifying CETT compressor and expander, both selected for optimum plant performance. Experiments have shown the good response of the turbomachines to run with R404a as working fluid. Power saving up to 12% under PRS derated conditions (50% loading) has been demonstrated. Such experiments allowed predicting a power saving up to 25% under CEG full load.

Keywords: Compressor, Expander, Power Saving, Refrigeration Plant, Turbine, Turbomachinery Selection, Vapor Pressure Booster.

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Authors: Alan C. Lin, Tzu-Kuan Lin, Tsong Der Lin

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This paper proposes a new method to find the equations of transformation matrix for the rotation angles of the two rotational axes and the coordinates of the three linear axes of an orthogonal multi-axis milling machine. This approach provides intuitive physical meanings for rotation angles of multi-axis machines, which can be used to evaluate the accuracy of the conversion from CL data to NC data.

Keywords: CAM, multi-axis milling machining.

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Authors: Salah Gariani, Taher Dao, Ahmed Lajili

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This paper presents an experimental optimisation of surface roughness (Ra) and tool wear in the precision turning of AISI 304L alloy using a wiper and conventional cutting tools under wet cutting conditions. The machining trials were conducted based on Taguchi methodology employing an L9 orthogonal array design with four process parameters: feed rate, spindle speed, depth of cut, and cutting tool type. The experimental results were utilised to characterise the main factors affecting Ra and tool wear using the analyses of means (AOM) and variance (ANOVA). The results show that the wiper tools outperformed conventional tools in terms of surface quality and tool wear at optimal cutting conditions. The ANOVA results indicate that the main factors contributing to lower Ra are cutting tool type and feed rate, with percentage contribution ratios (PCRs) of 58.69% and 25.18% respectively. This confirms that tool type is the most significant factor affecting surface quality when turning AISI 304L. Additionally, a substantial reduction in tool wear was observed when a wiper insert was used, whereas noticeable increases in tool wear occurred when higher cutting speeds were employed for both tool types. These trends confirm the ANOVA outcomes that cutting speed has a significant effect on tool wear, with a PCR value of 39.22%, followed by tool type with a PCR of 27.40%. All machining trials generated similar continuous spiral or curl-shaped chips. A noticeable difference was found in the radius of the produced curl-shaped chips at different cutting speeds when turning AISI 304L under wet cutting conditions.

Keywords: AISI 304L alloy, conventional and wiper carbide tools, wet turning, average surface roughness, tool wear.

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Authors: Michael P. Herring, Lavrent Khachatryan, Barry Dellinger

Abstract:

Low Temperature Matrix Isolation - Electron Paramagnetic Resonance (LTMI-EPR) Spectroscopy was utilized to identify the species of iron oxide nanoparticles generated during the oxidative pyrolysis of 1-methylnaphthalene (1-MN). The otherwise gas-phase reactions of 1--MN were impacted by a polypropylenimine tetra-hexacontaamine dendrimer complexed with iron (III) nitrate nonahydrate diluted in air under atmospheric conditions. The EPR fine structure of Fe (III)2O3 nanoparticles clusters, characterized by gfactors of 2.00, 2.28, 3.76 and 4.37 were detected on a cold finger maintained at 77 K after accumulation over a multitude of experiments. Additionally, a high valence Fe (IV) paramagnetic intermediate and superoxide anion-radicals, O2•- adsorbed on nanoparticle surfaces in the form of Fe (IV) --- O2•- were detected from the quenching area of Zone 1 in the gas-phase.

Keywords: Cryogenic trapping, EPFRs, dendrimer, Fe2O3 doped silica, soot.

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Authors: Koichi Yonemoto, Hiroshi Yamasaki, Masatomo Ichige, Yusuke Ura, Guna S. Gossamsetti, Takumi Ohki, Kento Shirakata, Ahsan R. Choudhuri, Shinji Ishimoto, Takashi Mugitani, Hiroya Asakawa, Hideaki Nanri

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This paper presents the strategic development plan of winged rockets WIRES (WInged REusable Sounding rocket) aiming at unmanned suborbital winged rocket for demonstrating future fully reusable space transportation technologies, such as aerodynamics, Navigation, Guidance and Control (NGC), composite structure, propulsion system, and cryogenic tanks etc., by universities in collaboration with government and industries, as well as the past and current flight test results.

Keywords: Autonomous guidance and control, reusable rocket, space transportation system, suborbital vehicle, winged rocket.

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Authors: Vineeth G. Kuriakose, Joseph C. Chen, Ye Li

Abstract:

The research follows a systematic approach to optimize the parameters for parts machined by turning and milling processes. The quality characteristic chosen is surface roughness since the surface finish plays an important role for parts that require surface contact. A tapered cylindrical surface is designed as a test specimen for the research. The material chosen for machining is aluminum alloy 6061 due to its wide variety of industrial and engineering applications. HAAS VF-2 TR computer numerical control (CNC) vertical machining center is used for milling and HAAS ST-20 CNC machine is used for turning in this research. Taguchi analysis is used to optimize the surface roughness of the machined parts. The L₉ Orthogonal Array is designed for four controllable factors with three different levels each, resulting in 18 experimental runs. Signal to Noise (S/N) Ratio is calculated for achieving the specific target value of 75 ± 15 µin. The controllable parameters chosen for turning process are feed rate, depth of cut, coolant flow and finish cut and for milling process are feed rate, spindle speed, step over and coolant flow. The uncontrollable factors are tool geometry for turning process and tool material for milling process. Hypothesis testing is conducted to study the significance of different uncontrollable factors on the surface roughnesses. The optimal parameter settings were identified from the Taguchi analysis and the process capability C_p and the process capability index C_pk were improved from 1.76 and 0.02 to 3.70 and 2.10 respectively for turning process and from 0.87 and 0.19 to 3.85 and 2.70 respectively for the milling process. The surface roughnesses were improved from 60.17 µin to 68.50 µin, reducing the defect rate from 52.39% to 0% for the turning process and from 93.18 µin to 79.49 µin, reducing the defect rate from 71.23% to 0% for the milling process. The purpose of this study is to efficiently utilize the Taguchi design analysis to improve the surface roughness.

Keywords: CNC milling, CNC turning, surface roughness, Taguchi analysis.

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Authors: Tânia Manso, Luís Teixeira, Paula M. Reis Correia

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Glazing is a process used to reduce undesirable drying or dehydration of fish during frozen or cold storage. To evaluate the effect of the time/ temperature binomial of the cryogenic frozen tunnel in the amount of glazing watera Central Composite Rotatable Design was used, with application of the Response Surface Methodology. The results reveal that the time/ temperature obtained for pink cusk-eel in experimental conditions for glazing water are similar to the industrial process, but for red fish and merluza the industrial process needs some adjustments. Control charts were established and implementedto control the amount of glazing water on sardine and merluza. They show that the freezing process was statistically controlled but there were some tendencies that must be analyzed, since the trend of sample mean values approached either of the limits, mainly in merluza. Thus, appropriate actions must be taken, in order to improve the process.

Keywords: Control charts, frozen fish, glazing, RSM.

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Authors: Jeong-Hyeon Kim, Ki-Yeob Kang, Myung-Hyun Kim, Jae-Myung Lee

Abstract:

Primary barrier of membrane type LNG containment system consist of corrugated 304L stainless steel. This 304L stainless steel is austenitic stainless steel which shows different material behaviors owing to phase transformation during the plastic work. Even though corrugated primary barriers are subjected to significant amounts of pre-strain due to press working, quantitative mechanical behavior on the effect of pre-straining at cryogenic temperatures are not available. In this study, pre-strain level and pre-strain temperature dependent tensile tests are carried to investigate mechanical behaviors. Also, constitutive equations with material parameters are suggested for a verification study.

Keywords: Constitutive equation, corrugated sheet, pre-strain effect, elasto-visco-plastic-damage model, 304L stainless steel.

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Authors: M.B. Aryanezhad, J. Aliabadi

Abstract:

This paper considers the integration of assembly operations and product structure to Cellular Manufacturing System (CMS) design so that to correct the drawbacks of previous researches in the literature. For this purpose, a new mathematical model is developed which dedicates machining and assembly operations to manufacturing cells while the objective function is to minimize the intercellular movements resulting due to both of them. A linearization method is applied to achieve optimum solution through solving aforementioned nonlinear model by common programming language such as Lingo. Then, using different examples and comparing the results, the importance of integrating assembly considerations is demonstrated.

Keywords: Assembly operations and Product structure, CellFormation, Genetic Algorithm.

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Authors: M. S. Said, J. A. Ghani, Che Hassan C. H., N. N. Wan, M. A. Selamat, R. Othman

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Metal matrix composites (MMCs) attract considerable attention as a result from its ability in providing a high strength, high modulus, high toughness, high impact properties, improving wear resistance and providing good corrosion resistance compared to unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been widely used in various industrial sectors such as in transportation, domestic equipment, aerospace, military, construction, etc. Aluminium silicon alloy is an MMC that had been reinforced with aluminium nitrate (AlN) particle and become a new generation material use in automotive and aerospace sector. The AlN is one of the advance material that have a bright prospect in future since it has features such as lightweight, high strength, high hardness and stiffness quality. However, the high degree of ceramic particle reinforcement and the irregular nature of the particles along the matrix material that contribute to its low density is the main problem which leads to difficulties in machining process. This paper examined the tool wear when milling AlSi/AlN Metal Matrix Composite using a TiB2 (Titanium diboride) coated carbide cutting tool. The volume of the AlN reinforced particle was 10% and milling process was carried out under dry cutting condition. The TiB2 coated carbide insert parameters used were at the cutting speed of (230, 300 and 370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The Sometech SV-35 video microscope system used to quantify of the tool wear. The result shown that tool life span increasing with the cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at 0.4mm) which constituted an optimum condition for longer tool life lasted until 123.2 mins. Meanwhile, at medium cutting speed which at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we found that tool life span lasted until 119.86 mins while at low cutting speed it lasted in 119.66 mins. High cutting speed will give the best parameter in cutting AlSi/AlN MMCs material. The result will help manufacturers in machining process of AlSi/AlN MMCs materials.

Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, TiB2 coated cemented carbide tool.

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Authors: K. B. Vinay, K. G. Vismay, S. Kasturirengan, G. A. Vivek

Abstract:

Cryosorption pumps are considered safe, quiet, and ultra-high vacuum production pumps which have their application from Semiconductor industries to ITER [International Thermonuclear Experimental Reactor] units. The principle of physisorption of gases over highly porous materials like activated charcoal at cryogenic temperatures (below -1500°C) is involved in determining the pumping speed of gases like Helium, Hydrogen, Argon, and Nitrogen. This paper aims at providing detailed overview of development of Cryosorption pump and characterization of different activated charcoal materials that optimizes the performance of the pump. Different grades of charcoal were tested in order to determine the pumping speed of the pump and were compared with commercially available Varian cryopanel. The results for bare panel, bare panel with adhesive, cryopanel with pellets, and cryopanel with granules were obtained and compared. The comparison showed that cryopanel adhered with small granules gave better pumping speeds than large sized pellets.

Keywords: Adhesive, cryopanel, granules, pellets.

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

Abstract:

The study of the generated defects on manufactured parts shows the difficulty to maintain parts in their positions during the machining process and to estimate them during the pre-process plan. This work presents a contribution to the development of 3D models for the optimization of the manufacturing tolerances. An experimental study allows the measurement of the defects of part positioning for the determination of ε and the choice of an optimal setup of the part. An approach of 3D tolerance based on the small displacements method permits the determination of the manufacturing errors upstream. A developed tool, allows an automatic generation of the tolerance intervals along the three axes.

Keywords: Manufacturing tolerances, 3D modeling, optimization, errors.

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Authors: Hanfei Tuo, Yanzhong Li

Abstract:

This paper presented a novel combined cycle of air separation and natural gas liquefaction. The idea is that natural gas can be liquefied, meanwhile gaseous or liquid nitrogen and oxygen are produced in one combined cryogenic system. Cycle simulation and exergy analysis were performed to evaluate the process and thereby reveal the influence of the crucial parameter, i.e., flow rate ratio through two stages expanders β on heat transfer temperature difference, its distribution and consequent exergy loss. Composite curves for the combined hot streams (feeding natural gas and recycled nitrogen) and the cold stream showed the degree of optimization available in this process if appropriate β was designed. The results indicated that increasing β reduces temperature difference and exergy loss in heat exchange process. However, the maximum limit value of β should be confined in terms of minimum temperature difference proposed in heat exchanger design standard and heat exchanger size. The optimal βopt under different operation conditions corresponding to the required minimum temperature differences was investigated.

Keywords: combined cycle simulation, exergy analysis, natural gas liquefaction.

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Authors: Sandipkumar Sonawane, Upendra Bhandarkar, Bhalchandra Puranik, S. Sunil Kumar

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The effect of Alumina nanoparticle size on thermophysical properties, heat transfer performance and pressure loss characteristics of Aviation Turbine Fuel (ATF)-Al2O3 nanofluids is studied experimentally for the proposed application of regenerative cooling of semi-cryogenic rocket engine thrust chambers. Al2O3 particles with mean diameters of 50 nm or 150 nm are dispersed in ATF. At 500C and 0.3% particle volume concentration, the bigger particles show increases of 17% in thermal conductivity and 55% in viscosity, whereas the smaller particles show corresponding increases of 21% and 22% for thermal conductivity and viscosity respectively. Contrary to these results, experiments to study the heat transfer performance and pressure loss characteristics show that at the same pumping power, the maximum enhancement in heat transfer coefficient at 500C and 0.3% concentration is approximately 47% using bigger particles, whereas it is only 36% using smaller particles.

Keywords: Heat transfer performance, Nanofluids, Thermalconductivity, Viscosity

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Authors: R. Kumaravelan, V. C. Sathish Gandhi, S. Ramesh, M. Venkatesan

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In the product design and development process, the prototyping or model making is one of the important step to finalize a product which helps in conceptualization of a design. Rapid Prototyping (RP) is layer-by-layer material deposition started during early 1980s with the enormous growth in Computer Aided Design and Manufacturing (CAD/CAM) technologies. The edges and surfaces of a complex solid model and their information are used for defining a product which is further manufactured as a finished product by CNC machining. This paper provides a better platform for researchers, new learners and product manufacturers for various applications of RP models. Subsequently it creates awareness among the peoples of recently developing RP method of manufacturing in product design, developments and its applications.

Keywords: Prototyping, layer-by-layer, CAD/CAM, product design.

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Authors: S. G. Ponnambalam, Low Seng Kiat

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In this paper, a particle swarm optimization (PSO) algorithm is proposed to solve machine loading problem in flexible manufacturing system (FMS), with bicriterion objectives of minimizing system unbalance and maximizing system throughput in the occurrence of technological constraints such as available machining time and tool slots. A mathematical model is used to select machines, assign operations and the required tools. The performance of the PSO is tested by using 10 sample dataset and the results are compared with the heuristics reported in the literature. The results support that the proposed PSO is comparable with the algorithms reported in the literature.

Keywords: Machine loading problem, FMS, Particle Swarm Optimization.

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Authors: Max Ti-Kuang Hou, Hui-Mei Shen, Chiang-Ni Lu, I-Jen Hsu

Abstract:

We present design, fabrication, and characterization of a small (12 mm × 12 mm × 8 mm) movable railway vehicle for sensor carrying. The miniature railway vehicle (MRV) was mainly composed of a vibrational structure and three legs. A railway was designed and fabricated to power and guide the MRV. It also transmits the sensed data from the MRV to the signal processing unit. The MRV with legs on the railway was moving due to its high-frequency vibration. A model was derived to describe the motion. Besides, FEM simulations were performed to design the legs. Then, the MRV and the railway were fabricated by precision machining. Finally, an infrared sensor was carried and tested. The result shows that the MRV without loading was moving along the railway and its maximum speed was 12.2 mm/s. Moreover, the testing signal was sensed by the MRV.

Keywords: Locomotion, Micro-Robot, Miniature Railway Vehicle, Stick-Slip.

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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: Dayananda Pai, Shrikantha S. Rao, Savitha G.Kini

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In this study, the effects of machining parameters on specific energy during surface grinding of 6061Al-SiC35P composites are investigated. Vol% of SiC, feed and depth of cut were chosen as process variables. The power needed for the calculation of the specific energy is measured from the two watt meter method. Experiments are conducted using standard RSM design called Central composite design (CCD). A second order response surface model was developed for specific energy. The results identify the significant influence factors to minimize the specific energy. The confirmation results demonstrate the practicability and effectiveness of the proposed approach.

Keywords: ANOVA, Metal matrix composites, Response surface methodology, Specific energy, Two watt meter method.

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Authors: Sol-Kil Oh, Hye-Jin Lee, Jung-Han Song, Kyoung-Tae Kim, Nak-Kyu Lee, Jong-Ho Kim

Abstract:

This paper deals with a novel technique for the fabrication of Spiral grooves in a dynamic thrust bearing. The main scheme proposed in this paper is to fabricate the microgrooves using desktop forming system. This process has advantages compared to the conventional electro-chemical machining in the viewpoint of a higher productivity. For this reason, a new testing apparatus is designed and built for press forming microgrooves on a surface of the thrust bearing. The material used in this study is sintered Cu-Fe alloy. The effects of the forming load on the performance of micro press forming are experimentally investigated. From the experimental results, formed depths are closed to the target ones with increasing the forming load.

Keywords: Desktop forming system, Fluid dynamic bearing, Thrust bearing, Microgroove.

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Authors: Mohammad Songolzadeh, Maryam Takht Ravanchi, Mansooreh Soleimani

Abstract:

CO2 is the primary anthropogenic greenhouse gas, accounting for 77% of the human contribution to the greenhouse effect in 2004. In the recent years, global concentration of CO2 in the atmosphere is increasing rapidly. CO2 emissions have an impact on global climate change. Anthropogenic CO2 is emitted primarily from fossil fuel combustion. Carbon capture and storage (CCS) is one option for reducing CO2 emissions. There are three major approaches for CCS: post-combustion capture, pre-combustion capture and oxyfuel process. Post-combustion capture offers some advantages as existing combustion technologies can still be used without radical changes on them. There are several post combustion gas separation and capture technologies being investigated, namely; (a) absorption, (b) cryogenic separation, (c) membrane separation (d) micro algal biofixation and (e) adsorption. Apart from establishing new techniques, the exploration of capture materials with high separation performance and low capital cost are paramount importance. However, the application of adsorption from either technology, require easily regenerable and durable adsorbents with a high CO2 adsorption capacity. It has recently been reported that the cost of the CO2 capture can be reduced by using this technology. In this paper, the research progress (from experimental results) in adsorbents for CO2 adsorption, storage, and separations were reviewed and future research directions were suggested as well.

Keywords: Carbon capture and storage, pre-combustion, postcombustion, adsorption

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Authors: Sasho Guergov

Abstract:

The purpose of the paper is to develop an informationcontrol environment for overall management and self-reconfiguration of the reconfigurable multifunctional machine tool for machining both rotation and prismatic parts and high concentration of different technological operations - turning, milling, drilling, grinding, etc. For the realization of this purpose on the basis of defined sub-processes for the implementation of the technological process, architecture of the information-search system for machine control is suggested. By using the object-oriented method, a structure and organization of the search system based on agents and manager with central control are developed. Thus conditions for identification of available information in DBs, self-reconfiguration of technological system and entire control of the reconfigurable multifunctional machine tool are created.

Keywords: Information system, multifunctional machine tool, reconfigurable machine tool, search system.

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Authors: M.A. Kamely, S.M. Kamil, C.W. Chong

Abstract:

A mathematical model of the surface roughness has been developed by using response surface methodology (RSM) in grinding of AISI D2 cold work tool steels. Analysis of variance (ANOVA) was used to check the validity of the model. Low and high value for work speed and feed rate are decided from design of experiment. The influences of all machining parameters on surface roughness have been analyzed based on the developed mathematical model. The developed prediction equation shows that both the feed rate and work speed are the most important factor that influences the surface roughness. The surface roughness was found to be the lowers with the used of low feed rate and low work speed. Accuracy of the best model was proved with the testing data.

Keywords: Mathematical Modeling, Response surfacemethodology, Surface roughness, Cylindrical Grinding.

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Authors: Farhad Kolahan, Vahid Kayvanfar

Abstract:

In this paper we address a multi-objective scheduling problem for unrelated parallel machines. In unrelated parallel systems, the processing cost/time of a given job on different machines may vary. The objective of scheduling is to simultaneously determine the job-machine assignment and job sequencing on each machine. In such a way the total cost of the schedule is minimized. The cost function consists of three components, namely; machining cost, earliness/tardiness penalties and makespan related cost. Such scheduling problem is combinatorial in nature. Therefore, a Simulated Annealing approach is employed to provide good solutions within reasonable computational times. Computational results show that the proposed approach can efficiently solve such complicated problems.

Keywords: Makespan, Parallel machines, Scheduling, Simulated Annealing

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Authors: Bo Wun Huang, Pu Ping Yu, Jao-Hwa Kuang

Abstract:

For smaller mechatronic device, especially for micro Electronic system, a micro machining is a must. However, most investigations on vibration of a mill have been limited to the traditional type mill. In this article, vibration and dynamic characteristics of a micro mill were investigated in this study. The trend towards higher precision manufacturing technology requires producing miniaturized components. To improve micro-milled product quality, obtain a higher production rate and avoid milling breakage, the dynamic characteristics of micro milling must be studied. A stepped pre-twisted mill is used to simulate the micro mill. The finite element analysis is employed in this work. The flute length and diameter effects of the micro mill are considered. It is clear that the effects of micro mill shape parameters on vibration in a micro mill are significant.

Keywords: micro system, micro mill, vibration.

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Authors: F.Agalianos, S.Patelis , P. Kyratsis, E. Maravelakis, E.Vasarmidis, A.Antoniadis

Abstract:

Laser engraving is a manufacturing method for those applications where previously Electrical Discharge Machining (EDM) was the only choice. Laser engraving technology removes material layer-by-layer and the thickness of layers is usually in the range of few microns. The aim of the present work is to investigate the influence of the process parameters on the surface quality when machined by laser engraving. The examined parameters were: the pulse frequency, the beam speed and the layer thickness. The surface quality was determined by the surface roughness for every set of parameters. Experimental results on Al7075 material showed that the surface roughness strictly depends on the process parameters used.

Keywords: Laser engraving, Al7075, Yb: YAG laser, laser process parameters, material roughness.

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Authors: V. Prasannavenkadesan, A. Elango, S. Chockalingam

Abstract:

During machining process, chatter is an unavoidable phenomenon. Boring bars possess the cantilever shape and due to this, it is subjected to chatter. The adverse effect of chatter includes the increase in temperature which will leads to excess tool wear. To overcome these problems, in this investigation, Cartridge brass (Cu – 70% and Zn – 30%) is passively fixed on the boring bar and also clearance is provided in order to reduce the displacement, tool wear and cutting temperature. A conventional all geared lathe is attached with vibrometer and pyrometer is used to measure the displacement and temperature. The influence of input parameters such as cutting speed, depth of cut and clearance on temperature, tool wear and displacement are investigated for various cutting conditions. From the result, the optimum conditions to obtain better damping in boring process for chatter reduction is identified.

Keywords: Boring, chatter, mass damping, passive damping.

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Authors: G. Kehl, P. Wagner

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A novel simulation method to determine the displacements of machine tools due to thermal factors is presented. The specific characteristic of this method is the employment of original CAD data from the design process chain, which is interpreted by an algorithm in terms of geometry-based allocation of convection and radiation parameters. Furthermore analogous models relating to the thermal behaviour of machine elements are automatically implemented, which were gained by extensive experimental testing with thermography imaging. With this a transient simulation of the thermal field and in series of the displacement of the machine tool is possible simultaneously during the design phase. This method was implemented and is already used industrially in the design of machining centres in order to improve the quality of herewith manufactured workpieces.

Keywords: Accuracy, design process, finite element analysis, machine tools, thermal simulation.

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Authors: S. Tangjitsitcharoen

Abstract:

The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the new three parameters are introduced from three dynamic cutting forces, which are calculated by taking the ratio of the average variances of dynamic cutting forces to the absolute variances of themselves. It had been proved that the chatter can be easier to detect during the in-process cutting by using the new parameters which are proposed in this research. The experimentally obtained results showed that the wavelet transform can provide the reliable results to detect the chatter under various cutting conditions.

Keywords: Ball end milling, wavelet transform, fast fourier transform, chatter.

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