Search results for: Ultrasonic Machining

Authors: Kious Mecheri, Hadjadj Abdechafik, Ameur Aissa

Abstract:

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

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

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Authors: Majid Tolouei-Rad

Abstract:

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

Keywords: CAD, Knowledge based system, Reconfigurable

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Authors: Saeedeh Bakhtiari, Johannes Depessemier, Stijn Hertelé, Wim De Waele

Abstract:

High cycle fatigue comprising up to 10⁷ load cycles has been the subject of many studies, and the behavior of many materials was recorded adequately in this regime. However, many applications involve larger numbers of load cycles during the lifetime of machine components. In this ultra-high cycle regime, other failure mechanisms play, and the concept of a fatigue endurance limit (assumed for materials such as steel) is often an oversimplification of reality. When machine component design demands a high geometrical complexity, cast iron grades become interesting candidate materials. Grey cast iron is known for its low cost, high compressive strength, and good damping properties. However, the ultra-high cycle fatigue behavior of cast iron is poorly documented. The current work focuses on the ultra-high cycle fatigue behavior of EN-GJL-250 (GG25) grey cast iron by developing an ultrasonic (20 kHz) fatigue testing system. Moreover, the testing machine is instrumented to measure the temperature and the displacement of  the specimen, and to control the temperature. The high resonance frequency allowed to assess the  behavior of the cast iron of interest within a matter of days for ultra-high numbers of cycles, and repeat the tests to quantify the natural scatter in fatigue resistance.

Keywords: GG25, cast iron, ultra-high cycle fatigue, ultrasonic test.

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

Abstract:

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

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

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Authors: J. Mendoza-López, S. Sánchez-Solano, J. L. Huertas-Díaz

Abstract:

An array of piezoelectric micro actuators can be used for radiation of an ultrasonic carrier signal modulated in amplitude with an acoustic signal, which yields audio frequency applications as the air acts as a self-demodulating medium. This application is known as the parametric array. We propose a parametric array with array elements based on existing piezoelectric micro ultrasonic transducer (pMUT) design techniques. In order to reach enough acoustic output power at a desired operating frequency, a proper ratio between number of array elements and array size needs to be used, with an array total area of the order of one cm square. The transducers presented are characterized via impedance, admittance, noise figure, transducer gain and frequency responses.

Keywords: Pizeoelectric, Microspeaker, MEMS, pMUT, Parametric Array

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

Abstract:

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

Keywords: Ellipse, Approximation, NURBS, Optimum.

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Authors: Mehdi Modabberifar, Behrouz Raad, Bahman Mirzakhani

Abstract:

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

Keywords: Die casting, finite element, flange.

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Authors: Abdulhamit Donder, Erhan Ilhan Konukseven

Abstract:

Grinding operation is performed in order to obtain desired surfaces precisely in machining process. The needed relative motion between the cutting tool and the workpiece is generally created either by the movement of the cutting tool or by the movement of the workpiece or by the movement of both of them as in our case. For all these cases, the coherence level between the movements and the interaction forces is a key influential parameter for efficient grinding. Therefore, in this work, spectral coherence analysis has been performed to investigate the coherence level between grinding interaction forces and the movement of the workpiece on our robotic-grinding experimental setup in METU Mechatronics Laboratory.

Keywords: Coherence analysis, correlation, FFT, grinding, Hanning window, machining, Piezo actuator, reverse arrangements test, spectral analysis.

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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. M. Ali, N. R. Dhar

Abstract:

Tool wear and surface roughness prediction plays a significant role in machining industry for proper planning and control of machining parameters and optimization of cutting conditions. This paper deals with developing an artificial neural network (ANN) model as a function of cutting parameters in turning steel under minimum quantity lubrication (MQL). A feed-forward backpropagation network with twenty five hidden neurons has been selected as the optimum network. The co-efficient of determination (R2) between model predictions and experimental values are 0.9915, 0.9906, 0.9761 and 0.9627 in terms of VB, VM, VS and Ra respectively. The results imply that the model can be used easily to forecast tool wear and surface roughness in response to cutting parameters.

Keywords: ANN, MQL, Surface Roughness, Tool Wear.

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Authors: S. Ghorbani, N. I. Polushin

Abstract:

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

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

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

Abstract:

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

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

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Authors: Shi-hong Lu, Chao-xun Liu, Yi-feng Zhu

Abstract:

Ultrasonic shot peening (USP) on AALY12 sheet was studied. Several parameters (arc heights, surface roughness, surface topography and micro hardness) with different USP process parameters were measured. The research proposes that radius of curvature of shot peened sheet increases with time and electric current decreasing, while increases with pin diameter increasing, and radius of curvature reaches a saturation level after a specific processing time and electric current. An empirical model of the relationship between radius of curvature and pin diameter, electric current, time was also obtained. The research shows that the increment of surface and vertical micro hardness of material is more obvious with longer time and higher value of electric current, which can be up to 20% and 28% respectively.

Keywords: USP forming, surface properties, radius of curvature, residual stress.

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Authors: A. Satour, F. Boubenider, R. Halimi, A. Badidibouda

Abstract:

Sandwich plates are finding an increasing range of application in the aircraft industry. The inspection of honeycomb composite structure by conventional ultrasonic technique is complex and very time consuming. The present study demonstrates a technique using guided Lamb waves at low frequencies to predict de-bond defects in aluminum skin-honeycomb core sandwich structure used in aeronautics. The numerical method was investigated for drawing the dispersion and displacement curves of ultrasonic Lamb wave propagated in Aluminum plate. An experimental study was carried out to check the theoretical prediction. The detection of unsticking between the skin and the core was tested by the two first modes for a low frequency. It was found that A0 mode is more sensitive to delamination defect compared to S0 mode.

Keywords: Damage detection, delamination, guided waves, Sandwich structure.

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Authors: S. Grace Sahaya Sheba, R. Omegala Priakumari

Abstract:

Polyethylene glycol (PEG) is a condensation polymer of ethylene oxide and water. It is soluble in water and in many organic solvents. PEG is used to make emulsifying agents, detergents, soaps, plasticizers, ointments etc. Ethanol (C₂H₅OH) also known as ethyl alcohol is a well-known organic compound and has wide applications in chemical industry as it is used as a solvent for paint, varnish, in preserving biological specimens, used as a fuel mixed with petrol etc. Though their chemical and physical properties are already studied, still because of their uses in day to day life the authors thought it is better to study some more of their physical properties like ultrasonic velocity and hence adiabatic compressibility, free length, etc. A detailed study of such properties and some excess parameters like excess adiabatic compressibility, excess free volume and few more in the liquid mixtures of these two compounds with PEG as a solute and Ethanol as a solvent at various mole fractions may throw some light on deeper understanding of molecular interaction between the solute and the solvent supported by NMR, IR etc. Hence the present research work is on ultrasonics/allied studies on these two liquid mixtures. Ultrasonic velocity (U), density (ρ) and viscosity (η) at room temperature and at different mole fraction from 0 to 0.055 of ethanol in PEG have been experimentally carried out by the authors. Acoustical parameters such as adiabatic compressibility (β), free volume (V_f), acoustic impedance (Z), internal pressure (π_i), intermolecular free length (L_f) and relaxation time (τ) were calculated from the experimental data. We have calculated excess parameters like excess adiabatic compressibility (β^E), excess internal pressure (π_i^E) free length (L_f^E) and excess acoustic impedance (Z^E) etc for these two chosen liquid mixtures. The excess compressibility is positive and maximum around a mole fraction 0.007 and excess internal pressure is negative and maximum at the same mole fraction and longer free length. The results are analyzed and it may be concluded that the molecular interactions between the solute and the solvent is not strong and it may be weak. Appropriate graphs are drawn.

Keywords: Adiabatic Compressibility, Binary mixture, Induce dipole, Polarizability, Ultrasonic.

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Authors: Farhad Kolahan, A. Hamid Khajavi

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

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

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

Abstract:

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

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

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Authors: Omid A. Zargar

Abstract:

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

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

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

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

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

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

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Authors: Moaz H. Ali, M. N. M. Ansari, Pang Jing Shen

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In present work, prediction the effect of nose radius, rz (mm) on the equivalent strain (PEEQ) and surface finish during the machining of titanium alloy (Ti-6Al-4V) through orthogonal cutting process. The results were performed at several of the nose radiuses, rz (mm) while the cutting speed, vc (m/min), feed rate, f (mm/tooth) and depth of cut, d (mm) were remained constant. The equivalent plastic strain (PEEQ) was estimated by using finite element modeling (FEM) and applied through ABAQUS/EXPLICIT software. The simulation results led to conclude that the equivalent plastic strain (PEEQ) was increased and surface roughness (Ra) decreased when increasing nose radius, rz (mm) during the machining of titanium alloy (Ti–6Al–4V) in dry cutting conditions.

Keywords: Finite element modeling (FEM), nose radius, plastic strain (PEEQ), titanium alloy (Ti-6Al-4V).

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Authors: Won-Pil Park, Qyoun-Jung Lee, Dae-Gon Woo, Chang-Yong Ko, Eun-Geun Kim, Dohyung Lim, Yong-Heum Lee, Tae-Min Shin, Han-Sung Kim

Abstract:

The disaster from functional gastrointestinal disorders has detrimental impact on the quality of life of the effected population and imposes a tremendous social and economic burden. There are, however, rare diagnostic methods for the functional gastrointestinal disorders. Our research group identified recently that the gastrointestinal tract well in the patients with the functional gastrointestinal disorders becomes more rigid than healthy people when palpating the abdominal regions overlaying the gastrointestinal tract. Objective of current study is, therefore, identify feasibility of a diagnostic system for the functional gastrointestinal disorders based on ultrasound technique, which can quantify the characteristics above. Two-dimensional finite difference (FD) models (one normal and two rigid model) were developed to analyze the reflective characteristic (displacement) on each soft-tissue layer responded after application of ultrasound signals. The FD analysis was then based on elastic ultrasound theory. Validation of the model was performed via comparison of the characteristic of the ultrasonic responses predicted by FD analysis with that determined from the actual specimens for the normal and rigid conditions. Based on the results from FD analysis, ultrasound system for diagnosis of the functional gastrointestinal disorders was developed and clinically tested via application of it to 40 human subjects with/without functional gastrointestinal disorders who were assigned to Normal and Patient Groups. The FD models were favorably validated. The results from FD analysis showed that the maximum displacement amplitude in the rigid models (0.12 and 0.16) at the interface between the fat and muscle layers was explicitly less than that in the normal model (0.29). The results from actual specimens showed that the maximum amplitude of the ultrasonic reflective signal in the rigid models (0.2±0.1Vp-p) at the interface between the fat and muscle layers was explicitly higher than that in the normal model (0.1±0.2 Vp-p). Clinical tests using our customized ultrasound system showed that the maximum amplitudes of the ultrasonic reflective signals near to the gastrointestinal tract well for the patient group (2.6±0.3 Vp-p) were generally higher than those in normal group (0.1±0.2 Vp-p). Here, maximum reflective signals was appeared at 20mm depth approximately from abdominal skin for all human subjects, corresponding to the location of the boundary layer close to gastrointestinal tract well. These findings suggest that our customized ultrasound system using the ultrasonic reflective signal may be helpful to the diagnosis of the functional gastrointestinal disorders.

Keywords: Finite Difference (FD) Analysis, FunctionalGastrointestinal Disorders, Gastrointestinal Tract, UltrasonicResponses.

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Authors: Alexandru Epureanu, Virgil Teodor

Abstract:

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

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

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Authors: Shiuh-Jer Huang, Yu-Sheng Hsu

Abstract:

On-board available parking space detecting system, parking trajectory planning and tracking control mechanism are the key components of vehicle backward auto-parking system. Firstly, pair of ultrasonic sensors is installed on each side of vehicle body surface to detect the relative distance between ego-car and surrounding obstacle. The dimension of a found empty space can be calculated based on vehicle speed and the time history of ultrasonic sensor detecting information. This result can be used for constructing the 2D vehicle environmental map and available parking type judgment. Finally, the auto-parking controller executes the on-line optimal parking trajectory planning based on this 2D environmental map, and monitors the real-time vehicle parking trajectory tracking control. This low cost auto-parking system was tested on a model car.

Keywords: Vehicle auto-parking, parking space detection, parking path tracking, intelligent fuzzy controller.

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Authors: Kechida Ahmed, Drai Redouane, Khelil Mohamed

Abstract:

In this paper we present a new approach to detecting a flaw in T.O.F.D (Time Of Flight Diffraction) type ultrasonic image based on texture features. Texture is one of the most important features used in recognizing patterns in an image. The paper describes texture features based on 2D Gabor functions, i.e., Gaussian shaped band-pass filters, with dyadic treatment of the radial spatial frequency range and multiple orientations, which represent an appropriate choice for tasks requiring simultaneous measurement in both space and frequency domains. The most relevant features are used as input data on a Fuzzy c-mean clustering classifier. The classes that exist are only two: 'defects' or 'no defects'. The proposed approach is tested on the T.O.F.D image achieved at the laboratory and on the industrial field.

Keywords: 2D Gabor Functions, flaw detection, fuzzy c-mean clustering, non destructive testing, texture analysis, T.O.F.D Image (Time of Flight Diffraction).

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

Abstract:

The machining performance is determined by the frequency characteristics of the machine-tool structure and the dynamics of the cutting process. Therefore, the prediction of dynamic vibration behavior of spindle tool system is of great importance for the design of a machine tool capable of high-precision and high-speed machining. The aim of this study is to develop a finite element model to predict the dynamic characteristics of milling machine tool and hence evaluate the influence of the preload of the spindle bearings. To this purpose, a three dimensional spindle bearing model of a high speed engraving spindle tool was created. In this model, the rolling interfaces with contact stiffness defined by Harris model were used to simulate the spindle bearing components. Then a full finite element model of a vertical milling machine was established by coupling the spindle tool unit with the machine frame structure. Using this model, the vibration mode that had a dominant influence on the dynamic stiffness was determined. The results of the finite element simulations reveal that spindle bearing with different preloads greatly affect the dynamic behavior of the spindle tool unit and hence the dynamic responses of the vertical column milling system. These results were validated by performing vibration on the individual spindle tool unit and the milling machine prototype, respectively. We conclude that preload of the spindle bearings is an important component affecting the dynamic characteristics and machining performance of the entire vertical column structure of the milling machine.

Keywords: Dynamic compliance, Milling machine, Spindle unit, Bearing preload.

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Authors: Arnab Majumdar, Sanjoy Sadhukhan

Abstract:

Although gun barrel steels are an important variety from defense view point, available literatures are very limited. In the present work, an IF grade Ni-Cr-Mo-V high strength low alloy steel is produced in Electric Earth Furnace-ESR Route. Ingot was hot forged to desired dimension with a reduction ratio of 70-75% followed by homogenization, hardening and tempering treatment. Sample chemistry, NMIR, macro and micro structural analyses were done. Mechanical properties which include tensile, impact, and fracture toughness were studied. Ultrasonic testing was done to identify internal flaws. The existing high strength low alloy Ni-Cr-Mo-V steel shows improved properties in modified processing route and heat treatment schedule in comparison to properties noted earlier for manufacturing of gun barrels. The improvement in properties seems to withstand higher explosive loads with the same amount of steel in gun barrel application.

Keywords: Gun barrel steels, IF grade, physical properties, thermal and mechanical processing, mechanical properties, ultrasonic testing.

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Authors: Mustafa Hasan Omar

Abstract:

The destruction effect of hydrocarbon solutions on concrete besides its high permeability have led researchers to try to improve the performance of concrete exposed to these solutions, hence improving the durability and usability of oil concrete structures. Recently, polymer concrete is considered one of the most important types of concrete, and its behavior after exposure to oil products is still unknown. In the present work, an experimental study has been carried out, in which the prepared epoxy polymer concrete immersed in different types of hydrocarbon exposure solutions (gasoline, kerosene, and gas oil) for 120 days and compared with the reference concrete left in the air. The results for outdoor specimens indicate that the mechanical properties are increased after 120 days, but the specimens that were immersed in gasoline, kerosene, and gas oil for the same period show a reduction in compressive strength by -21%, -27% and -23%, whereas in splitting tensile strength by -19%, -24% and -20%, respectively. The reductions in ultrasonic pulse velocity for cubic specimens are -17%, -22% and -19% and in cylindrical specimens are -20%, -25% and -22%, respectively.

Keywords: Epoxy resin, hydrocarbon solutions, mechanical properties, polymer concrete, ultrasonic pulse velocity.

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Authors: Sarabjeet Singh Sidhu, Ajay Batish, Sanjeev Kumar

Abstract:

This paper reports the optimal process conditions for machining of three different types of MMC’s 65vol%SiC/A356.2; 10vol%SiC-5vol%quartz/Al and 30vol%SiC/A359 using PMEDM process. MRR, TWR, SR and surface integrity were evaluated after each trial and contributing process parameters were identified. The four responses were then collectively optimized using TOPSIS and optimal process conditions were identified for each type of MMC. The density of reinforced particles shields the matrix material from spark energy hence the high MRR and SR was observed with lowest reinforced particle. TWR was highest with Cu-Gr electrode due to disintegration of the weakly bonded particles in the composite electrode. Each workpiece was examined for surface integrity and ranked as per severity of surface defects observed and their rankings were used for arriving at the most optimal process settings for each workpiece. 

Keywords: Metal matrix composites (MMCs), Metal removal rate (MRR), Surface roughness (SR), Surface integrity (SI), Tool wear rate (TWR), Technique for order preference by similarity to ideal solution (TOPSIS).

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Authors: Petr Homola, Roman Růžek

Abstract:

Laser beam micro-drilling (LBMD) is one of the most important non-contact machining processes of materials that are difficult to machine by means oeqf conventional machining methods used in various industries. The paper is focused on LBMD knock-down effect on Ti-6Al-4V (Grade 5) titanium alloy sheets properties. Two various process configurations were verified with a focus on laser damages in back-structure parts affected by the process. The effects of the LBMD on the material properties were assessed by means of tensile and fatigue tests and fracture surface analyses. Fatigue limit of LBMD configurations reached a significantly lower value between 15% and 30% of the static strength as compared to the reference raw material with 58% value. The farther back-structure configuration gives a two-fold fatigue life as compared to the closer LBMD configuration at a given stress applied.

Keywords: Fatigue, fracture surface, laser beam micro-drilling, titanium alloy.

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Authors: Rudy Bahouth, Farouk Benmeddour, Emmanuel Moulin, Jamal Assaad

Abstract:

Guided ultrasonic waves are used in Non-Destructive Testing and Structural Health Monitoring for inspection and damage detection. Recently, wireless data transmission using ultrasonic waves in solid metallic channels has gained popularity in some industrial applications such as nuclear, aerospace and smart vehicles. The idea is to find a good substitute for electromagnetic waves since they are highly attenuated near metallic components due to Faraday shielding. The proposed solution is to use ultrasonic guided waves such as Lamb waves as an information carrier due to their capability of propagation for long distances. In addition to this, valuable information about the health of the structure could be extracted simultaneously. In this work, the reliable frequency bandwidth for communication is extracted experimentally from dispersion curves at first. Then, an experimental platform for wireless communication using Lamb waves is described and built. After this, coherent demodulation algorithm used in telecommunications is tested for Amplitude Shift Keying, On-Off Keying and Binary Phase Shift Keying modulation techniques. Signal processing parameters such as threshold choice, number of cycles per bit and Bit Rate are optimized. Experimental results are compared based on the average bit error percentage. Results has shown high sensitivity to threshold selection for Amplitude Shift Keying and On-Off Keying techniques resulting a Bit Rate decrease. Binary Phase Shift Keying technique shows the highest stability and data rate between all tested modulation techniques.

Keywords: Lamb Wave Communication, wireless communication, coherent demodulation, bit error percentage.

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