Search results for: tool engineering

Authors: Rosziati Ibrahim, Tiu Kian Yong

Abstract:

Reverse Engineering is a very important process in Software Engineering. It can be performed backwards from system development life cycle (SDLC) in order to get back the source data or representations of a system through analysis of its structure, function and operation. We use reverse engineering to introduce an automatic tool to generate system requirements from its program source codes. The tool is able to accept the Cµ programming source codes, scan the source codes line by line and parse the codes to parser. Then, the engine of the tool will be able to generate system requirements for that specific program to facilitate reuse and enhancement of the program. The purpose of producing the tool is to help recovering the system requirements of any system when the system requirements document (SRD) does not exist due to undocumented support of the system.

Keywords: System Requirements, Reverse Engineering, SourceCodes.

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Authors: Fawaz A. Masoud, Heba_tallah Khattab, Mahmoud Al-Karazoon

Abstract:

The database reverse engineering problems and solving processes are getting mature, even though, the academic community is facing the complex problem of knowledge transfer, both in university and industrial contexts. This paper presents a new CASE tool developed at the University of Jordan which addresses an efficient support of this transfer, namely UJ-CASE-TOOL. It is a small and self-contained application exhibiting representative problems and appropriate solutions that can be understood in a limited time. It presents an algorithm that describes the developed academic CASE tool which has been used for several years both as an illustration of the principles of database reverse engineering and as an exercise aimed at academic and industrial students.

Keywords: Reverse engineering, ERD, DBRE, case tools.

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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: Amir Ngah, Masita Abdul Jalil, Zailani Abdullah

Abstract:

The aim of software maintenance is to maintain the software system in accordance with advancement in software and hardware technology. One of the early works on software maintenance is to extract information at higher level of abstraction. In this paper, we present the process of how to design an information extraction tool for software maintenance. The tool can extract the basic information from old programs such as about variables, based classes, derived classes, objects of classes, and functions. The tool have two main parts; the lexical analyzer module that can read the input file character by character, and the searching module which users can get the basic information from the existing programs. We implemented this tool for a patterned sub-C++ language as an input file.

Keywords: Extraction tool, software maintenance, reverse engineering, C++.

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Authors: M.A. Kamely, M.Y. Noordin

Abstract:

A judicious choice of insert material, tool geometry and cutting conditions can make hard turning produce better surfaces than grinding. In the present study, an attempt has been made to investigate the effect of cutting tool materials on cutting forces (feed force, thrust force and cutting force) in finish hard turning of AISI D2 cold work tool steel. In conclusion of the results obtained with a constant depth of cut and feed rate, it is important to note that cutting force is directly affected by cutting tool material.

Keywords: hard turning, cutting force, cutting tool materials, mixed ceramic, cbn

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Authors: M. Bagheri, P. Mottaghizadeh

Abstract:

Reliable information about tool temperature distribution is of central importance in metal cutting. In this study, tool-chip interface temperature was determined in cutting of ST37 steel workpiece by applying HSS as the cutting tool in dry turning. Two different approaches were implemented for temperature measuring: an embedded thermocouple (RTD) in to the cutting tool and infrared (IR) camera. Comparisons are made between experimental data and results of MSC.SuperForm and FLUENT software. An investigation of heat generation in cutting tool was performed by varying cutting parameters at the stable cutting tool geometry and results were saved in a computer; then the diagrams of tool temperature vs. various cutting parameters were obtained. The experimental results reveal that the main factors of the increasing cutting temperature are cutting speed (V ), feed rate ( S ) and depth of cut ( h ), respectively. It was also determined that simultaneously change in cutting speed and feed rate has the maximum effect on increasing cutting temperature.

Keywords: Cutting parameters, Finite element modeling, Temperature measurement, Tool-chip interface temperature.

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Authors: P. Mottaghizadeh, M. Bagheri

Abstract:

In the present paper, the three-dimensional temperature field of tool is determined during the machining and compared with experimental work on C45 workpiece using carbide cutting tool inserts. During the metal cutting operations, high temperature is generated in the tool cutting edge which influence on the rate of tool wear. Temperature is most important characteristic of machining processes; since many parameters such as cutting speed, surface quality and cutting forces depend on the temperature and high temperatures can cause high mechanical stresses which lead to early tool wear and reduce tool life. Therefore, considerable attention is paid to determine tool temperatures. The experiments are carried out for dry and orthogonal machining condition. The results show that the increase of tool temperature depends on depth of cut and especially cutting speed in high range of cutting conditions.

Keywords: Finite element method, Machining, Temperature measurement, Thermal fields

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Authors: Dagmar Monett, Sven-Erik Kujat, Marvin Hartmann

Abstract:

This paper discusses the use of a template-based approach for documenting high-quality requirements as part of course projects in an undergraduate Software Engineering course. In order to ease some of the Requirements Engineering activities that are performed when defining requirements by using the template, a new CASE tool, RED:WIRE, was first developed and later tested by students attending the course. Two questionnaires were conceived around a study that aims to analyze the new tool’s learnability as well as other obtained results concerning its usability in particular and the Requirements Engineering skills developed by the students in general.

Keywords: CASE tool, collaborative learning, requirements engineering, undergraduate teaching.

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Authors: S. Ghorbani, N. I. Polushin

Abstract:

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

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

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Authors: Da-Hye Kim, Won-Hyung Park, In-Ho Yun, Jeong Cheol Kim, Sang-Youn Kim

Abstract:

This paper presents an authoring tool which makes a user easily and intuitively design vibrotactile sensation. A mobile hardware platform powered by ANDROID, a multi-purpose haptic driver and a linear resonance actuator are used to implement the system of the presented authoring tool. The tool allows users to easily and simply create a vibrotactile sensation by drawing vibrotactile images and to feel the sensation by rubbing drawn images on the touch screen of a mobile device. The tool supports a graphical interface for designing, editing and playing vibrotactile images as well as a pre-defined file format for save and open.

Keywords: authoring tool, mobile device, vibrotactile pattern, vibrotactile sensation

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Authors: Rosziati Ibrahim, Noraini Ibrahim

Abstract:

Unified Modeling Language (UML) is a standard language for modeling of a system. UML is used to visually specify the structure and behavior of a system. The system requirements are captured and then converted into UML specification. UML specification uses a set of rules and notations, and diagrams to specify the system requirements. In this paper, we present a tool for developing the UML specification. The tool will ease the use of the notations and diagrams for UML specification as well as increase the understanding and familiarity of the UML specification. The tool will also be able to check the conformance of the diagrams against each other for basic compliance of UML specification.

Keywords: Software Engineering, Unified Modeling Language (UML), UML Specification.

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Authors: Sadílek M., Čep R.

Abstract:

This work deals with problems of tool axis inclination angles in ball-end milling. Tool axis inclination angle contributes to improvement of functional surface properties (surface integrity - surface roughness, residual stress, micro hardness, etc.), decreasing cutting forces and improving production. By milling with ball-end milling tool, using standard way of cutting, when work piece and cutting tool contain right angle, we have zero cutting speed on edge. At this point cutting tool only pushes material into the work piece. Here we can observe the following undesirable effects - chip contraction, increasing of cutting temperature, increasing vibrations or creation of built-up edge. These effects have negative results – low quality of surface and decreasing of tool life (in the worse case even it is pinching out). These effects can be eliminated with the tilt of cutting tool or tilt of work piece.

Keywords: CAD/CAM system, tool axis inclination angle, ballend milling, surface roughness, cutting forces.

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Authors: Cem Karacal, Sohyung Cho, William Yu

Abstract:

In metal cutting industries, mathematical/statistical models are typically used to predict tool replacement time. These off-line methods usually result in less than optimum replacement time thereby either wasting resources or causing quality problems. The few online real-time methods proposed use indirect measurement techniques and are prone to similar errors. Our idea is based on identifying the optimal replacement time using an electronic nose to detect the airborne compounds released when the tool wear reaches to a chemical substrate doped into tool material during the fabrication. The study investigates the feasibility of the idea, possible doping materials and methods along with data stream mining techniques for detection and monitoring different phases of tool wear.

Keywords: Tool condition monitoring, cutting tool replacement, data stream mining, e-Nose.

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Authors: Chris M. Taylor, Ian Cook, Raul Alegre, Pedro Arrazola, Phil Spiers

Abstract:

Noteworthy results have been obtained in the turning and drilling of hardened high-strength steels using tungsten carbide based cutting tools. In a finish turning process, it was seen that surface roughness and tool flank wear followed very different trends against cutting time. The suggested explanation for this behaviour is that the profile cut into the workpiece surface is determined by the tool’s cutting edge profile. It is shown that the profile appearing on the cut surface changes rapidly over time, so the profile of the tool cutting edge should also be changing rapidly. Workpiece material adhered onto the cutting tool, which is also known as a built-up edge, is a phenomenon which could explain the observations made. In terms of tool damage modes, workpiece material adhesion is believed to have contributed to tool wear in examples provided from finish turning, thread turning and drilling. Additionally, evidence of tool fracture and tool abrasion were recorded.

Keywords: Turning, drilling, adhesion, wear, hard steels.

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Authors: Raida El Mansouri, Elhillali Kerkouche, Allaoua Chaoui

Abstract:

The Petri net tool INA is a well known tool by the Petri net community. However, it lacks a graphical environment to cerate and analyse INA models. Building a modelling tool for the design and analysis from scratch (for INA tool for example) is generally a prohibitive task. Meta-Modelling approach is useful to deal with such problems since it allows the modelling of the formalisms themselves. In this paper, we propose an approach based on the combined use of Meta-modelling and Graph Grammars to automatically generate a visual modelling tool for INA for analysis purposes. In our approach, the UML Class diagram formalism is used to define a meta-model of INA models. The meta-modelling tool ATOM3 is used to generate a visual modelling tool according to the proposed INA meta-model. We have also proposed a graph grammar to automatically generate INA description of the graphically specified Petri net models. This allows the user to avoid the errors when this description is done manually. Then the INA tool is used to perform the simulation and the analysis of the resulted INA description. Our environment is illustrated through an example.

Keywords: INA, Meta-modelling, Graph Grammars, AToM3, Automatic Code Generation.

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Authors: Jui-Pui Hung, Yu-Sheng Lai, Tzuo-Liang Luo, Kung-Da Wu, Yun-Ji Zhan

Abstract:

This study presented the investigation of the influence of the tool holder interface stiffness on the dynamic characteristics of a spindle tool system. The interface stiffness was produced by drawbar force on the tool holder, which tends to affect the spindle dynamics. In order to assess the influence of interface stiffness on the vibration characteristic of spindle unit, we first created a three dimensional finite element model of a high speed spindle system integrated with tool holder. The key point for the creation of FEM model is the modeling of the rolling interface within the angular contact bearings and the tool holder interface. The former can be simulated by a introducing a series of spring elements between inner and outer rings. The contact stiffness was calculated according to Hertz contact theory and the preload applied on the bearings. The interface stiffness of the tool holder was identified through the experimental measurement and finite element modal analysis. Current results show that the dynamic stiffness was greatly influenced by the tool holder system. In addition, variations of modal damping, static stiffness and dynamic stiffness of the spindle tool system were greatly determined by the interface stiffness of the tool holder which was in turn dependent on the draw bar force applied on the tool holder. Overall, this study demonstrates that identification of the interface characteristics of spindle tool holder is of very importance for the refinement of the spindle tooling system to achieve the optimum machining performance.

Keywords: Dynamic stiffness, Drawbar force, Interface stiffness, Spindle-tool holder.

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Authors: Mohammed T. Hayajneh

Abstract:

Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al₂O₃ particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.

Keywords: Composite, fuzzy, tool life, wear.

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Authors: Mohd Shahrom Ismail, B.T. Hang Tuah Baharudin, K.K.B. Hon

Abstract:

In this paper, a methodology of a model based on predicting the tool forces oblique machining are introduced by adopting the orthogonal technique. The applied analytical calculation is mostly based on Devries model and some parts of the methodology are employed from Amareggo-Brown model. Model validation is performed by comparing experimental data with the prediction results on machining titanium alloy (Ti-6Al-4V) based on micro-cutting tool perspective. Good agreements with the experiments are observed. A detailed friction form that affected the tool forces also been examined with reasonable results obtained.

Keywords: dynamics machining, micro cutting tool, Tool forces

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Authors: Jaharah A. Ghani, Muhammad Rizal, Ahmad Sayuti, Mohd Zaki Nuawi, Mohd Nizam Ab. Rahman, Che Hassan Che Haron

Abstract:

This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals using the regression model and I-kaz method. The detection of tool wear was done automatically using the in-house developed regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out on a CNC turning machine Colchester Master Tornado T4 in dry cutting condition, and Kistler 9255B dynamometer was used to measure the cutting force signals, which then stored and displayed in the DasyLab software. The progression of the cutting tool flank wear land (VB) was indicated by the amount of the cutting force generated. Later, the I-kaz was used to analyze all the cutting force signals from beginning of the cut until the rejection stage of the cutting tool. Results of the IKaz analysis were represented by various characteristic of I-kaz 3D coefficient and 3D graphic presentation. The I-kaz 3D coefficient number decreases when the tool wear increases. This method can be used for real time tool wear monitoring.

Keywords: mathematical model, I-kaz method, tool wear

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Authors: YaoAn Lu, QingZhen Bi, BaoRui Du, ShuLin Chen, LiMin Zhu, Kai Huang

Abstract:

Taking the design tolerance into account, this paper presents a novel efficient approach to generate iso-scallop tool path for five-axis strip machining with a barrel cutter. The cutter location is first determined on the scallop surface instead of the design surface, and then the cutter is adjusted to locate the optimal tool position based on the differential rotation of the tool axis and satisfies the design tolerance simultaneously. The machining strip width and error are calculated with the aid of the grazing curve of the cutter. Based on the proposed tool positioning algorithm, the tool paths are generated by keeping the scallop height formed by adjacent tool paths constant. An example is conducted to confirm the validity of the proposed method.

Keywords: Strip machining, barrel cutter, iso-scallop tool path, sculptured surfaces, differential motion.

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Authors: A. Chandrashekar, H. N. Reddappa, B. S. Ajaykumar

Abstract:

A Friction stir welding tool is a critical component to the success of the process. The tool typically consists of a rotating round shoulder and a threaded cylindrical pin that heats the work piece, mostly by friction, and moves the softened alloy around it to form the joint. In this research work, an attempt has been made to investigate the relationship between FSW variables mainly tool profile, rotating speed, welding speed and the mechanical properties (tensile strength, yield strength, percentage elongation, and micro hardness) of friction stir welded aluminum alloy 5083 joints. From the experimental details, it can be assessed that the joint produced by using Triflute profile tool has contribute superior mechanical and structural properties as compared to Tapered unthreaded & Threaded tool for 1000rpm.

Keywords: Friction stir welding, Tool profile, Rotating speed, Strength, Speed ratio.

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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: Bogdan Walek, Jiri Bartos, Cyril Klimes, Jaroslav Prochazka, Pavel Smolka, Juraj Masar, Martin Pesl

Abstract:

This paper focuses on creating a component model of information system under uncertainty. The paper identifies problem in current approach of component modeling and proposes fuzzy tool, which will work with vague customer requirements and propose components of the resulting component model. The proposed tool is verified on specific information system and results are shown in paper. After finding suitable sub-components of the resulting component model, the component model is visualised by tool.

Keywords: Component, component model, fuzzy, fuzzy rules, fuzzy sets, information system, modelling, tool.

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

Abstract:

The stochastic nature of tool life using conventional discrete-wear data from experimental tests usually exists due to many individual and interacting parameters. It is a common practice in batch production to continually use the same tool to machine different parts, using disparate machining parameters. In such an environment, the optimal points at which tools have to be changed, while achieving minimum production cost and maximum production rate within the surface roughness specifications, have not been adequately studied. In the current study, two relevant aspects are investigated using coated and uncoated inserts in turning operations: (i) the accuracy of using machinability information, from fixed parameters testing procedures, when variable parameters situations are emerged, and (ii) the credibility of tool life machinability data from prior discrete testing procedures in a non-stop machining. A novel technique is proposed and verified to normalize the conventional fixed parameters machinability data to suit the cases when parameters have to be changed for the same tool. Also, an experimental investigation has been established to evaluate the error in the tool life assessment when machinability from discrete testing procedures is employed in uninterrupted practical machining.

Keywords: Machinability, tool life, tool wear, wear variability

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Authors: Juyi Park, Jung-Min Kim, Hee-Hwan Park, Jin-Wook Kim, Gye-Hyung Kang, Soo-Ho Kim

Abstract:

This paper presents an iterative algorithm to find a inverse kinematic solution of 5-DOF robot. The algorithm is to minimize the iteration number. Since the 5-DOF robot cannot give full orientation of tool. Only z-direction of tool is satisfied while rotation of tool is determined by kinematic constraint. This work therefore described how to specify the tool direction and let the tool rotation free. The simulation results show that this algorithm effectively worked. Using the proposed iteration algorithm, error due to inverse kinematics converged to zero rapidly in 5 iterations. This algorithm was applied in real welding robot and verified through various practical works.

Keywords: 5-DOF manipulator, Inverse kinematics, Iterative algorithm, Wrist offset.

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Authors: Rami Rashkovits, Ilana Lavy

Abstract:

In this study we present our developed formative assessment tool for students' assignments. The tool enables lecturers to define assignments for the course and assign each problem in each assignment a list of criteria and weights by which the students' work is evaluated. During assessment, the lecturers feed the scores for each criterion with justifications. When the scores of the current assignment are completely fed in, the tool automatically generates reports for both students and lecturers. The students receive a report by email including detailed description of their assessed work, their relative score and their progress across the criteria along the course timeline. This information is presented via charts generated automatically by the tool based on the scores fed in. The lecturers receive a report that includes summative (e.g., averages, standard deviations) and detailed (e.g., histogram) data of the current assignment. This information enables the lecturers to follow the class achievements and adjust the learning process accordingly. The tool was examined on two pilot groups of college students that study a course in (1) Object-Oriented Programming (2) Plane Geometry. Results reveal that most of the students were satisfied with the assessment process and the reports produced by the tool. The lecturers who used the tool were also satisfied with the reports and their contribution to the learning process.

Keywords: Computer-based formative assessment tool, science education.

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Authors: Tadahiro Wada, Koji Iwamoto

Abstract:

In turning hardened steel, polycrystalline cubic boron nitride (cBN) compacts are widely used, due to their higher hardness and higher thermal conductivity. However, in milling hardened steel, fracture of cBN cutting tools readily occurs because they have poor fracture toughness. Therefore, coated cemented carbide tools, which have good fracture toughness and wear resistance, are generally widely used. In this study, hardened steel (ASTM D2, JIS SKD11, 60HRC) was milled with three physical vapor deposition (PVD)-coated cemented carbide end mill cutters in order to determine effective tool materials for cutting hardened steel at high cutting speeds. The coating films used were (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating films. (Ti,W,Si,Al)N is a new type of coating film. The inner layer of the (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating system is (Ti,W)N coating film, and the outer layer is (Ti,W,Si)N and (Ti,W,Si,Al)N coating films, respectively. Furthermore, commercial (Ti,Al)N-based coating film was also used. The following results were obtained: (1) In milling hardened steel at a cutting speed of 3.33 m/s, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,W)N/(Ti,W,Si)N-coated tool. And, compared with the commercial (Ti,Al)N, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,Al)N-coated tool. (2) The tool wear of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool increased with an increase in cutting speed. (3) The (Ti,W)N/(Ti,W,Si,Al)N-coated cemented carbide was an effective tool material for high-speed cutting below a cutting speed of 3.33 m/s.

Keywords: cutting, physical vapor deposition (PVD) coating system, hardened steel, tool wear

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Authors: A. Fata, B. Nikuei

Abstract:

In this paper by measuring the cutting forces the effect of the tool shape and qualifications (sharp and worn cutting tools of both vee and knife edge profile) and cutting conditions (depth of cut and cutting speed) in the turning operation on the tool deflection and cutting force is investigated. The workpiece material was mild steel and the cutting tool was made of high speed steel. Cutting forces were measured by a dynamometer (type P.E.I. serial No 154). The dynamometer essentially consisted of a cantilever structure which held the cutting tool. Deflection of the cantilever was measured by an L.V.D.T (Mercer 122) deflection indicator. No cutting fluid was used during the turning operations. A modern CNC lathe machine (Okuma LH35-N) was used for the tests. It was noted that worn vee profile tools tended to produce a greater increase in the vertical force component than the axial component, whereas knife tools tended to show a more pronounced increase in the axial component.

Keywords: Cutting force, Tool deflection, Turning, Cuttingconditions.

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Authors: Majid Tolouei-Rad, Ankit Shah

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Drilling is the most common machining operation and it forms the highest machining cost in many manufacturing activities including automotive engine production. The outcome of this operation depends upon many factors including utilization of proper cutting tool geometry, cutting tool material and the type of coating used to improve hardness and resistance to wear, and also cutting parameters. With the availability of a large array of tool geometries, materials and coatings, is has become a challenging task to select the best tool and cutting parameters that would result in the lowest machining cost or highest profit rate. This paper describes an algorithm developed to help achieve good performances in drilling operations by automatically determination of proper cutting tools and cutting parameters. It also helps determine machining sequences resulting in minimum tool changes that would eventually reduce machining time and cost where multiple tools are used.

Keywords: Cutting tool, drilling, machining, algorithm.

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

Abstract:

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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