Search results for: tool life

Authors: Carlos J. Costa, Manuela Aparício

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In this paper we present the information life cycle and analyze the importance of managing the corporate application portfolio across this life cycle. The approach presented here corresponds not just to the extension of the traditional information system development life cycle. This approach is based in the generic life cycle. In this paper it is proposed a model of an information system life cycle, supported in the assumption that a system has a limited life. But, this limited life may be extended. This model is also applied in several cases; being reported here two examples of the framework application in a construction enterprise and in a manufacturing enterprise.

Keywords: Information systems/technology, information systems life cycle, organization engineering, information economics.

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Authors: Yukinori Taniguchi, Kazuyoshi Kurita, Kohei Mizuta, Keigo Nishitani, Ryuichi Fukuda

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Tungsten carbide is widely used as a tool material in metal manufacturing process. Since tungsten is typical rare metal, establishment of recycle process of tungsten carbide tools and restore into cemented carbide material bring great impact to metal manufacturing industry. Recently, recycle process of tungsten carbide has been developed and established gradually. However, the demands for quality of cemented carbide tool are quite severe because hardness, toughness, anti-wear ability, heat resistance, fatigue strength and so on should be guaranteed for precision machining and tool life. Currently, it is hard to restore the recycled tungsten carbide powder entirely as raw material for new processed cemented carbide tool. In this study, to suggest positive use of recycled tungsten carbide powder, we have tried to fabricate a carbon based sintered steel which shows reinforced mechanical properties with recycled tungsten carbide powder. We have made set of newly designed sintered steels. Compression test of sintered specimen in density ratio of 0.85 (which means 15% porosity inside) has been conducted. As results, at least 1.7 times higher in nominal strength in the amount of 7.0 wt.% was shown in recycled WC powder. The strength reached to over 600 MPa for the Fe-WC-Co-Cu sintered alloy. Wear test has been conducted by using ball-on-disk type friction tester using 5 mm diameter ball with normal force of 2 N in the dry conditions. Wear amount after 1,000 m running distance shows that about 1.5 times longer life was shown in designed sintered alloy. Since results of tensile test showed that same tendency in previous testing, it is concluded that designed sintered alloy can be used for several mechanical parts with special strength and anti-wear ability in relatively low cost due to recycled tungsten carbide powder.

Keywords: Tungsten carbide, recycle process, compression test, powder metallurgy, anti-wear ability.

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Authors: Sebastian Tschöpe, Konja Knüppel, Peter Nyhuis

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In times when product life cycles are decreasing, while market demands are increasing, manufacturing enterprises are confronted with the challenge of more frequent and more complex ramp-ups. Thus it becomes obvious that ramp-up management is going to be a topic enterprises have to focus on in the future. Since each ramp-up is unique concerning the product, the process, the technology, the circumstances and the coaction of these four factors, the knowledge of the ramp-up situation and the current ramp-up capability of the enterprise are fundamental requirements for the subsequent improvement of the ramp-up capability of the production system.

In this article a methodology is going to be presented which can be used to define typical production ramp-up situations, to identify the current ramp-up capability of a production system and to improve it with respect to a specific situation. Additionally there will be a description of the functionality of a software-tool developed based on this methodology.

Keywords: Assessment methodology, ramp-up, ramp-up capability, software-tool.

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Authors: Hatim Laalej, Salvador Sumohano-Verdeja, Thomas McLeay

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Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.

Keywords: Tool condition monitoring, tool wear prediction, milling operation, flute tracking.

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Authors: M. Armenteros, A. Domínguez, M. Fernández, A. J. Benítez

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The following paper describes the video database tool used by the Fédération Internationale de Football Association (FIFA) as part of the research project developed in collaboration with the Carlos III University of Madrid. The database project began in 2012, with the aim of creating an educational tool for the training of instructors, referees and assistant referees, and it has been used in all FUTURO III courses since 2013. The platform now contains 3,135 video clips of different match situations from FIFA competitions. It has 1,835 users (FIFA instructors, referees and assistant referees). In this work, the main features of the database are described, such as the use of a search tool and the creation of multimedia presentations and video quizzes. The database has been developed in MySQL, ActionScript, Ruby on Rails and HTML. This tool has been rated by users as "very good" in all courses, which prompt us to introduce it as an ideal tool for any other sport that requires the use of video analysis.

Keywords: Video database, FIFA, refereeing, e-learning.

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Authors: Onkar Bhat Kodical, Sridhar Srinivasan, N.K. Srinath

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Tool Tracker is a client-server based application. It is essentially a catalogue of various network monitoring and management tools that are available online. There is a database maintained on the server side that contains the information about various tools. Several clients can access this information simultaneously and utilize this information. The various categories of tools considered are packet sniffers, port mappers, port scanners, encryption tools, and vulnerability scanners etc for the development of this application. This application provides a front end through which the user can invoke any tool from a central repository for the purpose of packet sniffing, port scanning, network analysis etc. Apart from the tool, its description and the help files associated with it would also be stored in the central repository. This facility will enable the user to view the documentation pertaining to the tool without having to download and install the tool. The application would update the central repository with the latest versions of the tools. The application would inform the user about the availability of a newer version of the tool currently being used and give the choice of installing the newer version to the user. Thus ToolTracker provides any network administrator that much needed abstraction and ease-ofuse with respect to the tools that he can use to efficiently monitor a network.

Keywords: Network monitoring, single platform, client/server application, version management.

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Authors: M. R. Shabgard, B. Sadizadeh, H. Kakoulvand

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In the present work, a study has been made on the combination of the electrical discharge machining (EDM) with ultrasonic vibrations to improve the machining efficiency. In experiments the graphite used as tool electrode and material of workpiece was AISIH13 tool steel. The parameters such as discharge peak current and pulse duration were changed to explore their effect on the material removal rate (MRR), relative tool wear ratio (TWR) and surface roughness. From the experimental result it can be seen that ultrasonic vibration of the workpiece can significantly reduces the inactive pulses and improves the stability of process. It was found that ultrasonic assisted EDM (US-EDM) is effective in attaining a high material removal rate (MRR) in finishing regime.

Keywords: AISIH13 tool steel, Electrical discharge machining(EDM), Material removal rate (MRR), Surface roughness (Ra), Toolwear ratio (TWR), Ultrasonic assisted EDM (US-EDM)

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Authors: Murat Sarıkaya, Abdulkadir Güllü

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

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

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

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This paper was aimed at developing a computer aided design and manufacturing system for spatial cylindrical cams. In the proposed system, a milling tool with a diameter smaller than that of the roller, instead of the standard cutter for traditional machining process, was used to generate the tool path for spatial cams. To verify the feasibility of the proposed method, a multi-axis machining simulation software was further used to simulate the practical milling operation of spatial cams. It was observed from computer simulation that the tool path of small-sized cutter were within the motion range of a standard cutter, no occurrence of overcutting. Examination of a finished cam component clearly verifies the accuracy of the tool path generated for small-sized milling tool. It is believed that the use of small-sized cutter for the machining of the spatial cylindrical cams can generate a better surface morphology with higher accuracy. The improvement in efficiency and cost for the manufacturing of the spatial cylindrical cam can be expected through the proposed method.

Keywords: Cylindrical cams, Computer-aided manufacturing, Tool path.

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Authors: Agord M. Pinto Jr., Yuzo Iano, Leandro T. Manera, Raphael R. N. Souza

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This paper describes an optimization tool-based design strategy for a Current Mode Logic CML divide-by-2 circuit. Representing a building block for output frequency generation in a RFID protocol based-frequency synthesizer, the circuit was designed to minimize the power consumption for driving of multiple loads with unbalancing (at transceiver level). Implemented with XFAB XC08 180 nm technology, the circuit was optimized through MunEDA WiCkeD tool at Cadence Virtuoso Analog Design Environment ADE.

Keywords: Divide-by-2 circuit, CMOS technology, PLL phase locked-loop, optimization tool, CML current mode logic, RF transceiver.

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Authors: Youn-Sung Kim, Jin-Ho Jo, Mi-Sung Kim, Jae-Kun Lee

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Accelerated life cycle test is applied to various products or components in order to reduce the time of life cycle test in industry. It must be considered for many test conditions according to the product characteristics for the test and the selection of acceleration parameter is especially very important. We have carried out the general life cycle test and the accelerated life cycle test by applying the acceleration factor (AF) considering the characteristics of brushless DC (BLDC) motor for washing machine. The final purpose of this study is to verify the validity by analyzing the results of the general life cycle test and the accelerated life cycle test. It will make it possible to reduce the life test time through the reasonable accelerated life cycle test.

Keywords: Accelerated life cycle test, reliability test, motor for washing machine, brushless dc motor test.

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Authors: Rohaya Abdul Wahab, Raja Mohd Fuad Tengku Aziz, Nazaliza Othman, Sharifah Saleh, Nabihah Razali, Rozaimah Baharim, Md Hanif Md Nasir

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This paper will discuss flip chip methodology, in which I/O pads, standard cells, macros and bump cells array are placed in the floorplan, then routed using Astro place and route tool. Final DRC and LVS checking is done using Calibre verification tool. The design vehicle to run this methodology is an OpenRISC design targeted to Silterra 0.18 micrometer technology with 6 metal layers for routing. Astro has extensive support for flip chip placement and routing. Astro tool commands for flip chip are straightforward approach like the conventional standard wire bond packaging. However since we do not have flip chip commands in our Astro tool, no LEF file for bump cell and no LEF file for flip chip I/O pad, we create our own methodology to prepare for future flip chip tapeout. 

Keywords: Astro, bump cell, Calibre, flip chip, LEF, methodology, SCHEME, TCL.

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Authors: Sasho Guergov

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

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

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Authors: Kious Mecheri, Hadjadj Abdechafik, Ameur Aissa

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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: Alexandru Epureanu, Virgil Teodor

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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: Migbar Assefa

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The performance of a machine tool is eventually assessed by its ability to produce a component of the required geometry in minimum time and at small operating cost. It is customary to base the structural design of any machine tool primarily upon the requirements of static rigidity and minimum natural frequency of vibration. The operating properties of machines like cutting speed, feed and depth of cut as well as the size of the work piece also have to be kept in mind by a machine tool structural designer. This paper presents a novel approach to the design of machine tool column for static and dynamic rigidity requirement. Model evaluation is done effectively through use of General Finite Element Analysis software ANSYS. Studies on machine tool column are used to illustrate finite element based concept evaluation technique. This paper also presents results obtained from the computations of thin walled box type columns that are subjected to torsional and bending loads in case of static analysis and also results from modal analysis. The columns analyzed are square and rectangle based tapered open column, column with cover plate, horizontal partitions and with apertures. For the analysis purpose a total of 70 columns were analyzed for bending, torsional and modal analysis. In this study it is observed that the orientation and aspect ratio of apertures have no significant effect on the static and dynamic rigidity of the machine tool structure.

Keywords: Finite Element Modeling, Modal Analysis, Machine tool structure, Static Analysis.

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Authors: Farhad Kolahan, Mohsen Manoochehri, Abbas Hosseini

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Machining is an important manufacturing process used to produce a wide variety of metallic parts. Among various machining processes, turning is one of the most important one which is employed to shape cylindrical parts. In turning, the quality of finished product is measured in terms of surface roughness. In turn, surface quality is determined by machining parameters and tool geometry specifications. The main objective of this study is to simultaneously model and optimize machining parameters and tool geometry in order to improve the surface roughness for AISI1045 steel. Several levels of machining parameters and tool geometry specifications are considered as input parameters. The surface roughness is selected as process output measure of performance. A Taguchi approach is employed to gather experimental data. Then, based on signal-to-noise (S/N) ratio, the best sets of cutting parameters and tool geometry specifications have been determined. Using these parameters values, the surface roughness of AISI1045 steel parts may be minimized. Experimental results are provided to illustrate the effectiveness of the proposed approach.

Keywords: Taguchi method, turning parameters, tool geometry specifications, S/N ratio, statistical analysis.

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Authors: C. Kumjeera, T. Unchim, B. Marungsri, A. Oonsivilai

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The study of piezoelectric material in the past was in T-Domain form; however, no one has studied piezoelectric material in the S-Domain form. This paper will present the piezoelectric material in the transfer function or S-Domain model. S-Domain is a well known mathematical model, used for analyzing the stability of the material and determining the stability limits. By using S-Domain in testing stability of piezoelectric material, it will provide a new tool for the scientific world to study this material in various forms.

Keywords: Hard disk drive, failure analysis, tool, time

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Authors: Gregor Radonjič, Aleksandra P. Korda, Damijan Krajnc

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The aim of the study was to investigate whether there is the promotion of product ecodesign measures as a result of adopting ISO 14001 certification in manufacturing companies in the Republic of Slovenia. Companies gave the most of their product development attention to waste and energy reduction during manufacturing process and reduction of material consumption per unit of product. Regarding the importance of different ecodesign criteria reduction of material consumption per unit of product was reported as the most important criterion. Less attention is paid to endof- life issues considering recycling or packaging. Most manufacturing enterprises considered ISO 14001 standard as a very useful tool or at least a useful tool helping them to accelerate and establish product ecodesign activities. Two most frequently considered ecodesign drivers are increased competitive advantage and legal requirements and two most important barriers are high development costs and insufficient market demand.

Keywords: ecodesign, environmental management system, ISO 14001, products

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Authors: Reza Lotfalian, Sudarshan Martins, Peter Radziszewski

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The effect of reliability on life-cycle cost, including initial and maintenance cost of a system is studied. The failure probability of a component is used to calculate the average maintenance cost during the operation cycle of the component. The standard deviation of the life-cycle cost is also calculated as an error measure for the average life-cycle cost. As a numerical example, the model is used to study the average life-cycle cost of an electric motor.

Keywords: Initial Cost, Life-cycle cost, Maintenance Cost, Reliability.

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

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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: Jose J.CarreñoZagarra, Rodolfo Villamizar Mejía

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This work describes a CACSD tool for automatic design of robust controllers for hydraulic turbines. The tool calculates the optimal
 controller using the MATLAB hinfopt function and it serves as a practical and effective solution for the laborious task of designing a different controller for each type of turbine and generator, and different parameters and conditions of the plant. Results of the simulation of a generating unit subject to parameters variation show the accuracy and efficiency of the obtained robust controllers.

Keywords: Robust Control, Hydroelectric System Turbine, Control H∞, CACSD

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Authors: Sameerchand Pudaruth, Avinash Mantaye

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E-learning refers to the specific kind of learning experienced within the domain of educational technology, which can be used in or out of the classroom. In this paper, we give an overview of an e-learning platform 'An Innovative Interactive and Online English Platform for Upper Primary Students' is an interactive web-based application which will serve as an aid to the primary school students in Mauritius. The objectives of this platform are to offer quality learning resources for the English subject at our primary level of education, encourage self-learning and hence promote e-learning. The platform developed consists of several interesting features, for example, the English Verb Conjugation tool, Negative Form tool, Interrogative Form tool and Close Test Generator. Thus, this learning platform will be useful at a time where our country is looking for an alternative to private tuition and also, looking forward to increase the pass rate.

Keywords: educational technology, e-learning, Mauritius.

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Authors: David Downey

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With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical, aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: Additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear.

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Authors: Jihyun Park

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This research suggests that meaning in life or Ikigai can be associated with better academic performances in Japanese college students. To measure meaning in life in Japanese college students, the Ikigai questionnaire and the Meaning in Life Questionnaire (MLQ) are both used, and the survey was collected using Microsoft Teams Forms for a total of 80 Japanese college students. The data revealed that students who have a higher than a 3.0 grade point average (GPA) showed the highest score in both the Ikigai and MLQ. The participants with between a 2.0 and a 3.0 GPA reported lower scores in both MLQ and Ikigai than the previous participants. The group of students who have lower than a 2.0 GPA had the lowest scores for MLQ and Ikigai. This result can indicate that implementing meaning in life or Ikigai to early college students can bring about better academic performance, which also can improve students’ college life better as well.

Keywords: College students’ academic performance, Ikigai, meaning in life, purpose of life.

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Authors: S. M. Ali, N. R. Dhar

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

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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: A. Razavykia, A. Esmaeilzadeh, S. Iranmanesh

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Many orthopedic implants like proximal humerus cases require lower surface roughness and almost immediate/short lead time surgery. Thus, rapid response from the manufacturer is very crucial. Tool path strategy of milling process has a direct influence on the surface roughness and lead time of medical implant. High-speed milling as promised process would improve the machined surface quality, but conventional or super-abrasive grinding still required which imposes some drawbacks such as additional costs and time. Currently, many CAD/CAM software offers some different tool path strategies to milling free form surfaces. Nevertheless, the users must identify how to choose the strategies according to cutting tool geometry, geometry complexity, and their effects on the machined surface. This study investigates the effect of different tool path strategies for milling a proximal humerus head during finishing operation on stainless steel 316L. Experiments have been performed using MAHO MH700 S vertical milling machine and four machining strategies, namely, spiral outward, spiral inward, and radial as well as zig-zag. In all cases, the obtained surfaces were analyzed in terms of roughness and dimension accuracy compared with those obtained by simulation. The findings provide evidence that surface roughness, dimensional accuracy, and machining time have been affected by the considered tool path strategy.

Keywords: CAD/CAM software, milling, orthopedic implants, tool path strategy.

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Authors: Dunwen Zuo, Yongfang Deng, Bo Song

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An attempt is made here to measure the forces of three directions, under conditions of different feed speeds, different tilt angles of tool and without or with the pin on the tool, by using octagonal ring dynamometer in the AA2024 aluminum FSJ (Friction Stir Joining) process, and investigate how four main factors influence forces in the FSJ process. It is found that, high feed speed lead to small feed force and small lateral force, but high feed speed leads to large feed force in the stable joining stage of process. As the rotational speed increasing, the time of axial force drop from the maximum to the minimum required increased in the push-up process. In the stable joining stage, the rotational speed has little effect on the feed force; large rotational speed leads to small lateral force and axial force. The maximum axial force increases as the tilt angle of tool increases at the downward movement stage. At the moment of start feeding, as tilt angle of tool increases, the amplitudes of the axial force increasing become large. In the stable joining stage, with the increase of tilt angle of tool, the axial force is increased, the lateral force is decreased, and the feed force almost unchanged. The tool with pin will decrease axial force in the downward movement stage. The feed force and lateral force will increase, but the axial force will reduced in the stable joining stage by using the tool with pin compare to by using the tool without pin.

Keywords: FSJ, force factor, AA2024, friction stir joining.

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Authors: S. Srikiran, Dharmala Venkata Padmaja, P. N. L. Pavani, R. Pola Rao, K. Ramji

Abstract:

Technological advancements in the development of cutting tools and coolant/lubricant chemistry have enhanced the machining capabilities of hard materials under higher machining conditions. Generation of high temperatures at the cutting zone during machining is one of the most important and pertinent problems which adversely affect the tool life and surface finish of the machined components. Generally, cutting fluids and solid lubricants are used to overcome the problem of heat generation, which is not effectively addressing the problems. With technological advancements in the field of tribology, nano-level particulate solid lubricants are being used nowadays in machining operations, especially in the areas of turning and grinding. The present investigation analyses the effect of using nano-particulate graphite powder as lubricant in the turning of AISI 1040 steel under variable machining conditions and to study its effect on cutting forces, tool temperature and surface roughness of the machined component. Experiments revealed that the increase in cutting forces and tool temperature resulting in the decrease of surface quality with the decrease in the size of nano-particulate graphite powder as lubricant.

Keywords: Solid lubricant, graphite, minimum quantity lubrication, nanoparticles.

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