Search results for: cutting parameters

Authors: Tadahiro Wada, Shinichi Enoki, Hiroyuki Hanyu

Abstract:

In this study, WC-Ni-based cemented carbides having different nickel contents were used as the substrate for cutting tool materials. Hardened steel was turned by a (Ti,W,Si)N-coated WC-Ni-based cemented carbide tool, and the tool wear was experimentally investigated. The following results were obtained: (1) In the (Ti,W,Si)N-coated WC-Ni-based cemented carbide, the hardness of the coating film was not much different from the content of the binding material, Ni, and the adhesion strength increased with a decrease in Ni content. (2) There is little difference between the wear progress of the (Ti,W,Si)N-coated WC-7%Ni-based cemented carbide tool and that of the (Ti,W,Si)N-coated WC-6%Co-based cemented carbide tool. (3) The wear progress of the (Ti,W,Si)N-coated WC-Ni-based cemented carbide became slower with a decrease in Ni content.

From the above, it is has become clear that WC-Ni-based cemented carbide can be used as a substrate for cutting tool materials.

Keywords: Rare metals, turning, WC-Ni-based cemented carbide, (Ti, W, Si)N coating film, hardened steel.

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Authors: J. Chatthong, W. Boonchouytan, R. Burapa

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The purpose of study was to design and construction the semi-automatic sliced ginger machine for reduce production times in sheet and slice ginger procedure furthermore, reduced amount of labor of slides and cutting method. Take consider into clean and safety of workers and consumers. The principle of machines, used 1 horsepower motor, rotation speed of sliced blade 967 rpm, the diameter of sliced dish 310 mm, consists of 2 blades for sheet cutting ginger and the power from motor which transfer to rotate the sliced blade roller, rotation speed 440 rpm. The slice cutter roller was sliced ginger from sheet ginger to line ginger. The conveyer could adjustment level of motors, used to the beginning area that sheet ginger was transference to the roller for sheet and sliced cutting in next process. The cover of sliced cutting had channel for 1 tuber of ginger. The semi-automatic sliced ginger machine could produced sheet ginger 81.8 kg/h (6.2 times of labor) and line ginger 17.9 kg/h (2.5 times of labor) compare with, labor work could produced sheet ginger 13.2 kg/h and line ginger 7.1 kg/h, and when timekeeper, the total times of semi auto machine 30.86 kg/h and labor 4.6 kg/h, there for the semi auto machine was 6.7 times of labor. The semiautomatic sliced ginger machine convenient, easy for use and maintain, in addition to reduce fatigue of body and seriousness from works; must be used high skill, and protection accident in slicing procedure. Beside, machine could used with other vegetables for example potato, carrot .etc

Keywords: Sliced Machine, Sliced Ginger, Line Ginger

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Authors: S. Srinivas, N. Ramesh Babu

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This paper presents a model to predict the depth of penetration in polycrystalline ceramic material cut by abrasive waterjet. The proposed model considered the interaction of cylindrical jet with target material in upper region and neglected the role of threshold velocity in lower region. The results predicted with the proposed model are validated with the experimental results obtained with Silicon Carbide (SiC) blocks.

Keywords: Abrasive waterjet cutting, analytical modeling, ceramics, microcutting and intergranular cracking.

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Authors: Tadahiro Wada, Hiroyuki Hanyu

Abstract:

In this study, to clarify the effectiveness of an aluminum/chromium/tungsten-based-coated tool for cutting sintered steel, tool wear was experimentally investigated. The sintered steel was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and (Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the physical vapor deposition (PVD) method. Moreover, the tool wear of the aluminum/chromium/tungsten-based-coated item was compared with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool wear mechanism of the aluminum/chromium/tungsten-coating film for cutting sintered steel, Scanning Electron Microscope observation and Energy Dispersive x-ray Spectroscopy mapping analysis were conducted on the abraded surface. The following results were obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated tool was the slowest among that of the five coated tools. (2) Adding carbon (C) to the aluminum/chromium/tungsten-based-coating film was effective for improving the wear-resistance. (3) The main wear mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)- and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.

Keywords: Cutting, physical vapor deposition coating method, tool wear, tool wear mechanism, sintered steel.

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Authors: Felipe V. Díaz, Claudio A. Mammana, Armando P. M. Guidobono, Raúl E. Bolmaro

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Through a proper analysis of residual strain and stress distributions obtained at the surface of high speed milled specimens of AA 6082–T6 aluminium alloy, the performance of an improved indentation method is evaluated. This method integrates a special device of indentation to a universal measuring machine. The mentioned device allows introducing elongated indents allowing to diminish the absolute error of measurement. It must be noted that the present method offers the great advantage of avoiding both the specific equipment and highly qualified personnel, and their inherent high costs. In this work, the cutting tool geometry and high speed parameters are selected to introduce reduced plastic damage. Through the variation of the depth of cut, the stability of the shapes adopted by the residual strain and stress distributions is evaluated. The results show that the strain and stress distributions remain unchanged, compressive and small. Moreover, these distributions reveal a similar asymmetry when the gradients corresponding to conventional and climb cutting zones are compared.

Keywords: Residual strain, residual stress, high speed milling, indentation methods, aluminium alloys.

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Authors: Lydia Chan, Islam Shyha, Dale Dreyer, John Hamilton, Phil Hackney

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Nickel-based superalloys are generally known to be difficult to cut due to their strength, low thermal conductivity, and high work hardening tendency. Superalloy such as alloy 625 is often used in the oil and gas industry as a surfacing material to provide wear and corrosion resistance to components. The material is typically applied onto a metallic substrate through weld overlay cladding, an arc welding technique. Cladded surfaces are always rugged and carry a tough skin; this creates further difficulties to the machining process. The present work utilised design of experiment to optimise the internal cylindrical rough turning for weld overlay surfaces. An L27 orthogonal array was used to assess effects of the four selected key process variables: cutting insert, depth of cut, feed rate, and cutting speed. The optimal cutting conditions were determined based on productivity and the level of tool wear.

Keywords: Cylindrical turning, nickel superalloy, turning of overlay, weld overlay.

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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: Jehnming Lin

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The effects of the contact ball-lens on the soda lime glass in laser thermal cleavage with a cw Nd-YAG laser were investigated in this study. A contact ball-lens was adopted to generate a bending force on the crack formation of the soda-lime glass in the laser cutting process. The Nd-YAG laser beam (wavelength of 1064 nm) was focused through the ball-lens and transmitted to the soda-lime glass, which was coated with a carbon film on the surface with a bending force from a ball-lens to generate a tensile stress state on the surface cracking. The fracture was controlled by the contact ball-lens and a straight cutting was tested to demonstrate the feasibility. Experimental observations on the crack propagation from the leading edge, main section and trailing edge of the glass sheet were compared with various mechanical and thermal loadings. Further analyses on the stress under various laser powers and contact ball loadings were made to characterize the innovative technology. The results show that the distributions of the side crack at the leading and trailing edges are mainly dependent on the boundary condition, contact force, cutting speed and laser power. With the increase of the mechanical and thermal loadings, the region of the side cracks might be dramatically reduced with proper selection of the geometrical constrains. Therefore the application of the contact ball-lens is a possible way to control the fracture in laser cleavage with improved cutting qualities.

Keywords: Laser cleavage, controlled fracture, contact ball lens.

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Authors: Pushpendra S. Bharti, S. Maheshwari

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Electric discharge machining (EDM) is one of the most widely used non-conventional manufacturing process to shape difficult-to-cut materials. The process yield, in terms of material removal rate, surface roughness and tool wear rate, of EDM may considerably be improved by selecting the optimal combination(s) of process parameters. This paper employs Multi-response signal-to-noise (MRSN) ratio technique to find the optimal combination(s) of the process parameters during EDM of Inconel 718. Three cases v.i.z. high cutting efficiency, high surface finish, and normal machining have been taken and the optimal combinations of input parameters have been obtained for each case. Analysis of variance (ANOVA) has been employed to find the dominant parameter(s) in all three cases. The experimental verification of the obtained results has also been made. MRSN ratio technique found to be a simple and effective multi-objective optimization technique.

Keywords: EDM, material removal rate, multi-response signal-to-noise ratio, optimization, surface roughness.

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Authors: M. K. Pradhan, Mayank Meena, Shubham Sen, Arvind Singh

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In this study, a multi objective optimization for end milling of Al 6061 alloy has been presented to provide better surface quality and higher Material Removal Rate (MRR). The input parameters considered for the analysis are spindle speed, depth of cut and feed. The experiments were planned as per Taguchis design of experiment, with L27 orthogonal array. The Grey Relational Analysis (GRA) has been used for transforming multiple quality responses into a single response and the weights of the each performance characteristics are determined by employing the Principal Component Analysis (PCA), so that their relative importance can be properly and objectively described. The results reveal that Taguchi based G-PCA can effectively acquire the optimal combination of cutting parameters.

Keywords: Material Removal Rate, Surface Roughness, Taguchi Method, Grey Relational Analysis, Principal Component Analysis.

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Authors: Lin. Yan, Wenyu. Yang, Hongping. Jin, Zhiguang Wang

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This paper presents a experiment to estimate the influences of cutting conditions in microstructure changes of machining austenitic 304 stainless steel, especially for wear insert. The wear insert were prefabricated with a width of 0.5 mm. And the forces, temperature distribution, RS, and microstructure changes were measured by force dynamometer, infrared thermal camera, X-ray diffraction, XRD, SEM, respectively. The results told that the different combinations of machining condition have a significant influence on machined surface microstructure changes. In addition to that, the ANOVA and AOMwere used to tell the different influences of cutting speed, feed rate, and wear insert.

Keywords: Microstructure Changes, Wear width, Stainless steel

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Authors: Chalakorn Chitsaart, Suchada Rianmora, Mann Rattana-Areeyagon, Wutichai Namjaiprasert

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G-code is the main factor in computer numerical control (CNC) machine for controlling the toolpaths and generating the profile of the object’s features. For obtaining high surface accuracy of the surface finish, non-stop operation is required for CNC machine. Recently, to design a new product, the strategy that concerns about a change that has low impact on business and does not consume lot of resources has been introduced. Cost and time for designing minor changes can be reduced since the traditional geometric details of the existing models are applied. In order to support this strategy as the alternative channel for machining operation, this research proposes the automatic generating codes for CNC milling operation. Using this technique can assist the manufacturer to easily change the size and the geometric shape of the product during the operation where the time spent for setting up or processing the machine are reduced. The algorithm implemented on MATLAB platform is developed by analyzing and evaluating the geometric information of the part. Codes are created rapidly to control the operations of the machine. Comparing to the codes obtained from CAM, this developed algorithm can shortly generate and simulate the cutting profile of the part.

Keywords: Geometric shapes, Milling operation, Minor changes, CNC Machine, G-code, and Cutting parameters.

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

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

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

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Authors: Dinesh Setti, Sudarasan Ghosh, P. Venkateswara Rao

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Minimum Quantity Lubrication (MQL) technique obtained a significant attention in machining processes to reduce environmental loads caused by usage of conventional cutting fluids. Recently nanofluids are finding an extensive application in the field of mechanical engineering because of their superior lubrication and heat dissipation characteristics. This paper investigates the use of a nanofluid under MQL mode to improve grinding characteristics of Ti-6Al-4V alloy. Taguchi-s experimental design technique has been used in the present investigation and a second order model has been established to predict grinding forces and surface roughness. Different concentrations of water based Al2O3 nanofluids were applied in the grinding operation through MQL setup developed in house and the results have been compared with those of conventional coolant and pure water. Experimental results showed that grinding forces reduced significantly when nano cutting fluid was used even at low concentration of the nano particles and surface finish has been found to improve with higher concentration of the nano particles.

Keywords: MQL, Nanofluid, Taguchi method, Ti-6Al-4V.

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Authors: Swapnil Rajan Jadhav, Ajay Vasantrao Kashikar

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Lubrication, cooling and chip removal are the desired functions of any cutting fluid. Conventional or flood lubrication requires high volume flow rate and cost associated with this is higher. In addition, flood lubrication possesses health risks to machine operator. To avoid these consequences, dry machining and minimum quantity are two alternatives. Dry machining cannot be a suited alternative as it can generate greater heat and poor surface finish. Here, turning work is carried out on a Lathe machine using EN3 Mild steel. Variable cutting speeds and depth of cuts are provided and corresponding temperatures and surface roughness values were recorded. Experimental results are analyzed by Minitab software. Regression analysis, main effect plot, and interaction plot conclusion are drawn by using ANOVA. There is a 95.83% reduction in the use of cutting fluid. MQL gives a 9.88% reduction in tool temperature, this will improve tool life. MQL produced a 17.64% improved surface finish. MQL appears to be an economical and environmentally compatible lubrication technique for sustainable manufacturing.

Keywords: ANOVA, MQL, regression analysis, surface roughness

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Authors: Swapnil Rajan Jadhav, Ajay Vasantrao Kashikar

Abstract:

Lubrication, cooling and chip removal are the desired functions of any cutting fluid. Conventional or flood lubrication requires high volume flow rate and cost associated with this is higher. In addition, flood lubrication possesses health risks to machine operator. To avoid these consequences, dry machining and minimum quantity are two alternatives. Dry machining cannot be a suited alternative as it can generate greater heat and poor surface finish. Here, turning work is carried out on a Lathe machine using EN3 Mild steel. Variable cutting speeds and depth of cuts are provided and corresponding temperatures and surface roughness values were recorded. Experimental results are analyzed by Minitab software. Regression analysis, main effect plot, and interaction plot conclusion are drawn by using ANOVA. There is a 95.83% reduction in the use of cutting fluid. MQL gives a 9.88% reduction in tool temperature, this will improve tool life. MQL produced a 17.64% improved surface finish. MQL appears to be an economical and environmentally compatible lubrication technique for sustainable manufacturing.

Keywords: ANOVA, MQL, regression analysis, surface roughness

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Authors: Jui P. Hung, Yuan L. Lai, Hui T. You

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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, which can further be identified in terms of the stability lobe diagram. Therefore, realization on the machine tool dynamic behavior can help to enhance the cutting stability. To assess the dynamic characteristics and machining stability of a vertical milling system under the influence of a linear guide, this study developed a finite element model integrated the modeling of linear components with the implementation of contact stiffness at the rolling interface. Both the finite element simulations and experimental measurements reveal that the linear guide with different preload greatly affects the vibration behavior and milling stability of the vertical column spindle head system, which also clearly indicate that the predictions of the machining stability agree well with the cutting tests. It is believed that the proposed model can be successfully applied to evaluate the dynamics performance of machine tool systems of various configurations.

Keywords: Machining stability, Vertical milling machine, Linearguide, Contact stiffness.

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Authors: Panagiotis Kyratsis, Dr. Ing. Nikolaos Bilalis, Dr. Ing. Aristomenis Antoniadis

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Twist drills are geometrical complex tools and thus various researchers have adopted different mathematical and experimental approaches for their simulation. The present paper acknowledges the increasing use of modern CAD systems and using the API (Application Programming Interface) of a CAD system, drilling simulations are carried out. The developed DRILL3D software routine, creates parametrically controlled tool geometries and using different cutting conditions, achieves the generation of solid models for all the relevant data involved (drilling tool, cut workpiece, undeformed chip). The final data derived, consist a platform for further direct simulations regarding the determination of cutting forces, tool wear, drilling optimizations etc.

Keywords: Drilling, CAD based simulation, 3D-modelling.

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Authors: Majid Tolouei-Rad

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This paper describes a combined mathematicalgraphical approach for optimum tool path planning in order to improve machining efficiency. A methodology has been used that stabilizes machining operations by adjusting material removal rate in pocket milling operations while keeping cutting forces within limits. This increases the life of cutting tool and reduces the risk of tool breakage, machining vibration, and chatter. Case studies reveal the fact that application of this approach could result in a slight increase of machining time, however, a considerable reduction of tooling cost, machining vibration, noise and chatter can be achieved in addition to producing a better surface finish.

Keywords: CNC machines, milling, optimization, removal rate.

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Authors: Mengjun Zhang, Yuli Sun, Dunwen Zuo, Chunxiang Xie, Chunming Zhang

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Experimental study on slicing of sapphire with fixed abrasive diamond wire saw was conducted in this paper. The process parameters were optimized through orthogonal experiment of three factors and four levels. The effects of wire speed, feed speed and tension pressure on the surface roughness were analyzed. Surface roughness in cutting direction and feed direction were both detected. The results show that feed speed plays the most significant role on the surface roughness of sliced sapphire followed by wire speed and tension pressure. The optimized process parameters are as follows: wire speed 1.9 m/s, feed speed 0.187 mm/min and tension pressure 0.18 MPa. In the end, the results were verified by analysis of variance.

Keywords: Fixed abrasive, diamond wire saw, slicing, sapphire, orthogonal experiment.

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Authors: Amirhossein Lotfi, Huaizhong Li, Dzung Viet Dao

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Interest in natural fiber-reinforced composites (NFRC) is progressively growing both in terms of academia research and industrial applications thanks to their abundant advantages such as low cost, biodegradability, eco-friendly nature and relatively good mechanical properties. However, their widespread use is still presumed as challenging because of the specificity of their non-homogeneous structure, limited knowledge on their machinability characteristics and parameter settings, to avoid defects associated with the machining process. The present work is aimed to investigate the effect of the cutting tool geometry and material on the drilling-induced delamination, thrust force and hole quality produced when drilling a fully biodegradable flax/poly (lactic acid) composite laminate. Three drills with different geometries and material were used at different drilling conditions to evaluate the machinability of the fabricated composites. The experimental results indicated that the choice of cutting tool, in terms of material and geometry, has a noticeable influence on the cutting thrust force and subsequently drilling-induced damages. The lower value of thrust force and better hole quality was observed using high-speed steel (HSS) drill, whereas Carbide drill (with point angle of 130^o) resulted in the highest value of thrust force. Carbide drill presented higher wear resistance and stability in variation of thrust force with a number of holes drilled, while HSS drill showed the lower value of thrust force during the drilling process. Finally, within the selected cutting range, the delamination damage increased noticeably with feed rate and moderately with spindle speed.

Keywords: Natural fiber-reinforced composites, machinability, thrust force, delamination.

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Authors: Satish Kumar, Arun Kumar Gupta, Pankaj Chandna

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In the modern manufacturing systems, the use of thermal cutting techniques using oxyfuel, plasma and laser have become indispensable for the shape forming of high quality complex components; however, the conventional chip removal production techniques still have its widespread space in the manufacturing industry. Both these types of machining operations require the positioning of end effector tool at the edge where the cutting process commences. This repositioning of the cutting tool in every machining operation is repeated several times and is termed as non-productive time or airtime motion. Minimization of this non-productive machining time plays an important role in mass production with high speed machining. As, the tool moves from one region to the other by rapid movement and visits a meticulous region once in the whole operation, hence the non-productive time can be minimized by synchronizing the tool movements. In this work, this problem is being formulated as a general travelling salesman problem (TSP) and a genetic algorithm approach has been applied to solve the same. For improving the efficiency of the algorithm, the GA has been hybridized with a noble special heuristic and simulating annealing (SA). In the present work a novel heuristic in the combination of GA has been developed for synchronization of toolpath movements during repositioning of the tool. A comparative analysis of new Meta heuristic techniques with simple genetic algorithm has been performed. The proposed metaheuristic approach shows better performance than simple genetic algorithm for minimization of nonproductive toolpath length. Also, the results obtained with the help of hybrid simulated annealing genetic algorithm (HSAGA) are also found better than the results using simple genetic algorithm only.

Keywords: Non-productive time, Airtime, 2.5 D milling, Laser cutting, Metaheuristic, Genetic Algorithm, Simulated Annealing.

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

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

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

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Authors: A. Vaidya-Soocheta, K. M. Wong-Hon-Lang

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Craft and fashion have always been interlinked. The combination of both often gives stunning results. The present study introduces ‘Paper Cutting Craft Techniques’ like the Japanese –Kirigami, Mexican –PapelPicado, German –Scherenschnitte, Polish –Wycinankito in textiles to develop innovative and novel design structures as embellishments and ornamentation. The project studies various ways of using these paper cutting techniques to obtain interesting features and delicate design patterns on fabrics. While paper has its advantages and related uses, it is fragile rigid and thus not appropriate for clothing. Fabric is sturdy, flexible, dimensionally stable and washable. In the present study, the cut out techniques develop creative design motifs and patterns to give an inventive and unique appeal to the fabrics. The beauty and fascination of lace in garments have always given them a nostalgic charm. Laces with their intricate and delicate complexity in combination with other materials add a feminine touch to a garment and give it a romantic, mysterious appeal. Various textured and decorative effects through fabric manipulation are experimented along with the use of paper cutting craft skills as an innovative substitute for developing lace or “Broderie Anglaise” effects on textiles. A number of assorted fabric types with varied textures were selected for the study. Techniques to avoid fraying and unraveling of the design cut fabrics were introduced. Fabrics were further manipulated by use of interesting prints with embossed effects on cut outs. Fabric layering in combination with assorted techniques such as cutting of folded fabric, printing, appliqué, embroidery, crochet, braiding, weaving added a novel exclusivity to the fabrics. The fabrics developed by these innovative methods were then tailored into garments. The study thus tested the feasibility and practicability of using these fabrics by designing a collection of evening wear garments based on the theme ‘Nostalgia’. The prototypes developed were complemented by designing fashion accessories with the crafted fabrics. Prototypes of accessories add interesting features to the study. The adaptation and application of this novel technique of paper cutting craft on textiles can be an innovative start for a new trend in textile and fashion industry. The study anticipates that this technique will open new avenues in the world of fashion to incorporate its use commercially.

Keywords: Collection, fabric cutouts, nostalgia, prototypes.

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Authors: Gaurav D. Sonawane, Vikas G. Sargade

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The present investigation is a study of the effect of advanced Physical Vapor Deposition (PVD) coatings on cutting temperature residual stresses and surface roughness during Duplex Stainless Steel (DSS) 2205 turning. Austenite stabilizers like nickel, manganese, and molybdenum reduced the cost of DSS. Surface Integrity (SI) plays an important role in determining corrosion resistance and fatigue life. Resistance to various types of corrosion makes DSS suitable for applications with critical environments like Heat exchangers, Desalination plants, Seawater pipes and Marine components. However, lower thermal conductivity, poor chip control and non-uniform tool wear make DSS very difficult to machine. Cemented carbide tools (M grade) were used to turn DSS in a dry environment. AlTiN and AlTiCrN coatings were deposited using advanced PVD High Pulse Impulse Magnetron Sputtering (HiPIMS) technique. Experiments were conducted with cutting speed of 100 m/min, 140 m/min and 180 m/min. A constant feed and depth of cut of 0.18 mm/rev and 0.8 mm were used, respectively. AlTiCrN coated tools followed by AlTiN coated tools outperformed uncoated tools due to properties like lower thermal conductivity, higher adhesion strength and hardness. Residual stresses were found to be compressive for all the tools used for dry turning, increasing the fatigue life of the machined component. Higher cutting temperatures were observed for coated tools due to its lower thermal conductivity, which results in very less tool wear than uncoated tools. Surface roughness with uncoated tools was found to be three times higher than coated tools due to lower coefficient of friction of coating used.

Keywords: Cutting temperatures, DSS2205, dry turning, HiPIMS, surface integrity.

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

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Fiber reinforced polymeric (FRP) composites are finding wide-spread industrial applications because of their exceptionally high specific strength and specific modulus of elasticity. Nevertheless, it is very seldom to get ready-for-use components or products made of FRP composites. Secondary processing by machining, particularly drilling, is almost always required to make holes for fastening components together to produce assemblies. That creates problems since the FRP composites are neither homogeneous nor isotropic. Some of the problems that are encountered include the subsequent damage in the region around the drilled hole and the drilling – induced delamination of the layer of ply, that occurs both at the entrance and the exit planes of the work piece. Evidently, the functionality of the work piece would be detrimentally affected. The current work was carried out with the aim of eliminating or at least minimizing the work piece damage associated with drilling of FPR composites. Each test specimen involves a woven reinforced graphite fiber/epoxy composite having a thickness of 12.5 mm (0.5 inch). A large number of test specimens were subjected to drilling operations with different combinations of feed rates and cutting speeds. The drilling induced damage was taken as the absolute value of the difference between the drilled hole diameter and the nominal one taken as a percentage of the nominal diameter. The later was determined for each combination of feed rate and cutting speed, and a matrix comprising those values was established, where the columns indicate varying feed rate while and rows indicate varying cutting speeds. Next, the analysis of variance (ANOVA) approach was employed using Minitab software, in order to obtain the combination that would improve the drilling induced damage. Experimental results show that low feed rates coupled with low cutting speeds yielded the best results.

Keywords: Drilling of Composites, dimensional accuracy of holes drilled in composites, delamination and charring, graphite-epoxy composites.

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Authors: Ab. Rashid M.F.F., Gan S.Y., Muhammad N.Y.

Abstract:

Surface roughness (Ra) is one of the most important requirements in machining process. In order to obtain better surface roughness, the proper setting of cutting parameters is crucial before the process take place. This research presents the development of mathematical model for surface roughness prediction before milling process in order to evaluate the fitness of machining parameters; spindle speed, feed rate and depth of cut. 84 samples were run in this study by using FANUC CNC Milling α-Τ14ιE. Those samples were randomly divided into two data sets- the training sets (m=60) and testing sets(m=24). ANOVA analysis showed that at least one of the population regression coefficients was not zero. Multiple Regression Method was used to determine the correlation between a criterion variable and a combination of predictor variables. It was established that the surface roughness is most influenced by the feed rate. By using Multiple Regression Method equation, the average percentage deviation of the testing set was 9.8% and 9.7% for training data set. This showed that the statistical model could predict the surface roughness with about 90.2% accuracy of the testing data set and 90.3% accuracy of the training data set.

Keywords: Surface roughness, regression analysis.

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Authors: Yi Chao Huang, Yu Ling Liao, Chiu Shuang Lin

Abstract:

A data cutting and sorting method (DCSM) is proposed to optimize the performance of data mining. DCSM reduces the calculation time by getting rid of redundant data during the data mining process. In addition, DCSM minimizes the computational units by splitting the database and by sorting data with support counts. In the process of searching for the relationship between metabolic syndrome and lifestyles with the health examination database of an electronics manufacturing company, DCSM demonstrates higher search efficiency than the traditional Apriori algorithm in tests with different support counts.

Keywords: Data mining, Data cutting and sorting method, Apriori algorithm, Metabolic syndrome

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Authors: Jagmohan Datt, Uma Batra

Abstract:

Present investigations involve a systematic study on the machinability of austempered ductile irons (ADI) developed from four commercially viable ductile irons alloyed with different contents of 0, 0.1, 0.3 and 0.6 wt.% of Ni. The influence of Ni content, amount of retained austenite and hardness of ADI on machining behavior has been conducted systematically. Austempering heat treatment was carried out for 120 minutes at four temperatures- 270oC, 320oC, 370oC or 420oC, after austenitization at 900oC for 120 min. Milling tests were performed and machinability index, cutting forces and surface roughness measurements were used to evaluate the machinability. Higher cutting forces, lower machinability index and the poorer surface roughness of the samples austempered at lower temperatures indicated that austempering at higher temperatures resulted in better machinability. The machinability of samples austempered at 420oC, which contained higher fractions of retained austenite, was superior to that of samples austempered at lower temperatures, indicating that hardness is an important factor in assessing machinability in addition to high carbon austenite content. The ADI with 0.6% Ni, austempered at 420°C for 120 minutes, demonstrated best machinability.

Keywords: Austempering, machinability, machining index, cutting force, surface finish.

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Authors: Lorenzo Daghini, Andreas Archenti, Cornel Mihai Nicolescu

Abstract:

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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