Search results for: cutting tool materials

Authors: Majid Tolouei-Rad

Abstract:

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: Guillaume Mullier, Jean François Chatelain

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Carbon Fiber Reinforced Plastics (CFRPs) are widely used for advanced applications, in particular in aerospace, automotive and wind energy industries. Once cured to near net shape, CFRP parts need several finishing operations such as trimming, milling or drilling in order to accommodate fastening hardware and meeting the final dimensions. The present research aims to study the effect of the cutting temperature in trimming on the mechanical strength of high performance CFRP laminates used for aeronautics applications. The cutting temperature is of great importance when dealing with trimming of CFRP. Temperatures higher than the glass-transition temperature (Tg) of the resin matrix are highly undesirable: they cause degradation of the matrix in the trimmed edges area, which can severely affect the mechanical performance of the entire component. In this study, a 9.50mm diameter CVD diamond coated carbide tool with six flutes was used to trim 24-plies CFRP laminates. A 300m/min cutting speed and 1140mm/min feed rate were used in the experiments. The tool was heated prior to trimming using a blowtorch, for temperatures ranging from 20°C to 300°C. The temperature at the cutting edge was measured using embedded KType thermocouples. Samples trimmed for different cutting temperatures, below and above Tg, were mechanically tested using three-points bending short-beam loading configurations. New cutting tools as well as worn cutting tools were utilized for the experiments. The experiments with the new tools could not prove any correlation between the length of cut, the cutting temperature and the mechanical performance. Thus mechanical strength was constant, regardless of the cutting temperature. However, for worn tools, producing a cutting temperature rising up to 450°C, thermal damage of the resin was observed. The mechanical tests showed a reduced mean resistance in short beam configuration, while the resistance in three point bending decreases with increase of the cutting temperature.

Keywords: Composites, Trimming, Thermal Damage, Surface Quality.

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Authors: Vladimir Aleksandrovich Rogov, Ghorbani Siamak

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Determination of optimal conditions of machining parameters is important to reduce the production cost and achieve the desired surface quality. This paper investigates the influence of cutting parameters on surface roughness and natural frequency in turning of aluminum alloy AA2024. The experiments were performed at the lathe machine using two different cutting tools made of AISI 5140 and carbide cutting insert coated with TiC. Turning experiments were planned by Taguchi method L₉ orthogonal array.Three levels for spindle speed, feed rate, depth of cut and tool overhang were chosen as cutting variables. The obtained experimental data has been analyzed using signal to noise ratio and analysis of variance. The main effects have been discussed and percentage contributions of various parameters affecting surface roughness and natural frequency, and optimal cutting conditions have been determined. Finally, optimization of the cutting parameters using Taguchi method was verified by confirmation experiments.

Keywords: Turning, Cutting conditions, Surface roughness, Natural frequency, Taguchi method, ANOVA, S/N ratio.

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Authors: Anjan Kumar Kakati, M. Chandrasekaran, Amitava Mandal, Amit Kumar Singh

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End milling process is one of the common metal cutting operations used for machining parts in manufacturing industry. It is usually performed at the final stage in manufacturing a product and surface roughness of the produced job plays an important role. In general, the surface roughness affects wear resistance, ductility, tensile, fatigue strength, etc., for machined parts and cannot be neglected in design. In the present work an experimental investigation of end milling of aluminium alloy with carbide tool is carried out and the effect of different cutting parameters on the response are studied with three-dimensional surface plots. An artificial neural network (ANN) is used to establish the relationship between the surface roughness and the input cutting parameters (i.e., spindle speed, feed, and depth of cut). The Matlab ANN toolbox works on feed forward back propagation algorithm is used for modeling purpose. 3-12-1 network structure having minimum average prediction error found as best network architecture for predicting surface roughness value. The network predicts surface roughness for unseen data and found that the result/prediction is better. For desired surface finish of the component to be produced there are many different combination of cutting parameters are available. The optimum cutting parameter for obtaining desired surface finish, to maximize tool life is predicted. The methodology is demonstrated, number of problems are solved and algorithm is coded in Matlab®.

Keywords: End milling, Surface roughness, Neural networks.

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Authors: A. M. Alaskari, S. E. Oraby

Abstract:

The quality of a machined surface is becoming more and more important to justify the increasing demands of sophisticated component performance, longevity, and reliability. Usually, any machining operation leaves its own characteristic evidence on the machined surface in the form of finely spaced micro irregularities (surface roughness) left by the associated indeterministic characteristics of the different elements of the system: tool-machineworkpart- cutting parameters. However, one of the most influential sources in machining affecting surface roughness is the instantaneous state of tool edge. The main objective of the current work is to relate the in-process immeasurable cutting edge deformation and surface roughness to a more reliable easy-to-measure force signals using a robust non-linear time-dependent modeling regression techniques. Time-dependent modeling is beneficial when modern machining systems, such as adaptive control techniques are considered, where the state of the machined surface and the health of the cutting edge are monitored, assessed and controlled online using realtime information provided by the variability encountered in the measured force signals. Correlation between wear propagation and roughness variation is developed throughout the different edge lifetimes. The surface roughness is further evaluated in the light of the variation in both the static and the dynamic force signals. Consistent correlation is found between surface roughness variation and tool wear progress within its initial and constant regions. At the first few seconds of cutting, expected and well known trend of the effect of the cutting parameters is observed. Surface roughness is positively influenced by the level of the feed rate and negatively by the cutting speed. As cutting continues, roughness is affected, to different extents, by the rather localized wear modes either on the tool nose or on its flank areas. Moreover, it seems that roughness varies as wear attitude transfers from one mode to another and, in general, it is shown that it is improved as wear increases but with possible corresponding workpart dimensional inaccuracy. The dynamic force signals are found reasonably sensitive to simulate either the progressive or the random modes of tool edge deformation. While the frictional force components, feeding and radial, are found informative regarding progressive wear modes, the vertical (power) components is found more representative carrier to system instability resulting from the edge-s random deformation.

Keywords: Dynamic force signals, surface roughness (finish), tool wear and deformation, tool wear modes (nose, flank)

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

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

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

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Authors: 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: Jui P. Hung, Hsia C. Chang, Yuan L. Lai

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Introduction applicability of high-speed cutting stock problem (CSP) is presented in this paper. Due to the orders continued coming in from various on-line ways for a professional cutting company, to stay competitive, such a business has to focus on sustained production at high levels. In others words, operators have to keep the machine running to stay ahead of the pack. Therefore, the continuous stock cutting problem with setup is proposed to minimize the cutting time and pattern changing time to meet the on-line given demand. In this paper, a novel method is proposed to solve the problem directly by using cutting patterns directly. A major advantage of the proposed method in series on-line production is that the system can adjust the cutting plan according to the floating orders. Examples with multiple items are demonstrated. The results show considerable efficiency and reliability in high-speed cutting of CSP.

Keywords: Cutting stock, Optimization, Heuristics

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Authors: Moaz H. Ali, M. N. M. Ansari

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This paper presents a study the effect of nose radius (Rz-mm) on cutting force components and temperatures during the machining simulation in an orthogonal cutting process for titanium alloy (Ti-6Al-4V). The cutting process was performed at various nose radiuses (Rz-mm) while the depth of cut (d-mm), feed rate (fmm/ tooth) and cutting speed (vc-m/ min) were remained constant. The main cutting force (Fc), feed cutting force (Ft) and temperatures were estimated by using finite element modeling (FEM) through ABAQUS/EXPLICIT software and the simulation was developed the two-dimension via an orthogonal cutting process during machining titanium alloy (Ti-6Al-4V). The results led to the conclusion that the nose radius (Rz-mm) has affected directly on the cutting force components. However, temperature gave no indication or has no significant relation with nose radius during machining titanium alloy (Ti-6Al-4V). Hence, any increase or decrease in the nose radius (Rzmm) during machining operation led to effect on the cutting forces and thus it will be effective on surface finish, quality, and quantity of products.

Keywords: Finite element modeling (FEM), nose radius, cutting force, temperature, titanium alloy (Ti-6Al-4V).

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Authors: C. Tung, P.-L. Tso

Abstract:

This paper presents a complete procedure for tool path planning and blade machining in 5-axis manufacturing. The actual cutting contact and cutter locations can be determined by lead and tilt angles. The tool path generation is implemented by piecewise curved approximation and chordal deviation detection. An application about drive surface method promotes flexibility of tool control and stability of machine motion. A real manufacturing process is proposed to separate the operation into three regions with five stages and to modify the local tool orientation with an interactive algorithm.

Keywords: 5-axis machining, tool orientation, lead and tilt angles, tool path generation.

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Authors: Abdulmajeed Dabwan, Saqib Anwar, Ali Al-Samhan

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Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology, which uses computer-controlled electron beams to create fully dense three-dimensional near-net-shaped parts from metal powder. It gives the ability to produce any complex parts directly from a computer-aided design (CAD) model without tools and dies, and with a variety of materials. However, the quality of the surface finish in EBM process has limitations to meeting the performance requirements of additively manufactured components. The aim of this study is to investigate the cutting forces induced during milling Ti6Al4V produced by EBM as well as the surface quality of the milled surfaces. The effects of cutting speed and radial depth of cut on the cutting forces, surface roughness, and surface morphology were investigated. The results indicated that the cutting speed was found to be proportional to the resultant cutting force at any cutting conditions while the surface roughness improved significantly with the increase in cutting speed and radial depth of cut.

Keywords: Electron beam melting, additive manufacturing, Ti6Al4V, surface morphology.

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Authors: Suvradip Mullick, Yuvraj K. Madhukar, Subhranshu Roy, Ashish K. Nath

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We present the development of a new underwater laser cutting process in which a water-jet has been used along with the laser beam to remove the molten material through kerf. The conventional underwater laser cutting usually utilizes a high pressure gas jet along with laser beam to create a dry condition in the cutting zone and also to eject out the molten material. This causes a lot of gas bubbles and turbulence in water, and produces aerosols and waste gas. This may cause contamination in the surrounding atmosphere while cutting radioactive components like burnt nuclear fuel. The water-jet assisted underwater laser cutting process produces much less turbulence and aerosols in the atmosphere. Some amount of water vapor bubbles is formed at the laser-metal-water interface; however, they tend to condense as they rise up through the surrounding water. We present the design and development of a water-jet assisted underwater laser cutting head and the parametric study of the cutting of AISI 304 stainless steel sheets with a 2 kW CW fiber laser. The cutting performance is similar to that of the gas assist laser cutting; however, the process efficiency is reduced due to heat convection by water-jet and laser beam scattering by vapor. This process may be attractive for underwater cutting of nuclear reactor components.

Keywords: Laser, underwater cutting, water-jet.

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Authors: Salah Gariani, Islam Shyha, Osama Elgadi, Khaled Jegandi

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In this work, a cooling coherent round nozzle was developed and the impact of nozzle placement (i.e. nozzle angle and stand-off/impinging distance) on the machinability of Ti-6Al-4V was evaluated. Key process measures were cutting force, workpiece temperature, tool wear, burr formation and average surface roughness (Ra). Experimental results showed that nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. A stand-off distance of 55 and 75 mm is also necessary to control burr formation, workpiece temperature and Ra, but coherent nozzle orientation has no statistically significant impact on the mean values of cutting force and tool wear. It can be concluded that stand-off distance is more substantially significant than nozzle angles when step shoulder milling Ti-6Al- 4V using vegetable oil-based cutting fluid.

Keywords: Coherent round nozzle, step shoulder milling, Ti-6Al-4V, vegetable oil-based cutting fluid.

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Authors: B. Varaprasad, C. Srinivasa Rao

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

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

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Authors: S. Tangjitsitcharoen

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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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Authors: Njiri J. G., Ikua B. W., Nyakoe G. N.

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Optimization of cutting parameters important in precision machining in regards to efficiency and surface integrity of the machined part. Usually productivity and precision in machining is limited by the forces emanating from the cutting process. Due to the inherent varying nature of the workpiece in terms of geometry and material composition, the peak cutting forces vary from point to point during machining process. In order to increase productivity without compromising on machining accuracy, it is important to control these cutting forces. In this paper a fuzzy logic control algorithm is developed that can be applied in the control of peak cutting forces in milling of spherical surfaces using ball end mills. The controller can adaptively vary the feedrate to maintain allowable cutting force on the tool. This control algorithm is implemented in a computer numerical control (CNC) machine. It has been demonstrated that the controller can provide stable machining and improve the performance of the CNC milling process by varying feedrate.

Keywords: Ball-end mill, feedrate, fuzzy logic controller, machining optimization, spherical surface.

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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: Li Chen, ZhouLong Li, Qing-zhen Bi, LiMin Zhu

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A new tool path planning method for 5-axis flank milling of a globoidal indexing cam is developed in this paper. The globoidal indexing cam is a practical transmission mechanism due to its high transmission speed, accuracy and dynamic performance. Machining the cam profile is a complex and precise task. The profile surface of the globoidal cam is generated by the conjugate contact motion of the roller. The generated complex profile surface is usually machined by 5-axis point-milling method. The point-milling method is time-consuming compared with flank milling. The tool path for 5-axis flank milling of globoidal cam is developed to improve the cutting efficiency. The flank milling tool path is globally optimized according to the minimum zone criterion, and high accuracy is guaranteed. The computational example and cutting simulation finally validate the developed method.

Keywords: Globoidal cam, flank milling, LSQR, MINIMAX.

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Authors: Stephen C. H. Leung, Defu Zhang

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This paper addresses a stock-cutting problem with rotation of items and without the guillotine cutting constraint. In order to solve the large-scale problem effectively and efficiently, we propose a simple but fast heuristic algorithm. It is shown that this heuristic outperforms the latest published algorithms for large-scale problem instances.

Keywords: Combinatorial optimization, heuristic, large-scale, stock-cutting.

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

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Manufacturing tolerancing is intended to determine the intermediate geometrical and dimensional states of the part during its manufacturing process. These manufacturing dimensions also serve to satisfy not only the functional requirements given in the definition drawing, but also the manufacturing constraints, for example geometrical defects of the machine, vibration and the wear of the cutting tool. In this paper, an experimental study on the influence of the wear of the cutting tool (systematic dispersions) is explored. This study was carried out on three stages .The first stage allows machining without elimination of dispersions (random, systematic) so the tolerances of manufacture according to total dispersions. In the second stage, the results of the first stage are filtered in such way to obtain the tolerances according to random dispersions. Finally, from the two previous stages, the systematic dispersions are generated. The objective of this study is to model by the least squares method the error of manufacture based on systematic dispersion. Finally, an approach of optimization of the manufacturing tolerances was developed for machining on a CNC machine tool

Keywords: Dispersions, Compensation, modeling, manufacturing Tolerance, machine tool.

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Authors: Zone-Ching Lin, Hao-Yuan Jheng, Shih-Hung Ma

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The present paper proposes using atomic force microscopy (AFM) and the concept of specific down force energy (SDFE) to establish a method for fabricating and cutting the burr for Y shape nanochannel on silicon (Si) substrate. For fabricating Y shape nanochannel, it first makes the experimental cutting path planning for fabricating Y shape nanochannel until the fifth cutting layer. Using the constant down force by AFM and SDFE theory and following the experimental cutting path planning, the cutting depth and width of each pass of Y shape nanochannel can be predicted by simulation. The paper plans the path for cutting the burr at the edge of Y shape nanochannel. Then, it carries out cutting the burr along the Y nanochannel edge by using a smaller down force. The height of standing burr at the edge is required to be below the set value of 0.54 nm. The results of simulation and experiment of fabricating and cutting the burr for Y shape nanochannel is further compared.

Keywords: Atomic force microscopy, nanochannel, specific down force energy, Y shape, burr, silicon.

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Authors: R. Bhuvenesh, M.H. Norizaman, M.S. Abdul Manan

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Industrial surveys shows that manufacturing companies define the qualities of thermal removing process based on the dimension and physical appearance of the cutting material surface. Therefore, the roughness of the surface area of the material cut by the plasma arc cutting process and the rate of the removed material by the manual plasma arc cutting machine was importantly considered. Plasma arc cutter Selco Genesis 90 was used to cut Standard AISI 1017 Steel of 200 mm x100 mm x 6 mm manually based on the selected parameters setting. The material removal rate (MRR) was measured by determining the weight of the specimens before and after the cutting process. The surface roughness (SR) analysis was conducted using Mitutoyo CS-3100 to determine the average roughness value (Ra). Taguchi method was utilized to achieve optimum condition for both outputs studied. The microstructure analysis in the region of the cutting surface is performed using SEM. The results reveal that the SR values are inversely proportional to the MRR values. The quality of the surface roughness depends on the dross peak that occurred after the cutting process.

Keywords: Material removal rate, plasma arc cutting, surface roughness, Taguchi method

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Authors: M. R. Kamandar, J. Massah

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The information of the impact cutting behavior of plants stalk plays an important role in the design and fabrication of plants cutting equipment. It is difficult to investigate a theoretical method for defining cutting properties of plants stalks because the cutting process is complex. Thus, it is necessary to set up an experimental approach to determine cutting parameters for a single stalk. To measure the shear force, shear energy and shear strength of plant stalk, a special impact cutting tester was fabricated. It was similar to an Izod impact cutting tester for metals but a cutting blade and data acquisition system were attached to the end of pendulum's arm. The apparatus was included four strain gages and a digital indicator to show the real-time cutting force of plant stalk. To measure the shear force and also testing the apparatus, two plants’ stalks, like buxus and privet, were selected. The samples (buxus and privet stalks) were cut under impact cutting process at four loading rates 1, 2, 3 and 4 m.s^-1 and three internodes fifth, tenth and fifteenth by the apparatus. At buxus cutting analysis: the minimum value of cutting energy was obtained at fifth internode and loading rate 4 m.s^-1 and the maximum value of shear energy was obtained at fifteenth internode and loading rate 1 m.s^-1. At privet cutting analysis: the minimum value of shear consumption energy was obtained at fifth internode and loading rate: 4 m.s^-1 and the maximum value of shear energy was obtained at fifteenth internode and loading rate: 1 m.s^-1. The statistical analysis at both plants showed that the increase of impact cutting speed would decrease the shear consumption energy and shear strength. In two scenarios, the results showed that with increase the cutting speed, shear force would decrease.

Keywords: Buxus, privet, impact cutting, shear energy.

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Authors: A. Karimzad Ghavidel, M. Zadshakouyan

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Laser cutting is a very common production method for cutting 2D polymeric parts. Developing of polymer composites with nano-fibers makes important their other properties like laser workability. The aim of this research is investigation of the influence different laser cutting conditions on the dimensional accuracy of parts and holes from poly methyl methacrylate (PMMA)/carbon nanotubes (CNTs) material. Experiments were carried out by considering of CNTs (in four level 0,0.5, 1 and 1.5% wt.%), laser power (60, 80, and 100 watt) and cutting speed 20, 30, and 40 mm/s as input variable factors. The results reveal that CNTs adding improves the laser workability of PMMA and the increasing of power has a significant effect on the part and hole size. The findings also show cutting speed is effective parameter on the size accuracy. Eventually, the statistical analysis of results was done, and calculated mathematical equations by the regression are presented for determining relation between input and output factor.

Keywords: Dimensional accuracy-PMMA-CNTs-laser cutting.

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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

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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: Dean J. Callaghan, Mark M. McGrath

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Sensorized instruments that accurately measure the interaction forces (between biological tissue and instrument endeffector) during surgical procedures offer surgeons a greater sense of immersion during minimally invasive robotic surgery. Although there is ongoing research into force measurement involving surgical graspers little corresponding effort has been carried out on the measurement of forces between scissor blades and tissue. This paper presents the design and development of a force measurement test apparatus, which will serve as a sensor characterization and evaluation platform. The primary aim of the experiments is to ascertain whether the system can differentiate between tissue samples with differing mechanical properties in a reliable, repeatable manner. Force-angular displacement curves highlight trends in the cutting process as well the forces generated along the blade during a cutting procedure. Future applications of the test equipment will involve the assessment of new direct force sensing technologies for telerobotic surgery.

Keywords: Force measurement, minimally invasive surgery, scissor blades, tissue cutting.

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Authors: G. H. Li, M. Liu, H. J. Qi, Q. Zhu, W. Z. He

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The drilling and riveting processes are widely used in the assembly of carrier rocket, which makes the efficiency and quality of drilling become the important factor affecting the assembly process. According to the problem existing in the drilling of thick stacked plate (thickness larger than 10mm) of carrier rocket, such as drill break, large noise and burr etc., experimental study of the influence of tool material on the drilling was carried out. The cutting force was measured by a piezoelectric dynamometer, the aperture was measured with an outline projector, and the burr is observed and measured by a digital stereo microscope. Through the measurement, the effects of tool material on the drilling were analyzed from the aspects of drilling force, diameter, and burr. The results show that, compared with carbide drill and coated carbide one, the drilling force of high speed steel is larger. But, the application of high speed steel also has some advantages, e.g. a higher number of hole can be obtained, the height of burr is small, the exit is smooth and the slim burr is less, and the tool experiences wear but not fracture. Therefore, the high speed steel tool is suitable for the drilling of thick stacked plate of 2219 Aluminum alloy.

Keywords: 2219 aluminum alloy, thick stacked plate, drilling, tool material.

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Authors: Sahil Sharma, Mukesh Gupta, Raj Kumar, N. S Bindra

Abstract:

This paper presents an experimental investigation on the optimization and the effect of the cutting parameters on Material Removal Rate (MRR) in Plasma Arc Cutting (PAC) of EN-45A Material using Taguchi L ₁₆ orthogonal array method. Four process variables viz. cutting speed, current, stand-off-distance and plasma gas pressure have been considered for this experimental work. Analysis of variance (ANOVA) has been performed to get the percentage contribution of each process parameter for the response variable i.e. MRR. Based on ANOVA, it has been observed that the cutting speed, current and the plasma gas pressure are the major influencing factors that affect the response variable. Confirmation test based on optimal setting shows the better agreement with the predicted values.

Keywords: Analysis of variance, Material removal rate, plasma arc cutting, Taguchi method.

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Authors: M. N. Islam, B. Boswell, Y. R. Ginting

Abstract:

The influence of canned cycles and cutting parameters on hole quality in cryogenic drilling has been investigated experimentally and analytically. A three-level, three-parameter experiment was conducted by using the design-of-experiment methodology. The three levels of independent input parameters were the following: for canned cycles—a chip-breaking canned cycle (G73), a spot drilling canned cycle (G81), and a deep hole canned cycle (G83); for feed rates—0.2, 0.3, and 0.4 mm/rev; and for cutting speeds—60, 75, and 100 m/min. The selected work and tool materials were aluminum 6061-6T and high-speed steel (HSS), respectively. For cryogenic cooling, liquid nitrogen (LN2) was used and was applied externally. The measured output parameters were the three widely used quality characteristics of drilled holes—diameter error, circularity, and surface roughness. Pareto ANOVA was applied for analyzing the results. The findings revealed that the canned cycle has a significant effect on diameter error (contribution ratio 44.09%) and small effects on circularity and surface finish (contribution ratio 7.25% and 6.60%, respectively). The best results for the dimensional accuracy and surface roughness were achieved by G81. G73 produced the best circularity results; however, for dimensional accuracy, it was the worst level.

Keywords: Circularity, diameter error, drilling canned cycle, Pareto ANOVA, surface roughness.

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