Transition Towards Energy Efficient Machine Tools

CERN Document Server

Zein, André

2012-01-01

Energy efficiency represents a cost-effective and immediate strategy of a sustainable development. Due to substantial environmental and economic implications, a strong emphasis is put on the electrical energy requirements of machine tools for metalworking processes. The improvement of energy efficiency is however confronted with diverse barriers, which sustain an energy efficiency gap of unexploited potential. The deficiencies lie in the lack of information about the actual energy requirements of machine tools, a minimum energy reference to quantify improvement potential and the possible actions to improve the energy demand. Therefore, a comprehensive concept for energy performance management of machine tools is developed which guides the transition towards energy efficient machine tools. It is structured in four innovative concept modules, which are embedded into step-by-step workflow models. The capability of the performance management concept is demonstrated in an automotive manufacturing environment. The ...

Research on the tool holder mode in high speed machining

Science.gov (United States)

Zhenyu, Zhao; Yongquan, Zhou; Houming, Zhou; Xiaomei, Xu; Haibin, Xiao

2018-03-01

High speed machining technology can improve the processing efficiency and precision, but also reduce the processing cost. Therefore, the technology is widely regarded in the industry. With the extensive application of high-speed machining technology, high-speed tool system has higher and higher requirements on the tool chuck. At present, in high speed precision machining, several new kinds of clip heads are as long as there are heat shrinkage tool-holder, high-precision spring chuck, hydraulic tool-holder, and the three-rib deformation chuck. Among them, the heat shrinkage tool-holder has the advantages of high precision, high clamping force, high bending rigidity and dynamic balance, etc., which are widely used. Therefore, it is of great significance to research the new requirements of the machining tool system. In order to adapt to the requirement of high speed machining precision machining technology, this paper expounds the common tool holder technology of high precision machining, and proposes how to select correctly tool clamping system in practice. The characteristics and existing problems are analyzed in the tool clamping system.

Nanocomposites for Machining Tools

Directory of Open Access Journals (Sweden)

Daria Sidorenko

2017-10-01

Full Text Available Machining tools are used in many areas of production. To a considerable extent, the performance characteristics of the tools determine the quality and cost of obtained products. The main materials used for producing machining tools are steel, cemented carbides, ceramics and superhard materials. A promising way to improve the performance characteristics of these materials is to design new nanocomposites based on them. The application of micromechanical modeling during the elaboration of composite materials for machining tools can reduce the financial and time costs for development of new tools, with enhanced performance. This article reviews the main groups of nanocomposites for machining tools and their performance.

An expert machine tools selection system for turning operation

NARCIS (Netherlands)

Tan, C.F.; Khalil, S.N.; Karjanto, J.; Wahidin, L.S.; Chen, W.; Rauterberg, G.W.M.

2015-01-01

The turning machining process is an important process in the manufacturing industry. It is important to select the right tool for the turning process so that the manufacturing cost will be decreased. The main objective of this research is to select the most suitable machine tools with respect to

Study of on-machine error identification and compensation methods for micro machine tools

International Nuclear Information System (INIS)

Wang, Shih-Ming; Yu, Han-Jen; Lee, Chun-Yi; Chiu, Hung-Sheng

2016-01-01

Micro machining plays an important role in the manufacturing of miniature products which are made of various materials with complex 3D shapes and tight machining tolerance. To further improve the accuracy of a micro machining process without increasing the manufacturing cost of a micro machine tool, an effective machining error measurement method and a software-based compensation method are essential. To avoid introducing additional errors caused by the re-installment of the workpiece, the measurement and compensation method should be on-machine conducted. In addition, because the contour of a miniature workpiece machined with a micro machining process is very tiny, the measurement method should be non-contact. By integrating the image re-constructive method, camera pixel correction, coordinate transformation, the error identification algorithm, and trajectory auto-correction method, a vision-based error measurement and compensation method that can on-machine inspect the micro machining errors and automatically generate an error-corrected numerical control (NC) program for error compensation was developed in this study. With the use of the Canny edge detection algorithm and camera pixel calibration, the edges of the contour of a machined workpiece were identified and used to re-construct the actual contour of the work piece. The actual contour was then mapped to the theoretical contour to identify the actual cutting points and compute the machining errors. With the use of a moving matching window and calculation of the similarity between the actual and theoretical contour, the errors between the actual cutting points and theoretical cutting points were calculated and used to correct the NC program. With the use of the error-corrected NC program, the accuracy of a micro machining process can be effectively improved. To prove the feasibility and effectiveness of the proposed methods, micro-milling experiments on a micro machine tool were conducted, and the results

Nanocomposites for Machining Tools

DEFF Research Database (Denmark)

Sidorenko, Daria; Loginov, Pavel; Mishnaevsky, Leon

2017-01-01

Machining tools are used in many areas of production. To a considerable extent, the performance characteristics of the tools determine the quality and cost of obtained products. The main materials used for producing machining tools are steel, cemented carbides, ceramics and superhard materials...

Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines

OpenAIRE

Soori, Mohsen; Arezoo, Behrooz; Habibi, Mohsen

2014-01-01

Virtual manufacturing systems can provide useful means for products to be manufactured without the need of physical testing on the shop floor. As a result, the time and cost of part production can be decreased. There are different error sources in machine tools such as tool deflection, geometrical deviations of moving axis and thermal distortions of machine tool structures. Some of these errors can be decreased by controlling the machining process and environmental parameters. However other e...

Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines

OpenAIRE

Soori, Mohsen; Arezoo, Behrooz; Habibi, Mohsen

2016-01-01

Virtual manufacturing systems can provide useful means for products to be manufactured without the need of physical testing on the shop floor. As a result, the time and cost of part production can be decreased. There are different error sources in machine tools such as tool deflection, geometrical deviations of moving axis and thermal distortions of machine tool structures. Some of these errors can be decreased by controlling the machining process and environmental parameters. However other e...

Diamond turning on advanced machine tool prototypes

International Nuclear Information System (INIS)

Arnold, J.B.; Steger, P.J.

1975-01-01

Specular-quality metal mirrors are being machined for use in laser optical systems. The fabrication process incorporates special quality diamond tools and specially constructed turning machines. The machines are controlled by advanced control techniques and are housed in an environmentally controlled laboratory to insure ultimate machine stability and positional accuracy. The materials from which these mirrors are primarily produced are the softer face-center-cubic structure metals, such as gold, silver, copper, and aluminum. Mirror manufacturing by the single-point diamond machining process is in an early stage of development, but it is anticipated that this method will become the most economical way for producing high-quality metal mirrors. (U.S.)

Virtual reality solutions for the design of machine tools in practice

OpenAIRE

Zickner, H.; Neugebauer, Reimund; Weidlich, D.

2006-01-01

At the Virtual Reality Centre Production Engineering (VRCP) the Institute for Machine Tools and Production Processes (IWP) of the Chemnitz University of Technology and the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) have developed several practical Virtual Reality (VR) based solutions for the industry. Some practical examples will show the benefits gained by the application of Virtual Reality techniques in the design process of machine tools and assembly lines.

Traditional machining processes research advances

CERN Document Server

2015-01-01

This book collects several examples of research in machining processes. Chapter 1 provides information on polycrystalline diamond tool material and its emerging applications. Chapter 2 is dedicated to the analysis of orthogonal cutting experiments using diamond-coated tools with force and temperature measurements. Chapter 3 describes the estimation of cutting forces and tool wear using modified mechanistic models in high performance turning. Chapter 4 contains information on cutting under gas shields for industrial applications. Chapter 5 is dedicated to the machinability of magnesium and its alloys. Chapter 6 provides information on grinding science. Finally, chapter 7 is dedicated to flexible integration of shape and functional modelling of machine tool spindles in a design framework.    

Machinability of nickel based alloys using electrical discharge machining process

Science.gov (United States)

Khan, M. Adam; Gokul, A. K.; Bharani Dharan, M. P.; Jeevakarthikeyan, R. V. S.; Uthayakumar, M.; Thirumalai Kumaran, S.; Duraiselvam, M.

2018-04-01

The high temperature materials such as nickel based alloys and austenitic steel are frequently used for manufacturing critical aero engine turbine components. Literature on conventional and unconventional machining of steel materials is abundant over the past three decades. However the machining studies on superalloy is still a challenging task due to its inherent property and quality. Thus this material is difficult to be cut in conventional processes. Study on unconventional machining process for nickel alloys is focused in this proposed research. Inconel718 and Monel 400 are the two different candidate materials used for electrical discharge machining (EDM) process. Investigation is to prepare a blind hole using copper electrode of 6mm diameter. Electrical parameters are varied to produce plasma spark for diffusion process and machining time is made constant to calculate the experimental results of both the material. Influence of process parameters on tool wear mechanism and material removal are considered from the proposed experimental design. While machining the tool has prone to discharge more materials due to production of high energy plasma spark and eddy current effect. The surface morphology of the machined surface were observed with high resolution FE SEM. Fused electrode found to be a spherical structure over the machined surface as clumps. Surface roughness were also measured with surface profile using profilometer. It is confirmed that there is no deviation and precise roundness of drilling is maintained.

Machine tool evaluation

International Nuclear Information System (INIS)

Lunsford, B.E.

1976-01-01

Continued improvement in numerical control (NC) units and the mechanical components used in the construction of today's machine tools, necessitate the use of more precise instrumentation to calibrate and determine the capabilities of these systems. It is now necessary to calibrate most tape-control lathes to a tool-path positioning accuracy of +-300 microinches in the full slide travel and, on some special turning and boring machines, a capability of +-100 microinches must be achieved. The use of a laser interferometer to determine tool-path capabilities is described

Thermal Analysis for Condition Monitoring of Machine Tool Spindles

International Nuclear Information System (INIS)

Clough, D; Fletcher, S; Longstaff, A P; Willoughby, P

2012-01-01

Decreasing tolerances on parts manufactured, or inspected, on machine tools increases the requirement to have a greater understanding of machine tool capabilities, error sources and factors affecting asset availability. Continuous usage of a machine tool during production processes causes heat generation typically at the moving elements, resulting in distortion of the machine structure. These effects, known as thermal errors, can contribute a significant percentage of the total error in a machine tool. There are a number of design solutions available to the machine tool builder to reduce thermal error including, liquid cooling systems, low thermal expansion materials and symmetric machine tool structures. However, these can only reduce the error not eliminate it altogether. It is therefore advisable, particularly in the production of high value parts, for manufacturers to obtain a thermal profile of their machine, to ensure it is capable of producing in tolerance parts. This paper considers factors affecting practical implementation of condition monitoring of the thermal errors. In particular is the requirement to find links between temperature, which is easily measureable during production and the errors which are not. To this end, various methods of testing including the advantages of thermal images are shown. Results are presented from machines in typical manufacturing environments, which also highlight the value of condition monitoring using thermal analysis.

Machine Translation Tools - Tools of The Translator's Trade

DEFF Research Database (Denmark)

Kastberg, Peter

2012-01-01

In this article three of the more common types of translation tools are presented, discussed and critically evaluated. The types of translation tools dealt with in this article are: Fully Automated Machine Translation (or FAMT), Human Aided Machine Translation (or HAMT) and Machine Aided Human...... Translation (or MAHT). The strengths and weaknesses of the different types of tools are discussed and evaluated by means of a number of examples. The article aims at two things: at presenting a sort of state of the art of what is commonly referred to as “machine translation” as well as at providing the reader...... with a sound basis for considering what translation tool (if any) is the most appropriate in order to meet his or her specific translation needs....

corrosion and wear resistant ternary Cr-C-N coatings deposited by the ARC PVD process for machining tools and machining parts

International Nuclear Information System (INIS)

Knotek, O.; Lugscheider, E.; Zimmermann, H.; Bobzin, K.

1997-01-01

With the deposition of PVD hard coatings on the tools applied in machining operations it is possible to achieve significant improvements in the performance and quality of the machining processes. Depending on the machined material and the operating principle, e.g. turning, milling or drilling, not only different machining parameters but also different coating materials are necessary. In interrupted cut machining of tempered steel, for example, the life time of Ti-C-N coated inserts is several times greater than the Ti-C-N coated ones. This is a result of the favourable thermophysical and tribological properties of Ti-N-C. The potential for tool protection by CrN coatings is a result of the high ductility and low internal stress of this coating materials. CrN films can be deposited with greater film thickness, still maintaining very good adhesion. This paper presents the development of new arc PVD coatings in the system Cr-C-N. Owing to the carbon content in the coating an increased hardness and a better wear behavior in comparison to CrN was expected. The effects of various carbon carrier gases on the coating properties were examined. The coating properties were investigated by mechanical tests. X-ray diffraction, SEM analysis and corrosion tests. Some of the coatings were tested in machining tests. The results of these tests are presented in this paper. (author)

Design of a Three-Axis Machine Tool Module

National Research Council Canada - National Science Library

Childers, Marshal

2003-01-01

This report documents the design improvement process of the components in a tool module for a three-axis machine tool, which occurred during the period of March-April 2002 in support of a critical U.S...

Slide system for machine tools

Science.gov (United States)

Douglass, Spivey S.; Green, Walter L.

1982-01-01

The present invention relates to a machine tool which permits the machining of nonaxisymmetric surfaces on a workpiece while rotating the workpiece about a central axis of rotation. The machine tool comprises a conventional two-slide system (X-Y) with one of these slides being provided with a relatively short travel high-speed auxiliary slide which carries the material-removing tool. The auxiliary slide is synchronized with the spindle speed and the position of the other two slides and provides a high-speed reciprocating motion required for the displacement of the cutting tool for generating a nonaxisymmetric surface at a selected location on the workpiece.

Modeling of the flow stress for AISI H13 Tool Steel during Hard Machining Processes

Science.gov (United States)

Umbrello, Domenico; Rizzuti, Stefania; Outeiro, José C.; Shivpuri, Rajiv

2007-04-01

In general, the flow stress models used in computer simulation of machining processes are a function of effective strain, effective strain rate and temperature developed during the cutting process. However, these models do not adequately describe the material behavior in hard machining, where a range of material hardness between 45 and 60 HRC are used. Thus, depending on the specific material hardness different material models must be used in modeling the cutting process. This paper describes the development of a hardness-based flow stress and fracture models for the AISI H13 tool steel, which can be applied for range of material hardness mentioned above. These models were implemented in a non-isothermal viscoplastic numerical model to simulate the machining process for AISI H13 with various hardness values and applying different cutting regime parameters. Predicted results are validated by comparing them with experimental results found in the literature. They are found to predict reasonably well the cutting forces as well as the change in chip morphology from continuous to segmented chip as the material hardness change.

Modeling of the flow stress for AISI H13 Tool Steel during Hard Machining Processes

International Nuclear Information System (INIS)

Umbrello, Domenico; Rizzuti, Stefania; Outeiro, Jose C.; Shivpuri, Rajiv

2007-01-01

In general, the flow stress models used in computer simulation of machining processes are a function of effective strain, effective strain rate and temperature developed during the cutting process. However, these models do not adequately describe the material behavior in hard machining, where a range of material hardness between 45 and 60 HRC are used. Thus, depending on the specific material hardness different material models must be used in modeling the cutting process. This paper describes the development of a hardness-based flow stress and fracture models for the AISI H13 tool steel, which can be applied for range of material hardness mentioned above. These models were implemented in a non-isothermal viscoplastic numerical model to simulate the machining process for AISI H13 with various hardness values and applying different cutting regime parameters. Predicted results are validated by comparing them with experimental results found in the literature. They are found to predict reasonably well the cutting forces as well as the change in chip morphology from continuous to segmented chip as the material hardness change

Repurposing mainstream CNC machine tools for laser-based additive manufacturing

Science.gov (United States)

Jones, Jason B.

2016-04-01

The advent of laser technology has been a key enabler for industrial 3D printing, known as Additive Manufacturing (AM). Despite its commercial success and unique technical capabilities, laser-based AM systems are not yet able to produce parts with the same accuracy and surface finish as CNC machining. To enable the geometry and material freedoms afforded by AM, yet achieve the precision and productivity of CNC machining, hybrid combinations of these two processes have started to gain traction. To achieve the benefits of combined processing, laser technology has been integrated into mainstream CNC machines - effectively repurposing them as hybrid manufacturing platforms. This paper reviews how this engineering challenge has prompted beam delivery innovations to allow automated changeover between laser processing and machining, using standard CNC tool changers. Handling laser-processing heads using the tool changer also enables automated change over between different types of laser processing heads, further expanding the breadth of laser processing flexibility in a hybrid CNC. This paper highlights the development, challenges and future impact of hybrid CNCs on laser processing.

Machining tools in AISI M2 high-speed steel obtained by spray forming process

International Nuclear Information System (INIS)

Jesus, Edilson Rosa Barbosa de.

2004-01-01

The aim of the present work was the obtention of AISI M2 high-speed steel by spray forming technique and the material evaluation when used as machining tool. The obtained material was hot rolled at 50% and 72% reduction ratios, and from which it was manufactured inserts for machining tests. The performance of inserts made of the spray formed material was compared to inserts obtained from conventional and powder metallurgy (MP) processed materials. The spray formed material was chemical, physical, mechanical and microstructural characterised. For further characterisation, the materials were submitted to machining tests for performance evaluation under real work condition. The results of material characterisation highlight the potential of the spray forming technique, in the obtention of materials with good characteristics and properties. Under the current processing, hot rolling and heat treatments condition, the analysis of the results of the machining tests revealed a very similar behaviour among the tested materials. Proceeding a criterious analysis of the machining results tests, it was verified that the performance presented by the powder metallurgy material (MP) was slight superior, followed by conventional obtained material (MConv), which presented a insignificant advantage over the spray formed and hot rolled (72% reduction ratio) material. The worst result was encountered for the spray forming and hot rolled (50% reduction ratio) material that presented the highest wear values. (author)

3D cutting tool-wear monitoring in the process

Energy Technology Data Exchange (ETDEWEB)

Cerce, Luka; Pusavec, Franci; Kopac Janez [University of Ljubljana, Askerceva (Slovenia)

2015-09-15

The tool-wear of cutting tools has a very strong impact on the product quality as well as efficiency of the machining processes. Therefore, it in-the process characterization is crucial. This paper presents an innovative and reliable direct measuring procedure for measuring spatial cutting tool-wear with usage of laser profile sensor. The technique provides possibility for determination of 3D wear profiles, as advantage to currently used 2D techniques. The influence of the orientation of measurement head on the accuracy and the amount of captured reliable data was examined and the optimal setup of the measuring system was defined. Further, a special clamping system was designed to mount the measurement device on the machine tool turret. To test the measurement system, tool-life experiment was performed. Additionally, a new tool-life criterion was developed, including spatial characteristics of the tool-wear. The results showed that novel tool-wear and tool-life diagnostic represent objective and robust estimator of the machining process. Additionally, such automation of tool-wear diagnostics on machine tool provides higher productivity and quality of the machining process.

Research on Key Technologies of Unit-Based CNC Machine Tool Assembly Design

OpenAIRE

Zhongqi Sheng; Lei Zhang; Hualong Xie; Changchun Liu

2014-01-01

Assembly is the part that produces the maximum workload and consumed time during product design and manufacturing process. CNC machine tool is the key basic equipment in manufacturing industry and research on assembly design technologies of CNC machine tool has theoretical significance and practical value. This study established a simplified ASRG for CNC machine tool. The connection between parts, semantic information of transmission, and geometric constraint information were quantified to as...

Miniaturized multiwavelength digital holography sensor for extensive in-machine tool measurement

Science.gov (United States)

Seyler, Tobias; Fratz, Markus; Beckmann, Tobias; Bertz, Alexander; Carl, Daniel

2017-06-01

In this paper we present a miniaturized digital holographic sensor (HoloCut) for operation inside a machine tool. With state-of-the-art 3D measurement systems, short-range structures such as tool marks cannot be resolved inside a machine tool chamber. Up to now, measurements had to be conducted outside the machine tool and thus processing data are generated offline. The sensor presented here uses digital multiwavelength holography to get 3D-shape-information of the machined sample. By using three wavelengths, we get a large artificial wavelength with a large unambiguous measurement range of 0.5mm and achieve micron repeatability even in the presence of laser speckles on rough surfaces. In addition, a digital refocusing algorithm based on phase noise is implemented to extend the measurement range beyond the limits of the artificial wavelength and geometrical depth-of-focus. With complex wave field propagation, the focus plane can be shifted after the camera images have been taken and a sharp image with extended depth of focus is constructed consequently. With 20mm x 20mm field of view the sensor enables measurement of both macro- and micro-structure (such as tool marks) with an axial resolution of 1 µm, lateral resolution of 7 µm and consequently allows processing data to be generated online which in turn qualifies it as a machine tool control. To make HoloCut compact enough for operation inside a machining center, the beams are arranged in two planes: The beams are split into reference beam and object beam in the bottom plane and combined onto the camera in the top plane later on. Using a mechanical standard interface according to DIN 69893 and having a very compact size of 235mm x 140mm x 215mm (WxHxD) and a weight of 7.5 kg, HoloCut can be easily integrated into different machine tools and extends no more in height than a typical processing tool.

Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel

Science.gov (United States)

Outeiro, José C.; Umbrello, Domenico; Pina, José C.; Rizzuti, Stefania

2007-05-01

Residual stresses can enhance or impair the ability of a component to withstand loading conditions in service (fatigue, creep, stress corrosion cracking, etc.), depending on their nature: compressive or tensile, respectively. This poses enormous problems in structural assembly as this affects the structural integrity of the whole part. In addition, tool wear issues are of critical importance in manufacturing since these affect component quality, tool life and machining cost. Therefore, prediction and control of both tool wear and the residual stresses in machining are absolutely necessary. In this work, a two-dimensional Finite Element model using an implicit Lagrangian formulation with an automatic remeshing was applied to simulate the orthogonal cutting process of AISI H13 tool steel. To validate such model the predicted and experimentally measured chip geometry, cutting forces, temperatures, tool wear and residual stresses on the machined affected layers were compared. The proposed FE model allowed us to investigate the influence of tool geometry, cutting regime parameters and tool wear on residual stress distribution in the machined surface and subsurface of AISI H13 tool steel. The obtained results permit to conclude that in order to reduce the magnitude of surface residual stresses, the cutting speed should be increased, the uncut chip thickness (or feed) should be reduced and machining with honed tools having large cutting edge radii produce better results than chamfered tools. Moreover, increasing tool wear increases the magnitude of surface residual stresses.

Technique for Increasing Accuracy of Positioning System of Machine Tools

Directory of Open Access Journals (Sweden)

Sh. Ji

2014-01-01

Full Text Available The aim of research is to improve the accuracy of positioning and processing system using a technique for optimization of pressure diagrams of guides in machine tools. The machining quality is directly related to its accuracy, which characterizes an impact degree of various errors of machines. The accuracy of the positioning system is one of the most significant machining characteristics, which allow accuracy evaluation of processed parts.The literature describes that the working area of the machine layout is rather informative to characterize the effect of the positioning system on the macro-geometry of the part surfaces to be processed. To enhance the static accuracy of the studied machine, in principle, two groups of measures are possible. One of them points toward a decrease of the cutting force component, which overturns the slider moments. Another group of measures is related to the changing sizes of the guide facets, which may lead to their profile change.The study was based on mathematical modeling and optimization of the cutting zone coordinates. And we find the formula to determine the surface pressure of the guides. The selected parameters of optimization are vectors of the cutting force and values of slides and guides. Obtained results show that a technique for optimization of coordinates in the cutting zone was necessary to increase a processing accuracy.The research has established that to define the optimal coordinates of the cutting zone we have to change the sizes of slides, value and coordinates of applied forces, reaching the pressure equalization and improving the accuracy of positioning system of machine tools. In different points of the workspace a vector of forces is applied, pressure diagrams are found, which take into account the changes in the parameters of positioning system, and the pressure diagram equalization to provide the most accuracy of machine tools is achieved.

INFLUENCE OF STRUCTURE COMPONENTS ON MACHINE TOOL ACCURACY

Directory of Open Access Journals (Sweden)

ConstantinSANDU

2017-11-01

Full Text Available For machine tools, the accuracy of the parts of the machine tool structure (after roughing should be subject to relief and natural or artificial aging. The performance of the current accuracy of machine tools as linearity or flatness was higher than 5 μm/m. Under this value there are great difficulties. The performance of the structure of the machine tools in the manufacture of structural parts of machine tools, with a flatness accuracy that the linearity of about 2 μm/m, are significant deviations form of their half-finished. This article deals with the influence of errors of form of semifinished and machined parts on them, on their shape and especially what happens to structure machine tools when the components of the structure were assembling this.

Keeping you safe by making machine tools safe

CERN Multimedia

2012-01-01

CERN’s third safety objective for 2012 concerns the safety of equipment - and machine tools in particular.   There are three prerequisites for ensuring that a machine tool can be used safely: ·      the machine tool must comply with Directive 2009/104/EC, ·      the layout of the workshop must be compliant, and ·      everyone who uses the machine tool must be trained. Provided these conditions are met, the workshop head can grant authorisation to use the machine tool. To fulfil this objective, an inventory of the machine tools must be drawn up and the people responsible for them identified. The HSE Unit's Safety Inspection Service produces compliance reports for the machine tools. In order to meet the third objective set by the Director-General, the section has doubled its capacity to carry out inspections: ...

Smart Cutting Tools and Smart Machining: Development Approaches, and Their Implementation and Application Perspectives

Science.gov (United States)

Cheng, Kai; Niu, Zhi-Chao; Wang, Robin C.; Rakowski, Richard; Bateman, Richard

2017-09-01

Smart machining has tremendous potential and is becoming one of new generation high value precision manufacturing technologies in line with the advance of Industry 4.0 concepts. This paper presents some innovative design concepts and, in particular, the development of four types of smart cutting tools, including a force-based smart cutting tool, a temperature-based internally-cooled cutting tool, a fast tool servo (FTS) and smart collets for ultraprecision and micro manufacturing purposes. Implementation and application perspectives of these smart cutting tools are explored and discussed particularly for smart machining against a number of industrial application requirements. They are contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications, high speed micro milling and micro drilling, etc. Furthermore, implementation techniques are presented focusing on: (a) plug-and-produce design principle and the associated smart control algorithms, (b) piezoelectric film and surface acoustic wave transducers to measure cutting forces in process, (c) critical cutting temperature control in real-time machining, (d) in-process calibration through machining trials, (e) FE-based design and analysis of smart cutting tools, and (f) application exemplars on adaptive smart machining.

Assisting the Tooling and Machining Industry to Become Energy Efficient

Energy Technology Data Exchange (ETDEWEB)

Curry, Bennett [Arizona Commerce Authority, Phoenix, AZ (United States)

2016-12-30

The Arizona Commerce Authority (ACA) conducted an Innovation in Advanced Manufacturing Grant Competition to support and grow southern and central Arizona’s Aerospace and Defense (A&D) industry and its supply chain. The problem statement for this grant challenge was that many A&D machining processes utilize older generation CNC machine tool technologies that can result an inefficient use of resources – energy, time and materials – compared to the latest state-of-the-art CNC machines. Competitive awards funded projects to develop innovative new tools and technologies that reduce energy consumption for older generation machine tools and foster working relationships between industry small to medium-sized manufacturing enterprises and third-party solution providers. During the 42-month term of this grant, 12 competitive awards were made. Final reports have been included with this submission.

Program Design Report of the CNC Machine Tool(II)

International Nuclear Information System (INIS)

Kim, Jong Kiun; Youm, K. U.; Kim, K. S.; Lee, I. B.; Yoon, K. B.; Lee, C. K.; Youm, J. H.

2007-06-01

The application of CNC machine tool being widely expanded according to variety of machine work method and rapid promotion of machine tool, cutting tool, for high speed efficient machine work. In order to conduct of the project of manufacture and maintenance of laboratory equipment, production design and machine work technology are continually developed, especially the application of CNC machine tool is very important for the improvement of productivity, quality and clearing up a manpower shortage. We publish technical report which it includes CNC machine tool program and drawing, it contributes to the systematic development of CNC program design and machine work technology

Program Design Report of the CNC Machine Tool(II)

Energy Technology Data Exchange (ETDEWEB)

Kim, Jong Kiun; Youm, K. U.; Kim, K. S.; Lee, I. B.; Yoon, K. B.; Lee, C. K.; Youm, J. H

2007-06-15

The application of CNC machine tool being widely expanded according to variety of machine work method and rapid promotion of machine tool, cutting tool, for high speed efficient machine work. In order to conduct of the project of manufacture and maintenance of laboratory equipment, production design and machine work technology are continually developed, especially the application of CNC machine tool is very important for the improvement of productivity, quality and clearing up a manpower shortage. We publish technical report which it includes CNC machine tool program and drawing, it contributes to the systematic development of CNC program design and machine work technology.

Program Design Report of the CNC Machine Tool(III)

International Nuclear Information System (INIS)

Kim, Jong Kiun; Youm, K. U.; Kim, K. S.; Lee, I. B.; Yoon, K. B.; Lee, C. K.; Youm, J. H.

2008-08-01

The application of CNC machine tool being widely expanded according to variety of machine work method and rapid promotion of machine tool, cutting tool, for high speed efficient machine work. In order to conduct of the project of manufacture and maintenance of laboratory equipment, production design and machine work technology are continually developed, especially the application of CNC machine tool is very important for the improvement of productivity, quality and clearing up a manpower shortage. We publish technical report which it includes CNC machine tool program and drawing, it contributes to the systematic development of CNC program design and machine work technology

Program Design Report of the CNC Machine Tool (I)

International Nuclear Information System (INIS)

Kim, Jong Kiun; Youm, K. U.; Kim, K. S.

2006-08-01

The application of CNC machine tool being widely expanded according to variety of machine work method and rapid promotion of machine tool, cutting tool, for high speed efficient machine work. In order to conduct of the project of manufacture and maintenance of laboratory equipment, production design and machine work technology are continually developed, especially the application of CNC machine tool is very important for the improvement of productivity, quality and clearing up a manpower shortage. We publish technical report which it includes CNC machine tool program and drawing, it contributes to the systematic development of CNC program design and machine work technology

Program Design Report of the CNC Machine Tool(IV)

International Nuclear Information System (INIS)

Youm, Ki Un; Lee, I. B.; Youm, J. H.

2009-09-01

The application of CNC machine tool being widely expanded according to variety of machine work method and rapid promotion of machine tool, cutting tool, for high speed efficient machine work. In order to conduct of the project of manufacture and maintenance of laboratory equipment, production design and machine work technology are continually developed, especially the application of CNC machine tool is very important for the improvement of productivity, quality and clearing up a manpower shortage. We publish technical report which it includes CNC machine tool program and drawing, it contributes to the systematic development of CNC program design and machine work technology

Effect of cutting parameters on sustainable machining performance of coated carbide tool in dry turning process of stainless steel 316

Science.gov (United States)

Bagaber, Salem A.; Yusoff, Ahmed Razlan

2017-04-01

The manufacturing industry aims to produce many products of high quality with relatively less cost and time. Different cutting parameters affect the machining performance of surface roughness, cutting force, and material removal rate. Nevertheless, a few studies reported on the effects of sustainable factors such as power consumed, cycle time during machining, and tool life on the dry turning of AISI 316. The present study aims to evaluate the machining performance of coated carbide in the machining of hard steel AISI 316 under the dry turning process. The influence of cutting parameters of cutting speed, feed rate, and depth of cut with their five (5) levels is established by a central composite design. Highly significant parameters were determined by analysis of variance (ANOVA), and the main effects of power consumed and time during machining, surface roughness, and tool wear were observed. Results showed that the cutting speed was proportional to power consumption and tool wear. Meanwhile, insignificant to surface roughness, feed rate most significantly affected surface roughness and power consumption followed by depth of cut.

Tool vibration detection with eddy current sensors in machining process and computation of stability lobes using fuzzy classifiers

Science.gov (United States)

Devillez, Arnaud; Dudzinski, Daniel

2007-01-01

Today the knowledge of a process is very important for engineers to find optimal combination of control parameters warranting productivity, quality and functioning without defects and failures. In our laboratory, we carry out research in the field of high speed machining with modelling, simulation and experimental approaches. The aim of our investigation is to develop a software allowing the cutting conditions optimisation to limit the number of predictive tests, and the process monitoring to prevent any trouble during machining operations. This software is based on models and experimental data sets which constitute the knowledge of the process. In this paper, we deal with the problem of vibrations occurring during a machining operation. These vibrations may cause some failures and defects to the process, like workpiece surface alteration and rapid tool wear. To measure on line the tool micro-movements, we equipped a lathe with a specific instrumentation using eddy current sensors. Obtained signals were correlated with surface finish and a signal processing algorithm was used to determine if a test is stable or unstable. Then, a fuzzy classification method was proposed to classify the tests in a space defined by the width of cut and the cutting speed. Finally, it was shown that the fuzzy classification takes into account of the measurements incertitude to compute the stability limit or stability lobes of the process.

Methods of In-Process On-Machine Auto-Inspection of Dimensional Error and Auto-Compensation of Tool Wear for Precision Turning

Directory of Open Access Journals (Sweden)

Shih-Ming Wang

2016-04-01

Full Text Available The purpose of this study is mainly to develop an information and communication technology (ICT-based intelligent dimension inspection and tool wear compensation method for precision tuning. With the use of vibration signal processing/characteristics analysis technology combined with ICT, statistical analysis, and diagnosis algorithms, the method can be used to proceed with an on-line dimension inspection and on-machine tool wear auto-compensation for the turning process. Meanwhile, the method can also monitor critical tool life to identify the appropriate time for cutter replacement to reduce machining costs and improve the production efficiency of the turning process. Compared to the traditional ways, the method offers the advantages of requiring less manpower, and having better production efficiency, high tool life, fewer scrap parts, and low costs for inspection instruments. Algorithms and diagnosis threshold values for the detection, cutter wear compensation, and cutter life monitoring were developed. In addition, a bilateral communication module utilizing FANUC Open CNC (computer numerical control Application Programming Interface (API Spec was developed for the on-line extraction of instant NC (numerical control codes for monitoring and transmit commands to CNC controllers for cutter wear compensation. With use of local area networks (LAN to deliver the detection and correction information, the proposed method was able to remotely control the on-machine monitoring process and upload the machining and inspection data to a remote central platform for further production optimization. The verification experiments were conducted on a turning production line. The results showed that the system provided 93% correction for size inspection and 100% correction for cutter wear compensation.

Design principles of metal-cutting machine tools

CERN Document Server

Koenigsberger, F

1964-01-01

Design Principles of Metal-Cutting Machine Tools discusses the fundamentals aspects of machine tool design. The book covers the design consideration of metal-cutting machine, such as static and dynamic stiffness, operational speeds, gearboxes, manual, and automatic control. The text first details the data calculation and the general requirements of the machine tool. Next, the book discusses the design principles, which include stiffness and rigidity of the separate constructional elements and their combined behavior under load, as well as electrical, mechanical, and hydraulic drives for the op

Preliminary Development of Real Time Usage-Phase Monitoring System for CNC Machine Tools with a Case Study on CNC Machine VMC 250

Science.gov (United States)

Budi Harja, Herman; Prakosa, Tri; Raharno, Sri; Yuwana Martawirya, Yatna; Nurhadi, Indra; Setyo Nogroho, Alamsyah

2018-03-01

The production characteristic of job-shop industry at which products have wide variety but small amounts causes every machine tool will be shared to conduct production process with dynamic load. Its dynamic condition operation directly affects machine tools component reliability. Hence, determination of maintenance schedule for every component should be calculated based on actual usage of machine tools component. This paper describes study on development of monitoring system to obtaining information about each CNC machine tool component usage in real time approached by component grouping based on its operation phase. A special device has been developed for monitoring machine tool component usage by utilizing usage phase activity data taken from certain electronics components within CNC machine. The components are adaptor, servo driver and spindle driver, as well as some additional components such as microcontroller and relays. The obtained data are utilized for detecting machine utilization phases such as power on state, machine ready state or spindle running state. Experimental result have shown that the developed CNC machine tool monitoring system is capable of obtaining phase information of machine tool usage as well as its duration and displays the information at the user interface application.

Tool feed influence on the machinability of CO(2) laser optics.

Science.gov (United States)

Arnold, J B; Steger, P J; Saito, T T

1975-08-01

Influence of tool feed on reflectivity of diamond-machined surfaces was evaluated using materials (gold, silver, and copper) from which CO(2) laser optics are primarily produced. Fifteen specimens were machined by holding all machining parameters constant, except tool feed. Tool feed was allowed to vary by controlled amounts from one evaluation zone (or part) to another. Past experience has verified that the quality of a diamond-machined surface is not a function of the cutting velocity; therefore, this experiment was conducted on the basis that a variation in cutting velocity was not an influencing factor on the diamondturning process. Inspection results of the specimens indicated that tool feeds significantly higher than 5.1 micro/rev (200 microin./rev) produced detrimental effects on the machined surfaces. In some cases, at feeds as high as 13 microm/rev (500 microin./rev), visible scoring was evident. Those surfaces produced with tool feeds less than 5.1 microm/rev had little difference in reflectivity. Measurements indicat d that their reflectivity existed in a range from 96.7% to 99.3% at 10.6 microm.

Machinability of Stainless Tool Steel using Nitrogen Oil-Mist coalant

Directory of Open Access Journals (Sweden)

Amad E. Elshwain

2017-01-01

Full Text Available For all dry machining process, temperature generated in the cutting zone is the major challenge. It causes tool failure and results in unsatisfactory surface finish. Application of flood coolant method during machining processes can significantly reduce the temperature and consequently extend the cutting tool life. However, it has serious concerns regarding environmental pollution, operator health and manufacturing cost. These issues are usually attempts to be overcame by using minimum quantity lubrication (MQL technique. This method merges the advantages of both dry cutting and flood cooling by spraying a small amount of lubricant to the cutting zone using vegetable oil. In this paper, another technique is proposed in order to further enhance the machineability of the stainless tool steel (STAVAX ESR 48 HRC. This involves using of nitrogen gas (N2 and air as cooling medium in combination with oil mist lubricant (MQL. The results show that the combination between nitrogen and oil-mist lubricant much more prolonged the tool life and improved the surface finish than the air-oil mist lubricant medium.

ATST telescope mount: telescope of machine tool

Science.gov (United States)

Jeffers, Paul; Stolz, Günter; Bonomi, Giovanni; Dreyer, Oliver; Kärcher, Hans

2012-09-01

The Advanced Technology Solar Telescope (ATST) will be the largest solar telescope in the world, and will be able to provide the sharpest views ever taken of the solar surface. The telescope has a 4m aperture primary mirror, however due to the off axis nature of the optical layout, the telescope mount has proportions similar to an 8 meter class telescope. The technology normally used in this class of telescope is well understood in the telescope community and has been successfully implemented in numerous projects. The world of large machine tools has developed in a separate realm with similar levels of performance requirement but different boundary conditions. In addition the competitive nature of private industry has encouraged development and usage of more cost effective solutions both in initial capital cost and thru-life operating cost. Telescope mounts move relatively slowly with requirements for high stability under external environmental influences such as wind buffeting. Large machine tools operate under high speed requirements coupled with high application of force through the machine but with little or no external environmental influences. The benefits of these parallel development paths and the ATST system requirements are being combined in the ATST Telescope Mount Assembly (TMA). The process of balancing the system requirements with new technologies is based on the experience of the ATST project team, Ingersoll Machine Tools who are the main contractor for the TMA and MT Mechatronics who are their design subcontractors. This paper highlights a number of these proven technologies from the commercially driven machine tool world that are being introduced to the TMA design. Also the challenges of integrating and ensuring that the differences in application requirements are accounted for in the design are discussed.

Calibration apparatus for a machine-tool

International Nuclear Information System (INIS)

Crespin, G.

1985-01-01

The invention proposes a calibration apparatus for a machine-tool comprising a torque measuring device, where the tool is driven by a motor of which supply electric current is proportional to the torque applied upon the tool and can be controlled and measured, a housing having an aperture through which the rotatable tool can pass. This device alloys to apply a torque on the tool and to measure it from the supply current of the motor. The invention applies, more particularly to the screwing machines used for the mounting of the core containment plates [fr

Practical implementation of machine tool metrology and maintenance management systems

International Nuclear Information System (INIS)

Perkins, C; Longstaff, A P; Fletcher, S; Willoughby, P

2012-01-01

Maximising asset utilisation and minimising downtime and waste are becoming increasingly important to all manufacturing facilities as competition increases and profits decrease. The tools to assist with monitoring these machining processes are becoming more and more in demand. A system designed to fulfil the needs of machine tool operators and supervisors has been developed and its impact on the precision manufacturing industry is being considered. The benefits of implementing this system, compared to traditional methods, will be discussed here.

Effect of machining fluid on the process performance of wire electrical discharge machining of nanocomposite ceramic

Directory of Open Access Journals (Sweden)

Zhang Chengmao

2015-01-01

Full Text Available Wire electric discharge machining (WEDM promise to be effective and economical techniques for the production of tools and parts from conducting ceramic blanks. However, the manufacturing of nanocomposite ceramics blanks with these processes is a long and costly process. This paper presents a new process of machining nanocomposite ceramics using WEDM. WEDM uses water based emulsion, polyvinyl alcohol and distilled water as the machining fluid. Machining fluid is a primary factor that affects the material removal rate and surface quality of WEDM. The effects of emulsion concentration, polyvinyl alcohol concentration and distilled water of the machining fluid on the process performance have been investigated.

Machining of high performance workpiece materials with CBN coated cutting tools

International Nuclear Information System (INIS)

Uhlmann, E.; Fuentes, J.A. Oyanedel; Keunecke, M.

2009-01-01

The machining of high performance workpiece materials requires significantly harder cutting materials. In hard machining, the early tool wear occurs due to high process forces and temperatures. The hardest known material is the diamond, but steel materials cannot be machined with diamond tools because of the reactivity of iron with carbon. Cubic boron nitride (cBN) is the second hardest of all known materials. The supply of such PcBN indexable inserts, which are only geometrically simple and available, requires several work procedures and is cost-intensive. The development of a cBN coating for cutting tools, combine the advantages of a thin film system and of cBN. Flexible cemented carbide tools, in respect to the geometry can be coated. The cBN films with a thickness of up to 2 μm on cemented carbide substrates show excellent mechanical and physical properties. This paper describes the results of the machining of various workpiece materials in turning and milling operations regarding the tool life, resultant cutting force components and workpiece surface roughness. In turning tests of Inconel 718 and milling tests of chrome steel the high potential of cBN coatings for dry machining was proven. The results of the experiments were compared with common used tool coatings for the hard machining. Additionally, the wear mechanisms adhesion, abrasion, surface fatigue and tribo-oxidation were researched in model wear experiments.

Cutting force model for high speed machining process

International Nuclear Information System (INIS)

Haber, R. E.; Jimenez, J. E.; Jimenez, A.; Lopez-Coronado, J.

2004-01-01

This paper presents cutting force-based models able to describe a high speed machining process. The model considers the cutting force as output variable, essential for the physical processes that are taking place in high speed machining. Moreover, this paper shows the mathematical development to derive the integral-differential equations, and the algorithms implemented in MATLAB to predict the cutting force in real time MATLAB is a software tool for doing numerical computations with matrices and vectors. It can also display information graphically and includes many toolboxes for several research and applications areas. Two end mill shapes are considered (i. e. cylindrical and ball end mill) for real-time implementation of the developed algorithms. the developed models are validated in slot milling operations. The results corroborate the importance of the cutting force variable for predicting tool wear in high speed machining operations. The developed models are the starting point for future work related with vibration analysis, process stability and dimensional surface finish in high speed machining processes. (Author) 19 refs

Program Design Report of the CNC Machine Tool(V-1)

International Nuclear Information System (INIS)

Youm, Ki Un; Moon, J. S.; Lee, I. B.; Youn, J. H.

2010-08-01

The application of CNC machine tool being widely expanded according to variety of machine work method and rapid promotion of machine tool, cutting tool, for high speed efficient machine work. In order to conduct of the project of manufacture and maintenance of laboratory equipment, production design and machine work technology are continually developed, especially the application of CNC machine tool is very important for the improvement of productivity, quality and clearing up a manpower shortage. We publish technical report which it includes CNC machine tool program and drawing, it contributes to the systematic development of CNC program design and machine work technology

Effect of electrical discharge machining on surface characteristics and machining damage of AISI D2 tool steel

International Nuclear Information System (INIS)

Guu, Y.H.; Hocheng, H.; Chou, C.Y.; Deng, C.S.

2003-01-01

In this work the electrical discharge machining (EDM) of AISI D2 tool steel was investigated. The surface characteristics and machining damage caused by EDM were studied in terms of machining parameters. Based on the experimental data, an empirical model of the tool steel was also proposed. A new damage variable was used to study the EDM damage. The workpiece surface and re-solidified layers were examined by a scanning electron microscopy. Surface roughness was determined with a surface profilometer. The residual stress acting on the EDM specimen was measured by the X-ray diffraction technique. Experimental results indicate that the thickness of the recast layer, and surface roughness are proportional to the power input. The EDM process introduces tensile residual stress on the machined surface. The EDM damage leads to strength degradation

Stagnant zone formation on diamond cutting tools during machining

International Nuclear Information System (INIS)

Izman, S.; Tamin, M.N.; Mon, T.T.; Venkatesh, V.C.; Shaharoun, A.M.

2007-01-01

Formation of an intact region on the rake face of cutting tool during machining is quite common phenomenon but its significance in maintaining tool edge sharpness has not been recognized by many researchers. This region is sometimes called stagnant zone. It is believed that when an intact zone present on the rake face, it delays the crater wear progress and hence maintaining the tool edge sharpness longer. This paper investigates the effect of edge radius, surface roughness of the rake face and cutting parameters on the formation of stagnant zone on two different type of diamond tools i.e. polycrystalline diamond PCD-KD100 and diamond-coated inserts when machining titanium alloy. The used inserta and post-processed chips were examined under FESEM and optical microscope after cutting at three different conditions. Experimental results show that the speed and feel, the tool edge radius, and the tool rake surface roughness significantly affect the stagnant zone formation. (author)

High Accuracy Nonlinear Control and Estimation for Machine Tool Systems

DEFF Research Database (Denmark)

Papageorgiou, Dimitrios

Component mass production has been the backbone of industry since the second industrial revolution, and machine tools are producing parts of widely varying size and design complexity. The ever-increasing level of automation in modern manufacturing processes necessitates the use of more...... sophisticated machine tool systems that are adaptable to different workspace conditions, while at the same time being able to maintain very narrow workpiece tolerances. The main topic of this thesis is to suggest control methods that can maintain required manufacturing tolerances, despite moderate wear and tear....... The purpose is to ensure that full accuracy is maintained between service intervals and to advice when overhaul is needed. The thesis argues that quality of manufactured components is directly related to the positioning accuracy of the machine tool axes, and it shows which low level control architectures...

Effect of Micro Electrical Discharge Machining Process Conditions on Tool Wear Characteristics: Results of an Analytic Study

DEFF Research Database (Denmark)

Puthumana, Govindan; P., Rajeev

2016-01-01

Micro electrical discharge machining is one of the established techniques to manufacture high aspect ratio features on electrically conductive materials. This paper presents the results and inferences of an analytical study for estimating theeffect of process conditions on tool electrode wear...... characteristicsin micro-EDM process. A new approach with two novel factors anticipated to directly control the material removal mechanism from the tool electrode are proposed; using discharge energyfactor (DEf) and dielectric flushing factor (DFf). The results showed that the correlation between the tool wear rate...... (TWR) and the factors is poor. Thus, individual effects of each factor on TWR are analyzed. The factors selected for the study of individual effects are pulse on-time, discharge peak current, gap voltage and gap flushing pressure. The tool wear rate decreases linearly with an increase in the pulse on...

Analysis on machine tool systems using spindle vibration monitoring for automatic tool changer

Directory of Open Access Journals (Sweden)

Shang-Liang Chen

2015-12-01

Full Text Available Recently, the intelligent systems of technology have become one of the major items in the development of machine tools. One crucial technology is the machinery status monitoring function, which is required for abnormal warnings and the improvement of cutting efficiency. During processing, the mobility act of the spindle unit determines the most frequent and important part such as automatic tool changer. The vibration detection system includes the development of hardware and software, such as vibration meter, signal acquisition card, data processing platform, and machine control program. Meanwhile, based on the difference between the mechanical configuration and the desired characteristics, it is difficult for a vibration detection system to directly choose the commercially available kits. For this reason, it was also selected as an item for self-development research, along with the exploration of a significant parametric study that is sufficient to represent the machine characteristics and states. However, we also launched the development of functional parts of the system simultaneously. Finally, we entered the conditions and the parameters generated from both the states and the characteristics into the developed system to verify its feasibility.

New active machine tool drive mounting on the frame

Directory of Open Access Journals (Sweden)

Švéda J.

2007-10-01

Full Text Available The paper deals with the new active mounting of the machine tool drives. The commonly used machine tools are at this time mainly equipped with fix-mounting of the feed drives. This structure causes full transmission of the force shocks to the machine bed and thereby restricts the dynamic properties of the motion axis and the whole machine. The spring-mounting of the feed drives is one of the possibilities how to partially suppress the vibrations. The force that reacts to the machine tool bed is transformed thereby the vibrations are lightly reduced. Unfortunately the transformation is not fully controlled. The new active mounting of the machine tool drives allows to fully control the force behaviour that react to the machine body. Thereby the number of excited frequencies on the machine tool bed is significantly reduced. The active variant of the feed drive mounting is characterized by the synergistic cooperation between two series-connected actuators (“motor on motor”. The paper briefly describes design, control techniques and optimization of the feed drives with the new active mounting conception.

ANN Based Tool Condition Monitoring System for CNC Milling Machines

Directory of Open Access Journals (Sweden)

Mota-Valtierra G.C.

2011-10-01

Full Text Available Most of the companies have as objective to manufacture high-quality products, then by optimizing costs, reducing and controlling the variations in its production processes it is possible. Within manufacturing industries a very important issue is the tool condition monitoring, since the tool state will determine the quality of products. Besides, a good monitoring system will protect the machinery from severe damages. For determining the state of the cutting tools in a milling machine, there is a great variety of models in the industrial market, however these systems are not available to all companies because of their high costs and the requirements of modifying the machining tool in order to attach the system sensors. This paper presents an intelligent classification system which determines the status of cutt ers in a Computer Numerical Control (CNC milling machine. This tool state is mainly detected through the analysis of the cutting forces drawn from the spindle motors currents. This monitoring system does not need sensors so it is no necessary to modify the machine. The correct classification is made by advanced digital signal processing techniques. Just after acquiring a signal, a FIR digital filter is applied to the data to eliminate the undesired noisy components and to extract the embedded force components. A Wavelet Transformation is applied to the filtered signal in order to compress the data amount and to optimize the classifier structure. Then a multilayer perceptron- type neural network is responsible for carrying out the classification of the signal. Achieving a reliability of 95%, the system is capable of detecting breakage and a worn cutter.

Study of the stiffness for predicting the accuracy of machine tools

International Nuclear Information System (INIS)

Ortega, N.; Campa, F.J.; Fernandez Valdivielso, A.; Alonso, U.; Olvera, D.; Compean, F.I.

2010-01-01

Machining processes are frequently faced with the challenge of achieving more and more precision and surface qualities. These requirements are usually attained taking into account some process variables, including the cutting parameters and the use or not of refrigerant, leaving aside the mechanical aspects associated with the influence of machine tool itself. There are many sources of error linked with machine-workpiece interaction, but, in general, we can summarize them into two types of error: quasi-static and dynamic. This paper shows the influence of quasi-static error caused by low machine rigidity on the accuracy applied on two very different processes: turning and grinding. For the study of the static stiffness of these two machines, two different methods are proposed, both of them equally valid. The first one is based on separated parameters and the second one on finite elements. (Author).

Analysis on machine tool systems using spindle vibration monitoring for automatic tool changer

OpenAIRE

Shang-Liang Chen; Yin-Ting Cheng; Chin-Fa Su

2015-01-01

Recently, the intelligent systems of technology have become one of the major items in the development of machine tools. One crucial technology is the machinery status monitoring function, which is required for abnormal warnings and the improvement of cutting efficiency. During processing, the mobility act of the spindle unit determines the most frequent and important part such as automatic tool changer. The vibration detection system includes the development of hardware and software, such as ...

Tool path in torus tool CNC machining

Directory of Open Access Journals (Sweden)

XU Ying

2016-10-01

Full Text Available This paper is about tool path in torus tool CNC machining.The mathematical model of torus tool is established.The tool path planning algorithm is determined through calculation of the cutter location,boundary discretization,calculation of adjacent tool path and so on,according to the conversion formula,the cutter contact point will be converted to the cutter location point and then these points fit a toolpath.Lastly,the path planning algorithm is implemented by using Matlab programming.The cutter location points for torus tool are calculated by Matlab,and then fit these points to a toolpath.While using UG software,another tool path of free surface is simulated of the same data.It is drew compared the two tool paths that using torus tool is more efficient.

CONDITIONS FOR STABLE CHIP BREAKING AND PROVISION OF MACHINED SURFACE QUALITY WHILE TURNING WITH ASYMMETRIC TOOL VIBRATIONS

Directory of Open Access Journals (Sweden)

V. K. Sheleh

2015-01-01

Full Text Available The paper considers a process of turning structural steel with asymmetric tool vibrations directed along feeding. Asymmetric vibrations characterized by asymmetry coefficient of vibration cycle, their frequency and amplitude are additionally transferred to the tool in the turning process with the purpose to crush chips. Conditions of stable chip breaking and obtaining optimum dimensions of chip elements have been determined in the paper. In order to reduce a negative impact of the vibration amplitude on a cutting process and quality of the machined surfaces machining must be carried out with its minimum value. In this case certain ratio of the tool vibration frequency to the work-piece rotation speed has been ensured in the paper. A formula has been obtained for calculation of this ratio with due account of the expected length of chip elements and coefficient of vibration cycle asymmetry.Influence of the asymmetric coefficient of the tool vibration cycle on roughness of the machined surfaces and cutting tool wear has been determined in the paper. According to the results pertaining to machining of work-pieces made of 45 and ШХ15 steel the paper presents mathematical relationships of machined surface roughness with cutting modes and asymmetry coefficient of tool vibration cycle. Tool feeding being one of the cutting modes exerts the most significant impact on the roughness value and increase of the tool feeding entails increase in roughness. Reduction in coefficient of vibration cycle asymmetry contributes to surface roughness reduction. However, the cutting tool wear occurs more intensive. Coefficient of the vibration cycle asymmetry must be increased in order to reduce wear rate. Therefore, the choice of the coefficient of the vibration cycle asymmetry is based on the parameters of surface roughness which must be obtained after machining and intensity of tool wear rate.The paper considers a process of turning structural steel with asymmetric

Material Choice for spindle of machine tools

Science.gov (United States)

Gouasmi, S.; Merzoug, B.; Abba, G.; Kherredine, L.

2012-02-01

The requirements of contemporary industry and the flashing development of modern sciences impose restrictions on the majority of the elements of machines; the resulting financial constraints can be satisfied by a better output of the production equipment. As for those concerning the design, the resistance and the correct operation of the product, these require the development of increasingly precise parts, therefore the use of increasingly powerful tools [5]. The precision of machining and the output of the machine tools are generally determined by the precision of rotation of the spindle, indeed, more this one is large more the dimensions to obtain are in the zone of tolerance and the defects of shape are minimized. During the development of the machine tool, the spindle which by definition is a rotating shaft receiving and transmitting to the work piece or the cutting tool the rotational movement, must be designed according to certain optimal parameters to be able to ensure the precision required. This study will be devoted to the choice of the material of the spindle fulfilling the imposed requirements of precision.

Material Choice for spindle of machine tools

International Nuclear Information System (INIS)

Gouasmi, S; Merzoug, B; Kherredine, L; Abba, G

2012-01-01

The requirements of contemporary industry and the flashing development of modern sciences impose restrictions on the majority of the elements of machines; the resulting financial constraints can be satisfied by a better output of the production equipment. As for those concerning the design, the resistance and the correct operation of the product, these require the development of increasingly precise parts, therefore the use of increasingly powerful tools [5]. The precision of machining and the output of the machine tools are generally determined by the precision of rotation of the spindle, indeed, more this one is large more the dimensions to obtain are in the zone of tolerance and the defects of shape are minimized. During the development of the machine tool, the spindle which by definition is a rotating shaft receiving and transmitting to the work piece or the cutting tool the rotational movement, must be designed according to certain optimal parameters to be able to ensure the precision required. This study will be devoted to the choice of the material of the spindle fulfilling the imposed requirements of precision.

Eddy currents self-tuning dynamic vibration absorber for machine tool chatter suppression

OpenAIRE

Aguirre , Gorka; Gorostiaga , Mikel; Porchez , Thomas; Munoa , Jokin

2013-01-01

International audience; The current trend in machine tool design aims at stiffer machines with lowerinfluence of friction, leading to faster and more precise machines. However, this is atthe expense of reducing the machine damping, which is mainly produced by friction,and thus increasing the risk of suffering from a self-excited vibration named chatter,which limits the productivity of the process. Dynamic vibration absorbers (DVAs)offer a relatively simple and low cost solution to reduce chat...

THE CONFORMITY OF MACHINE TOOLS WITH RESPECT TO EUROPEAN SAFETY STANDARDS

CERN Multimedia

TIS/TE

2001-01-01

European regulations require that all motorized machine tools conform to the latest safety standards by the end of the year 2000. CERN must follow these regulations and has already modified most of its machine tools accordingly. However, there is still a small number of machine tools which have not yet been modified as required. These machines should not be used until they are brought up to the required safety standards, failing which the machines should be discarded. One can recognise which machine tools conform with the latest standards by the indication 'CS' on the identification plate of the machine, see foto below. In cases of doubt about the status of a machine tool you should contact K. Altherr/EST or C. Margaroli/TIS for advice.

THE CONFORMITY OF MACHINE TOOLS WITH RESPECT TO EUROPEAN SAFETY STANDARDS

CERN Multimedia

TIS/TE

2000-01-01

European regulations require that all motorized machine tools conform to the latest safety standards by the end of the year 2000. CERN must follow these regulations and has already modified most of its machine tools accordingly. However, there is still a small number of machine tools which have not yet been modified as required. These machines should not be used until they are brought up to the required safety standards, failing which the machines should be discarded. One can recognise which machine tools conform with the latest standards by the indication 'CS' on the identification plate of the machine, see foto below. In cases of doubt about the status of a machine tool you should contact K. Altherr/EST or C. Margaroli/TIS for advice.

Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools

Directory of Open Access Journals (Sweden)

Okokpujie Imhade Princess

2017-12-01

Full Text Available In recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N, feed rate (f, axial depth of cut (a and radial depth of cut (r. The experiment was designed using central composite design (CCD in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM. The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.

Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools

Science.gov (United States)

Okokpujie, Imhade Princess; Ikumapayi, Omolayo M.; Okonkwo, Ugochukwu C.; Salawu, Enesi Y.; Afolalu, Sunday A.; Dirisu, Joseph O.; Nwoke, Obinna N.; Ajayi, Oluseyi O.

2017-12-01

In recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N), feed rate (f), axial depth of cut (a) and radial depth of cut (r). The experiment was designed using central composite design (CCD) in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM). The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.

Progressive Tool Wear in Cryogenic Machining: The Effect of Liquid Nitrogen and Carbon Dioxide

Directory of Open Access Journals (Sweden)

Yusuf Kaynak

2018-05-01

Full Text Available This experimental study focuses on various cooling strategies and lubrication-assisted cooling strategies to improve machining performance in the turning process of AISI 4140 steel. Liquid nitrogen (LN2 and carbon dioxide (CO2 were used as cryogenic coolants, and their performances were compared with respect to progression of tool wear. Minimum quantity lubrication (MQL was also used with carbon dioxide. Progression of wear, including flank and nose, are the main outputs examined during experimental study. This study illustrates that carbon dioxide-assisted cryogenic machining alone and with minimum quantity lubrication does not contribute to decreasing the progression of wear within selected cutting conditions. This study also showed that carbon dioxide-assisted cryogenic machining helps to increase chip breakability. Liquid nitrogen-assisted cryogenic machining results in a reduction of tool wear, including flank and nose wear, in the machining process of AISI 4140 steel material. It was also observed that in the machining process of this material at a cutting speed of 80 m/min, built-up edges occurred in both cryogenic cooling conditions. Additionally, chip flow damage occurs in particularly dry machining.

Research on Key Technologies of Unit-Based CNC Machine Tool Assembly Design

Directory of Open Access Journals (Sweden)

Zhongqi Sheng

2014-01-01

Full Text Available Assembly is the part that produces the maximum workload and consumed time during product design and manufacturing process. CNC machine tool is the key basic equipment in manufacturing industry and research on assembly design technologies of CNC machine tool has theoretical significance and practical value. This study established a simplified ASRG for CNC machine tool. The connection between parts, semantic information of transmission, and geometric constraint information were quantified to assembly connection strength to depict the assembling difficulty level. The transmissibility based on trust relationship was applied on the assembly connection strength. Assembly unit partition based on assembly connection strength was conducted, and interferential assembly units were identified and revised. The assembly sequence planning and optimization of parts in each assembly unit and between assembly units was conducted using genetic algorithm. With certain type of high speed CNC turning center, as an example, this paper explored into the assembly modeling, assembly unit partition, and assembly sequence planning and optimization and realized the optimized assembly sequence of headstock of CNC machine tool.

A linear maglev guide for machine tools

Energy Technology Data Exchange (ETDEWEB)

Tieste, K D [Inst. of Mechanics, Univ. of Hannover (Germany); Popp, K [Inst. of Mechanics, Univ. of Hannover (Germany)

1996-12-31

Machine tools require linear guides with high slide velocity and very high position accuracy. The three tasks of a linear guide - supporting, guiding and driving - shall be realised by means of active magnetic bearings (AMB). The resulting linear magnetically levitated (maglev) guide has to accomplish the following characteristics: High stiffness, good damping and low noise as well as low heat production. First research on a one degree-of-freedom (DOF) support magnet unit aimed at the development of components and efficient control strategies for the linear maglev guide. The actual research is directed to realise a five DOF linear maglev guide for machine tools without drive to answer the question whether the maglev principle can be used for a linear axis in a machine tool. (orig.)

The use of machine learning and nonlinear statistical tools for ADME prediction.

Science.gov (United States)

Sakiyama, Yojiro

2009-02-01

Absorption, distribution, metabolism and excretion (ADME)-related failure of drug candidates is a major issue for the pharmaceutical industry today. Prediction of ADME by in silico tools has now become an inevitable paradigm to reduce cost and enhance efficiency in pharmaceutical research. Recently, machine learning as well as nonlinear statistical tools has been widely applied to predict routine ADME end points. To achieve accurate and reliable predictions, it would be a prerequisite to understand the concepts, mechanisms and limitations of these tools. Here, we have devised a small synthetic nonlinear data set to help understand the mechanism of machine learning by 2D-visualisation. We applied six new machine learning methods to four different data sets. The methods include Naive Bayes classifier, classification and regression tree, random forest, Gaussian process, support vector machine and k nearest neighbour. The results demonstrated that ensemble learning and kernel machine displayed greater accuracy of prediction than classical methods irrespective of the data set size. The importance of interaction with the engineering field is also addressed. The results described here provide insights into the mechanism of machine learning, which will enable appropriate usage in the future.

Data Mining Practical Machine Learning Tools and Techniques

CERN Document Server

Witten, Ian H; Hall, Mark A

2011-01-01

Data Mining: Practical Machine Learning Tools and Techniques offers a thorough grounding in machine learning concepts as well as practical advice on applying machine learning tools and techniques in real-world data mining situations. This highly anticipated third edition of the most acclaimed work on data mining and machine learning will teach you everything you need to know about preparing inputs, interpreting outputs, evaluating results, and the algorithmic methods at the heart of successful data mining. Thorough updates reflect the technical changes and modernizations that have taken place

The research on construction and application of machining process knowledge base

Science.gov (United States)

Zhao, Tan; Qiao, Lihong; Qie, Yifan; Guo, Kai

2018-03-01

In order to realize the application of knowledge in machining process design, from the perspective of knowledge in the application of computer aided process planning(CAPP), a hierarchical structure of knowledge classification is established according to the characteristics of mechanical engineering field. The expression of machining process knowledge is structured by means of production rules and the object-oriented methods. Three kinds of knowledge base models are constructed according to the representation of machining process knowledge. In this paper, the definition and classification of machining process knowledge, knowledge model, and the application flow of the process design based on the knowledge base are given, and the main steps of the design decision of the machine tool are carried out as an application by using the knowledge base.

A new tool for man/machine integration

International Nuclear Information System (INIS)

Sommer, W.C.

1981-01-01

A popular term within the nuclear power industry today, as a result of TMI, is man/machine interface. It has been determined that greater acknowledgement of this interface is necessary within the industry to integrate the design and operational aspects of a system. What is required is an operational tool that can be used early in the engineering stages of a project and passed on later in time to those who will be responsible to operate that particular system. This paper discusses one such fundamental operations tool that is applied to a process system, its display devices, and its operator actions in a methodical fashion to integrate the machine for man's understanding and proper use. This new tool, referred to as an Operational Schematic, is shown and described. Briefly, it unites, in one location, the important operational display devices with the system process devices. A man can now see the beginning and end of each information and control loop to better understand its function within the system. A method is presented whereby in designing for operability, the schematic is utilized in three phases. The method results in two basic documents, one describes ''what'' is to be operated and the other ''how'' it is to be operated. This integration concept has now considered the hardware spectrum from sensor-to-display and operated the display (on paper) to confirm its operability. Now that the design aspects are complete, the later-in-time operational aspects need to be addressed for the man using the process system. Training personnel in operating and testing the process system is as important as the original design. To accomplish these activities, documents are prepared to instruct personnel how to operate (and test) the system under a variety of circumstances

Simultaneous Scheduling of Jobs, AGVs and Tools Considering Tool Transfer Times in Multi Machine FMS By SOS Algorithm

Science.gov (United States)

Sivarami Reddy, N.; Ramamurthy, D. V., Dr.; Prahlada Rao, K., Dr.

2017-08-01

This article addresses simultaneous scheduling of machines, AGVs and tools where machines are allowed to share the tools considering transfer times of jobs and tools between machines, to generate best optimal sequences that minimize makespan in a multi-machine Flexible Manufacturing System (FMS). Performance of FMS is expected to improve by effective utilization of its resources, by proper integration and synchronization of their scheduling. Symbiotic Organisms Search (SOS) algorithm is a potent tool which is a better alternative for solving optimization problems like scheduling and proven itself. The proposed SOS algorithm is tested on 22 job sets with makespan as objective for scheduling of machines and tools where machines are allowed to share tools without considering transfer times of jobs and tools and the results are compared with the results of existing methods. The results show that the SOS has outperformed. The same SOS algorithm is used for simultaneous scheduling of machines, AGVs and tools where machines are allowed to share tools considering transfer times of jobs and tools to determine the best optimal sequences that minimize makespan.

A Method to Optimize Geometric Errors of Machine Tool based on SNR Quality Loss Function and Correlation Analysis

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Cai Ligang

2017-01-01

Full Text Available Instead improving the accuracy of machine tool by increasing the precision of key components level blindly in the production process, the method of combination of SNR quality loss function and machine tool geometric error correlation analysis to optimize five-axis machine tool geometric errors will be adopted. Firstly, the homogeneous transformation matrix method will be used to build five-axis machine tool geometric error modeling. Secondly, the SNR quality loss function will be used for cost modeling. And then, machine tool accuracy optimal objective function will be established based on the correlation analysis. Finally, ISIGHT combined with MATLAB will be applied to optimize each error. The results show that this method is reasonable and appropriate to relax the range of tolerance values, so as to reduce the manufacturing cost of machine tools.

Hybrid machining processes perspectives on machining and finishing

CERN Document Server

Gupta, Kapil; Laubscher, R F

2016-01-01

This book describes various hybrid machining and finishing processes. It gives a critical review of the past work based on them as well as the current trends and research directions. For each hybrid machining process presented, the authors list the method of material removal, machining system, process variables and applications. This book provides a deep understanding of the need, application and mechanism of hybrid machining processes.

Design and Analysis of a Collision Detector for Hybrid Robotic Machine Tools

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Dan ZHANG

2015-10-01

Full Text Available Capacitive sensing depends on the physical parameter changing either the spacing between the two plates or the dielectric constant. Based on this idea, a capacitive based collision detection sensor is proposed and designed in this paper for the purpose of detecting any collision between the end effector and peripheral equipment (e.g., fixture for the three degrees of freedom hybrid robotic machine tools when it is in operation. One side of the finger-like capacitor is attached to the moving platform of the hybrid robotic manipulator and the other side of the finger-like capacitor is attached to the tool. When the tool accidently hits the peripheral equipment, the vibration will make the distance of the capacitor change and therefore trigger the machine to stop. The new design is illustrated and modelled. The capacitance, sensitivity and frequency response of the detector are analyzed in detail, and finally, the fabrication process is presented. The proposed collision detector can also be applied to other machine tools.

Process parameter optimization based on principal components analysis during machining of hardened steel

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Suryakant B. Chandgude

2015-09-01

Full Text Available The optimum selection of process parameters has played an important role for improving the surface finish, minimizing tool wear, increasing material removal rate and reducing machining time of any machining process. In this paper, optimum parameters while machining AISI D2 hardened steel using solid carbide TiAlN coated end mill has been investigated. For optimization of process parameters along with multiple quality characteristics, principal components analysis method has been adopted in this work. The confirmation experiments have revealed that to improve performance of cutting; principal components analysis method would be a useful tool.

Study on effect of tool electrodes on surface finish during electrical discharge machining of Nitinol

Science.gov (United States)

Sahu, Anshuman Kumar; Chatterjee, Suman; Nayak, Praveen Kumar; Sankar Mahapatra, Siba

2018-03-01

Electrical discharge machining (EDM) is a non-traditional machining process which is widely used in machining of difficult-to-machine materials. EDM process can produce complex and intrinsic shaped component made of difficult-to-machine materials, largely applied in aerospace, biomedical, die and mold making industries. To meet the required applications, the EDMed components need to possess high accuracy and excellent surface finish. In this work, EDM process is performed using Nitinol as work piece material and AlSiMg prepared by selective laser sintering (SLS) as tool electrode along with conventional copper and graphite electrodes. The SLS is a rapid prototyping (RP) method to produce complex metallic parts by additive manufacturing (AM) process. Experiments have been carried out varying different process parameters like open circuit voltage (V), discharge current (Ip), duty cycle (τ), pulse-on-time (Ton) and tool material. The surface roughness parameter like average roughness (Ra), maximum height of the profile (Rt) and average height of the profile (Rz) are measured using surface roughness measuring instrument (Talysurf). To reduce the number of experiments, design of experiment (DOE) approach like Taguchi’s L27 orthogonal array has been chosen. The surface properties of the EDM specimen are optimized by desirability function approach and the best parametric setting is reported for the EDM process. Type of tool happens to be the most significant parameter followed by interaction of tool type and duty cycle, duty cycle, discharge current and voltage. Better surface finish of EDMed specimen can be obtained with low value of voltage (V), discharge current (Ip), duty cycle (τ) and pulse on time (Ton) along with the use of AlSiMg RP electrode.

Direct numerical control of machine tools in a nuclear research center by the CAMAC system

International Nuclear Information System (INIS)

Zwoll, K.; Mueller, K.D.; Becks, B.; Erven, W.; Sauer, M.

1977-01-01

The production of mechanical parts in research centers can be improved by connecting several numerically controlled machine tools to a central process computer via a data link. The CAMAC Serial Highway with its expandable structure yields an economic and flexible system for this purpose. The CAMAC System also facilitates the development of modular components controlling the machine tools itself. A CAMAC installation controlling three different machine tools connected to a central computer (PDP11) via the CAMAC Serial Highway is described. Besides this application, part of the CAMAC hardware and software can also be used for a great variety of scientific experiments

High speed dry machining of MMCs with diamond tools

International Nuclear Information System (INIS)

Collins, J.L.

2001-01-01

The increasing use of metal matrix composites (MMCs) has raised new issues in their machining. Industrial demands for higher speed and dry machining of MMCs with improved component production to closer tolerances have driven the development of new tool materials. In particular, the wear characteristics of synthetic diamond tooling satisfy many of the requirements imposed in cutting these highly abrasive workpieces. The use of diamond tool materials, such as polycrystalline diamond (PCD), has resulted in tool life improvements which, allied with environmental considerations, show great potential for the development of dry cutting. This paper explores the wear characteristics of PCD, which is highly suited to the dry machining of particulate silicon carbide MMCs. Also, two further diamond tool materials are evaluated - chemical vapor deposition (CVD) thick layer diamond and synthetic single crystal diamond. Their suitability for the efficient machining of high volume fraction MMC materials is shown and their potential impact an the subsequent acceptance and integration of MMCs into engineering components is discussed. (author)

A methodology for online visualization of the energy flow in a machine tool

DEFF Research Database (Denmark)

Mohammadi, Ali; Züst, Simon; Mayr, Josef

2017-01-01

the machining process and by this increasing its energy efficiency. This study intents to propose a method which has the capability of real-time monitoring of the entire energetic flows in a CNC machine tool including motors, pumps and cooling fluid. The structure of this approach is based on categorizing...

Development and evaluation of intelligent machine tools based on knowledge evolution in M2M environment

International Nuclear Information System (INIS)

Kim, Dong Hoon; Song, Jun Yeob; Lee, Jong Hyun; Cha, Suk Keun

2009-01-01

In the near future, the foreseen improvement in machine tools will be in the form of a knowledge evolution-based intelligent device. The goal of this study is to develop intelligent machine tools having knowledge-evolution capability in Machine to Machine (M2M) wired and wireless environment. The knowledge evolution-based intelligent machine tools are expected to be capable of gathering knowledge autonomously, producing knowledge, understanding knowledge, applying reasoning to knowledge, making new decisions, dialoguing with other machines, etc. The concept of the knowledge-evolution intelligent machine originated from the process of machine control operation by the sense, dialogue and decision of a human expert. The structure of knowledge evolution in M2M and the scheme for a dialogue agent among agent-based modules such as a sensory agent, a dialogue agent and an expert system (decision support agent) are presented in this paper, and work-offset compensation from thermal change and recommendation of cutting condition are performed on-line for knowledge-evolution verification

Effect of the Cutting Tool Geometry on the Tool Wear Resistance When Machining Inconel 625

Directory of Open Access Journals (Sweden)

Tomáš Zlámal

2017-12-01

Full Text Available The paper deals with the design of a suitable cutting geometry of a tool for the machining of the Inconel 625 nickel alloy. This alloy is among the hard-to-machine refractory alloys that cause very rapid wear on cutting tools. Therefore, SNMG and RCMT indexable cutting insert were used to machine the alloy. The selected insert geometry should prevent notch wear and extend tool life. The alloy was machined under predetermined cutting conditions. The angle of the main edge and thus the size and nature of the wear changed with the depth of the material layer being cut. The criterion for determining a more suitable cutting geometry was the tool’s durability and the roughness of the machined surface.

Effect of the Cutting Tool Geometry on the Tool Wear Resistance when Machining Inconel 625

Directory of Open Access Journals (Sweden)

Tomáš Zlámal

2018-03-01

Full Text Available The paper deals with the design of a suitable cutting geometry of a tool for the machining of the Inconel 625 nickel alloy. This alloy is among the hard-to-machine refractory alloys that cause very rapid wear on cutting tools. Therefore, SNMG and RCMT indexable cutting insert were used to machine the alloy. The selected insert geometry should prevent notch wear and extend tool life. The alloy was machined under predetermined cutting conditions. The angle of the main edge and thus the size and nature of the wear changed with the depth of the material layer being cut. The criterion for determining a more suitable cutting geometry was the tool’s durability and the roughness of the machined surface.

Advancing Research in Second Language Writing through Computational Tools and Machine Learning Techniques: A Research Agenda

Science.gov (United States)

Crossley, Scott A.

2013-01-01

This paper provides an agenda for replication studies focusing on second language (L2) writing and the use of natural language processing (NLP) tools and machine learning algorithms. Specifically, it introduces a range of the available NLP tools and machine learning algorithms and demonstrates how these could be used to replicate seminal studies…

Sine-Bar Attachment For Machine Tools

Science.gov (United States)

Mann, Franklin D.

1988-01-01

Sine-bar attachment for collets, spindles, and chucks helps machinists set up quickly for precise angular cuts that require greater precision than provided by graduations of machine tools. Machinist uses attachment to index head, carriage of milling machine or lathe relative to table or turning axis of tool. Attachment accurate to 1 minute or arc depending on length of sine bar and precision of gauge blocks in setup. Attachment installs quickly and easily on almost any type of lathe or mill. Requires no special clamps or fixtures, and eliminates many trial-and-error measurements. More stable than improvised setups and not jarred out of position readily.

Tool wear of a single-crystal diamond tool in nano-groove machining of a quartz glass plate

International Nuclear Information System (INIS)

Yoshino, Masahiko; Nakajima, Satoshi; Terano, Motoki

2015-01-01

Tool wear characteristics of a diamond tool in ductile mode machining are presented in this paper. Nano-groove machining of a quartz glass plate was conducted to examine the tool wear rate of a single-crystal diamond tool. Effects of lubrication on the tool wear rate were also evaluated. A numerical simulation technique was developed to evaluate the tool temperature and normal stress acting on the wear surface. From the simulation results it was found that the tool temperature does not increase during the machining experiment. It is also demonstrated that tool wear is attributed to the abrasive wear mechanism, but the effect of the adhesion wear mechanism is minor in nano-groove machining. It is found that the tool wear rate is reduced by using water or kerosene as a lubricant. (paper)

New tool holder design for cryogenic machining of Ti6Al4V

Science.gov (United States)

Bellin, Marco; Sartori, Stefano; Ghiotti, Andrea; Bruschi, Stefania

2017-10-01

The renewed demand of increasing the machinability of the Ti6Al4V titanium alloy to produce biomedical and aerospace parts working at high temperature has recently led to the application of low-temperature coolants instead of conventional cutting fluids to increase both the tool life and the machined surface integrity. In particular, the liquid nitrogen directed to the tool rake face has shown a great capability of reducing the temperature at the chip-tool interface, as well as the chemical interaction between the tool coating and the titanium to be machined, therefore limiting the tool crater wear, and improving, at the same time, the chip breakability. Furthermore, the nitrogen is a safe, non-harmful, non-corrosive, odorless, recyclable, non-polluting and abundant gas, characteristics that further qualify it as an environmental friendly coolant to be applied to machining processes. However, the behavior of the system composed by the tool and the tool holder, exposed to the cryogenics temperatures may represent a critical issue in order to obtain components within the required geometrical tolerances. On this basis, the paper aims at presenting the design of an innovative tool holder installed on a CNC lathe, which includes the cryogenic coolant provision system, and which is able to hinder the part possible distortions due to the liquid nitrogen adduction by stabilizing its dimensions through the use of heating cartridges and appropriate sensors to monitor the temperature evolution of the tool holder.

Case study of virtual reality in CNC machine tool exhibition

Directory of Open Access Journals (Sweden)

Kao Yung-Chou

2017-01-01

Full Text Available Exhibition and demonstration are generally used in the promotion and sale-assistance of manufactured products. However, the transportation cost of the real goods from the vender factory to the exposition venue is generally expensive for huge and heavy commodity. With the advancement of computing, graphics, mobile apps, and mobile hardware the 3D visibility technology is getting more and more popular to be adopted in visual-assisted communication such as amusement games. Virtual reality (VR technology has therefore being paid great attention in emulating expensive small and/or huge and heavy equipment. Virtual reality can be characterized as 3D extension with Immersion, Interaction and Imagination. This paper was then be focused on the study of virtual reality in the assistance of CNC machine tool demonstration and exhibition. A commercial CNC machine tool was used in this study to illustrate the effectiveness and usability of using virtual reality for an exhibition. The adopted CNC machine tool is a large and heavy mill-turn machine with the width up to eleven meters and weighted about 35 tons. A head-mounted display (HMD was attached to the developed VR CNC machine tool for the immersion viewing. A user can see around the 3D scene of the large mill-turn machine and the operation of the virtual CNC machine can be actuated by bare hand. Coolant was added to demonstrate more realistic operation while collision detection function was also added to remind the operator. The developed VR demonstration system has been presented in the 2017 Taipei International Machine Tool Show (TIMTOS 2017. This case study has shown that young engineers and/or students are very impressed by the VR-based demonstration while elder persons could not adapt themselves easily to the VR-based scene because of eyesight issues. However, virtual reality has successfully being adopted and integrated with the CNC machine tool in an international show. Another machine tool on

Planificación del proceso de fresado de una pieza compleja utilizando una máquina herramienta virtual//Milling process planning of a complex workpiece using a virtual machine tool

Directory of Open Access Journals (Sweden)

Jorge‐Andrés García‐Barbosa

2014-08-01

Full Text Available Se diseñó y se fabricó exitosamente una pieza experimental compleja compuesta de superficies con curvatura cero, positiva y negativa. Se planificó y se ejecutó el proceso de fabricación por maquinado usando el proceso de fresado con herramientas de punta esférica en un centro de maquinado vertical equipado con un cuarto eje de rotación externo. Para la planificación, simulación y verificación del proceso se desarrolló un modelo virtual de la máquina herramienta disponible y sus accesorios en un sistema comercial de maquinado asistido por computador. Se implementó el montaje virtual del sistema de manufactura con el que se verificó y se ajustó el proceso hasta observar un buen desempeño. Se comprobaron así las ventajas de utilizar los recientes métodos virtuales ofrecidos por varios sistemas de maquinado asistido por computador para la simulación del proceso, especialmente cuando se trata de componentes complejos procesados en máquinas herramienta de más de tres ejes.Palabras claves: máquinas herramienta virtuales, planificación de procesos, maquinado de piezas complejas, simulación y verificación de procesos, maquinado multiejes.______________________________________________________________________________AbstractWe designed and successfully manufactured a complex experimental piece composed of surfaces with zero, positive and negative curvatures. We planned and executed the machining manufacturing process by using milling process with end ball nose tools on a vertical machining center equipped with a fourth external rotational axis. For planning, simulation and verification of the machiningprocess, we developed a virtual model of the machine tool and its accessories in a commercial system for computer aided machining. By mounting the virtual manufacturing system, we verified the process and adjusted it until observe a good performance. We tested and confirmed the advantages of using the recent virtual methods for

Optimization of Surface Finish in Turning Operation by Considering the Machine Tool Vibration using Taguchi Method

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Muhammad Munawar

2012-01-01

Full Text Available Optimization of surface roughness has been one of the primary objectives in most of the machining operations. Poor control on the desired surface roughness generates non conforming parts and results into increase in cost and loss of productivity due to rework or scrap. Surface roughness value is a result of several process variables among which machine tool condition is one of the significant variables. In this study, experimentation was carried out to investigate the effect of machine tool condition on surface roughness. Variable used to represent machine tool\\'s condition was vibration amplitude. Input parameters used, besides vibration amplitude, were feed rate and insert nose radius. Cutting speed and depth of cut were kept constant. Based on Taguchi orthogonal array, a series of experimentation was designed and performed on AISI 1040 carbon steel bar at default and induced machine tool\\'s vibration amplitudes. ANOVA (Analysis of Variance, revealed that vibration amplitude and feed rate had moderate effect on the surface roughness and insert nose radius had the highest significant effect on the surface roughness. It was also found that a machine tool with low vibration amplitude produced better surface roughness. Insert with larger nose radius produced better surface roughness at low feed rate.

Possibilities of Application of High Pressure Jet Assisted Machining in Hard Turning with Carbide Tools

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G. Globočki Lakić

2017-06-01

Full Text Available High Pressure Jet Assisted Machining (HPJAM in turning is a hybrid machining method in which a high pressure jet of cooling and lubrication fluid, under high pressure (50 MPa, leads to the zone between the cutting tool edge and workpiece. An experimental study was performed to investigate the capabilities of conventional and high pressure cooling (HPC in the turning of hard-to-machine materials: hard-chromed and surface hardened steel Ck45 (58 HRc and hardened bearing steel 100Cr6 (62 HRc. Machining experiments were performed using coated carbide tools and highly cutting speed. Experimental measurements were performed for different input process parameters. The cooling capabilities are compared by monitoring of tool wear, tool life, cooling efficiency, and surface roughness. Connection between the tool wear and surface roughness is established. Experimental research show that the hard turning with carbide cutting tools and HP supply CLF provides numerous advantages from the techno-economic aspect: greater productivity, reduce of temperature in the cutting zone, improved control chip formation, extended tool life, low intensity of tool wear, surface roughness in acceptable limits, significant reduce of production costs related to the CLF.

Parameterization of mechanical process operations taking into consideration a coefficient of variation and tool life

Directory of Open Access Journals (Sweden)

A. S. Sgibnev

2014-01-01

Full Text Available This article describes the results of studies on methods for improving the reliability of mechanical process operations of hard-to-machine materials. In serial production hard-to-machine materials processing should be characterized by high reliability, in particular, low dispersion tool life.The aim is to analyze the reliability of a part of the technological system, i.e. the tool for mechanical processing of hard-to-machine materials.The paper analyzes the effect of various input parameters of the technological system (processed material, tool material, technological environment, operating parameters (processing modes on the reliability of the technological system. A feature of this work is to obtain quantitative characteristics of reliability for processing just the hard-to-machine materials. It is an important problem-solving because of the high cost of both the materials and the tool.For various tool, processed materials, and process operation conditions the experiments have been conducted, and, when machining, the tool life has been recorded, thus allowing to obtain the coefficient of variation for high production run of tool. Comparison of coefficients of variation resulted in offering the tool material, process environment, and operation conditions to improve the reliability of the technological system for the specific brands of corrosion resistant steels and alloys and tungsten.It is shown that the tool material and technological environment have the biggest influence on the tool life period T and its coefficient of variation varT. It is noted that materials with a complicated composition have the higher life volatility as compared with the resistance simple alloys. It is shown that an increasing cutting speed is reduced after a certain value of the coefficient of variation due to entrainment outgrowth formed on the cutting edge of the tool.The results obtained allow machining production engineers at the enterprises of serial

Quantitative Evaluation of Heavy Duty Machine Tools Remanufacturing Based on Modified Catastrophe Progression Method

Science.gov (United States)

shunhe, Li; jianhua, Rao; lin, Gui; weimin, Zhang; degang, Liu

2017-11-01

The result of remanufacturing evaluation is the basis for judging whether the heavy duty machine tool can remanufacture in the EOL stage of the machine tool lifecycle management.The objectivity and accuracy of evaluation is the key to the evaluation method.In this paper, the catastrophe progression method is introduced into the quantitative evaluation of heavy duty machine tools’ remanufacturing,and the results are modified by the comprehensive adjustment method,which makes the evaluation results accord with the standard of human conventional thinking.Using the catastrophe progression method to establish the heavy duty machine tools’ quantitative evaluation model,to evaluate the retired TK6916 type CNC floor milling-boring machine’s remanufacturing.The evaluation process is simple,high quantification,the result is objective.

Linear parallel processing machines I

Energy Technology Data Exchange (ETDEWEB)

Von Kunze, M

1984-01-01

As is well-known, non-context-free grammars for generating formal languages happen to be of a certain intrinsic computational power that presents serious difficulties to efficient parsing algorithms as well as for the development of an algebraic theory of contextsensitive languages. In this paper a framework is given for the investigation of the computational power of formal grammars, in order to start a thorough analysis of grammars consisting of derivation rules of the form aB ..-->.. A/sub 1/ ... A /sub n/ b/sub 1/...b /sub m/ . These grammars may be thought of as automata by means of parallel processing, if one considers the variables as operators acting on the terminals while reading them right-to-left. This kind of automata and their 2-dimensional programming language prove to be useful by allowing a concise linear-time algorithm for integer multiplication. Linear parallel processing machines (LP-machines) which are, in their general form, equivalent to Turing machines, include finite automata and pushdown automata (with states encoded) as special cases. Bounded LP-machines yield deterministic accepting automata for nondeterministic contextfree languages, and they define an interesting class of contextsensitive languages. A characterization of this class in terms of generating grammars is established by using derivation trees with crossings as a helpful tool. From the algebraic point of view, deterministic LP-machines are effectively represented semigroups with distinguished subsets. Concerning the dualism between generating and accepting devices of formal languages within the algebraic setting, the concept of accepting automata turns out to reduce essentially to embeddability in an effectively represented extension monoid, even in the classical cases.

Visualization tool for human-machine interface designers

Science.gov (United States)

Prevost, Michael P.; Banda, Carolyn P.

1991-06-01

As modern human-machine systems continue to grow in capabilities and complexity, system operators are faced with integrating and managing increased quantities of information. Since many information components are highly related to each other, optimizing the spatial and temporal aspects of presenting information to the operator has become a formidable task for the human-machine interface (HMI) designer. The authors describe a tool in an early stage of development, the Information Source Layout Editor (ISLE). This tool is to be used for information presentation design and analysis; it uses human factors guidelines to assist the HMI designer in the spatial layout of the information required by machine operators to perform their tasks effectively. These human factors guidelines address such areas as the functional and physical relatedness of information sources. By representing these relationships with metaphors such as spring tension, attractors, and repellers, the tool can help designers visualize the complex constraint space and interacting effects of moving displays to various alternate locations. The tool contains techniques for visualizing the relative 'goodness' of a configuration, as well as mechanisms such as optimization vectors to provide guidance toward a more optimal design. Also available is a rule-based design checker to determine compliance with selected human factors guidelines.

Finite Element Analysis as a response to frequently asked questions of machine tool mechanical design-engineers

Directory of Open Access Journals (Sweden)

Kehl Gerhard

2017-01-01

Full Text Available The finite element analysis (FEA nowadays is indispensable in the product development of machining centres and production machinery for metal cutting processes. It enables extensive static, dynamic and thermal simulation of digital prototypes of machine tools before production start-up. But until now less reflection has been made about what are the most pressing questions to be answered in this application field, with the intention to align the modelling and simulation methods with substantial requirements. Based on 3D CAD geometry data for a modern machining centre (Deckel-Maho-Gildemeister DMG 635 V eco merely the basic steps of a static analysis are reconstructed by FEA. Particularly the two most frequently asked questions by the design departments of machine tool manufacturers are discussed and highlighted. For this authentic simulation results are used, at which their selection is a consequence of long lasting experience in the industrial application of FEA in the design process chain. Noticing that such machine tools are mechatronic systems applying a considerable number of actuators, sensors and controllers in addition to mechanical structures, the answers to those core questions are required for design enhancement, to save costs and to improve the productivity and the quality of machined workpieces.

A Method for Design of Modular Reconfigurable Machine Tools

Directory of Open Access Journals (Sweden)

Zhengyi Xu

2017-02-01

Full Text Available Presented in this paper is a method for the design of modular reconfigurable machine tools (MRMTs. An MRMT is capable of using a minimal number of modules through reconfiguration to perform the required machining tasks for a family of parts. The proposed method consists of three steps: module identification, module determination, and layout synthesis. In the first step, the module components are collected from a family of general-purpose machines to establish a module library. In the second step, for a given family of parts to be machined, a set of needed modules are selected from the module library to construct a desired reconfigurable machine tool. In the third step, a final machine layout is decided though evaluation by considering a number of performance indices. Based on this method, a software package has been developed that can design an MRMT for a given part family.

Effect of changing polarity of graphite tool/ Hadfield steel workpiece couple on machining performances in die sinking EDM

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Özerkan Haci Bekir

2017-01-01

Full Text Available In this study, machining performance ouput parameters such as machined surface roughness (SR, material removal rate (MRR, tool wear rate (TWR, were experimentally examined and analyzed with the diversifying and changing machining parameters in (EDM. The processing parameters (input par. of this research are stated as tool material, peak current (I, pulse duration (ton and pulse interval (toff. The experimental machinings were put into practice by using Hadfield steel workpiece (prismatic and cylindrical graphite electrodes with kerosene dielectric at different machining current, polarity and pulse time settings. The experiments have shown that the type of tool material, polarity (direct polarity forms higher MRR, SR and TWR, current (high current lowers TWR and enhances MRR, TWR and pulse on time (ton=48□s is critical threshold value for MRR and TWR were influential on machining performance in electrical discharge machining.

Application of a 16-bit microprocessor to the digital control of machine tools

International Nuclear Information System (INIS)

Issaly, Alain

1979-01-01

After an overview of machine tools (various types, definition standardization, associated technologies for motors and position sensors), this research thesis describes the principles of computer-based digital control: classification of machine tool command systems, machining programming, programming languages, dialog function, interpolation function, servo-control function, tool compensation function. The author reports the application of a 16-bit microprocessor to the computer-based digital control of a machine tool: feasibility, selection of microprocessor, hardware presentation, software development and description, machining mode, translation-loading mode

VIRTUAL MODELING OF A NUMERICAL CONTROL MACHINE TOOL USED FOR COMPLEX MACHINING OPERATIONS

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POPESCU Adrian

2015-11-01

Full Text Available This paper presents the 3D virtual model of the numerical control machine Modustar 100, in terms of machine elements. This is a CNC machine of modular construction, all components allowing the assembly in various configurations. The paper focused on the design of the subassemblies specific to the axes numerically controlled by means of CATIA v5, which contained different drive kinematic chains of different translation modules that ensures translation on X, Y and Z axis. Machine tool development for high speed and highly precise cutting demands employment of advanced simulation techniques witch it reflect on cost of total development of the machine.

Method and apparatus for characterizing and enhancing the functional performance of machine tools

Science.gov (United States)

Barkman, William E; Babelay, Jr., Edwin F; Smith, Kevin Scott; Assaid, Thomas S; McFarland, Justin T; Tursky, David A; Woody, Bethany; Adams, David

2013-04-30

Disclosed are various systems and methods for assessing and improving the capability of a machine tool. The disclosure applies to machine tools having at least one slide configured to move along a motion axis. Various patterns of dynamic excitation commands are employed to drive the one or more slides, typically involving repetitive short distance displacements. A quantification of a measurable merit of machine tool response to the one or more patterns of dynamic excitation commands is typically derived for the machine tool. Examples of measurable merits of machine tool performance include workpiece surface finish, and the ability to generate chips of the desired length.

Adaption of commercial off the shelf modules for reconfigurable machine tool design

CSIR Research Space (South Africa)

Mpofu, K

2008-01-01

Full Text Available . University of Ljubljana (Slovenia) Machine Design Approach. Butala and Sluga [4] view the architecture of the machine tool as a system structure which is reflected in its configuration and which impacts the systems performance. The interfaces... process movements. This approach was also implemented in a computer aided planning system, they clarify the need of having the features to be implemented embedded in the collective drives that constitute it. This resulted in an adaption...

Nontraditional machining processes research advances

CERN Document Server

2013-01-01

Nontraditional machining employs processes that remove material by various methods involving thermal, electrical, chemical and mechanical energy or even combinations of these. Nontraditional Machining Processes covers recent research and development in techniques and processes which focus on achieving high accuracies and good surface finishes, parts machined without burrs or residual stresses especially with materials that cannot be machined by conventional methods. With applications to the automotive, aircraft and mould and die industries, Nontraditional Machining Processes explores different aspects and processes through dedicated chapters. The seven chapters explore recent research into a range of topics including laser assisted manufacturing, abrasive water jet milling and hybrid processes. Students and researchers will find the practical examples and new processes useful for both reference and for developing further processes. Industry professionals and materials engineers will also find Nontraditional M...

CrN-based wear resistant hard coatings for machining and forming tools

Energy Technology Data Exchange (ETDEWEB)

Yang, S; Cooke, K E; Teer, D G [Teer Coatings Ltd, West Stone House, Berry Hill Industrial Estate, Droitwich, Worcestershire WR9 9AS (United Kingdom); Li, X [School of Metallurgy and Materials, University of Birmingham, Birmingham B15 2TT (United Kingdom); McIntosh, F [Rolls-Royce plc, Inchinnan, Renfrewshire PA4 9AF, Scotland (United Kingdom)

2009-05-21

Highly wear resistant multicomponent or multilayer hard coatings, based on CrN but incorporating other metals, have been developed using closed field unbalanced magnetron sputter ion plating technology. They are exploited in coated machining and forming tools cutting and forming of a wide range of materials in various application environments. These coatings are characterized by desirable properties including good adhesion, high hardness, high toughness, high wear resistance, high thermal stability and high machining capability for steel. The coatings appear to show almost universal working characteristics under operating conditions of low and high temperature, low and high machining speed, machining of ordinary materials and difficult to machine materials, and machining under lubricated and under minimum lubricant quantity or even dry conditions. These coatings can be used for cutting and for forming tools, for conventional (macro-) machining tools as well as for micromachining tools, either as a single coating or in combination with an advanced, self-lubricating topcoat.

Multi-Parameter Analysis of Surface Finish in Electro-Discharge Machining of Tool Steels

Directory of Open Access Journals (Sweden)

Cornelia Victoria Anghel

2006-10-01

Full Text Available The paper presents a multi- parameter analysis of surface finish imparted to tool-steel plates by electro-discharge machining (EDM is presented. The interrelationship between surface texture parameters and process parameters is emphasized. An increased number of parameters is studied including amplitude, spacing, hybrid and fractal parameters,, as well. The correlation of these parameters with the machining conditions is investigated. Observed characteristics become more pronounced, when intensifying machining conditions. Close correlation exists between certain surface finish parameters and EDM input variables and single and multiple statistical regression models are developed.

NEW ASPECTS OF MANUFACTURING ON MACHINE TOOLS

Directory of Open Access Journals (Sweden)

Dorian ŞTEF

2012-11-01

Full Text Available In the paper are presented the modality to minimize the production time and increase the machining accuracy in the milling operations and to analyze different milling strategies. In this analyze the only on modification for face milling operation was to change the tool geometry by mounted a special shape insert WIPER, that have a different geometry, and for pocketing operations the changes was by using different milling strategies for manufacturing pockets. The application for this analyze is a simulation between the process technologies in virtual fabrication made using Esprit CAM (Computer Aided Manufacturing software.

Multi criteria decision making of machining parameters for Die Sinking EDM Process

Directory of Open Access Journals (Sweden)

G. K. Bose

2015-04-01

Full Text Available Electrical Discharge Machining (EDM is one of the most basic non-conventional machining processes for production of complex geometries and process of hard materials, which are difficult to machine by conventional process. It is capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat-treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. The present study is focusing on the die sinking electric discharge machining (EDM of AISI H 13, W.-Nr. 1.2344 Grade: Ovar Supreme for finding out the effect of machining parameters such as discharge current (GI, pulse on time (POT, pulse off time (POF and spark gap (SG on performance response like Material removal rate (MRR, Surface Roughness (Ra & Overcut (OC using Square-shaped Cu tool with Lateral flushing. A well-designed experimental scheme is used to reduce the total number of experiments. Parts of the experiment are conducted with the L9 orthogonal array based on the Taguchi methodology and significant process parameters are identified using Analysis of Variance (ANOVA. It is found that MRR is affected by gap current & Ra is affected by pulse on time. Moreover, the signal-to-noise ratios associated with the observed values in the experiments are determined by which factor is most affected by the responses of MRR, Ra and OC. These experimental data are further investigated using Grey Relational Analysis to optimize multiple performances in which different levels combination of the factors are ranked based on grey relational grade. The analysis reveals that substantial improvement in machining performance takes place following this technique.

Development of Dual-Axis MEMS Accelerometers for Machine Tools Vibration Monitoring

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Chih-Yung Huang

2016-07-01

Full Text Available With the development of intelligent machine tools, monitoring the vibration by the accelerometer is an important issue. Accelerometers used for measuring vibration signals during milling processes require the characteristics of high sensitivity, high resolution, and high bandwidth. A commonly used accelerometer is the lead zirconate titanate (PZT type; however, integrating it into intelligent modules is excessively expensive and difficult. Therefore, the micro electro mechanical systems (MEMS accelerometer is an alternative with the advantages of lower price and superior integration. In the present study, we integrated two MEMS accelerometer chips into a low-pass filter and housing to develop a low-cost dual-axis accelerometer with a bandwidth of 5 kHz and a full scale range of ±50 g for measuring machine tool vibration. In addition, a platform for measuring the linearity, cross-axis sensitivity and frequency response of the MEMS accelerometer by using the back-to-back calibration method was also developed. Finally, cutting experiments with steady and chatter cutting were performed to verify the results of comparing the MEMS accelerometer with the PZT accelerometer in the time and frequency domains. The results demonstrated that the dual-axis MEMS accelerometer is suitable for monitoring the vibration of machine tools at low cost.

The Total Energy Efficiency Index for machine tools

International Nuclear Information System (INIS)

Schudeleit, Timo; Züst, Simon; Weiss, Lukas; Wegener, Konrad

2016-01-01

Energy efficiency in industries is one of the dominating challenges of the 21st century. Since the release of the eco-design directive 2005/32/EC in 2005, great research effort has been spent on the energy efficiency assessment for energy using products. The ISO (International Organization for Standardization) standardization body (ISO/TC 39 WG 12) currently works on the ISO 14955 series in order to enable the assessment of energy efficient design of machine tools. A missing piece for completion of the ISO 14955 series is a metric to quantify the design of machine tools regarding energy efficiency based on the respective assembly of components. The metric needs to take into account each machine tool components' efficiency and the need-oriented utilization in combination with the other components while referring to efficiency limits. However, a state of the art review reveals that none of the existing metrics is feasible to adequately match this goal. This paper presents a metric that matches all these criteria to promote the development of the ISO 14955 series. The applicability of the metric is proven in a practical case study on a turning machine. - Highlights: • Study for pushing forward the standardization work on the ISO 14955 series. • Review of existing energy efficiency indicators regarding three basic strategies to foster sustainability. • Development of a metric comprising the three basic strategies to foster sustainability. • Metric application for quantifying the energy efficiency of a turning machine.

Machine tool metrology an industrial handbook

CERN Document Server

Smith, Graham T

2016-01-01

Maximizing reader insights into the key scientific disciplines of Machine Tool Metrology, this text will prove useful for the industrial-practitioner and those interested in the operation of machine tools. Within this current level of industrial-content, this book incorporates significant usage of the existing published literature and valid information obtained from a wide-spectrum of manufacturers of plant, equipment and instrumentation before putting forward novel ideas and methodologies. Providing easy to understand bullet points and lucid descriptions of metrological and calibration subjects, this book aids reader understanding of the topics discussed whilst adding a voluminous-amount of footnotes utilised throughout all of the chapters, which adds some additional detail to the subject. Featuring an extensive amount of photographic-support, this book will serve as a key reference text for all those involved in the field. .

Monitoring wear and corrosion in industrial machines and systems: A radiation tool

International Nuclear Information System (INIS)

Konstantinov, I.O.; Zatolokin, B.V.

1994-01-01

Industrial equipment and machines, transport systems, nuclear and conventional power plants, pipelines, and other materials is substantially influenced by degradation processes such as wear and corrosion. For safety and economic reasons, appropriately monitoring the damage could prevent dangerous accidents. When the surfaces of machine parts under investigation are not easy to reach or are concealed by overlying structures, nuclear methods have become powerful tools for examination. They include X-ray radiography, neutron radiography, and a technique known as thin layer activation (TLA)

Five-axis Control Processing Using NC Machine Tools : A Tool Posture Decision Using the Tangent Slope at a Cut Point on a Work

OpenAIRE

小島, 龍広; 西田, 知照; 扇谷, 保彦

2003-01-01

This report deals with the way to decide tool posture and the way to analytically calculate tool path for the work shape requiring 5-axis control machining. In the tool path calculation, basic equations are derived using the principle that the tangent slope at a cut point on a work and the one at a cutting point on a tool edge are identical. A tool posture decision procedure using the tangent slope at each cut point on a work is proposed for any shape of tool edge. The valid- ity of the way t...

Modelling Machine Tools using Structure Integrated Sensors for Fast Calibration

Directory of Open Access Journals (Sweden)

Benjamin Montavon

2018-02-01

Full Text Available Monitoring of the relative deviation between commanded and actual tool tip position, which limits the volumetric performance of the machine tool, enables the use of contemporary methods of compensation to reduce tolerance mismatch and the uncertainties of on-machine measurements. The development of a primarily optical sensor setup capable of being integrated into the machine structure without limiting its operating range is presented. The use of a frequency-modulating interferometer and photosensitive arrays in combination with a Gaussian laser beam allows for fast and automated online measurements of the axes’ motion errors and thermal conditions with comparable accuracy, lower cost, and smaller dimensions as compared to state-of-the-art optical measuring instruments for offline machine tool calibration. The development is tested through simulation of the sensor setup based on raytracing and Monte-Carlo techniques.

Effect of Tip Shape of Frictional Stir Burnishing Tool on Processed Layer’s Hardness, Residual Stress and Surface Roughness

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Yoshimasa Takada

2018-01-01

Full Text Available Friction stir burnishing (FSB is a surface-enhancement method used after machining, without the need for an additional device. The FSB process is applied on a machine that uses rotation tools (e.g., machining center or multi-tasking machine. Therefore, the FSB process can be applied immediately after the cutting process using the same machine tool. Here, we apply the FSB to the shaft materials of 0.45% C steel using a multi-tasking machine. In the FSB process, the burnishing tool rotates at a high-revolution speed. The thin surface layer is rubbed and stirred as the temperature is increased and decreased. With the FSB process, high hardness or compressive residual stress can be obtained on the surface layer. However, when we applied the FSB process using a 3 mm diameter sphere tip shape tool, the surface roughness increased substantially (Ra = 20 µm. We therefore used four types of tip shape tools to examine the effect of burnishing tool tip radius on surface roughness, hardness, residual stress in the FSB process. Results indicated that the surface roughness was lowest (Ra = 10 µm when the tip radius tool diameter was large (30 mm.

Simulation Tools for Electrical Machines Modelling: Teaching and ...

African Journals Online (AJOL)

Simulation tools are used both for research and teaching to allow a good comprehension of the systems under study before practical implementations. This paper illustrates the way MATLAB is used to model non-linearites in synchronous machine. The machine is modeled in rotor reference frame with currents as state ...

A new accurate curvature matching and optimal tool based five-axis machining algorithm

International Nuclear Information System (INIS)

Lin, Than; Lee, Jae Woo; Bohez, Erik L. J.

2009-01-01

Free-form surfaces are widely used in CAD systems to describe the part surface. Today, the most advanced machining of free from surfaces is done in five-axis machining using a flat end mill cutter. However, five-axis machining requires complex algorithms for gouging avoidance, collision detection and powerful computer-aided manufacturing (CAM) systems to support various operations. An accurate and efficient method is proposed for five-axis CNC machining of free-form surfaces. The proposed algorithm selects the best tool and plans the tool path autonomously using curvature matching and integrated inverse kinematics of the machine tool. The new algorithm uses the real cutter contact tool path generated by the inverse kinematics and not the linearized piecewise real cutter location tool path

Optimization process planning using hybrid genetic algorithm and intelligent search for job shop machining.

Science.gov (United States)

Salehi, Mojtaba; Bahreininejad, Ardeshir

2011-08-01

Optimization of process planning is considered as the key technology for computer-aided process planning which is a rather complex and difficult procedure. A good process plan of a part is built up based on two elements: (1) the optimized sequence of the operations of the part; and (2) the optimized selection of the machine, cutting tool and Tool Access Direction (TAD) for each operation. In the present work, the process planning is divided into preliminary planning, and secondary/detailed planning. In the preliminary stage, based on the analysis of order and clustering constraints as a compulsive constraint aggregation in operation sequencing and using an intelligent searching strategy, the feasible sequences are generated. Then, in the detailed planning stage, using the genetic algorithm which prunes the initial feasible sequences, the optimized operation sequence and the optimized selection of the machine, cutting tool and TAD for each operation based on optimization constraints as an additive constraint aggregation are obtained. The main contribution of this work is the optimization of sequence of the operations of the part, and optimization of machine selection, cutting tool and TAD for each operation using the intelligent search and genetic algorithm simultaneously.

Machine intelligence and signal processing

CERN Document Server

Vatsa, Mayank; Majumdar, Angshul; Kumar, Ajay

2016-01-01

This book comprises chapters on key problems in machine learning and signal processing arenas. The contents of the book are a result of a 2014 Workshop on Machine Intelligence and Signal Processing held at the Indraprastha Institute of Information Technology. Traditionally, signal processing and machine learning were considered to be separate areas of research. However in recent times the two communities are getting closer. In a very abstract fashion, signal processing is the study of operator design. The contributions of signal processing had been to device operators for restoration, compression, etc. Applied Mathematicians were more interested in operator analysis. Nowadays signal processing research is gravitating towards operator learning – instead of designing operators based on heuristics (for example wavelets), the trend is to learn these operators (for example dictionary learning). And thus, the gap between signal processing and machine learning is fast converging. The 2014 Workshop on Machine Intel...

Cyclic machine scheduling with tool transportation - additional calculations

NARCIS (Netherlands)

Kuijpers, C.M.H.

2001-01-01

In the PhD Thesis of Kuijpers a cyclic machine scheduling problem with tool transportation is considered. For the problem with two machines, it is shown that there always exists an optimal schedule with a certain structure. This is done by means of an elaborate case study. For a number of cases some

Tool management in manufacturing systems equipped with CNC machines

Directory of Open Access Journals (Sweden)

Giovanni Tani

1997-12-01

Full Text Available This work has been carried out for the purpose of realizing an automated system for the integrated management of tools within a company. By integrating planning, inspection and tool-room functions, automated tool management can ensure optimum utilization of tools on the selected machines, guaranteeing their effective availability. The first stage of the work consisted of defining and developing a Tool Management System whose central nucleus is a unified Data Base for all of the tools, forming part of the company's Technological Files (files on machines, materials, equipment, methods, etc., interfaceable with all of the company departments that require information on tools. The system assigns code numbers to the individual components of the tools and file them on the basis of their morphological and functional characteristics. The system is also designed to effect assemblies of tools, from which are obtained the "Tool Cards" required for compiling working cycles (CAPP, for CAM programming and for the Tool-room where the tools are physically prepared. Methods for interfacing with suitable systems for the aforesaid functions have also been devised

Finite Element Modelling of the effect of tool rake angle on tool temperature and cutting force during high speed machining of AISI 4340 steel

International Nuclear Information System (INIS)

Sulaiman, S; Roshan, A; Ariffin, M K A

2013-01-01

In this paper, a Finite Element Method (FEM) based on the ABAQUS explicit software which involves Johnson-Cook material model was used to simulate cutting force and tool temperature during high speed machining (HSM) of AISI 4340 steel. In this simulation work, a tool rake angle ranging from 0° to 20° and a range of cutting speeds between 300 to 550 m/min was investigated. The purpose of this simulation analysis was to find optimum tool rake angle where cutting force is smallest as well as tool temperature is lowest during high speed machining. It was found that cutting forces to have a decreasing trend as rake angle increased to positive direction. The optimum rake angle observed between 10° and 18° due to decrease of cutting force as 20% for all simulated cutting speeds. In addition, increasing cutting tool rake angle over its optimum value had negative influence on tool's performance and led to an increase in cutting temperature. The results give a better understanding and recognition of the cutting tool design for high speed machining processes

Flat Milling Process Simulation Taking into Consideration a Dependence of Dynamic Characteristics of the Machine

Directory of Open Access Journals (Sweden)

D. A. Zavarzin

2016-01-01

Full Text Available The milling process inherently is on/off, and therefore inevitably there is vibration excitation in the Machine/Fixture/Tool/Part (MFTP system, which results in a different quality of the treated surface, depending on the machining conditions. The objective is to identify effective operation conditions to cut a part on the 3-way easy class machines when there is no unwanted regenerative self-oscillation, leading to a significant deterioration in the quality of the surface machined. The paper describes vibrations arising during a milling process and their effect on the surface shape and the working tool. To solve this problem we apply a numerical simulation method of cutting dynamics, which consist of 4 modules. The main module is an algorithm of the geometric simulation. The second module is a phenomenological model of the cutting forces. Two remaining modules are responsible for dynamics simulation of the part machined and the cutting tool under time-varying cutting forces. The calculated values are transferred back to the geometric modelling algorithm at each step in time. Thus, the model is closed and allows us to take into account an effect of delay in a dynamic system. A finite element machine model to perform calculation in 3DCUT software has been a selected and compiled. The paper presents geometrical mapping of the machining process and natural frequencies and shapes found for the finite element model. Conducting multivariate calculations allowed us to analyse the dependences of a dynamic behaviour of the system on changing spindle speed. The multivariate modelling results are presented as the Poincare maps for a moving free end of the tool. These Poincare maps allow us to select the operation conditions domains coming both with forced vibration and with self-excited oscillations. On the Poincaré map for two operation conditions of different domains there are graphics of the cutting forces, a thickness of the cutting layer, tool

Effect of the Machining Processes on Low Cycle Fatigue Behavior of a Powder Metallurgy Disk

Science.gov (United States)

Telesman, J.; Kantzos, P.; Gabb, T. P.; Ghosn, L. J.

2010-01-01

A study has been performed to investigate the effect of various machining processes on fatigue life of configured low cycle fatigue specimens machined out of a NASA developed LSHR P/M nickel based disk alloy. Two types of configured specimen geometries were employed in the study. To evaluate a broach machining processes a double notch geometry was used with both notches machined using broach tooling. EDM machined notched specimens of the same configuration were tested for comparison purposes. Honing finishing process was evaluated by using a center hole specimen geometry. Comparison testing was again done using EDM machined specimens of the same geometry. The effect of these machining processes on the resulting surface roughness, residual stress distribution and microstructural damage were characterized and used in attempt to explain the low cycle fatigue results.

Machining of Molybdenum by EDM-EP and EDC Processes

Science.gov (United States)

Wu, K. L.; Chen, H. J.; Lee, H. M.; Lo, J. S.

2017-12-01

Molybdenum metal (Mo) can be machined with conventional tools and equipment, however, its refractory propertytends to chip when being machined. In this study, the nonconventional processes of electrical discharge machining (EDM) and electro-polishing (EP) have been conducted to investigate the machining of Mo metal and fabrication of Mo grid. Satisfactory surface quality was obtained using appropriate EDM parameters of Ip ≦ 3A and Ton EDMed Mo metal. Experimental results proved that the appropriate parameters of Ip = 5A and Ton = 50μs at Toff = 10μs can obtain the deposit with about 60μm thickness. The major phase of deposit on machined Mo surface was SiC ceramic, while the minor phases included MoSi2 and/or SiO2 with the presence of free Si due to improper discharging parameters and the use of silicone oil as the dielectric fluid.

PECULIARITIES OF THE TECHNOLOGY OF CONTINUOUS CASTING OF SLUGS OF MACHINE- AND MACHINE-TOOL-BUILDING

OpenAIRE

E. B. Demchenko; E. I. Marukovich

2006-01-01

The peculiarities of technology of continuous casting of ingots of machine- and machine tool building are shown. At development of technology it is necessary to subject the nomenclature of ingots to analysis in order to reveal expediency of their production by means of continuous casting.

Analyzing the effect of cutting parameters on surface roughness and tool wear when machining nickel based hastelloy - 276

International Nuclear Information System (INIS)

Khidhir, Basim A; Mohamed, Bashir

2011-01-01

Machining parameters has an important factor on tool wear and surface finish, for that the manufacturers need to obtain optimal operating parameters with a minimum set of experiments as well as minimizing the simulations in order to reduce machining set up costs. The cutting speed is one of the most important cutting parameter to evaluate, it clearly most influences on one hand, tool life, tool stability, and cutting process quality, and on the other hand controls production flow. Due to more demanding manufacturing systems, the requirements for reliable technological information have increased. For a reliable analysis in cutting, the cutting zone (tip insert-workpiece-chip system) as the mechanics of cutting in this area are very complicated, the chip is formed in the shear plane (entrance the shear zone) and is shape in the sliding plane. The temperature contributed in the primary shear, chamfer and sticking, sliding zones are expressed as a function of unknown shear angle on the rake face and temperature modified flow stress in each zone. The experiments were carried out on a CNC lathe and surface finish and tool tip wear are measured in process. Machining experiments are conducted. Reasonable agreement is observed under turning with high depth of cut. Results of this research help to guide the design of new cutting tool materials and the studies on evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy - 276 machining.

Parametric optimization of ultrasonic machining process using gravitational search and fireworks algorithms

Directory of Open Access Journals (Sweden)

Debkalpa Goswami

2015-03-01

Full Text Available Ultrasonic machining (USM is a mechanical material removal process used to erode holes and cavities in hard or brittle workpieces by using shaped tools, high-frequency mechanical motion and an abrasive slurry. Unlike other non-traditional machining processes, such as laser beam and electrical discharge machining, USM process does not thermally damage the workpiece or introduce significant levels of residual stress, which is important for survival of materials in service. For having enhanced machining performance and better machined job characteristics, it is often required to determine the optimal control parameter settings of an USM process. The earlier mathematical approaches for parametric optimization of USM processes have mostly yielded near optimal or sub-optimal solutions. In this paper, two almost unexplored non-conventional optimization techniques, i.e. gravitational search algorithm (GSA and fireworks algorithm (FWA are applied for parametric optimization of USM processes. The optimization performance of these two algorithms is compared with that of other popular population-based algorithms, and the effects of their algorithm parameters on the derived optimal solutions and computational speed are also investigated. It is observed that FWA provides the best optimal results for the considered USM processes.

Simulation of dynamic processes when machining transition surfaces of stepped shafts

Science.gov (United States)

Maksarov, V. V.; Krasnyy, V. A.; Viushin, R. V.

2018-03-01

The paper addresses the characteristics of stepped surfaces of parts categorized as "solids of revolution". It is noted that in the conditions of transition modes during the switch to end surface machining, there is cutting with varied load intensity in the section of the cut layer, which leads to change in cutting force, onset of vibrations, an increase in surface layer roughness, a decrease of size precision, and increased wear of a tool's cutting edge. This work proposes a method that consists in developing a CNC program output code that allows one to process complex forms of stepped shafts with only one machine setup. The authors developed and justified a mathematical model of a technological system for mechanical processing with consideration for the resolution of tool movement at the stages of transition processes to assess the dynamical stability of a system in the process of manufacturing stepped surfaces of parts of “solid of revolution” type.

Micro-EDM process modeling and machining approaches for minimum tool electrode wear for fabrication of biocompatible micro-components

DEFF Research Database (Denmark)

Puthumana, Govindan

2017-01-01

Micro-electrical discharge machining (micro-EDM) is a potential non-contact method for fabrication of biocompatible micro devices. This paper presents an attempt to model the tool electrode wear in micro-EDM process using multiple linear regression analysis (MLRA) and artificial neural networks...... linear regression model was developed for prediction of TWR in ten steps at a significance level of 90%. The optimum architecture of the ANN was obtained with 7 hidden layers at an R-sq value of 0.98. The predicted values of TWR using ANN matched well with the practically measured and calculated values...... (ANN). The governing micro-EDM factors chosen for this investigation were: voltage (V), current (I), pulse on time (Ton) and pulse frequency (f). The proposed predictive models generate a functional correlation between the tool electrode wear rate (TWR) and the governing micro-EDM factors. A multiple...

Human Functions, Machine Tools, and the Role of the Analyst

Directory of Open Access Journals (Sweden)

Gordon R. Middleton

2015-09-01

Full Text Available In an era of rapidly increasing technical capability, the intelligence focus is often on the modes of collection and tools of analysis rather than the analyst themselves. Data are proliferating and so are tools to help analysts deal with the flood of data and the increasingly demanding timeline for intelligence production, but the role of the analyst in such a data-driven environment needs to be understood in order to support key management decisions (e.g., training and investment priorities. This paper describes a model of the analytic process, and analyzes the roles played by humans and machine tools in each process element. It concludes that human analytic functions are as critical in the intelligence process as they have ever been, and perhaps even more so due to the advance of technology in the intelligence business. Human functions performed by analysts are critical in nearly every step in the process, particularly at the front end of the analytic process, in defining and refining the problem statement, and at the end of the process, in generating knowledge, presenting the story in understandable terms, tailoring the presentation of the results of the analysis to various audiences, as well as in determining when to initiate iterative loops in the process. The paper concludes with observations on the necessity of enabling expert analysts, tools to deal with big data, developing analysts with advanced analytic methods as well as with techniques for optimal use of advanced tools, and suggestions for further quantitative research.

Efficient thermal error prediction in a machine tool using finite element analysis

International Nuclear Information System (INIS)

Mian, Naeem S; Fletcher, Simon; Longstaff, Andrew P; Myers, Alan

2011-01-01

Thermally induced errors have a major significance on the positional accuracy of a machine tool. Heat generated during the machining process produces thermal gradients that flow through the machine structure causing linear and nonlinear thermal expansions and distortions of associated complex discrete structures, producing deformations that adversely affect structural stability. The heat passes through structural linkages and mechanical joints where interfacial parameters such as the roughness and form of the contacting surfaces affect the thermal resistance and thus the heat transfer coefficients. This paper presents a novel offline technique using finite element analysis (FEA) to simulate the effects of the major internal heat sources such as bearings, motors and belt drives of a small vertical milling machine (VMC) and the effects of ambient temperature pockets that build up during the machine operation. Simplified models of the machine have been created offline using FEA software and evaluated experimental results applied for offline thermal behaviour simulation of the full machine structure. The FEA simulated results are in close agreement with the experimental results ranging from 65% to 90% for a variety of testing regimes and revealed a maximum error range of 70 µm reduced to less than 10 µm

A defect-driven diagnostic method for machine tool spindles.

Science.gov (United States)

Vogl, Gregory W; Donmez, M Alkan

2015-01-01

Simple vibration-based metrics are, in many cases, insufficient to diagnose machine tool spindle condition. These metrics couple defect-based motion with spindle dynamics; diagnostics should be defect-driven. A new method and spindle condition estimation device (SCED) were developed to acquire data and to separate system dynamics from defect geometry. Based on this method, a spindle condition metric relying only on defect geometry is proposed. Application of the SCED on various milling and turning spindles shows that the new approach is robust for diagnosing the machine tool spindle condition.

Stochastic Distribution of Wear of Carbide Tools during Machining ...

African Journals Online (AJOL)

Journal of the Nigerian Association of Mathematical Physics ... The stochastic point model was used to determine the rate of wear distribution of the carbide tool ... Keywords: cutting speed, feed rate, machining time, tool life, reliability, wear.

Machine and Woodworking Tool Safety. Module SH-24. Safety and Health.

Science.gov (United States)

Center for Occupational Research and Development, Inc., Waco, TX.

This student module on machine and woodworking tool safety is one of 50 modules concerned with job safety and health. This module discusses specific practices and precautions concerned with the efficient operation and use of most machine and woodworking tools in use today. Following the introduction, 13 objectives (each keyed to a page in the…

Investigation into the accuracy of a proposed laser diode based multilateration machine tool calibration system

International Nuclear Information System (INIS)

Fletcher, S; Longstaff, A P; Myers, A

2005-01-01

Geometric and thermal calibration of CNC machine tools is required in modern machine shops with volumetric accuracy assessment becoming the standard machine tool qualification in many industries. Laser interferometry is a popular method of measuring the errors but this, and other alternatives, tend to be expensive, time consuming or both. This paper investigates the feasibility of using a laser diode based system that capitalises on the low cost nature of the diode to provide multiple laser sources for fast error measurement using multilateration. Laser diode module technology enables improved wavelength stability and spectral linewidth which are important factors for laser interferometry. With more than three laser sources, the set-up process can be greatly simplified while providing flexibility in the location of the laser sources improving the accuracy of the system

Manufacturing process applications team (MATEAM). [technology transfer in the areas of machine tools and robots

Science.gov (United States)

1979-01-01

The transfer of NASA technology to the industrial sector is reported. Presentations to the machine tool and robot industries and direct technology transfers of the Adams Manipulator arm, a-c motor control, and the bolt tension monitor are discussed. A listing of proposed RTOP programs with strong potential is included. A detailed description of the rotor technology available to industry is given.

Environmentally Friendly Machining

CERN Document Server

Dixit, U S; Davim, J Paulo

2012-01-01

Environment-Friendly Machining provides an in-depth overview of environmentally-friendly machining processes, covering numerous different types of machining in order to identify which practice is the most environmentally sustainable. The book discusses three systems at length: machining with minimal cutting fluid, air-cooled machining and dry machining. Also covered is a way to conserve energy during machining processes, along with useful data and detailed descriptions for developing and utilizing the most efficient modern machining tools. Researchers and engineers looking for sustainable machining solutions will find Environment-Friendly Machining to be a useful volume.

Study on Dynamic Characteristics of Heavy Machine Tool-Composite Pile Foundation-Soil

Directory of Open Access Journals (Sweden)

CAI Li-Gang

2014-09-01

Full Text Available Heavy duty computer numerical control machine tools have characteristics of large self-weight, load and. The insufficiency of foundation bearing capacity leads to deformation of lathe bed, which effects machining accuracy. A combined-layer foundation model is created to describe the pile group foundation of multi-soil layer in this paper. Considering piles and soil in pile group as transversely isotropic material, equivalent constitutive relationship of composite foundation is constructed. A mathematical model is established by the introduction of boundary conditions, which is based on heavy duty computer numerical control machine tools-composite pile foundation-soil interaction system. And then, the response of different soil and pile depth is studied by a case. The model improves motion accuracy of machine tools.

Micro tooling technologies for polymer micro replication: direct, indirect and hybrid process chains

DEFF Research Database (Denmark)

Tosello, Guido; Hansen, Hans Nørgaard

2009-01-01

The increasing employment of micro products, of products containing micro parts and of products with micro-structured surfaces calls for mass fabrication technologies based on replication processes. In many cases, a suitable solution is given by the use of polymer micro products, whose production...... and performance of the corresponding micro mould. Traditional methods of micro tooling, such as various machining processes (e.g. micro milling, micro electrical discharge machining) have already reached their limitations with decreasing dimensions of mould inserts and cavities. To this respect, tooling process...... chains based on combination of micro manufacturing processes (defined as hybrid tooling) have been established in order to obtain further features miniaturization and increased accuracy. In this paper, examples and performance of different hybrid tooling approaches as well as challenges, opportunities...

Fiscal 2000 achievement report. Research on machine tool not necessitating hydraulic system; 2000 nendo yuatsu resu kosaku kikai no kenkyu seika hokokusho

Energy Technology Data Exchange (ETDEWEB)

NONE

2001-03-01

From the viewpoint that the manufacturing process, expendable items, and recycling should all be taken into consideration when machine tool energy consumption is the matter to discuss, it is concluded that the most important policy to follow in the effort to enhance energy conservation is to enable the tool to operate without hydraulic systems. For the realization of a general-purpose machine tool (lathe) to operate free of hydraulic systems, efforts are exerted to develop element technologies, tool rests, tail stocks, and chuck drives usable for the construction of a practical hydraulic system-free machine tool. In fiscal 2000, comprehensive evaluation of experimental machine tools continued, problems to solve for practical application were put together for the fabrication of improved units, and the improved units and an improved control method were integrated into a prototype of practical machine tools. The prototype was exhibited at Japan International Machine Tool Fair (JIMTOF) as a hydraulic system-free NC (numerically controlled) lathe Type LB300, and won a high valuation. The prototype was then tested for basic performance and for possibility of improvement, and problems to be solved before commercialization were isolated. (NEDO)

Concepts of increasing productivity and reducing the processing cost of machine parts

Directory of Open Access Journals (Sweden)

О. С. Кленов

2017-06-01

Full Text Available The basic conditions to reduce the cost of processing technology and improve productivity through the use of modern cutting tools produced by leading foreign firms producing tools have been appraised from theory in the work. Theoretically, it has been found that an increase in the cost of processing varies according to extremum dependence, passing the minimum point. It is possible to reduce the minimum processing cost due to the increase of productivity using cutting edge tools, characterized by a high capacity for work in high cutting temperatures. The criterion showing the technological price cost minimum is the ratio of the expenditures on workers’ wages to the expenditures on the cutting tools, it being quite specific for various processing conditions. To analyze the possibilities of practical use of the proposed criterion, a complex of experimental researches of the technological prime cost and productivity of the processing with hard alloy cutting tools with wear-resistant coatings produced by the company «Iscar» has been carried out. It has been established that their use makes it possible by more than one half to reduce the labour consumption and overall costs as compared to the hard alloy cutting tools traditionally used in home industry. It has been shown that this effect is achieved by increasing the cutting speed and feed due to increased wear resistance and heat resistance of the «Iscar» company tools. It was established that it is much more possible to achieve low processing cost at milling than at turning. It was stated with regard to all major expenditures including the workers' wages, the cost of the cutting tools, equipment and other costs, allowing more correctly estimate the cost-effectiveness of mechanical processing. Experiments confirmed that the main condition for reducing the processing cost to its minimum value is to increase the processing performance through the use of a heat-resistant and wear-resistant cutting

An Integrated Approach of Fuzzy Linguistic Preference Based AHP and Fuzzy COPRAS for Machine Tool Evaluation.

Directory of Open Access Journals (Sweden)

Huu-Tho Nguyen

Full Text Available Globalization of business and competitiveness in manufacturing has forced companies to improve their manufacturing facilities to respond to market requirements. Machine tool evaluation involves an essential decision using imprecise and vague information, and plays a major role to improve the productivity and flexibility in manufacturing. The aim of this study is to present an integrated approach for decision-making in machine tool selection. This paper is focused on the integration of a consistent fuzzy AHP (Analytic Hierarchy Process and a fuzzy COmplex PRoportional ASsessment (COPRAS for multi-attribute decision-making in selecting the most suitable machine tool. In this method, the fuzzy linguistic reference relation is integrated into AHP to handle the imprecise and vague information, and to simplify the data collection for the pair-wise comparison matrix of the AHP which determines the weights of attributes. The output of the fuzzy AHP is imported into the fuzzy COPRAS method for ranking alternatives through the closeness coefficient. Presentation of the proposed model application is provided by a numerical example based on the collection of data by questionnaire and from the literature. The results highlight the integration of the improved fuzzy AHP and the fuzzy COPRAS as a precise tool and provide effective multi-attribute decision-making for evaluating the machine tool in the uncertain environment.

Job Grading Standard for Machine Tool Operator, WG-3431.

Science.gov (United States)

Civil Service Commission, Washington, DC. Bureau of Policies and Standards.

The standard covers nonsupervisory work involved in the set up, adjustment, and operation of conventional machine tools to perform machining operations in the manufacture and repair of castings, forgings, or parts from raw stock made of various metals, metal alloys, and other materials. A general description of the job at both the WG-8 and WG-9…

Identification of Technological Parameters of Ni-Alloys When Machining by Monolithic Ceramic Milling Tool

Science.gov (United States)

Czán, Andrej; Kubala, Ondrej; Danis, Igor; Czánová, Tatiana; Holubják, Jozef; Mikloš, Matej

2017-12-01

The ever-increasing production and the usage of hard-to-machine progressive materials are the main cause of continual finding of new ways and methods of machining. One of these ways is the ceramic milling tool, which combines the pros of conventional ceramic cutting materials and pros of conventional coating steel-based insert. These properties allow to improve cutting conditions and so increase the productivity with preserved quality known from conventional tools usage. In this paper, there is made the identification of properties and possibilities of this tool when machining of hard-to-machine materials such as nickel alloys using in airplanes engines. This article is focused on the analysis and evaluation ordinary technological parameters and surface quality, mainly roughness of surface and quality of machined surface and tool wearing.

Robotic edge machining using elastic abrasive tool

Science.gov (United States)

Sidorova, A. V.; Semyonov, E. N.; Belomestnykh, A. S.

2018-03-01

The article describes a robotic center designed for automation of finishing operations, and analyzes technological aspects of an elastic abrasive tool applied for edge machining. Based on the experimental studies, practical recommendations on the application of the robotic center for finishing operations were developed.

Tool set for distributed real-time machine control

Science.gov (United States)

Carrott, Andrew J.; Wright, Christopher D.; West, Andrew A.; Harrison, Robert; Weston, Richard H.

1997-01-01

Demands for increased control capabilities require next generation manufacturing machines to comprise intelligent building elements, physically located at the point where the control functionality is required. Networks of modular intelligent controllers are increasingly designed into manufacturing machines and usable standards are slowly emerging. To implement a control system using off-the-shelf intelligent devices from multi-vendor sources requires a number of well defined activities, including (a) the specification and selection of interoperable control system components, (b) device independent application programming and (c) device configuration, management, monitoring and control. This paper briefly discusses the support for the above machine lifecycle activities through the development of an integrated computing environment populated with an extendable software toolset. The toolset supports machine builder activities such as initial control logic specification, logic analysis, machine modeling, mechanical verification, application programming, automatic code generation, simulation/test, version control, distributed run-time support and documentation. The environment itself consists of system management tools and a distributed object-oriented database which provides storage for the outputs from machine lifecycle activities and specific target control solutions.

Finite Element Method in Machining Processes

CERN Document Server

Markopoulos, Angelos P

2013-01-01

Finite Element Method in Machining Processes provides a concise study on the way the Finite Element Method (FEM) is used in the case of manufacturing processes, primarily in machining. The basics of this kind of modeling are detailed to create a reference that will provide guidelines for those who start to study this method now, but also for scientists already involved in FEM and want to expand their research. A discussion on FEM, formulations and techniques currently in use is followed up by machining case studies. Orthogonal cutting, oblique cutting, 3D simulations for turning and milling, grinding, and state-of-the-art topics such as high speed machining and micromachining are explained with relevant examples. This is all supported by a literature review and a reference list for further study. As FEM is a key method for researchers in the manufacturing and especially in the machining sector, Finite Element Method in Machining Processes is a key reference for students studying manufacturing processes but al...

Mathematical support for automated geometry analysis of lathe machining of oblique peakless round-nose tools

Science.gov (United States)

Filippov, A. V.; Tarasov, S. Yu; Podgornyh, O. A.; Shamarin, N. N.; Filippova, E. O.

2017-01-01

Automatization of engineering processes requires developing relevant mathematical support and a computer software. Analysis of metal cutting kinematics and tool geometry is a necessary key task at the preproduction stage. This paper is focused on developing a procedure for determining the geometry of oblique peakless round-nose tool lathe machining with the use of vector/matrix transformations. Such an approach allows integration into modern mathematical software packages in distinction to the traditional analytic description. Such an advantage is very promising for developing automated control of the preproduction process. A kinematic criterion for the applicable tool geometry has been developed from the results of this study. The effect of tool blade inclination and curvature on the geometry-dependent process parameters was evaluated.

A Design to Digitalize Hydraulic Cylinder Control of a Machine Tool ...

African Journals Online (AJOL)

Conventionally hydraulic piston - cylinder servos are actuated using analogue controls for machine tool axis drives. In this paper a design of the axis control system of an NC milling machine which employs a small stepping motor to digitally actuated hydraulic piston - cylinder servo drives existing on the machines Y-axis is ...

Optimizing the way kinematical feed chains with great distance between slides are chosen for CNC machine tools

Science.gov (United States)

Lucian, P.; Gheorghe, S.

2017-08-01

This paper presents a new method, based on FRISCO formula, for optimizing the choice of the best control system for kinematical feed chains with great distance between slides used in computer numerical controlled machine tools. Such machines are usually, but not limited to, used for machining large and complex parts (mostly in the aviation industry) or complex casting molds. For such machine tools the kinematic feed chains are arranged in a dual-parallel drive structure that allows the mobile element to be moved by the two kinematical branches and their related control systems. Such an arrangement allows for high speed and high rigidity (a critical requirement for precision machining) during the machining process. A significant issue for such an arrangement it’s the ability of the two parallel control systems to follow the same trajectory accurately in order to address this issue it is necessary to achieve synchronous motion control for the two kinematical branches ensuring that the correct perpendicular position it’s kept by the mobile element during its motion on the two slides.

Intellectual Control System of Processing on CNC Machines

OpenAIRE

Nekrasov, R. Y.; Lasukov, Aleksandr Aleksandrovich; Starikov, A. I.; Soloviev, I. V.; Bekareva, O. V.

2016-01-01

Scientific and technical progress makes great demands for quality of engineering production. The priority is to ensure metalworking equipment with required dimensional accuracy during the entire period of operation at minimum manufacturing costs. In article considered the problem of increasing of accuracy of processing products on CNC. The authors offers a solution to the problem by providing compensating adjustment in the trajectory of the cutting tool and machining mode. The necessity of cr...

Modelling and Development of a High Performance Milling Process with Monolithic Cutting Tools

International Nuclear Information System (INIS)

Ozturk, E.; Taylor, C. M.; Turner, S.; Devey, M.

2011-01-01

Critical aerospace components usually require difficult to machine workpiece materials like nickel based alloys. Moreover; there is a pressing need to maximize the productivity of machining operations. This need can be satisfied by selection of higher feed velocity, axial and radial depths. But there may be several problems during machining in this case. Due to high cutting speeds in high performance machining, the tool life may be unacceptably low. If magnitudes of cutting forces are high, out of tolerance static form errors may result; moreover in the extreme cases, the cutting tool may break apart. Forced vibrations may deteriorate the surface quality. Chatter vibrations may develop if the selected parameters result in instability. In this study, in order to deal with the tool life issue, several experimental cuts are made with different tool geometries, and the best combination in terms of tool life is selected. A force model is developed and the results of the force model are verified by experimental results. The force model is used in predicting the effect of process parameters on cutting forces. In order to account for the other concerns such as static form errors, forced and chatter vibrations, additional process models are currently under development.

The Engineering Of PCB Processing Machine

International Nuclear Information System (INIS)

Handoyo, Demon; Satmoko, Ari; T, Sapta; Heru, G. B.

2001-01-01

The engineering of PCB processing machine had been done. Purposes of the engineering of PCB processing machine are used to process PCB and to get the data's of characteristic of PCB processing. Further, these data's will be used as setting point when processing of PCB is done with manual and automatic control. The method of processing of PCB are inserting and pulling of the PCB rack to and from Ferro chlorite using electrical motor to corrosive Cu shield parts witch is not used. The experiment have result that the characteristic of operation of PCB processing machine as we hope when designing

Small machine tools for small workpieces final report of the DFG priority program 1476

CERN Document Server

Sanders, Adam

2017-01-01

This contributed volume presents the research results of the program “Small machine tools for small work pieces” (SPP 1476), funded by the German Research Society (DFG). The book contains the final report of the priority program, presenting novel approached for size-adapted, reconfigurable micro machine tools. The target audience primarily comprises research experts and practitioners in the field of micro machine tools, but the book may also be beneficial for graduate students.

One approach to determining the optimal coefficient of slenderness scraping and tool materials when processing on a lathe for known machine

Directory of Open Access Journals (Sweden)

Pejović Branko B.

2014-01-01

Full Text Available Starting from the expression for the thrust in the field of full utilization cross section scrapings and tool life, an expression is derived for the maximum required thrust of universal machine. Then, using a working diagram the analysis of the main features of the simultaneous utilization of machines was performed and determined the optimal area of its utilization for given optimal diameter of treatment. Based on this, the well-known machine using its structural details and the corresponding function workability, derived relations to determine the optimal coefficient slenderness of scrapings suitable for practical use. In this case we think that is known critical material for work piece. Considering the critical and authoritative material of the work piece, based on the expression for the cutting speed was determined by the characteristic constant workability as the basis for establishing optimum tool material which is adequate for optimum regime. Both obtained relation can be considered as general model that can be applied directly to solving setting problems. Also, given the possibilities of practical application of the presented relations, especially in the case of other typical kinds of treatment. Finally, the model is verified on a one calculation example from practice for a Specific machine tool, where certain important characteristics of the optimal treatment are defined.

Machinability of lithium disilicate glass ceramic in in vitro dental diamond bur adjusting process.

Science.gov (United States)

Song, Xiao-Fei; Ren, Hai-Tao; Yin, Ling

2016-01-01

Esthetic high-strength lithium disilicate glass ceramics (LDGC) are used for monolithic crowns and bridges produced in dental CAD/CAM and oral adjusting processes, which machinability affects the restorative quality. A machinability study has been made in the simulated oral clinical machining of LDGC with a dental handpiece and diamond burs, regarding the diamond tool wear and chip control, machining forces and energy, surface finish and integrity. Machining forces, speeds and energy in in vitro dental adjusting of LDGC were measured by a high-speed data acquisition and force sensor system. Machined LDGC surfaces were assessed using three-dimensional non-contact chromatic confocal optical profilometry and scanning electron microscopy (SEM). Diamond bur morphology and LDGC chip shapes were also examined using SEM. Minimum tool wear but significant LDGC chip accumulations were found. Machining forces and energy significantly depended on machining conditions (pceramics (pceramics (pceramics. Surface roughness for machined LDGC was comparable for other glass ceramics. The removal mechanisms of LDGC were dominated by penetration-induced brittle fracture and shear-induced plastic deformation. Unlike most other glass ceramics, distinct intergranular and transgranular fractures of lithium disilicate crystals were found in LDGC. This research provides the fundamental data for dental clinicians on the machinability of LDGC in intraoral adjustments. Copyright © 2015 Elsevier Ltd. All rights reserved.

The Effect of Machining Conditions on the Forces in the Process of Roller Brush Machining

Directory of Open Access Journals (Sweden)

Jakub Matuszak

2017-12-01

Full Text Available Because of its advantages, brushing processing has many uses. The main ones include the removal of corrosion products, surface cleaning, deburring and shaping the properties of the surface layer. The intensity of these processes depends on the degree of impact of brush fibres on the work surface. In the case of tools, in which the resilient fibres are the working elements, forces in the brushing process, apart from the machining parameters, depend on the characteristics and overall dimensions of individual fibres. The paper presents the results of studies of the influence of technological parameters and type of fibres on the radial force in the brushing process.

Modeling and simulation of the fluid flow in wire electrochemical machining with rotating tool (wire ECM)

Science.gov (United States)

Klocke, F.; Herrig, T.; Zeis, M.; Klink, A.

2017-10-01

Combining the working principle of electrochemical machining (ECM) with a universal rotating tool, like a wire, could manage lots of challenges of the classical ECM sinking process. Such a wire-ECM process could be able to machine flexible and efficient 2.5-dimensional geometries like fir tree slots in turbine discs. Nowadays, established manufacturing technologies for slotting turbine discs are broaching and wire electrical discharge machining (wire EDM). Nevertheless, high requirements on surface integrity of turbine parts need cost intensive process development and - in case of wire-EDM - trim cuts to reduce the heat affected rim zone. Due to the process specific advantages, ECM is an attractive alternative manufacturing technology and is getting more and more relevant for sinking applications within the last few years. But ECM is also opposed with high costs for process development and complex electrolyte flow devices. In the past, few studies dealt with the development of a wire ECM process to meet these challenges. However, previous concepts of wire ECM were only suitable for micro machining applications. Due to insufficient flushing concepts the application of the process for machining macro geometries failed. Therefore, this paper presents the modeling and simulation of a new flushing approach for process assessment. The suitability of a rotating structured wire electrode in combination with an axial flushing for electrodes with high aspect ratios is investigated and discussed.

Influence of Workpiece Material on Tool Wear Performance and Tribofilm Formation in Machining Hardened Steel

Directory of Open Access Journals (Sweden)

Junfeng Yuan

2016-04-01

Full Text Available In addition to the bulk properties of a workpiece material, characteristics of the tribofilms formed as a result of workpiece material mass transfer to the friction surface play a significant role in friction control. This is especially true in cutting of hardened materials, where it is very difficult to use liquid based lubricants. To better understand wear performance and the formation of beneficial tribofilms, this study presents an assessment of uncoated mixed alumina ceramic tools (Al2O3+TiC in the turning of two grades of steel, AISI T1 and AISI D2. Both workpiece materials were hardened to 59 HRC then machined under identical cutting conditions. Comprehensive characterization of the resulting wear patterns and the tribofilms formed at the tool/workpiece interface were made using X-ray Photoelectron Spectroscopy and Scanning Electron Microscopy. Metallographic studies on the workpiece material were performed before the machining process and the surface integrity of the machined part was investigated after machining. Tool life was 23% higher when turning D2 than T1. This improvement in cutting tool life and wear behaviour was attributed to a difference in: (1 tribofilm generation on the friction surface and (2 the amount and distribution of carbide phases in the workpiece materials. The results show that wear performance depends both on properties of the workpiece material and characteristics of the tribofilms formed on the friction surface.

Complex Ornament Machining Process on a CNC Router

Directory of Open Access Journals (Sweden)

Camelia COŞEREANU

2014-03-01

Full Text Available The paper investigates the CNC routering possibilities for three species of wood, namely ash (Fraxinus Excelsior, lime wood (Tilia cordata and fir wood (Abies Alba, in order to obtain right surfaces of Art Nouveau sculptured ornaments. Given the complexity of the CNC tool path for getting wavy shapes of Art Nouveau decorations, the choice of processing parameters for each processed species of wood requires a laborious research work to correlate these parameters. Two Art Nouveau ornaments are proposed for the investigation. They are CNC routered using two types of cutting tools. The processed parameters namely the spindle speed, feed speed and depth of cut were the three variables of the machining process for the three species of wood, which were combined so, to provide good surface finish as a quality attribute. There were totally forty six variants of combining the processing parameter which were applied for CNC routering the samples made of the three species of wood. At the end, an optimum combination of the processed parameters is recommended for each species of wood.

Intellectual Control System of Processing on CNC Machines

Science.gov (United States)

Nekrasov, R. Y.; Lasukov, A. A.; Starikov, A. I.; Soloviev, I. V.; Bekareva, O. V.

2016-04-01

Scientific and technical progress makes great demands for quality of engineering production. The priority is to ensure metalworking equipment with required dimensional accuracy during the entire period of operation at minimum manufacturing costs. In article considered the problem of increasing of accuracy of processing products on CNC. The authors offers a solution to the problem by providing compensating adjustment in the trajectory of the cutting tool and machining mode. The necessity of creation of mathematical models of processes behavior in an automated technological system operations (OATS). Based on the research, authors have proposed a generalized diagram of diagnosis and input operative correction and approximate mathematical models of individual processes of diagnosis.

Lathe tool bit and holder for machining fiberglass materials

Science.gov (United States)

Winn, L. E. (Inventor)

1972-01-01

A lathe tool and holder combination for machining resin impregnated fiberglass cloth laminates is described. The tool holder and tool bit combination is designed to accommodate a conventional carbide-tipped, round shank router bit as the cutting medium, and provides an infinite number of cutting angles in order to produce a true and smooth surface in the fiberglass material workpiece with every pass of the tool bit. The technique utilizes damaged router bits which ordinarily would be discarded.

CONTROL SYSTEM EVALUATION AND IMPLEMENTATION FOR THE ABRASIVE MACHINING PROCESS ON WOOD

Directory of Open Access Journals (Sweden)

Stephen Jackson

2011-06-01

Full Text Available Continuous process improvement and automation have proven to be powerful tools for the wood processing industries in order to obtain better final product quality and thus increase profits. Abrasive machining represents an important and relevant process in the manufacturing and processing of wood products, which also implies high cost of materials and labor; therefore, special attention to this process is necessary. The objective of this work was to evaluate and demonstrate a process control system for use in the abrasive machining of wood and wood-based products. A control system was created on LabView® to integrate the monitoring process and the actions required, depending on the abrasive machining process conditions. The system acquires information from the optical sensor to detect loading and activate the cleaning system. The system continuously monitors the condition of the abrasive belt (tool wear by using an acoustic emission sensor and alerts the operator of the status of the belt (green, yellow, and red lights indicating satisfactory, medium, and poor belt condition. The system also incorporates an additional safety device, which helps prevent permanent damage to the belt, equipment, or workpiece by alerting the operator when an excessive temperature has been reached. The process control system proved that automation permits enhancement in the consistency of the belt cleaning technique by the elimination of the human errors. Furthermore, this improvement also affects the cost by extending the life of the belt, which reduces setup time, belt cost, operation cost, as well as others.

Analysis of the application of poly-nanocrystalline diamond tools for ultra precision machining of steel with ultrasonic assistance

Science.gov (United States)

Doetz, M.; Dambon, O.; Klocke, F.; Bulla, B.; Schottka, K.; Robertson, D. J.

2017-10-01

Ultra-precision diamond turning enables the manufacturing of parts with mirror-like surfaces and highest form accuracies out of non-ferrous, a few crystalline and plastic materials. Furthermore, an ultrasonic assistance has the ability to push these boundaries and enables the machining of materials like steel, which is not possible in a conventional way due to the excessive tool wear caused by the affinity of carbon to iron. Usually monocrystalline diamonds tools are applied due to their unsurpassed cutting edge properties. New cutting tool material developments have shown that it is possible to produce tools made of nano-polycrystalline diamonds with cutting edges equivalent to monocrystalline diamonds. In nano-polycrystalline diamonds ultra-fine grains of a few tens of nanometers are firmly and directly bonded together creating an unisotropic structure. The properties of this material are described to be isotropic, harder and tougher than those of the monocrystalline diamonds, which are unisotropic. This publication will present machining results from the newest investigations of the process potential of this new polycrystalline cutting material. In order to provide a baseline with which to characterize the cutting material cutting experiments on different conventional machinable materials like Cooper or Aluminum are performed. The results provide information on the roughness and the topography of the surface focusing on the comparison to the results while machining with monocrystalline diamond. Furthermore, the cutting material is tested in machining steel with ultrasonic assistance with a focus on tool life time and surface roughness. An outlook on the machinability of other materials will be given.

Analysis and prediction of dimensions and cost of laser micro-machining internal channel fabrication process

Directory of Open Access Journals (Sweden)

Brabazon D.

2010-06-01

Full Text Available This paper presents the utilisation of Response Surface Methodology (RSM as the prediction tool for the laser micro-machining process. Laser internal microchannels machined using pulsed Nd:YVO4 laser in polycarbonate were investigated. The experiments were carried out according to 33 factorial Design of Experiment (DoE. In this work the three input process set as control parameters were laser power, P; pulse repetition frequency, PRF; and sample translation speed, U. Measured responses were the channel width and the micro-machining operating cost per metre of produced microchannels. The responses were sufficiently predicted within the set micro-machining parameters limits. Two factorial interaction (2FI and quadratic polynomial regression equations for both responses were constructed. It is proposed that the developed prediction equations can be used to find locally optimal micro-machining process parameters under experimental and operational conditions.

Effect of dispersion hardening process on machinability of EN AB-AlSi9Mg silumin

Directory of Open Access Journals (Sweden)

J. Pezda

2009-07-01

Full Text Available Nowadays, aluminum and its alloys found their application in any type design structures, many’s the time being an alternative for a ferrous alloys due to their technological properties like low density, ductility, high strength and good corrosion resistance. Among different fabrication processes the machining stage has a significant importance considering fabrication costs and processing time. Therefore, optimization of the process parameters that affect machining stages such as, tool wear, alloy machinability, machining effort and cutting speed becomes an area of constant development and study. To the most important factors having impact on machining properties belong: initial condition of machined material, which depends on a method and conditions of material preparation. In the paper are presented initial tests of machining properties of the EN AB-AlSi9Mg silumin subjected to heat treatment. Machinability measurements of the investigated alloy were performed with use of reboring method with constant force of feed. It enabled determination of an effect of heat treatment on machining properties of the investigated alloy. A further investigation shall be connected with determination of optimal parameters of solutionizing and ageing treatments in aspects of improvement of both mechanical properties and its machinability.

A comparative machining study of diamond-coated tools made by ...

Indian Academy of Sciences (India)

R. Narasimhan (Krishtel eMaging) 1461 1996 Oct 15 13:05:22

adherent diamond films on WC–CO tools by all three deposition models and has allowed completion of the ..... cesses with hard turning machining will affect future demand for PCBN (and cBN coated) tools. 6. ... Business Communication Co.

Bayesian networks modeling for thermal error of numerical control machine tools

Institute of Scientific and Technical Information of China (English)

Xin-hua YAO; Jian-zhong FU; Zi-chen CHEN

2008-01-01

The interaction between the heat source location,its intensity,thermal expansion coefficient,the machine system configuration and the running environment creates complex thermal behavior of a machine tool,and also makes thermal error prediction difficult.To address this issue,a novel prediction method for machine tool thermal error based on Bayesian networks (BNs) was presented.The method described causal relationships of factors inducing thermal deformation by graph theory and estimated the thermal error by Bayesian statistical techniques.Due to the effective combination of domain knowledge and sampled data,the BN method could adapt to the change of running state of machine,and obtain satisfactory prediction accuracy.Ex-periments on spindle thermal deformation were conducted to evaluate the modeling performance.Experimental results indicate that the BN method performs far better than the least squares(LS)analysis in terms of modeling estimation accuracy.

A study on the effect of tool electrode thickness on MRR, and TWR in electrical discharge turning process

Science.gov (United States)

Gohil, Vikas; Puri, YM

2018-04-01

Turning by electrical discharge machining (EDM) is an emerging area of research. Generally, wire-EDM is used in EDM turning because it is not concerned with electrode tooling cost. In EDM turning wire electrode leaves cusps on the machined surface because of its small diameters and wire breakage which greatly affect the surface finish of the machined part. Moreover, one of the limitations of the process is low machining speed as compared to constituent processes. In this study, conventional EDM was employed for turning purpose in order to generate free-form cylindrical geometries on difficult-to-cut materials. Therefore, a specially designed turning spindle was mounted on a conventional die-sinking EDM machine to rotate the work piece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating work piece; thus, a mirror image of the tool is formed on the circumference of the work piece. In this way, an axisymmetric work piece can be made with small tools. The developed process is termed as the electrical discharge turning (EDT). In the experiments, the effect of machining parameters, such as pulse-on time, peak current, gap voltage and tool thickness on the MRR, and TWR were investigated and practical machining was carried out by turning of SS-304 stainless steel work piece.

Design of a novel parallel reconfigurable machine tool

CSIR Research Space (South Africa)

Modungwa, D

2008-06-01

Full Text Available of meeting the demands for high mechanical dexterity adaptation as well as high stiffness necessary for mould and die re-conditioning. This paper presents, the design of parallel reconfigurable machine tool (PRMT) based on both application...

Study of Cutting Edge Temperature and Cutting Force of End Mill Tool in High Speed Machining

Directory of Open Access Journals (Sweden)

Kiprawi Mohammad Ashaari

2017-01-01

Full Text Available A wear of cutting tools during machining process is unavoidable due to the presence of frictional forces during removing process of unwanted material of workpiece. It is unavoidable but can be controlled at slower rate if the cutting speed is fixed at certain point in order to achieve optimum cutting conditions. The wear of cutting tools is closely related with the thermal deformations that occurred between the frictional contact point of cutting edge of cutting tool and workpiece. This research paper is focused on determinations of relationship among cutting temperature, cutting speed, cutting forces and radial depth of cutting parameters. The cutting temperature is determined by using the Indium Arsenide (InAs and Indium Antimonide (InSb photocells to measure infrared radiation that are emitted from cutting tools and cutting forces is determined by using dynamometer. The high speed machining process is done by end milling the outer surface of carbon steel. The signal from the photocell is digitally visualized in the digital oscilloscope. Based on the results, the cutting temperature increased as the radial depth and cutting speed increased. The cutting forces increased when radial depth increased but decreased when cutting speed is increased. The setup for calibration and discussion of the experiment will be explained in this paper.

Precise gouging-free tool orientations for 5-axis CNC machining

KAUST Repository

Kim, Yong-Joon

2014-08-19

We present a precise approach to the generation of optimized collision-free and gouging-free tool paths for 5-axis CNC machining of freeform NURBS surfaces using flat-end and rounded-end (bull nose) tools having cylindrical shank. To achieve high approximation quality, we employ analysis of hyper-osculating circles (HOCs) (Wang et al., 1993a,b), that have third order contact with the target surface, and lead to a locally collision-free configuration between the tool and the target surface. At locations where an HOC is not possible, we aim at a double tangential contact among the tool and the target surface, and use it as a bridge between the feasible HOC tool paths. We formulate all such possible two-contact configurations as systems of algebraic constraints and solve them. For all feasible HOCs and two-contact configurations, we perform a global optimization to find the tool path that maximizes the approximation quality of the machining, while being gouge-free and possibly satisfying constraints on the tool tilt and the tool acceleration. We demonstrate the effectiveness of our approach via several experimental results.

Precise gouging-free tool orientations for 5-axis CNC machining

KAUST Repository

Kim, Yong-Joon; Elber, Gershon; Barton, Michael; Pottmann, Helmut

2014-01-01

We present a precise approach to the generation of optimized collision-free and gouging-free tool paths for 5-axis CNC machining of freeform NURBS surfaces using flat-end and rounded-end (bull nose) tools having cylindrical shank. To achieve high approximation quality, we employ analysis of hyper-osculating circles (HOCs) (Wang et al., 1993a,b), that have third order contact with the target surface, and lead to a locally collision-free configuration between the tool and the target surface. At locations where an HOC is not possible, we aim at a double tangential contact among the tool and the target surface, and use it as a bridge between the feasible HOC tool paths. We formulate all such possible two-contact configurations as systems of algebraic constraints and solve them. For all feasible HOCs and two-contact configurations, we perform a global optimization to find the tool path that maximizes the approximation quality of the machining, while being gouge-free and possibly satisfying constraints on the tool tilt and the tool acceleration. We demonstrate the effectiveness of our approach via several experimental results.

CONTROL SYSTEM EVALUATION AND IMPLEMENTATION FOR THE ABRASIVE MACHINING PROCESS ON WOOD

OpenAIRE

Stephen Jackson; Richard Lemaster; Daniel E. Saloni

2011-01-01

Continuous process improvement and automation have proven to be powerful tools for the wood processing industries in order to obtain better final product quality and thus increase profits. Abrasive machining represents an important and relevant process in the manufacturing and processing of wood products, which also implies high cost of materials and labor; therefore, special attention to this process is necessary. The objective of this work was to evaluate and demonstrate a process control s...

Assessing thermally induced errors of machine tools by 3D length measurements

NARCIS (Netherlands)

Florussen, G.H.J.; Delbressine, F.L.M.; Schellekens, P.H.J.

2003-01-01

A new measurement technique is proposed for the assessment of thermally induced errors of machine tools. The basic idea is to measure changes of length by a telescopic double ball bar (TDEB) at multiple locations in the machine's workspace while the machine is thermally excited. In addition thermal

Formability behavior studies on CP-Al sheets processed through the helical tool path of incremental forming process

Science.gov (United States)

Markanday, H.; Nagarajan, D.

2018-02-01

Incremental sheet forming (ISF) is a novel die-less sheet metal forming process, which can produce components directly from the CAD geometry using a CNC milling machine at less production time and cost. The formability of the sheet material used is greatly affected by the process parameters involved and tool path adopted, and the present study is aimed to investigate the influence of different process parameter values using the helical tool path strategy on the formability of a commercial pure Al and to achieve maximum formability in the material. ISF experiments for producing an 80 mm diameter axisymmetric dome were carried out on 2 mm thickness commercially pure Al sheets for different tool speeds and feed rates in a CNC milling machine with a 10 mm hemispherical forming tool. The obtained parts were analyzed for springback, amount of thinning and maximum forming depth. The results showed that when the tool speed was increased by keeping the feed rate constant, the forming depth and thinning were also increased. On contrary, when the feed rate was increased by keeping the tool speed constant, the forming depth and thinning were decreased. Springback was found to be higher when the feed rate was increased rather than the tool speed was increased.

Servo scanning 3D micro EDM for array micro cavities using on-machine fabricated tool electrodes

Science.gov (United States)

Tong, Hao; Li, Yong; Zhang, Long

2018-02-01

Array micro cavities are useful in many fields including in micro molds, optical devices, biochips and so on. Array servo scanning micro electro discharge machining (EDM), using array micro electrodes with simple cross-sectional shape, has the advantage of machining complex 3D micro cavities in batches. In this paper, the machining errors caused by offline-fabricated array micro electrodes are analyzed in particular, and then a machining process of array servo scanning micro EDM is proposed by using on-machine fabricated array micro electrodes. The array micro electrodes are fabricated on-machine by combined procedures including wire electro discharge grinding, array reverse copying and electrode end trimming. Nine-array tool electrodes with Φ80 µm diameter and 600 µm length are obtained. Furthermore, the proposed process is verified by several machining experiments for achieving nine-array hexagonal micro cavities with top side length of 300 µm, bottom side length of 150 µm, and depth of 112 µm or 120 µm. In the experiments, a chip hump accumulates on the electrode tips like the built-up edge in mechanical machining under the conditions of brass workpieces, copper electrodes and the dielectric of deionized water. The accumulated hump can be avoided by replacing the water dielectric by an oil dielectric.

Limitations Of The Current State Space Modelling Approach In Multistage Machining Processes Due To Operation Variations

Science.gov (United States)

Abellán-Nebot, J. V.; Liu, J.; Romero, F.

2009-11-01

The State Space modelling approach has been recently proposed as an engineering-driven technique for part quality prediction in Multistage Machining Processes (MMP). Current State Space models incorporate fixture and datum variations in the multi-stage variation propagation, without explicitly considering common operation variations such as machine-tool thermal distortions, cutting-tool wear, cutting-tool deflections, etc. This paper shows the limitations of the current State Space model through an experimental case study where the effect of the spindle thermal expansion, cutting-tool flank wear and locator errors are introduced. The paper also discusses the extension of the current State Space model to include operation variations and its potential benefits.

Investigation of tool engagement and cutting performance in machining a pocket

Science.gov (United States)

Adesta, E. Y. T.; Hamidon, R.; Riza, M.; Alrashidi, R. F. F. A.; Alazemi, A. F. F. S.

2018-01-01

This study investigates the variation of tool engagement for different profile of cutting. In addition, behavior of cutting force and cutting temperature for different tool engagements for machining a pocket also been explored. Initially, simple tool engagement models were developed for peripheral and slot cutting for different types of corner. Based on these models, the tool engagements for contour and zig zag tool path strategies for a rectangular shape pocket with dimension 80 mm x 60 mm were analyzed. Experiments were conducted to investigate the effect of tool engagements on cutting force and cutting temperature for the machining of a pocket of AISI H13 material. The cutting parameters used were 150m/min cutting speed, 0.05mm/tooth feed, and 0.1mm depth of cut. Based on the results obtained, the changes of cutting force and cutting temperature performance there exist a relationship between cutting force, cutting temperature and tool engagement. A higher cutting force and cutting temperature is obtained when the cutting tool goes through up milling and when the cutting tool makes a full engagement with the workpiece.

On-line Cutting Tool Condition Monitoring in Machining Processes Using Artificial Intelligence

OpenAIRE

Vallejo, Antonio J.; Morales-Menéndez, Rub&#;n; Alique, J.R.

2008-01-01

This chapter presented new ideas for monitoring and diagnosis of the cutting tool condition with two different algorithms for pattern recognition: HMM, and ANN. The monitoring and diagnosis system was implemented for peripheral milling process in HSM, where several Aluminium alloys and cutting tools were used. The flank wear (VB) was selected as the criterion to evaluate the tool's life and four cutting tool conditions were defined to be recognized: New, half new, half worn, and worn conditio...

Influence of Cooling Lubricants on the Surface Roughness and Energy Efficiency of the Cutting Machine Tools

Directory of Open Access Journals (Sweden)

Jersák J.

2017-08-01

Full Text Available The Technical University of Liberec and Brandenburg University of Technology Cottbus-Senftenberg investigated the influence of cooling lubricants on the surface roughness and energy efficiency of cutting machine tools. After summarizing the achieved experimental results, the authors conclude that cooling lubricants extensively influence the cutting temperature, cutting forces and energy consumption. Also, it is recognizable that cooling lubricants affect the cutting tools lifetime and the workpiece surface quality as well. Furthermore, costs of these cooling lubricants and the related environmental burden need to be considered. A current trend is to reduce the amount of lubricants that are used, e.g., when the Minimum Quantity Lubrication (MQL technique is applied. The lubricant or process liquid is thereby transported by the compressed air in the form of an aerosol to the contact area between the tool and workpiece. The cutting process was monitored during testing by the three following techniques: lubricant-free cutting, cutting with the use of a lubricant with the MQL technique, and only utilizing finish-turning and finish-face milling. The research allowed the authors to monitor the cutting power and mark the achieved surface quality in relation to the electrical power consumption of the cutting machine. In conclusions, the coherence between energy efficiency of the cutting machine and the workpiece surface quality regarding the used cooling lubricant is described.

Gaussian processes for machine learning.

Science.gov (United States)

Seeger, Matthias

2004-04-01

Gaussian processes (GPs) are natural generalisations of multivariate Gaussian random variables to infinite (countably or continuous) index sets. GPs have been applied in a large number of fields to a diverse range of ends, and very many deep theoretical analyses of various properties are available. This paper gives an introduction to Gaussian processes on a fairly elementary level with special emphasis on characteristics relevant in machine learning. It draws explicit connections to branches such as spline smoothing models and support vector machines in which similar ideas have been investigated. Gaussian process models are routinely used to solve hard machine learning problems. They are attractive because of their flexible non-parametric nature and computational simplicity. Treated within a Bayesian framework, very powerful statistical methods can be implemented which offer valid estimates of uncertainties in our predictions and generic model selection procedures cast as nonlinear optimization problems. Their main drawback of heavy computational scaling has recently been alleviated by the introduction of generic sparse approximations.13,78,31 The mathematical literature on GPs is large and often uses deep concepts which are not required to fully understand most machine learning applications. In this tutorial paper, we aim to present characteristics of GPs relevant to machine learning and to show up precise connections to other "kernel machines" popular in the community. Our focus is on a simple presentation, but references to more detailed sources are provided.

Investigations on the performance of ultrasonic drilling process with special reference to precision machining of advanced ceramics

International Nuclear Information System (INIS)

Adithan, M.; Laroiya, S.C.

1997-01-01

Advanced ceramics are assuming an important role in modern industrial technology. The applications and advantages of using advanced ceramics are many. There are several reasons why we should go in for machining of advanced ceramics after their compacting and sintering. These are discussed in this paper. However, precision machining of advanced ceramics must be economical. Critical technological issues to be addressed in cost effective machining of ceramics include design of machine tools, tooling arrangements, improved yield and precision, relationship of part dimensions and finish specifications to functional performance, and on-line inspection. Considering the above ultrasonic drilling is an important process used for the precision machining of advanced ceramics. Extensive studies on tool wear occurring in the ultrasonic machining of advanced ceramics have been carried out. In addition, production accuracy of holes drilled, surface finish obtained and surface integrity aspects in the machining of advanced ceramics have also been investigated. Some specific findings with reference to surface integrity are: a) there were no cracks or micro-cracks developed during or after ultrasonic machining of advanced ceramics, b) while machining Hexoloy alpha silicon carbide a recast layer is formed as a result of ultrasonic machining. This is attributed to the viscous heating resulting from high energy impacts during ultrasonic machining. While machining all other types of ceramics no such formation of recast layer was observed, and , c) there is no change in the microstructure of the advanced ceramics as a result of ultrasonic machining

TU-FG-201-05: Varian MPC as a Statistical Process Control Tool

International Nuclear Information System (INIS)

Carver, A; Rowbottom, C

2016-01-01

Purpose: Quality assurance in radiotherapy requires the measurement of various machine parameters to ensure they remain within permitted values over time. In Truebeam release 2.0 the Machine Performance Check (MPC) was released allowing beam output and machine axis movements to be assessed in a single test. We aim to evaluate the Varian Machine Performance Check (MPC) as a tool for Statistical Process Control (SPC). Methods: Varian’s MPC tool was used on three Truebeam and one EDGE linac for a period of approximately one year. MPC was commissioned against independent systems. After this period the data were reviewed to determine whether or not the MPC was useful as a process control tool. Analyses on individual tests were analysed using Shewhart control plots, using Matlab for analysis. Principal component analysis was used to determine if a multivariate model was of any benefit in analysing the data. Results: Control charts were found to be useful to detect beam output changes, worn T-nuts and jaw calibration issues. Upper and lower control limits were defined at the 95% level. Multivariate SPC was performed using Principal Component Analysis. We found little evidence of clustering beyond that which might be naively expected such as beam uniformity and beam output. Whilst this makes multivariate analysis of little use it suggests that each test is giving independent information. Conclusion: The variety of independent parameters tested in MPC makes it a sensitive tool for routine machine QA. We have determined that using control charts in our QA programme would rapidly detect changes in machine performance. The use of control charts allows large quantities of tests to be performed on all linacs without visual inspection of all results. The use of control limits alerts users when data are inconsistent with previous measurements before they become out of specification. A. Carver has received a speaker’s honorarium from Varian

Appendix to rationally designing of machine tools for example of universal lathe

Directory of Open Access Journals (Sweden)

Pejović Branko B.

2015-01-01

Full Text Available In this paper, for the universal machine tool for turning and function of the thrust of the cutting speed for blasting area efficiency and stability of the tool and sectional filings. These dependencies were used to determine the main characteristics of the optimal and maximum operating power equipment. Based on this, an analysis of the increase in operating power equipment typical cases in order to adapt to the new needs of exploitation properties and improve productivity. Using the previous analysis, it was determined the best solution in terms of the rational design of machines, by ensuring the simultaneous use of the main features on the basis of increase in speed with the use of tools and higher stability. In order to better display problems, an analysis of the appropriate diagrams P-V and V-D. On a typical example of the manufacturing practice at the end of the work, we demonstrate improvement of exploitation characteristics of a universal machine through appropriate calculations in terms of new needs adjustment feature, where it is expected that the reconstruction of the smallest machines.

Report on tool transfer and alignment methods

DEFF Research Database (Denmark)

Tosello, Guido; Gasparin, Stefania; De Grave, Arnaud

2010-01-01

In the last few years, research work has been carried out regarding the feature miniaturization and tooling performance achievable with specific process chains combining different micro machining processes. On the other hand, technologies, strategies and tool design rules in order to optimize the...... process chain for tooling (i.e. hybrid tooling) based on the combination of micro milling and micro electrical discharge machining (EDM) milling, both at machine tool and at machining technology levels....

Using the modern CNC controllers capabilities for estimating the machining forces during the milling process

Directory of Open Access Journals (Sweden)

Breaz Radu-Eugen

2017-01-01

Full Text Available Machining forces can nowadays be measured by using 3D dynamometers, which are usually very expensive devices and hardly available for most of the CNC machine-tools users. On the other hand, modern CNC controllers have nowadays the ability to display and save many outputs within the machining process, such as the currents or even the torques at the shaft's level for the feed motors on each axis. These outputs can be used for estimating the machining forces, but it is to be noticed that the above-mentioned currents and torques are proportional with the overall resistant forces, which includes not only technological forces, but also friction, inertial and pre-tensioning forces. This paper presents an approach for estimating the machining forces during a milling process, by using the outputs stored in the CNC controller and separating the effects of technological forces from the other forces involved in the process. The separation was made by running two sets of experiments, one set for dry-run regime and the other one for machining regime.

Coordinate measurement machines as an alignment tool

International Nuclear Information System (INIS)

Wand, B.T.

1991-03-01

In February of 1990 the Stanford Linear Accelerator Center (SLAC) purchased a LEITZ PM 12-10-6 CMM (Coordinate measurement machine). The machine is shared by the Quality Control Team and the Alignment Team. One of the alignment tasks in positioning beamline components in a particle accelerator is to define the component's magnetic centerline relative to external fiducials. This procedure, called fiducialization, is critical to the overall positioning tolerance of a magnet. It involves the definition of the magnetic center line with respect to the mechanical centerline and the transfer of the mechanical centerline to the external fiducials. To perform the latter a magnet coordinate system has to be established. This means defining an origin and the three rotation angles of the magnet. The datum definition can be done by either optical tooling techniques or with a CMM. As optical tooling measurements are very time consuming, not automated and are prone to errors, it is desirable to use the CMM fiducialization method instead. The establishment of a magnet coordinate system based on the mechanical center and the transfer to external fiducials will be discussed and presented with 2 examples from the Stanford Linear Collider (SLC). 7 figs

FINITE ELEMENT ANALYSIS OF CONCRETE FILLER INFLUENCE ON DYNAMIC RIGIDITY OF HEAVY MACHINE TOOL PORTAL

Directory of Open Access Journals (Sweden)

Yu. V. Vasilevich

2016-01-01

Full Text Available Virtual testing of portal machine tool has been carried out with the help of finite elements method (FEM. Static, modal and harmonic analyses have been made for a heavy planer. The paper reveals influence of concrete filler on machine tool dynamic flexibility. A peculiar feature of the simulation is concrete filling of a high-level transverse beam. Such approach oes look a typical one for machine-tool industry. Concrete has been considered as generalized material in two variants. It has been established that concrete application provides approximately 3-fold increase in machine tool rigidity per each coordinate. In this regard it is necessary to arrange closure of rigidity contour by filling all the cavities inside of the portal. Modal FEA makes it possible to determine that concrete increases comparatively weakly (1.3–1.4-fold frequencies of resonance modes. Frequency of the lowest mode rises only from 30.25 to 42.86 Hz. The following most active whole-machine eigenmodes have been revealed in the paper: “Portal pecking”, “Parallelogram” and “Traverse pecking”. In order to restrain the last mode it is necessary to carry out concrete filling of the traverse, in particular. Frequency-response characteristics and curves of dynamic rigidity for a spindle have been plotted for 0–150 Hz interval while using harmonic FEM. It has been determined that concrete increases dynamic machine tool rigidity by 2.5–3.5-fold. The effect is obtained even in the case when weakly damping concrete (2 % is used. This is due to distribution of vibrational energy flow along concrete and along cast iron as well. Thus energy density and vibration amplitudes must decrease. The paper shows acceptability for internal reinforcement of high-level machine tool parts (for example, portal traverses and fillers are applied for this purpose. Traverse weighting is compensated by additional torsional, shear and bending rigidity. The machine tool obtains the

Monitoring of laser material processing using machine integrated low-coherence interferometry

Science.gov (United States)

Kunze, Rouwen; König, Niels; Schmitt, Robert

2017-06-01

Laser material processing has become an indispensable tool in modern production. With the availability of high power pico- and femtosecond laser sources, laser material processing is advancing into applications, which demand for highest accuracies such as laser micro milling or laser drilling. In order to enable narrow tolerance windows, a closedloop monitoring of the geometrical properties of the processed work piece is essential for achieving a robust manufacturing process. Low coherence interferometry (LCI) is a high-precision measuring principle well-known from surface metrology. In recent years, we demonstrated successful integrations of LCI into several different laser material processing methods. Within this paper, we give an overview about the different machine integration strategies, that always aim at a complete and ideally telecentric integration of the measurement device into the existing beam path of the processing laser. Thus, highly accurate depth measurements within machine coordinates and a subsequent process control and quality assurance are possible. First products using this principle have already found its way to the market, which underlines the potential of this technology for the monitoring of laser material processing.

An open CAM system for dentistry on the basis of China-made 5-axis simultaneous contouring CNC machine tool and industrial CAM software.

Science.gov (United States)

Lu, Li; Liu, Shusheng; Shi, Shenggen; Yang, Jianzhong

2011-10-01

China-made 5-axis simultaneous contouring CNC machine tool and domestically developed industrial computer-aided manufacture (CAM) technology were used for full crown fabrication and measurement of crown accuracy, with an attempt to establish an open CAM system for dental processing and to promote the introduction of domestic dental computer-aided design (CAD)/CAM system. Commercially available scanning equipment was used to make a basic digital tooth model after preparation of crown, and CAD software that comes with the scanning device was employed to design the crown by using domestic industrial CAM software to process the crown data in order to generate a solid model for machining purpose, and then China-made 5-axis simultaneous contouring CNC machine tool was used to complete machining of the whole crown and the internal accuracy of the crown internal was measured by using 3D-MicroCT. The results showed that China-made 5-axis simultaneous contouring CNC machine tool in combination with domestic industrial CAM technology can be used for crown making and the crown was well positioned in die. The internal accuracy was successfully measured by using 3D-MicroCT. It is concluded that an open CAM system for dentistry on the basis of China-made 5-axis simultaneous contouring CNC machine tool and domestic industrial CAM software has been established, and development of the system will promote the introduction of domestically-produced dental CAD/CAM system.

GEOMETRICAL CHARACTERIZATION OF MICRO END MILLING TOOLS

DEFF Research Database (Denmark)

Borsetto, Francesca; Bariani, Paolo

The milling process is one of the most common metal removal operation used in industry. This machining process is well known since the beginning of last century and has experienced, along the years, many improvements of the basic technology, as concerns tools, machine tools, coolants/lubricants, ......The milling process is one of the most common metal removal operation used in industry. This machining process is well known since the beginning of last century and has experienced, along the years, many improvements of the basic technology, as concerns tools, machine tools, coolants....../lubricants, milling strategies and controls. Moreover the accuracy of tool geometry directly affects the performance of the milling process influencing the dimensional tolerances of the machined part, the surface topography, the chip formation, the cutting forces and the tool-life. The dimensions of certain...... geometrical details, as for instance the cutting edge radius, are determined by characteristics of the manufacturing process, tool material, coating etc. While for conventional size end mills the basic tool manufacturing process is well established, the reduction of the size of the tools required...

Application of machine learning and expert systems to Statistical Process Control (SPC) chart interpretation

Science.gov (United States)

Shewhart, Mark

1991-01-01

Statistical Process Control (SPC) charts are one of several tools used in quality control. Other tools include flow charts, histograms, cause and effect diagrams, check sheets, Pareto diagrams, graphs, and scatter diagrams. A control chart is simply a graph which indicates process variation over time. The purpose of drawing a control chart is to detect any changes in the process signalled by abnormal points or patterns on the graph. The Artificial Intelligence Support Center (AISC) of the Acquisition Logistics Division has developed a hybrid machine learning expert system prototype which automates the process of constructing and interpreting control charts.

Feasibility of using acoustic emission to determine in-process tool wear

Energy Technology Data Exchange (ETDEWEB)

Lazarus, L.J.

1996-04-01

Acoustic emission (AE) was evaluated for its ability to predict and recognize failure of cutting tools during machining processes when the cutting tool rotates and the workpiece is stationary. AE output was evaluated with a simple algorithm. AE was able to detect drill failure when the transducer was mounted on the workpiece holding fixture. Drill failure was recognized as size was reduced to 0.0003 in. diameter. The ability to predict failure was reduced with drill size, drill material elasticity, and tool coating. AE output for the turning process on a lathe was compared to turning tool insert wear. The turning tool must have sufficient wear to produce a detectable change in AE output to predict insert failure.

Wear of Cutting Tool with Excel Geometry in Turning Process of Hardened Steel

Science.gov (United States)

Samardžiová, Michaela

2016-09-01

This paper deals with hard turning using a cutting tool with Xcel geometry. This is one of the new geometries, and there is not any information about Xcel wear in comparison to the conventional geometry. It is already known from cutting tools producers that using the Xcel geometry leads to higher quality of machined surface, perticularly surface roughness. It is possible to achieve more than 4 times lower Ra and Rz values after turning than after using conventional geometry with radius. The workpiece material was 100Cr6 hardened steel with hardness of 60 ± 1 HRC. The machine used for the experiment was a lathe with counter spindle DMG CTX alpha 500, which is located in the Centre of Excellence of 5-axis Machining at the Faculty of Materials Science and Technology in Trnava. The cutting tools made by CBN were obtained from Sandvik COROMANT Company. The aim of this paper is to investigate the cutting tool wear in hard turning process by the Xcel cutting tool geometry.

Tool Wear Prediction in Ti-6Al-4V Machining through Multiple Sensor Monitoring and PCA Features Pattern Recognition

Directory of Open Access Journals (Sweden)

Alessandra Caggiano

2018-03-01

Full Text Available Machining of titanium alloys is characterised by extremely rapid tool wear due to the high cutting temperature and the strong adhesion at the tool-chip and tool-workpiece interface, caused by the low thermal conductivity and high chemical reactivity of Ti alloys. With the aim to monitor the tool conditions during dry turning of Ti-6Al-4V alloy, a machine learning procedure based on the acquisition and processing of cutting force, acoustic emission and vibration sensor signals during turning is implemented. A number of sensorial features are extracted from the acquired sensor signals in order to feed machine learning paradigms based on artificial neural networks. To reduce the large dimensionality of the sensorial features, an advanced feature extraction methodology based on Principal Component Analysis (PCA is proposed. PCA allowed to identify a smaller number of features (k = 2 features, the principal component scores, obtained through linear projection of the original d features into a new space with reduced dimensionality k = 2, sufficient to describe the variance of the data. By feeding artificial neural networks with the PCA features, an accurate diagnosis of tool flank wear (VBmax was achieved, with predicted values very close to the measured tool wear values.

Tool Wear Prediction in Ti-6Al-4V Machining through Multiple Sensor Monitoring and PCA Features Pattern Recognition

Science.gov (United States)

2018-01-01

Machining of titanium alloys is characterised by extremely rapid tool wear due to the high cutting temperature and the strong adhesion at the tool-chip and tool-workpiece interface, caused by the low thermal conductivity and high chemical reactivity of Ti alloys. With the aim to monitor the tool conditions during dry turning of Ti-6Al-4V alloy, a machine learning procedure based on the acquisition and processing of cutting force, acoustic emission and vibration sensor signals during turning is implemented. A number of sensorial features are extracted from the acquired sensor signals in order to feed machine learning paradigms based on artificial neural networks. To reduce the large dimensionality of the sensorial features, an advanced feature extraction methodology based on Principal Component Analysis (PCA) is proposed. PCA allowed to identify a smaller number of features (k = 2 features), the principal component scores, obtained through linear projection of the original d features into a new space with reduced dimensionality k = 2, sufficient to describe the variance of the data. By feeding artificial neural networks with the PCA features, an accurate diagnosis of tool flank wear (VBmax) was achieved, with predicted values very close to the measured tool wear values. PMID:29522443

Tool Wear Prediction in Ti-6Al-4V Machining through Multiple Sensor Monitoring and PCA Features Pattern Recognition.

Science.gov (United States)

Caggiano, Alessandra

2018-03-09

Machining of titanium alloys is characterised by extremely rapid tool wear due to the high cutting temperature and the strong adhesion at the tool-chip and tool-workpiece interface, caused by the low thermal conductivity and high chemical reactivity of Ti alloys. With the aim to monitor the tool conditions during dry turning of Ti-6Al-4V alloy, a machine learning procedure based on the acquisition and processing of cutting force, acoustic emission and vibration sensor signals during turning is implemented. A number of sensorial features are extracted from the acquired sensor signals in order to feed machine learning paradigms based on artificial neural networks. To reduce the large dimensionality of the sensorial features, an advanced feature extraction methodology based on Principal Component Analysis (PCA) is proposed. PCA allowed to identify a smaller number of features ( k = 2 features), the principal component scores, obtained through linear projection of the original d features into a new space with reduced dimensionality k = 2, sufficient to describe the variance of the data. By feeding artificial neural networks with the PCA features, an accurate diagnosis of tool flank wear ( VB max ) was achieved, with predicted values very close to the measured tool wear values.

Development of new metal matrix composite electrodes for electrical discharge machining through powder metallurgy process

Directory of Open Access Journals (Sweden)

C. Mathalai Sundaram

2014-12-01

Full Text Available Electrical discharge machining (EDM is one of the widely used nontraditional machining methods to produce die cavities by the erosive effect of electrical discharges. This method is popular due to the fact that a relatively soft electrically conductive tool electrode can machine hard work piece. Copper electrode is normally used for machining process. Electrode wear rate is the major drawback for EDM researchers. This research focus on fabrication of metal matrix composite (MMC electrode by mixing copper powder with titanium carbide (TiC and Tungsten carbide (WC powder through powder metallurgy process, Copper powder is the major amount of mixing proportion with TiC and WC. However, this paper focus on the early stage of the project where powder metallurgy route was used to determine suitable mixing time, compaction pressure and sintering and compacting process in producing EDM electrode. The newly prepared composite electrodes in different composition are tested in EDM for OHNS steel.

Machinability of Stellite 6 hardfacing

Directory of Open Access Journals (Sweden)

Dudzinski D.

2010-06-01

Full Text Available This paper reports some experimental findings concerning the machinability at high cutting speed of nickel-base weld-deposited hardfacings for the manufacture of hot tooling. The forging work involves extreme impacts, forces, stresses and temperatures. Thus, mould dies must be extremely resistant. The aim of the project is to create a rapid prototyping process answering to forging conditions integrating a Stellite 6 hardfacing deposed PTA process. This study talks about the dry machining of the hardfacing, using a two tips machining tool and a high speed milling machine equipped by a power consumption recorder Wattpilote. The aim is to show the machinability of the hardfacing, measuring the power and the tip wear by optical microscope and white light interferometer, using different strategies and cutting conditions.

Statistical investigations into the erosion of material from the tool in micro-electrical discharge machining

DEFF Research Database (Denmark)

Puthumana, Govindan

2018-01-01

This paper presents a statistical study of the erosion of material from the tool electrode in a micro-electrical discharge machining process. The work involves analysis of variance and analysis of means approaches on the results of the tool electrode wear rate obtained based on design...... current (Id) and discharge frequency (fd) control the erosion of material from the tool electrode. The material erosion from the tool electrode (Me) increases linearly with the discharge frequency. As the current index increases from 20 to 35, the Me decreases linearly by 29%, and then increases by of 36......%. The current index of 35 gives the minimum material erosion from the tool. It is observed that none of the two-factor interactions are significant in controlling the erosion of the material from the tool....

Autocoding State Machine in Erlang

DEFF Research Database (Denmark)

Guo, Yu; Hoffman, Torben; Gunder, Nicholas

2008-01-01

This paper presents an autocoding tool suit, which supports development of state machine in a model-driven fashion, where models are central to all phases of the development process. The tool suit, which is built on the Eclipse platform, provides facilities for the graphical specification...... of a state machine model. Once the state machine is specified, it is used as input to a code generation engine that generates source code in Erlang....

The effects of ergonomic stressors on process tool maintenance and utilization

Energy Technology Data Exchange (ETDEWEB)

Miller, D.

1998-03-31

This study examines ergonomic stressors associated with front-end process tool maintenance, relates them to decreased machine utilization, and proposes solution strategies to reduce their negative impact on productivity. Member company ergonomists observed technicians performing field maintenance tasks on seven different bottleneck tools and recorded ergonomic stressors using SEMaCheck, a graphics-based, integrated checklist developed by Sandia National Laboratories. The top ten stressors were prioritized according to a cost formula that accounted for difficulty, time, and potential errors. Estimates of additional time on a task caused by ergonomic stressors demonstrated that machine utilization could be increased from 6% to 25%. Optimal solution strategies were formulated based on redesign budget, stressor cost, and estimates of solution costs and benefits

Hybrid metallic nanocomposites for extra wear-resistant diamond machining tools

DEFF Research Database (Denmark)

Loginov, P.A.; Sidorenko, D.A.; Levashov, E.A.

2018-01-01

The applicability of metallic nanocomposites as binder for diamond machining tools is demonstrated. The various nanoreinforcements (carbon nanotubes, boron nitride hBN, nanoparticles of tungsten carbide/WC) and their combinations are embedded into metallic matrices and their mechanical properties...... are determined in experiments. The wear resistance of diamond tools with metallic binders modified by various nanoreinforcements was estimated. 3D hierarchical computational finite element model of the tool binder with hybrid nanoscale reinforcements is developed, and applied for the structure...

Delay dynamical systems and applications to nonlinear machine-tool chatter

International Nuclear Information System (INIS)

Fofana, M.S.

2003-01-01

The stability behaviour of machine chatter that exhibits Hopf and degenerate bifurcations has been examined without the assumption of small delays between successive cuts. Delay dynamical system theory leading to the reduction of the infinite-dimensional character of the governing delay differential equations (DDEs) to a finite-dimensional set of ordinary differential equations have been employed. The essential mathematical arguments for these systems in the context of retarded DDEs are summarized. Then the application of these arguments in the stability study of machine-tool chatter with multiple time delays is presented. Explicit analytical expressions ensuring stable and unstable machining when perturbations are periodic, stochastic and nonlinear have been derived using the integral averaging method and Lyapunov exponents

Parameter identification and optimization of slide guide joint of CNC machine tools

Science.gov (United States)

Zhou, S.; Sun, B. B.

2017-11-01

The joint surface has an important influence on the performance of CNC machine tools. In order to identify the dynamic parameters of slide guide joint, the parametric finite element model of the joint is established and optimum design method is used based on the finite element simulation and modal test. Then the mode that has the most influence on the dynamics of slip joint is found through harmonic response analysis. Take the frequency of this mode as objective, the sensitivity analysis of the stiffness of each joint surface is carried out using Latin Hypercube Sampling and Monte Carlo Simulation. The result shows that the vertical stiffness of slip joint surface constituted by the bed and the slide plate has the most obvious influence on the structure. Therefore, this stiffness is taken as the optimization variable and the optimal value is obtained through studying the relationship between structural dynamic performance and stiffness. Take the stiffness values before and after optimization into the FEM of machine tool, and it is found that the dynamic performance of the machine tool is improved.

Tribological and Wear Performance of Carbide Tools with TiB2 PVD Coating under Varying Machining Conditions of TiAl6V4 Aerospace Alloy

Directory of Open Access Journals (Sweden)

Jose Mario Paiva

2017-11-01

Full Text Available Tribological phenomena and tool wear mechanisms during machining of hard-to-cut TiAl6V4 aerospace alloy have been investigated in detail. Since cutting tool wear is directly affected by tribological phenomena occurring between the surfaces of the workpiece and the cutting tool, the performance of the cutting tool is strongly associated with the conditions of the machining process. The present work shows the effect of different machining conditions on the tribological and wear performance of TiB2-coated cutting tools compared to uncoated carbide tools. FEM modeling of the temperature profile on the friction surface was performed for wet machining conditions under varying cutting parameters. Comprehensive characterization of the TiB2 coated vs. uncoated cutting tool wear performance was made using optical 3D imaging, SEM/EDX and XPS methods respectively. The results obtained were linked to the FEM modeling. The studies carried out show that during machining of the TiAl6V4 alloy, the efficiency of the TiB2 coating application for carbide cutting tools strongly depends on cutting conditions. The TiB2 coating is very efficient under roughing at low speeds (with strong buildup edge formation. In contrast, it shows similar wear performance to the uncoated tool under finishing operations at higher cutting speeds when cratering wear predominates.

Machining NiTi micro-parts by micro-milling

International Nuclear Information System (INIS)

Weinert, K.; Petzoldt, V.

2008-01-01

The machinability of NiTi by milling has been examined using solid carbide end milling cutters. First results were obtained from machining simple slots applying TiAlN-coated tools with a diameter of 0.4 mm. The machining process was evaluated in terms of tool wear, cutting forces and machining quality. The tool wear and work piece quality was analysed with a scanning electron microscope and a white-light confocal microscope. Despite the poor machinability of NiTi good results concerning tool wear and shape accuracy of the milled slots were achieved. Essential for a good machining result is the application of minimum quantity lubrication. This clearly reduces NiTi adherences compared to dry machining. Work piece quality is improved and tool life is extended. Based on these results different structures could be produced by micro-milling

Thermal Error Test and Intelligent Modeling Research on the Spindle of High Speed CNC Machine Tools

Science.gov (United States)

Luo, Zhonghui; Peng, Bin; Xiao, Qijun; Bai, Lu

2018-03-01

Thermal error is the main factor affecting the accuracy of precision machining. Through experiments, this paper studies the thermal error test and intelligent modeling for the spindle of vertical high speed CNC machine tools in respect of current research focuses on thermal error of machine tool. Several testing devices for thermal error are designed, of which 7 temperature sensors are used to measure the temperature of machine tool spindle system and 2 displacement sensors are used to detect the thermal error displacement. A thermal error compensation model, which has a good ability in inversion prediction, is established by applying the principal component analysis technology, optimizing the temperature measuring points, extracting the characteristic values closely associated with the thermal error displacement, and using the artificial neural network technology.

Configuration design and accuracy analysis of a novel magneto rheological finishing machine tool for concave surfaces with small radius of curvature

International Nuclear Information System (INIS)

Liu, Henan; Chen, Mingjun; Yu, Bo; Zhen, Fang

2016-01-01

Magnetorheological finishing (MRF) is a computer-controlled deterministic polishing technique that is widely used in the production of high-quality optics. In order to overcome the defects of existing MRF processes that are unable to achieve concave surfaces with small radius of curvature, a configuration method of a novel structured MRF machine tool using small ball-end permanent-magnet polishing head is proposed in this paper. The preliminary design focuses on the structural configuration of the machine, which includes the machine body, motion units and accessory equipment, and so on. Structural deformation and fabrication accuracy of the machine are analyzed theoretically, in which the reasonable structure sizes, manufacturing errors and assembly errors of main structural components are given for configuration optimization. Based on the theoretical analysis, a four-axes linkage MRF machine tool is developed. Preliminary experiments of spot polishing are carried out and the results indicate that the proposed MRF process can achieve stable polishing area which meets requirement of deterministic polishing. A typical small-bore complex component is polished on the developed device and fine surface quality is obtained with sphericity of the finished spherical surfaces 1.3 μm and surface roughness Ra less than 0.018 μm.

Effect of processing parameters of rotary ultrasonic machining on surface integrity of potassium dihydrogen phosphate crystals

Directory of Open Access Journals (Sweden)

Jianfu Zhang

2015-09-01

Full Text Available Potassium dihydrogen phosphate is an important optical crystal. However, high-precision processing of large potassium dihydrogen phosphate crystal workpieces is difficult. In this article, surface roughness and subsurface damage characteristics of a (001 potassium dihydrogen phosphate crystal surface produced by traditional and rotary ultrasonic machining are studied. The influence of process parameters, including spindle speed, feed speed, type and size of sintered diamond wheel, ultrasonic power, and selection of cutting fluid on potassium dihydrogen phosphate crystal surface integrity, was analyzed. The surface integrity, especially the subsurface damage depth, was affected significantly by the ultrasonic power. Metal-sintered diamond tools with high granularity were most suitable for machining potassium dihydrogen phosphate crystal. Cutting fluid played a key role in potassium dihydrogen phosphate crystal machining. A more precise surface can be obtained in machining with a higher spindle speed, lower feed speed, and using kerosene as cutting fluid. Based on the provided optimized process parameters for machining potassium dihydrogen phosphate crystal, a processed surface quality with Ra value of 33 nm and subsurface damage depth value of 6.38 μm was achieved.

Machining dynamics fundamentals, applications and practices

CERN Document Server

Cheng, Kai

2008-01-01

Machining dynamics are vital to the performance of machine tools and machining processes in manufacturing. This book discusses the state-of-the-art applications, practices and research in machining dynamics. It presents basic theory, analysis and control methodology. It is useful for manufacturing engineers, supervisors, engineers and designers.

Strategic Performance Measurement Using Balanced Scorecard: A Case of Machine Tool Industry

Directory of Open Access Journals (Sweden)

Kshatriya Anil

2017-02-01

Full Text Available This paper focuses on implementation, monitoring, and application of balanced scorecard (BSC techniques in an organization involved in providing machine tool solutions to the industrial sector. The growth of the company considered in real time constituted improvements of both top and bottom lines. In the industry under consideration, it was observed that in our company, the top line was steadily growing but not the bottom line. This is when we started getting down to brass tacks and strategically focusing on growth in overall profits of the company. This included growing revenues by improving of EBITDA (earnings before interests, taxes, depreciation, and amortization and by increasing efficiency (i.e., cutting costs. These improvements were implemented by chalking out a comprehensive BSC designed to suit the machine tool industry. The four perspectives of the management, namely, internal business process, organizational learning, financial perspective, and customer perspective, have been considered lucidly and enunciate the parameters that affect the BSC very aptly. The BSC designed considered 9 objectives and 27 relative measures of these factors to quantify the various quantitative and qualitative dimensions that affect the company’s performance. A Balanced Lean Index (BL Score was used to measure the results for company X.

Restrictions of process machine retooling at machine-building enterprises

Directory of Open Access Journals (Sweden)

Kuznetsova Elena

2017-01-01

Full Text Available The competitiveness of the national economy depends on the technological level of the machine-building enterprises production equipment. Today in Russia there are objective and subjective restrictions for the optimum policy formation of the manufacturing equipment renewal. The analysis of the manufacturing equipment age structure dynamics in the Russian machine-building complex indicates the negative tendencies intensification: increase in the equipment service life, reduction in the share of up-to-date equipment, and drop in its use efficiency. The article investigates and classifies the main restrictions of the manufacturing equipment renewal process, such as regulatory and legislative, financial, organizational, competency-based. The economic consequences of the revealed restrictions influence on the machine-building enterprises activity are shown.

The Python Spectral Analysis Tool (PySAT): A Powerful, Flexible, Preprocessing and Machine Learning Library and Interface

Science.gov (United States)

Anderson, R. B.; Finch, N.; Clegg, S. M.; Graff, T. G.; Morris, R. V.; Laura, J.; Gaddis, L. R.

2017-12-01

Machine learning is a powerful but underutilized approach that can enable planetary scientists to derive meaningful results from the rapidly-growing quantity of available spectral data. For example, regression methods such as Partial Least Squares (PLS) and Least Absolute Shrinkage and Selection Operator (LASSO), can be used to determine chemical concentrations from ChemCam and SuperCam Laser-Induced Breakdown Spectroscopy (LIBS) data [1]. Many scientists are interested in testing different spectral data processing and machine learning methods, but few have the time or expertise to write their own software to do so. We are therefore developing a free open-source library of software called the Python Spectral Analysis Tool (PySAT) along with a flexible, user-friendly graphical interface to enable scientists to process and analyze point spectral data without requiring significant programming or machine-learning expertise. A related but separately-funded effort is working to develop a graphical interface for orbital data [2]. The PySAT point-spectra tool includes common preprocessing steps (e.g. interpolation, normalization, masking, continuum removal, dimensionality reduction), plotting capabilities, and capabilities to prepare data for machine learning such as creating stratified folds for cross validation, defining training and test sets, and applying calibration transfer so that data collected on different instruments or under different conditions can be used together. The tool leverages the scikit-learn library [3] to enable users to train and compare the results from a variety of multivariate regression methods. It also includes the ability to combine multiple "sub-models" into an overall model, a method that has been shown to improve results and is currently used for ChemCam data [4]. Although development of the PySAT point-spectra tool has focused primarily on the analysis of LIBS spectra, the relevant steps and methods are applicable to any spectral data. The

Influence of Wire Electrical Discharge Machining (WEDM) process parameters on surface roughness

Science.gov (United States)

Yeakub Ali, Mohammad; Banu, Asfana; Abu Bakar, Mazilah

2018-01-01

In obtaining the best quality of engineering components, the quality of machined parts surface plays an important role. It improves the fatigue strength, wear resistance, and corrosion of workpiece. This paper investigates the effects of wire electrical discharge machining (WEDM) process parameters on surface roughness of stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The parameters selected are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical model was developed for the estimation of surface roughness. The analysis revealed that off time has a major influence on surface roughness. The optimum machining parameters for minimum surface roughness were found to be at a 10 V open voltage, 2.84 μs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap.

Modeling and simulation of five-axis virtual machine based on NX

Science.gov (United States)

Li, Xiaoda; Zhan, Xianghui

2018-04-01

Virtual technology in the machinery manufacturing industry has shown the role of growing. In this paper, the Siemens NX software is used to model the virtual CNC machine tool, and the parameters of the virtual machine are defined according to the actual parameters of the machine tool so that the virtual simulation can be carried out without loss of the accuracy of the simulation. How to use the machine builder of the CAM module to define the kinematic chain and machine components of the machine is described. The simulation of virtual machine can provide alarm information of tool collision and over cutting during the process to users, and can evaluate and forecast the rationality of the technological process.

Developing Parametric Models for the Assembly of Machine Fixtures for Virtual Multiaxial CNC Machining Centers

Science.gov (United States)

Balaykin, A. V.; Bezsonov, K. A.; Nekhoroshev, M. V.; Shulepov, A. P.

2018-01-01

This paper dwells upon a variance parameterization method. Variance or dimensional parameterization is based on sketching, with various parametric links superimposed on the sketch objects and user-imposed constraints in the form of an equation system that determines the parametric dependencies. This method is fully integrated in a top-down design methodology to enable the creation of multi-variant and flexible fixture assembly models, as all the modeling operations are hierarchically linked in the built tree. In this research the authors consider a parameterization method of machine tooling used for manufacturing parts using multiaxial CNC machining centers in the real manufacturing process. The developed method allows to significantly reduce tooling design time when making changes of a part’s geometric parameters. The method can also reduce time for designing and engineering preproduction, in particular, for development of control programs for CNC equipment and control and measuring machines, automate the release of design and engineering documentation. Variance parameterization helps to optimize construction of parts as well as machine tooling using integrated CAE systems. In the framework of this study, the authors demonstrate a comprehensive approach to parametric modeling of machine tooling in the CAD package used in the real manufacturing process of aircraft engines.

Toward transient finite element simulation of thermal deformation of machine tools in real-time

Science.gov (United States)

Naumann, Andreas; Ruprecht, Daniel; Wensch, Joerg

2018-01-01

Finite element models without simplifying assumptions can accurately describe the spatial and temporal distribution of heat in machine tools as well as the resulting deformation. In principle, this allows to correct for displacements of the Tool Centre Point and enables high precision manufacturing. However, the computational cost of FE models and restriction to generic algorithms in commercial tools like ANSYS prevents their operational use since simulations have to run faster than real-time. For the case where heat diffusion is slow compared to machine movement, we introduce a tailored implicit-explicit multi-rate time stepping method of higher order based on spectral deferred corrections. Using the open-source FEM library DUNE, we show that fully coupled simulations of the temperature field are possible in real-time for a machine consisting of a stock sliding up and down on rails attached to a stand.

The study on force, surface integrity, tool life and chip on laser assisted machining of inconel 718 using Nd:YAG laser source.

Science.gov (United States)

Venkatesan, K

2017-07-01

Inconel 718, a high-temperature alloy, is a promising material for high-performance aerospace gas turbine engines components. However, the machining of the alloy is difficult owing to immense shear strength, rapid work hardening rate during turning, and less thermal conductivity. Hence, like ceramics and composites, the machining of this alloy is considered as difficult-to-turn materials. Laser assisted turning method has become a promising solution in recent years to lessen cutting stress when materials that are considered difficult-to-turn, such as Inconel 718 is employed. This study investigated the influence of input variables of laser assisted machining on the machinability aspect of the Inconel 718. The comparison of machining characteristics has been carried out to analyze the process benefits with the variation of laser machining variables. The laser assisted machining variables are cutting speeds of 60-150 m/min, feed rates of 0.05-0.125 mm/rev with a laser power between 1200 W and 1300 W. The various output characteristics such as force, roughness, tool life and geometrical characteristic of chip are investigated and compared with conventional machining without application of laser power. From experimental results, at a laser power of 1200 W, laser assisted turning outperforms conventional machining by 2.10 times lessening in cutting force, 46% reduction in surface roughness as well as 66% improvement in tool life when compared that of conventional machining. Compared to conventional machining, with the application of laser, the cutting speed of carbide tool has increased to a cutting condition of 150 m/min, 0.125 mm/rev. Microstructural analysis shows that no damage of the subsurface of the workpiece.

Machining of Fibre Reinforced Plastic Composite Materials

Science.gov (United States)

2018-01-01

Fibre reinforced plastic composite materials are difficult to machine because of the anisotropy and inhomogeneity characterizing their microstructure and the abrasiveness of their reinforcement components. During machining, very rapid cutting tool wear development is experienced, and surface integrity damage is often produced in the machined parts. An accurate selection of the proper tool and machining conditions is therefore required, taking into account that the phenomena responsible for material removal in cutting of fibre reinforced plastic composite materials are fundamentally different from those of conventional metals and their alloys. To date, composite materials are increasingly used in several manufacturing sectors, such as the aerospace and automotive industry, and several research efforts have been spent to improve their machining processes. In the present review, the key issues that are concerning the machining of fibre reinforced plastic composite materials are discussed with reference to the main recent research works in the field, while considering both conventional and unconventional machining processes and reporting the more recent research achievements. For the different machining processes, the main results characterizing the recent research works and the trends for process developments are presented. PMID:29562635

Machining of Fibre Reinforced Plastic Composite Materials

Directory of Open Access Journals (Sweden)

Alessandra Caggiano

2018-03-01

Full Text Available Fibre reinforced plastic composite materials are difficult to machine because of the anisotropy and inhomogeneity characterizing their microstructure and the abrasiveness of their reinforcement components. During machining, very rapid cutting tool wear development is experienced, and surface integrity damage is often produced in the machined parts. An accurate selection of the proper tool and machining conditions is therefore required, taking into account that the phenomena responsible for material removal in cutting of fibre reinforced plastic composite materials are fundamentally different from those of conventional metals and their alloys. To date, composite materials are increasingly used in several manufacturing sectors, such as the aerospace and automotive industry, and several research efforts have been spent to improve their machining processes. In the present review, the key issues that are concerning the machining of fibre reinforced plastic composite materials are discussed with reference to the main recent research works in the field, while considering both conventional and unconventional machining processes and reporting the more recent research achievements. For the different machining processes, the main results characterizing the recent research works and the trends for process developments are presented.

ASPECTS REGARDING THE OPTIMUM CUTTING TOOL PATH IN PROCESSING FREE-FORM

Directory of Open Access Journals (Sweden)

Florin CHIFAN

2014-11-01

Full Text Available This paper describes an approach on tool paths optimization in CAM-type software for milling free forms, with the goal to improve efficiency in processing using CNC machine tools. The methodology proposed in this paper, tackles the problem of mechanical processing in 3 axes using ball nose milling cutters of small diameters, which follows a free form profile. I will consider two cases: the first one considers the ball nose end mill route on a free form with an angle of less than 30°, the second one with a tool path greater than 30°. The main objective of this paper is to determine the optimum angle in order to obtain a better surface roughness, a shorter time of processing and also a higher tool-life, all these by considering all other factors that occurs in the manufacturing process. This will be done by indicating and editing the tool path so that the tools will the minimum entries and exits on the surface of the piece. This will lead to a 10% decrease of the working time.

Gaussian process regression for tool wear prediction

Science.gov (United States)

Kong, Dongdong; Chen, Yongjie; Li, Ning

2018-05-01

To realize and accelerate the pace of intelligent manufacturing, this paper presents a novel tool wear assessment technique based on the integrated radial basis function based kernel principal component analysis (KPCA_IRBF) and Gaussian process regression (GPR) for real-timely and accurately monitoring the in-process tool wear parameters (flank wear width). The KPCA_IRBF is a kind of new nonlinear dimension-increment technique and firstly proposed for feature fusion. The tool wear predictive value and the corresponding confidence interval are both provided by utilizing the GPR model. Besides, GPR performs better than artificial neural networks (ANN) and support vector machines (SVM) in prediction accuracy since the Gaussian noises can be modeled quantitatively in the GPR model. However, the existence of noises will affect the stability of the confidence interval seriously. In this work, the proposed KPCA_IRBF technique helps to remove the noises and weaken its negative effects so as to make the confidence interval compressed greatly and more smoothed, which is conducive for monitoring the tool wear accurately. Moreover, the selection of kernel parameter in KPCA_IRBF can be easily carried out in a much larger selectable region in comparison with the conventional KPCA_RBF technique, which helps to improve the efficiency of model construction. Ten sets of cutting tests are conducted to validate the effectiveness of the presented tool wear assessment technique. The experimental results show that the in-process flank wear width of tool inserts can be monitored accurately by utilizing the presented tool wear assessment technique which is robust under a variety of cutting conditions. This study lays the foundation for tool wear monitoring in real industrial settings.

STUDY OF THE VIBRATION LEVEL IN CASE OF MANUFACTURING ON A CNC MACHINE-TOOL

Directory of Open Access Journals (Sweden)

Ioan Călin ROȘCA

2015-12-01

Full Text Available The paper presents the results of an experimental research performed on a CNC machine tool type ISEL-GFV considering the vibration level developed during the manufacturing of different pieces of particleboard at six processing regimes. There were recorded signals on both time and frequency domains on the three main directions. Based on recorded data there are presented the main conclusions referring to the level of vibrations and the frequencies associated to the highest levels.

Additive Manufacturing of Tooling for Refrigeration Cabinet Foaming Processes

Energy Technology Data Exchange (ETDEWEB)

Post, Brian K [ORNL; Nuttall, David [ORNL; Cukier, Michael Z [ORNL; Hile, Michael B [ORNL

2016-07-29

The primary objective of this project was to leverage the Big Area Additive Manufacturing (BAAM) process and materials into a long term, quick change tooling concept to drastically reduce product lead and development timelines and costs. Current refrigeration foam molds are complicated to manufacture involving casting several aluminum parts in an approximate shape, machining components of the molds and post fitting and shimming of the parts in an articulated fixture. The total process timeline can take over 6 months. The foaming process is slower than required for production, therefore multiple fixtures, 10 to 27, are required per refrigerator model. Molds are particular to a specific product configuration making mixed model assembly challenging for sequencing, mold changes or auto changeover features. The initial goal was to create a tool leveraging the ORNL materials and additive process to build a tool in 4 to 6 weeks or less. A secondary goal was to create common fixture cores and provide lightweight fixture sections that could be revised in a very short time to increase equipment flexibility reduce lead times, lower the barriers to first production trials, and reduce tooling costs.

Virtual Machine in Automation Projects

OpenAIRE

Xing, Xiaoyuan

2010-01-01

Virtual machine, as an engineering tool, has recently been introduced into automation projects in Tetra Pak Processing System AB. The goal of this paper is to examine how to better utilize virtual machine for the automation projects. This paper designs different project scenarios using virtual machine. It analyzes installability, performance and stability of virtual machine from the test results. Technical solutions concerning virtual machine are discussed such as the conversion with physical...

High resolution micro ultrasonic machining for trimming 3D microstructures

International Nuclear Information System (INIS)

Viswanath, Anupam; Li, Tao; Gianchandani, Yogesh

2014-01-01

This paper reports on the evaluation of a high resolution micro ultrasonic machining (HR-µUSM) process suitable for post fabrication trimming of complex 3D microstructures made from fused silica. Unlike conventional USM, the HR-µUSM process aims for low machining rates, providing high resolution and high surface quality. The machining rate is reduced by keeping the micro-tool tip at a fixed distance from the workpiece and vibrating it at a small amplitude. The surface roughness is improved by an appropriate selection of abrasive particles. Fluidic modeling is performed to study interaction among the vibrating micro-tool tip, workpiece, and the slurry. Using 304 stainless steel (SS304) tool tips of 50 µm diameter, the machining performance of the HR-µUSM process is characterized on flat fused silica substrates. The depths and surface finish of machined features are evaluated as functions of slurry concentrations, separation between the micro-tool and workpiece, and machining time. Under the selected conditions, the HR-µUSM process achieves machining rates as low as 10 nm s −1  averaged over the first minute of machining of a flat virgin sample. This corresponds to a mass removal rate of ≈20 ng min −1 . The average surface roughness, S a , achieved is as low as 30 nm. Analytical and numerical modeling are used to explain the typical profile of the machined features as well as machining rates. The process is used to demonstrate trimming of hemispherical 3D shells made of fused silica. (paper)

VIRTUAL MACHINES IN EDUCATION – CNC MILLING MACHINE WITH SINUMERIK 840D CONTROL SYSTEM

Directory of Open Access Journals (Sweden)

Ireneusz Zagórski

2014-11-01

Full Text Available Machining process nowadays could not be conducted without its inseparable element: cutting edge and frequently numerically controlled milling machines. Milling and lathe machining centres comprise standard equipment in many companies of the machinery industry, e.g. automotive or aircraft. It is for that reason that tertiary education should account for this rising demand. This entails the introduction into the curricula the forms which enable visualisation of machining, milling process and virtual production as well as virtual machining centres simulation. Siemens Virtual Machine (Virtual Workshop sets an example of such software, whose high functionality offers a range of learning experience, such as: learning the design of machine tools, their configuration, basic operation functions as well as basics of CNC.

A Practical Framework Toward Prediction of Breaking Force and Disintegration of Tablet Formulations Using Machine Learning Tools.

Science.gov (United States)

Akseli, Ilgaz; Xie, Jingjin; Schultz, Leon; Ladyzhynsky, Nadia; Bramante, Tommasina; He, Xiaorong; Deanne, Rich; Horspool, Keith R; Schwabe, Robert

2017-01-01

Enabling the paradigm of quality by design requires the ability to quantitatively correlate material properties and process variables to measureable product performance attributes. Conventional, quality-by-test methods for determining tablet breaking force and disintegration time usually involve destructive tests, which consume significant amount of time and labor and provide limited information. Recent advances in material characterization, statistical analysis, and machine learning have provided multiple tools that have the potential to develop nondestructive, fast, and accurate approaches in drug product development. In this work, a methodology to predict the breaking force and disintegration time of tablet formulations using nondestructive ultrasonics and machine learning tools was developed. The input variables to the model include intrinsic properties of formulation and extrinsic process variables influencing the tablet during manufacturing. The model has been applied to predict breaking force and disintegration time using small quantities of active pharmaceutical ingredient and prototype formulation designs. The novel approach presented is a step forward toward rational design of a robust drug product based on insight into the performance of common materials during formulation and process development. It may also help expedite drug product development timeline and reduce active pharmaceutical ingredient usage while improving efficiency of the overall process. Copyright © 2016 American Pharmacists Association®. Published by Elsevier Inc. All rights reserved.

High productivity machining of holes in Inconel 718 with SiAlON tools

Science.gov (United States)

Agirreurreta, Aitor Arruti; Pelegay, Jose Angel; Arrazola, Pedro Jose; Ørskov, Klaus Bonde

2016-10-01

Inconel 718 is often employed in aerospace engines and power generation turbines. Numerous researches have proven the enhanced productivity when turning with ceramic tools compared to carbide ones, however there is considerably less information with regard to milling. Moreover, no knowledge has been published about machining holes with this type of tools. Additional research on different machining techniques, like for instance circular ramping, is critical to expand the productivity improvements that ceramics can offer. In this a 3D model of the machining and a number of experiments with SiAlON round inserts have been carried out in order to evaluate the effect of the cutting speed and pitch on the tool wear and chip generation. The results of this analysis show that three different types of chips are generated and also that there are three potential wear zones. Top slice wear is identified as the most critical wear type followed by the notch wear as a secondary wear mechanism. Flank wear and adhesion are also found in most of the tests.

Heuristic algorithms for solving of the tool routing problem for CNC cutting machines

Science.gov (United States)

Chentsov, P. A.; Petunin, A. A.; Sesekin, A. N.; Shipacheva, E. N.; Sholohov, A. E.

2015-11-01

The article is devoted to the problem of minimizing the path of the cutting tool to shape cutting machines began. This problem can be interpreted as a generalized traveling salesman problem. Earlier version of the dynamic programming method to solve this problem was developed. Unfortunately, this method allows to process an amount not exceeding thirty circuits. In this regard, the task of constructing quasi-optimal route becomes relevant. In this paper we propose options for quasi-optimal greedy algorithms. Comparison of the results of exact and approximate algorithms is given.

The study on force, surface integrity, tool life and chip on laser assisted machining of inconel 718 using Nd:YAG laser source

Directory of Open Access Journals (Sweden)

K. Venkatesan

2017-07-01

Full Text Available Inconel 718, a high-temperature alloy, is a promising material for high-performance aerospace gas turbine engines components. However, the machining of the alloy is difficult owing to immense shear strength, rapid work hardening rate during turning, and less thermal conductivity. Hence, like ceramics and composites, the machining of this alloy is considered as difficult-to-turn materials. Laser assisted turning method has become a promising solution in recent years to lessen cutting stress when materials that are considered difficult-to-turn, such as Inconel 718 is employed. This study investigated the influence of input variables of laser assisted machining on the machinability aspect of the Inconel 718. The comparison of machining characteristics has been carried out to analyze the process benefits with the variation of laser machining variables. The laser assisted machining variables are cutting speeds of 60–150 m/min, feed rates of 0.05–0.125 mm/rev with a laser power between 1200 W and 1300 W. The various output characteristics such as force, roughness, tool life and geometrical characteristic of chip are investigated and compared with conventional machining without application of laser power. From experimental results, at a laser power of 1200 W, laser assisted turning outperforms conventional machining by 2.10 times lessening in cutting force, 46% reduction in surface roughness as well as 66% improvement in tool life when compared that of conventional machining. Compared to conventional machining, with the application of laser, the cutting speed of carbide tool has increased to a cutting condition of 150 m/min, 0.125 mm/rev. Microstructural analysis shows that no damage of the subsurface of the workpiece.

Manufacturing technology development of plasma/ion nitriding for improvement of hardness of machine components and tools

International Nuclear Information System (INIS)

Suprapto; Tjipto Sujitno; Saminto

2015-01-01

The manufacturing technology development of plasma/ion nitriding to improve of hardness of machine components and tools has been done. The development of this technology aims to improve device performance plasma nitriding double chamber and conducted with the addition of thermal radiation shield. Testing was done by testing for preheating operation (start-up), test operation for conditions nitriding and test for nitriding process. The results show that: the plasma nitriding device can be operated for nitriding process at the temperature of about 500 °C for 6 hours, using the thermal radiation shield obtained outside wall temperature of about 65 °C and shorten start-up time to about 60 minutes. The use of thermal radiation shield can also improve the efficiency of the electric power supply and increase the operating temperature for nitriding process. Test for nitriding obtained increase of hardness 1.33 times for the original camshaft (genuine parts) and 1.8 times for the imitation camshaft (imitation parts), the results are compared with after the tempering process at a temperature of 600 °C. For sample SS 304 was 2.45 times compared with before nitrided These results indicate that the development of manufacturing technology of plasma/ion nitriding to increase hardness of machine components and tools have been successfully able to increase the hardness, although still need to be optimized. Besides that, these devices can be developed to use for the process of carburizing and carbonitriding. (author)

Machining tools in AISI M2 high-speed steel obtained by spray forming process; Ferramentas de usinagem em aco rapido AISI M2 obtido por conformacao por 'spray'

Energy Technology Data Exchange (ETDEWEB)

Jesus, Edilson Rosa Barbosa de. E-mail: erbjesus@usp.br

2004-07-01

The aim of the present work was the obtention of AISI M2 high-speed steel by spray forming technique and the material evaluation when used as machining tool. The obtained material was hot rolled at 50% and 72% reduction ratios, and from which it was manufactured inserts for machining tests. The performance of inserts made of the spray formed material was compared to inserts obtained from conventional and powder metallurgy (MP) processed materials. The spray formed material was chemical, physical, mechanical and microstructural characterised. For further characterisation, the materials were submitted to machining tests for performance evaluation under real work condition. The results of material characterisation highlight the potential of the spray forming technique, in the obtention of materials with good characteristics and properties. Under the current processing, hot rolling and heat treatments condition, the analysis of the results of the machining tests revealed a very similar behaviour among the tested materials. Proceeding a criterious analysis of the machining results tests, it was verified that the performance presented by the powder metallurgy material (MP) was slight superior, followed by conventional obtained material (MConv), which presented a insignificant advantage over the spray formed and hot rolled (72% reduction ratio) material. The worst result was encountered for the spray forming and hot rolled (50% reduction ratio) material that presented the highest wear values. (author)

Study on the Optimization and Process Modeling of the Rotary Ultrasonic Machining of Zerodur Glass-Ceramic

Science.gov (United States)

Pitts, James Daniel

Rotary ultrasonic machining (RUM), a hybrid process combining ultrasonic machining and diamond grinding, was created to increase material removal rates for the fabrication of hard and brittle workpieces. The objective of this research was to experimentally derive empirical equations for the prediction of multiple machined surface roughness parameters for helically pocketed rotary ultrasonic machined Zerodur glass-ceramic workpieces by means of a systematic statistical experimental approach. A Taguchi parametric screening design of experiments was employed to systematically determine the RUM process parameters with the largest effect on mean surface roughness. Next empirically determined equations for the seven common surface quality metrics were developed via Box-Behnken surface response experimental trials. Validation trials were conducted resulting in predicted and experimental surface roughness in varying levels of agreement. The reductions in cutting force and tool wear associated with RUM, reported by previous researchers, was experimentally verified to also extended to helical pocketing of Zerodur glass-ceramic.

Research on Error Modelling and Identification of 3 Axis NC Machine Tools Based on Cross Grid Encoder Measurement

International Nuclear Information System (INIS)

Du, Z C; Lv, C F; Hong, M S

2006-01-01

A new error modelling and identification method based on the cross grid encoder is proposed in this paper. Generally, there are 21 error components in the geometric error of the 3 axis NC machine tools. However according our theoretical analysis, the squareness error among different guide ways affects not only the translation error component, but also the rotational ones. Therefore, a revised synthetic error model is developed. And the mapping relationship between the error component and radial motion error of round workpiece manufactured on the NC machine tools are deduced. This mapping relationship shows that the radial error of circular motion is the comprehensive function result of all the error components of link, worktable, sliding table and main spindle block. Aiming to overcome the solution singularity shortcoming of traditional error component identification method, a new multi-step identification method of error component by using the Cross Grid Encoder measurement technology is proposed based on the kinematic error model of NC machine tool. Firstly, the 12 translational error components of the NC machine tool are measured and identified by using the least square method (LSM) when the NC machine tools go linear motion in the three orthogonal planes: XOY plane, XOZ plane and YOZ plane. Secondly, the circular error tracks are measured when the NC machine tools go circular motion in the same above orthogonal planes by using the cross grid encoder Heidenhain KGM 182. Therefore 9 rotational errors can be identified by using LSM. Finally the experimental validation of the above modelling theory and identification method is carried out in the 3 axis CNC vertical machining centre Cincinnati 750 Arrow. The entire 21 error components have been successfully measured out by the above method. Research shows the multi-step modelling and identification method is very suitable for 'on machine measurement'

Hardware and software and machine-tool simulation with parallel structures mechanisms

Directory of Open Access Journals (Sweden)

Keba P.V.

2016-12-01

Full Text Available The usage spectrum of mechanisms with parallel structure is spreading all the time. The mechanisms of machine-tools and manipulators become more complicated and it is necessary to improve the program-controlled modules. Closed circuit mechanisms are mostly spread in robotic complexes, where manipulator performs complicated spatial movements by the given trajectory. The usage spectrum is very wide and the most popular are sorting, welding, assembling and others. However, the problem of designing the operating programs is still present even today. It is just because the developed post-processors are created for the equipment that we have for now. But new machine tool constructions appear every day and there is a necessity to control them. The problems associated with using of hardware and software of mechanisms with parallel structure in computer-aided simulation are considered. The program for inverse problem kinematics solving is designed. New method of designing the control programs is found. The kinematic analysis methods options and calculated data obtained by computer mathematics systems are shown with «Tools Glide» software taken as an example.

Machine learning and predictive data analytics enabling metrology and process control in IC fabrication

Science.gov (United States)

Rana, Narender; Zhang, Yunlin; Wall, Donald; Dirahoui, Bachir; Bailey, Todd C.

2015-03-01

Integrate circuit (IC) technology is going through multiple changes in terms of patterning techniques (multiple patterning, EUV and DSA), device architectures (FinFET, nanowire, graphene) and patterning scale (few nanometers). These changes require tight controls on processes and measurements to achieve the required device performance, and challenge the metrology and process control in terms of capability and quality. Multivariate data with complex nonlinear trends and correlations generally cannot be described well by mathematical or parametric models but can be relatively easily learned by computing machines and used to predict or extrapolate. This paper introduces the predictive metrology approach which has been applied to three different applications. Machine learning and predictive analytics have been leveraged to accurately predict dimensions of EUV resist patterns down to 18 nm half pitch leveraging resist shrinkage patterns. These patterns could not be directly and accurately measured due to metrology tool limitations. Machine learning has also been applied to predict the electrical performance early in the process pipeline for deep trench capacitance and metal line resistance. As the wafer goes through various processes its associated cost multiplies. It may take days to weeks to get the electrical performance readout. Predicting the electrical performance early on can be very valuable in enabling timely actionable decision such as rework, scrap, feedforward, feedback predicted information or information derived from prediction to improve or monitor processes. This paper provides a general overview of machine learning and advanced analytics application in the advanced semiconductor development and manufacturing.

Combining human and machine processes (CHAMP)

Science.gov (United States)

Sudit, Moises; Sudit, David; Hirsch, Michael

2015-05-01

Machine Reasoning and Intelligence is usually done in a vacuum, without consultation of the ultimate decision-maker. The late consideration of the human cognitive process causes some major problems in the use of automated systems to provide reliable and actionable information that users can trust and depend to make the best Course-of-Action (COA). On the other hand, if automated systems are created exclusively based on human cognition, then there is a danger of developing systems that don't push the barrier of technology and are mainly done for the comfort level of selected subject matter experts (SMEs). Our approach to combining human and machine processes (CHAMP) is based on the notion of developing optimal strategies for where, when, how, and which human intelligence should be injected within a machine reasoning and intelligence process. This combination is based on the criteria of improving the quality of the output of the automated process while maintaining the required computational efficiency for a COA to be actuated in timely fashion. This research addresses the following problem areas: • Providing consistency within a mission: Injection of human reasoning and intelligence within the reliability and temporal needs of a mission to attain situational awareness, impact assessment, and COA development. • Supporting the incorporation of data that is uncertain, incomplete, imprecise and contradictory (UIIC): Development of mathematical models to suggest the insertion of a cognitive process within a machine reasoning and intelligent system so as to minimize UIIC concerns. • Developing systems that include humans in the loop whose performance can be analyzed and understood to provide feedback to the sensors.

Study of the stiffness for predicting the accuracy of machine tools; Estudio de la rigidez para la prediccion de la precision de las maquinas-herramientas

Energy Technology Data Exchange (ETDEWEB)

Ortega, N.; Campa, F.J.; Fernandez Valdivielso, A.; Alonso, U.; Olvera, D.; Compean, F.I.

2010-07-01

Machining processes are frequently faced with the challenge of achieving more and more precision and surface qualities. These requirements are usually attained taking into account some process variables, including the cutting parameters and the use or not of refrigerant, leaving aside the mechanical aspects associated with the influence of machine tool itself. There are many sources of error linked with machine-workpiece interaction, but, in general, we can summarize them into two types of error: quasi-static and dynamic. This paper shows the influence of quasi-static error caused by low machine rigidity on the accuracy applied on two very different processes: turning and grinding. For the study of the static stiffness of these two machines, two different methods are proposed, both of them equally valid. The first one is based on separated parameters and the second one on finite elements. (Author).

Automated business process management – in times of digital transformation using machine learning or artificial intelligence

Directory of Open Access Journals (Sweden)

Paschek Daniel

2017-01-01

Full Text Available The continuous optimization of business processes is still a challenge for companies. In times of digital transformation, faster changing internal and external framework conditions and new customer expectations for fastest delivery and best quality of goods and many more, companies should set up their internal process at the best way. But what to do if framework conditions changed unexpectedly? The purpose of the paper is to analyse how the digital transformation will impact the Business Process Management (BPM while using methods like machine learning or artificial intelligence. Therefore, the core components will be explained, compared and set up in relation. To identify application areas interviews and analysis will be held up with digital companies. The finding of the paper will be recommendation for action in the field of BPM and process optimization through machine learning and artificial intelligence. The Approach of optimizing and management processes via machine learning and artificial intelligence will support companies to decide which tool will be the best for automated BPM.

The dynamic analysis of drum roll lathe for machining of rollers

Science.gov (United States)

Qiao, Zheng; Wu, Dongxu; Wang, Bo; Li, Guo; Wang, Huiming; Ding, Fei

2014-08-01

An ultra-precision machine tool for machining of the roller has been designed and assembled, and due to the obvious impact which dynamic characteristic of machine tool has on the quality of microstructures on the roller surface, the dynamic characteristic of the existing machine tool is analyzed in this paper, so is the influence of circumstance that a large scale and slender roller is fixed in the machine on dynamic characteristic of the machine tool. At first, finite element model of the machine tool is built and simplified, and based on that, the paper carries on with the finite element mode analysis and gets the natural frequency and shaking type of four steps of the machine tool. According to the above model analysis results, the weak stiffness systems of machine tool can be further improved and the reasonable bandwidth of control system of the machine tool can be designed. In the end, considering the shock which is caused by Z axis as a result of fast positioning frequently to feeding system and cutting tool, transient analysis is conducted by means of ANSYS analysis in this paper. Based on the results of transient analysis, the vibration regularity of key components of machine tool and its impact on cutting process are explored respectively.

Heat-Assisted Machining for Material Removal Improvement

Science.gov (United States)

Mohd Hadzley, A. B.; Hafiz, S. Muhammad; Azahar, W.; Izamshah, R.; Mohd Shahir, K.; Abu, A.

2015-09-01

Heat assisted machining (HAM) is a process where an intense heat source is used to locally soften the workpiece material before machined by high speed cutting tool. In this paper, an HAM machine is developed by modification of small CNC machine with the addition of special jig to hold the heat sources in front of the machine spindle. Preliminary experiment to evaluate the capability of HAM machine to produce groove formation for slotting process was conducted. A block AISI D2 tool steel with100mm (width) × 100mm (length) × 20mm (height) size has been cut by plasma heating with different setting of arc current, feed rate and air pressure. Their effect has been analyzed based on distance of cut (DOC).Experimental results demonstrated the most significant factor that contributed to the DOC is arc current, followed by the feed rate and air pressure. HAM improves the slotting process of AISI D2 by increasing distance of cut due to initial cutting groove that formed during thermal melting and pressurized air from the heat source.

Influence of export control policy on the competitiveness of machine tool producing organizations

Science.gov (United States)

Ahrstrom, Jeffrey D.

The possible influence of export control policies on producers of export controlled machine tools is examined in this quantitative study. International market competitiveness theories hold that market controlling policies such as export control regulations may influence an organization's ability to compete (Burris, 2010). Differences in domestic application of export control policy on machine tool exports may impose throttling effects on the competitiveness of participating firms (Freedenberg, 2010). Commodity shipments from Japan, Germany, and the United States to the Russian market will be examined using descriptive statistics; gravity modeling of these specific markets provides a foundation for comparison to actual shipment data; and industry participant responses to a user developed survey will provide additional data for analysis using a Kruskal-Wallis one-way analysis of variance. There is scarce academic research data on the topic of export control effects within the machine tool industry. Research results may be of interest to industry leadership in market participation decisions, advocacy arguments, and strategic planning. Industry advocates and export policy decision makers could find data of interest in supporting positions for or against modifications of export control policies.

Application of grey-fuzzy approach in parametric optimization of EDM process in machining of MDN 300 steel

Science.gov (United States)

Protim Das, Partha; Gupta, P.; Das, S.; Pradhan, B. B.; Chakraborty, S.

2018-01-01

Maraging steel (MDN 300) find its application in many industries as it exhibits high hardness which are very difficult to machine material. Electro discharge machining (EDM) is an extensively popular machining process which can be used in machining of such materials. Optimization of response parameters are essential for effective machining of these materials. Past researchers have already used Taguchi for obtaining the optimal responses of EDM process for this material with responses such as material removal rate (MRR), tool wear rate (TWR), relative wear ratio (RWR), and surface roughness (SR) considering discharge current, pulse on time, pulse off time, arc gap, and duty cycle as process parameters. In this paper, grey relation analysis (GRA) with fuzzy logic is applied to this multi objective optimization problem to check the responses by an implementation of the derived parametric setting. It was found that the parametric setting derived by the proposed method results in better a response than those reported by the past researchers. Obtained results are also verified using the technique for order of preference by similarity to ideal solution (TOPSIS). The predicted result also shows that there is a significant improvement in comparison to the results of past researchers.

High-speed micro electrode tool fabrication by a twin-wire EDM system

International Nuclear Information System (INIS)

Sheu, Dong-Yea

2008-01-01

This paper describes a new machining process which combines twin-electro-wire together with two electro discharge circuits to rapidly fabricate micro electrode tools. The results show that transistor electro discharge and RC electro discharge circuits coexist to fabricate micro tools with rough and finish machining both on the same machine. Compared to conventional wire electro discharge grinding (WEDG) technology, a twin-wire EDM system that combines rough and finish machining into one process allows the efficient fabrication of micro tools. This high-speed micro tool fabrication process can be applied not only to micro electrode machining but also to micro punching tool and micro probing tips machining

Proceedings of the IEEE Machine Learning for Signal Processing XVII

DEFF Research Database (Denmark)

The seventeenth of a series of workshops sponsored by the IEEE Signal Processing Society and organized by the Machine Learning for Signal Processing Technical Committee (MLSP-TC). The field of machine learning has matured considerably in both methodology and real-world application domains and has...... become particularly important for solution of problems in signal processing. As reflected in this collection, machine learning for signal processing combines many ideas from adaptive signal/image processing, learning theory and models, and statistics in order to solve complex real-world signal processing......, and two papers from the winners of the Data Analysis Competition. The program included papers in the following areas: genomic signal processing, pattern recognition and classification, image and video processing, blind signal processing, models, learning algorithms, and applications of machine learning...

Obtaining Global Picture From Single Point Observations by Combining Data Assimilation and Machine Learning Tools

Science.gov (United States)

Shprits, Y.; Zhelavskaya, I. S.; Kellerman, A. C.; Spasojevic, M.; Kondrashov, D. A.; Ghil, M.; Aseev, N.; Castillo Tibocha, A. M.; Cervantes Villa, J. S.; Kletzing, C.; Kurth, W. S.

2017-12-01

Increasing volume of satellite measurements requires deployment of new tools that can utilize such vast amount of data. Satellite measurements are usually limited to a single location in space, which complicates the data analysis geared towards reproducing the global state of the space environment. In this study we show how measurements can be combined by means of data assimilation and how machine learning can help analyze large amounts of data and can help develop global models that are trained on single point measurement. Data Assimilation: Manual analysis of the satellite measurements is a challenging task, while automated analysis is complicated by the fact that measurements are given at various locations in space, have different instrumental errors, and often vary by orders of magnitude. We show results of the long term reanalysis of radiation belt measurements along with fully operational real-time predictions using data assimilative VERB code. Machine Learning: We present application of the machine learning tools for the analysis of NASA Van Allen Probes upper-hybrid frequency measurements. Using the obtained data set we train a new global predictive neural network. The results for the Van Allen Probes based neural network are compared with historical IMAGE satellite observations. We also show examples of predictions of geomagnetic indices using neural networks. Combination of machine learning and data assimilation: We discuss how data assimilation tools and machine learning tools can be combine so that physics-based insight into the dynamics of the particular system can be combined with empirical knowledge of it's non-linear behavior.

Diamond machining of micro-optical components and structures

Science.gov (United States)

Gläbe, Ralf; Riemer, Oltmann

2010-05-01

Diamond machining originates from the 1950s to 1970s in the USA. This technology was originally designed for machining of metal optics at macroscopic dimensions with so far unreached tolerances. During the following decades the machine tools, the monocrystalline diamond cutting tools, the workpiece materials and the machining processes advanced to even higher precision and flexibility. For this reason also the fabrication of small functional components like micro optics at a large spectrum of geometries became technologically and economically feasible. Today, several kinds of fast tool machining and multi axis machining operations can be applied for diamond machining of micro optical components as well as diffractive optical elements. These parts can either be machined directly as single or individual component or as mold insert for mass production by plastic replication. Examples are multi lens arrays, micro mirror arrays and fiber coupling lenses. This paper will give an overview about the potentials and limits of the current diamond machining technology with respect to micro optical components.

Prediction Of Abrasive And Diffusive Tool Wear Mechanisms In Machining

Science.gov (United States)

Rizzuti, S.; Umbrello, D.

2011-01-01

Tool wear prediction is regarded as very important task in order to maximize tool performance, minimize cutting costs and improve the quality of workpiece in cutting. In this research work, an experimental campaign was carried out at the varying of cutting conditions with the aim to measure both crater and flank tool wear, during machining of an AISI 1045 with an uncoated carbide tool P40. Parallel a FEM-based analysis was developed in order to study the tool wear mechanisms, taking also into account the influence of the cutting conditions and the temperature reached on the tool surfaces. The results show that, when the temperature of the tool rake surface is lower than the activation temperature of the diffusive phenomenon, the wear rate can be estimated applying an abrasive model. In contrast, in the tool area where the temperature is higher than the diffusive activation temperature, the wear rate can be evaluated applying a diffusive model. Finally, for a temperature ranges within the above cited values an adopted abrasive-diffusive wear model furnished the possibility to correctly evaluate the tool wear phenomena.

On Intelligent Design and Planning Method of Process Route Based on Gun Breech Machining Process

Science.gov (United States)

Hongzhi, Zhao; Jian, Zhang

2018-03-01

The paper states an approach of intelligent design and planning of process route based on gun breech machining process, against several problems, such as complex machining process of gun breech, tedious route design and long period of its traditional unmanageable process route. Based on gun breech machining process, intelligent design and planning system of process route are developed by virtue of DEST and VC++. The system includes two functional modules--process route intelligent design and its planning. The process route intelligent design module, through the analysis of gun breech machining process, summarizes breech process knowledge so as to complete the design of knowledge base and inference engine. And then gun breech process route intelligently output. On the basis of intelligent route design module, the final process route is made, edited and managed in the process route planning module.

Experimental Investigation of Surface Layer Properties of High Thermal Conductivity Tool Steel after Electrical Discharge Machining

Directory of Open Access Journals (Sweden)

Rafał Świercz

2017-12-01

Full Text Available New materials require the use of advanced technology in manufacturing complex shape parts. One of the modern materials widely used in the tool industry for injection molds or hot stamping dies is high conductivity tool steel (HTCS 150. Due to its hardness (55 HRC and thermal conductivity at 66 W/mK, this material is difficult to machine by conventional treatment and is being increasingly manufactured by nonconventional technology such as electrical discharge machining (EDM. In the EDM process, material is removed from the workpiece by a series of electrical discharges that cause changes to the surface layers properties. The final state of the surface layer directly influences the durability of the produced elements. This paper presents the influence of EDM process parameters: discharge current Ic and the pulse time ton on surface layer properties. The experimental investigation was carried out with an experimental methodology design. Surface layers properties including roughness 3D parameters, the thickness of the white layer, heat affected zone, tempered layer and occurring micro cracks were investigated and described. The influence of the response surface methodology (RSM of discharge current Ic and the pulse time ton on the thickness of the white layer and roughness parameters Sa, Sds and Ssc were described and established.

High Metal Removal Rate Process for Machining Difficult Materials

Energy Technology Data Exchange (ETDEWEB)

Bates, Robert; McConnell, Elizabeth

2016-06-29

Machining methods across many industries generally require multiple operations to machine and process advanced materials, features with micron precision, and complex shapes. The resulting multiple machining platforms can significantly affect manufacturing cycle time and the precision of the final parts, with a resultant increase in cost and energy consumption. Ultrafast lasers represent a transformative and disruptive technology that removes material with micron precision and in a single step manufacturing process. Such precision results from athermal ablation without modification or damage to the remaining material which is the key differentiator between ultrafast laser technologies and traditional laser technologies or mechanical processes. Athermal ablation without modification or damage to the material eliminates post-processing or multiple manufacturing steps. Combined with the appropriate technology to control the motion of the work piece, ultrafast lasers are excellent candidates to provide breakthrough machining capability for difficult-to-machine materials. At the project onset in early 2012, the project team recognized that substantial effort was necessary to improve the application of ultrafast laser and precise motion control technologies (for micromachining difficult-to-machine materials) to further the aggregate throughput and yield improvements over conventional machining methods. The project described in this report advanced these leading-edge technologies thru the development and verification of two platforms: a hybrid enhanced laser chassis and a multi-application testbed.

MLViS: A Web Tool for Machine Learning-Based Virtual Screening in Early-Phase of Drug Discovery and Development.

Science.gov (United States)

Korkmaz, Selcuk; Zararsiz, Gokmen; Goksuluk, Dincer

2015-01-01

Virtual screening is an important step in early-phase of drug discovery process. Since there are thousands of compounds, this step should be both fast and effective in order to distinguish drug-like and nondrug-like molecules. Statistical machine learning methods are widely used in drug discovery studies for classification purpose. Here, we aim to develop a new tool, which can classify molecules as drug-like and nondrug-like based on various machine learning methods, including discriminant, tree-based, kernel-based, ensemble and other algorithms. To construct this tool, first, performances of twenty-three different machine learning algorithms are compared by ten different measures, then, ten best performing algorithms have been selected based on principal component and hierarchical cluster analysis results. Besides classification, this application has also ability to create heat map and dendrogram for visual inspection of the molecules through hierarchical cluster analysis. Moreover, users can connect the PubChem database to download molecular information and to create two-dimensional structures of compounds. This application is freely available through www.biosoft.hacettepe.edu.tr/MLViS/.

Parameter optimization of electrochemical machining process using black hole algorithm

Science.gov (United States)

Singh, Dinesh; Shukla, Rajkamal

2017-12-01

Advanced machining processes are significant as higher accuracy in machined component is required in the manufacturing industries. Parameter optimization of machining processes gives optimum control to achieve the desired goals. In this paper, electrochemical machining (ECM) process is considered to evaluate the performance of the considered process using black hole algorithm (BHA). BHA considers the fundamental idea of a black hole theory and it has less operating parameters to tune. The two performance parameters, material removal rate (MRR) and overcut (OC) are considered separately to get optimum machining parameter settings using BHA. The variations of process parameters with respect to the performance parameters are reported for better and effective understanding of the considered process using single objective at a time. The results obtained using BHA are found better while compared with results of other metaheuristic algorithms, such as, genetic algorithm (GA), artificial bee colony (ABC) and bio-geography based optimization (BBO) attempted by previous researchers.

Investigation of material removal rate and surface roughness during wire electrical discharge machining (WEDM of Inconel 625 super alloy by cryogenic treated tool electrode

Directory of Open Access Journals (Sweden)

Ashish Goyal

2017-10-01

Full Text Available The present investigation focuses the effect of process parameters on material removal rate (MRR and surface roughness (Ra in wire electric discharge machining of Inconel 625. Machining was done by using a normal zinc coated wire and cryogenic treated zinc coated wire. The experiments were performed by considering different process parameters viz. tool electrode, current intensity, pulse on time, pulse off time, wire feed and wire tension. The thickness of work material and dia. of wire are kept constant. Taguchi L18 (21 * 35 orthogonal array of experimental design is used to perform the experiments. Analysis of variance (ANOVA is employed to optimize the material removal rate and surface roughness. Based on analysis it is found that pulse on time, tool electrode and current intensity are the significant parameters that affect the material removal rate and surface roughness. The scanning electron microscopy (SEM are used to identify the microstructure of the machined work piece.

Control processes and machine protection on ASDEX Upgrade

International Nuclear Information System (INIS)

Raupp, G.; Treutterer, W.; Mertens, V.; Neu, G.; Sips, A.; Zasche, D.; Zehetbauer, Th.

2007-01-01

Safe operation of ASDEX Upgrade is guaranteed by a conventional hierarchy of simple and robust hard-wired systems for personnel and machine protection featuring standardized switch-off procedures. Machine protection and handling of off-normal events is further enhanced and peak and lifetime stress minimized through the plasma control system. Based on a real-time process model supporting safety critical applications with data quality tagging, process self-monitoring, watchdog monitoring and alarm propagation, processes detect complex and critical failures and reliably perform case-sensitive counter measures. Intelligent real-time failure handling is done with hardware or software redundancy and performance degradation, or modification of reference values to continue or terminate discharges with reduced machine stress. Examples implemented so far on ASDEX Upgrade are given, such as recovery from measurement failures, switch-over of redundant actuators, handling of actuator limitations, detection of plasma instabilities, plasma state dependent soft landing, or handling of failed switch-off procedures through breakers disconnecting the machine from grid

Process Optimization of EDM Cutting Process on Tool Steel using Zinc Coated Electrode

Directory of Open Access Journals (Sweden)

Hanizam H.

2017-01-01

Full Text Available In WEDM machining process, surface finish quality depends on intensity and duration of spark plasma. Electrode wire diameter has significant effect on the spark intensity and yet the studies on this matter still less. Therefore, the main objectives of this studies are to compare the different diameters of zinc coated and uncoated brass electrode on H13 tool steel surface roughness. The experiments were conducted on Sodick VZ300L WEDM and work piece material of tool steel AISI H13 block. Electrode of zinc coated brass with diameters of 0.1 mm, 0.2 mm, 0.25 mm and uncoated brass 0.2 mm were used. The surface roughness of cutting was measured using the SUR-FTEST SJ-410 Mitutoyo, surface roughness tester. The results suggest that better surface roughness quality can be achieved through smaller electrode wire diameter. The zinc coated improves flushing ability and sparks intensity resulting in better surface finish of H13 tool steel. New alloys and coating materials shall be experimented to optimized the process further.

“Investigations on the machinability of Waspaloy under dry environment”

Science.gov (United States)

Deepu, J.; Kuppan, P.; SBalan, A. S.; Oyyaravelu, R.

2016-09-01

Nickel based superalloy, Waspaloy is extensively used in gas turbine, aerospace and automobile industries because of their unique combination of properties like high strength at elevated temperatures, resistance to chemical degradation and excellent wear resistance in many hostile environments. It is considered as one of the difficult to machine superalloy due to excessive tool wear and poor surface finish. The present paper is an attempt for removing cutting fluids from turning process of Waspaloy and to make the processes environmentally safe. For this purpose, the effect of machining parameters such as cutting speed and feed rate on the cutting force, cutting temperature, surface finish and tool wear were investigated barrier. Consequently, the strength and tool wear resistance and tool life increased significantly. Response Surface Methodology (RSM) has been used for developing and analyzing a mathematical model which describes the relationship between machining parameters and output variables. Subsequently ANOVA was used to check the adequacy of the regression model as well as each machining variables. The optimal cutting parameters were determined based on multi-response optimizations by composite desirability approach in order to minimize cutting force, average surface roughness and maximum flank wear. The results obtained from the experiments shown that machining of Waspaloy using coated carbide tool with special ranges of parameters, cutting fluid could be completely removed from machining process

Evaluation on machined surface of hardened stainless steel generated by hard turning using coated carbide tools with wiper geometry

International Nuclear Information System (INIS)

Noordin, M.Y.; Kurniawan, D.; Sharif, S.

2007-01-01

Hard turning has been explored to be the finish machining operation for parts made of hardened steel. Its feasibility is determined partially by the quality of the resulting machined surface. This study evaluates the surface integrity of martensitic stainless steel (48 HRC) resulting from hard turning using coated carbide tool with wiper geometry at various cutting speed and feed and compares to that obtained using coated carbide tool with conventional geometry. The wiper coated carbide tool is able to produce machined surface which is of finer finish (Ra is finer than 0.4 μm at most cutting parameters) and yet is similarly inducing only minor microstructural alteration compared to its conventional counterpart. From the view of the chip morphology where continuous type of chip is desired rather than sawtooth chip type, the wiper tool generates continuous chip at almost similar range of cutting parameters compared to the case when using conventional tool. Additionally, the use of wiper tool also induces the preferred compressive residual stress at the machined surface. (author)

A new optimization tool path planning for 3-axis end milling of free-form surfaces based on efficient machining intervals

Science.gov (United States)

Vu, Duy-Duc; Monies, Frédéric; Rubio, Walter

2018-05-01

A large number of studies, based on 3-axis end milling of free-form surfaces, seek to optimize tool path planning. Approaches try to optimize the machining time by reducing the total tool path length while respecting the criterion of the maximum scallop height. Theoretically, the tool path trajectories that remove the most material follow the directions in which the machined width is the largest. The free-form surface is often considered as a single machining area. Therefore, the optimization on the entire surface is limited. Indeed, it is difficult to define tool trajectories with optimal feed directions which generate largest machined widths. Another limiting point of previous approaches for effectively reduce machining time is the inadequate choice of the tool. Researchers use generally a spherical tool on the entire surface. However, the gains proposed by these different methods developed with these tools lead to relatively small time savings. Therefore, this study proposes a new method, using toroidal milling tools, for generating toolpaths in different regions on the machining surface. The surface is divided into several regions based on machining intervals. These intervals ensure that the effective radius of the tool, at each cutter-contact points on the surface, is always greater than the radius of the tool in an optimized feed direction. A parallel plane strategy is then used on the sub-surfaces with an optimal specific feed direction for each sub-surface. This method allows one to mill the entire surface with efficiency greater than with the use of a spherical tool. The proposed method is calculated and modeled using Maple software to find optimal regions and feed directions in each region. This new method is tested on a free-form surface. A comparison is made with a spherical cutter to show the significant gains obtained with a toroidal milling cutter. Comparisons with CAM software and experimental validations are also done. The results show the

a design to digitalize hydraulic cylinder control of a machine tool

African Journals Online (AJOL)

Dr Obe

1995-09-01

Sep 1, 1995 ... Department of Mechanical Engineering. FEDERAL UNIVERSITY OF TECHNOLOGY, OWERRI,. P.M.B. 1526, OWERRI. ABSTRACT. Conventionally hydraulic piston - cylinder servos are actuated using analogue controls for machine tool axis drives. In this paper a design of the axis control system of an NC ...

MODEL OF THE QUALITY MANAGEMENT SYSTEM OF A MACHINE TOOL COMPANY

Directory of Open Access Journals (Sweden)

Катерина Вікторівна КОЛЕСНІКОВА

2016-02-01

Full Text Available Development of models and methods such that would improve the competitive position of enterprises by improving management processes is an important task of project management. Lack of project management within the information technology and continuous improvement of methods for the management of the environment, interaction, community, value and trust, based on the strategic objectives of enterprises and based on models that take into account the relationship of the system, resulting in significant material and resource costs. In the current work the improvement of the quality management system machine-tool company HC MIKRON® and proved that the introduction of new processes critical analysis requirements for products, support processes of the products to consumers and enterprises in the formation of a system of responsibility, division of responsibilities and reporting (according to ISO 9001: 2009 is an important scientific and reasonable step to improve the level of technological maturity and structural modernization of enterprise management. For the improved structure of the analysis model and test the properties of ergodicity, as a condition of efficiency, a new quality management system.

Evaluation of Surface Roughness and Power Consumption in Machining FCD 450 Cast Iron using Coated and Uncoated Irregular Milling Tools

International Nuclear Information System (INIS)

Yusoff, Ahmad Razlan; Arsyad, Fitriyanti

2016-01-01

In this project, the effects of different cutting parameters on surface roughness and power consumption when machining FCD450 cast iron were studied using coated and uncoated irregular milling tool geometry of variable helix and pitch. Their responses on roughness and power consumption were evaluated based on the spindle speed, feed rate, and depth of cut, machining length and machining time. Results showed that except spindle speed and machining length, other parameters such as feed rate, axial and radial depth of cut and also machining time proportionate with surface roughness. The power consumption proportionately increase for all cutting parameters except feedrate. It is showed that the average decrement 27.92 percent for surface roughness and average decrement 9.32 percent for power consumption by using coated compared to uncoated tool. Optimum cutting parameters for both minimum surface roughness and power consumption can be determined. The coated tools performed better than uncoated milling tools for responses of surface roughness and power consumption to increase machining productivity and profit. (paper)

Effect of machining parameters on surface integrity of silicon carbide ceramic using end electric discharge milling and mechanical grinding hybrid machining

International Nuclear Information System (INIS)

Ji, Renjie; Liu, Yonghong; Zhang, Yanzhen; Cai, Baoping; Li, Xiaopeng; Zheng, Chao

2013-01-01

A novel hybrid process that integrates end electric discharge (ED) milling and mechanical grinding is proposed. The process is able to effectively machine a large surface area on SiC ceramic with good surface quality and fine working environmental practice. The polarity, pulse on-time, and peak current are varied to explore their effects on the surface integrity, such as surface morphology, surface roughness, micro-cracks, and composition on the machined surface. The results show that positive tool polarity, short pulse on-time, and low peak current cause a fine surface finish. During the hybrid machining of SiC ceramic, the material is mainly removed by end ED milling at rough machining mode, whereas it is mainly removed by mechanical grinding at finish machining mode. Moreover, the material from the tool can transfer to the workpiece, and a combination reaction takes place during machining.

Development of a new universal machine device for eccentric shafts processing

Directory of Open Access Journals (Sweden)

Михайло Володимирович Маргуліс

2015-11-01

Full Text Available The analysis of the existing lathe devices for machining of eccentric details and the reasons for the development of a new universal machine device– a shifting lathe center-have been described in the article. The device design, its operating principle, the main parts functions and elements of the case were described and illustrated One of the most complicated cases of eccentric shaft turning, that is turning design and scheme of the eccentric shaft of precessional harmonic drive with intermediate rolling bodies when the proposed device was used was described in the article. The shifting lathe center can reduce the complexity of the machine tool for turning eccentric shafts configuration. The ability to install the shifting center in the tailstock and headstock of the lathe, and the availability of the leash makes it possible to turn various eccentric parts, conical surfaces, to apply the device to compensate for the emerging taper in cylindrical shafts processing. All the above mentioned makes the device universal. The specific feature of this device is the use of a ball center and the connection of the centering element with the adjusting screw by a fine thread screw, this increasing the precision machining. The protective cover of the device makes it possible to reduce the chance of possible injury from protruding parts of the device, namely the leash and the centering element

Proceedings of IEEE Machine Learning for Signal Processing Workshop XVI

DEFF Research Database (Denmark)

Larsen, Jan

These proceedings contains refereed papers presented at the sixteenth IEEE Workshop on Machine Learning for Signal Processing (MLSP'2006), held in Maynooth, Co. Kildare, Ireland, September 6-8, 2006. This is a continuation of the IEEE Workshops on Neural Networks for Signal Processing (NNSP......). The name of the Technical Committee, hence of the Workshop, was changed to Machine Learning for Signal Processing in September 2003 to better reflect the areas represented by the Technical Committee. The conference is organized by the Machine Learning for Signal Processing Technical Committee...... the same standard as the printed version and facilitates the reading and searching of the papers. The field of machine learning has matured considerably in both methodology and real-world application domains and has become particularly important for solution of problems in signal processing. As reflected...

A Tool for Assessing the Text Legibility of Digital Human Machine Interfaces

Energy Technology Data Exchange (ETDEWEB)

Roger Lew; Ronald L. Boring; Thomas A. Ulrich

2015-08-01

A tool intended to aid qualified professionals in the assessment of the legibility of text presented on a digital display is described. The assessment of legibility is primarily for the purposes of designing and analyzing human machine interfaces in accordance with NUREG-0700 and MIL-STD 1472G. The tool addresses shortcomings of existing guidelines by providing more accurate metrics of text legibility with greater sensitivity to design alternatives.

Financial signal processing and machine learning

CERN Document Server

Kulkarni,Sanjeev R; Dmitry M. Malioutov

2016-01-01

The modern financial industry has been required to deal with large and diverse portfolios in a variety of asset classes often with limited market data available. Financial Signal Processing and Machine Learning unifies a number of recent advances made in signal processing and machine learning for the design and management of investment portfolios and financial engineering. This book bridges the gap between these disciplines, offering the latest information on key topics including characterizing statistical dependence and correlation in high dimensions, constructing effective and robust risk measures, and their use in portfolio optimization and rebalancing. The book focuses on signal processing approaches to model return, momentum, and mean reversion, addressing theoretical and implementation aspects. It highlights the connections between portfolio theory, sparse learning and compressed sensing, sparse eigen-portfolios, robust optimization, non-Gaussian data-driven risk measures, graphical models, causal analy...

Optimization processing of the elementary surfaces of the composite body parts on machines such as «machining center»

Directory of Open Access Journals (Sweden)

Євген Іванович Іванов

2015-11-01

Full Text Available This article describes the processing optimization and minimizing the number of tool changes. Two versions for setting the processing scheme, according to the rules for processing scheme setting for the «processing center» machines were offered. In the first version, according to the classical technology processing of each hole is carried out over all the passes, providing for the required accuracy of sizes and shapes. In the second version the number of tool changes is minimized. This method consists of dividing all the holes into groups according to their diameters. All the holes of the same diameter are processed over one pass; then the tools are changed and the holes of some other diameter are processed and so on. Let us consider the optimization problem. The traveling salesman problem - is one of the most famous problems in the theory of combinatorics. The problem is as follows: a travelling salesman (hawker must find the most advantageous route coming out of a town and visiting all other towns from 2,3,…to...n just once in an unknown order and come back to the first town. The distances between all the towns are known. It is necessary to determine in what order the Salesman must visit the towns so that the route should be the shortest. There exists just one absolutely precise algorithm - sorting options. This option is the longest, so the most inefficient. There are also simpler methods to solve the traveling salesman problem: the branch and bound algorithm and ant colony method and method of genetic algorithms

Research on criticality analysis method of CNC machine tools components under fault rate correlation

Science.gov (United States)

Gui-xiang, Shen; Xian-zhuo, Zhao; Zhang, Ying-zhi; Chen-yu, Han

2018-02-01

In order to determine the key components of CNC machine tools under fault rate correlation, a system component criticality analysis method is proposed. Based on the fault mechanism analysis, the component fault relation is determined, and the adjacency matrix is introduced to describe it. Then, the fault structure relation is hierarchical by using the interpretive structure model (ISM). Assuming that the impact of the fault obeys the Markov process, the fault association matrix is described and transformed, and the Pagerank algorithm is used to determine the relative influence values, combined component fault rate under time correlation can obtain comprehensive fault rate. Based on the fault mode frequency and fault influence, the criticality of the components under the fault rate correlation is determined, and the key components are determined to provide the correct basis for equationting the reliability assurance measures. Finally, taking machining centers as an example, the effectiveness of the method is verified.

Study of PVD AlCrN Coating for Reducing Carbide Cutting Tool Deterioration in the Machining of Titanium Alloys.

Science.gov (United States)

Cadena, Natalia L; Cue-Sampedro, Rodrigo; Siller, Héctor R; Arizmendi-Morquecho, Ana M; Rivera-Solorio, Carlos I; Di-Nardo, Santiago

2013-05-24

The manufacture of medical and aerospace components made of titanium alloys and other difficult-to-cut materials requires the parallel development of high performance cutting tools coated with materials capable of enhanced tribological and resistance properties. In this matter, a thin nanocomposite film made out of AlCrN (aluminum-chromium-nitride) was studied in this research, showing experimental work in the deposition process and its characterization. A heat-treated monolayer coating, competitive with other coatings in the machining of titanium alloys, was analyzed. Different analysis and characterizations were performed on the manufactured coating by scanning electron microscopy and energy-dispersive X-ray spectroscopy (SEM-EDXS), and X-ray diffraction (XRD). Furthermore, the mechanical behavior of the coating was evaluated through hardness test and tribology with pin-on-disk to quantify friction coefficient and wear rate. Finally, machinability tests using coated tungsten carbide cutting tools were executed in order to determine its performance through wear resistance, which is a key issue of cutting tools in high-end cutting at elevated temperatures. It was demonstrated that the specimen (with lower friction coefficient than previous research) is more efficient in machinability tests in Ti6Al4V alloys. Furthermore, the heat-treated monolayer coating presented better performance in comparison with a conventional monolayer of AlCrN coating.

Cutting Zone Temperature Identification During Machining of Nickel Alloy Inconel 718

Science.gov (United States)

Czán, Andrej; Daniš, Igor; Holubják, Jozef; Zaušková, Lucia; Czánová, Tatiana; Mikloš, Matej; Martikáň, Pavol

2017-12-01

Quality of machined surface is affected by quality of cutting process. There are many parameters, which influence on the quality of the cutting process. The cutting temperature is one of most important parameters that influence the tool life and the quality of machined surfaces. Its identification and determination is key objective in specialized machining processes such as dry machining of hard-to-machine materials. It is well known that maximum temperature is obtained in the tool rake face at the vicinity of the cutting edge. A moderate level of cutting edge temperature and a low thermal shock reduce the tool wear phenomena, and a low temperature gradient in the machined sublayer reduces the risk of high tensile residual stresses. The thermocouple method was used to measure the temperature directly in the cutting zone. An original thermocouple was specially developed for measuring of temperature in the cutting zone, surface and subsurface layers of machined surface. This paper deals with identification of temperature and temperature gradient during dry peripheral milling of Inconel 718. The measurements were used to identification the temperature gradients and to reconstruct the thermal distribution in cutting zone with various cutting conditions.

Development of hole inspection program using touch trigger probe on CNC machine tools

International Nuclear Information System (INIS)

Lee, Chan Ho; Lee, Eung Suk

2012-01-01

According to many customers' requests, optical measurement module (OMM) applications using automatic measuring devices to measure the machined part rapidly on a machine tool have increased steeply. Touch trigger probes are being used for job setup and feature inspection as automatic measuring devices, and this makes quality checking and machining compensation possible. Therefore, in this study, the use of touch trigger probes for accurate measurement of the machined part has been studied and a macro program for a hole measuring cycle has been developed. This hole is the most common feature to be measured, but conventional methods are still not free from measuring error. In addition, the eccentricity change of the least square circle was simulated according to the roundness error in a hole measurement. To evaluate the reliability of this study, the developed hole measuring program was executed to measure the hole plate on the machine and verify the roundness error in the eccentricity simulation result

Advanced SLARette delivery machine

International Nuclear Information System (INIS)

Bodner, R.R.

1995-01-01

SLARette 1 equipment, comprising of a SLARette Delivery Machine, SLAR Tools, SLAR power supplies and SLAR Inspection Systems was designed, developed and manufactured to service fuel channels of CANDU 6 stations during the regular yearly station outages. The Mark 2 SLARette Delivery Machine uses a Push Tube system to provide the axial and rotary movements of the SLAR Tool. The Push Tubes are operated remotely but must be attached and removed manually. Since this operation is performed at the Reactor face, there is radiation dose involved for the workers. An Advanced SLARette Delivery Machine which incorporates a computer controlled telescoping Ram in the place of the Push Tubes has been recently designed and manufactured. Utilization of the Advanced SLARette Delivery Machine significantly reduces the amount of radiation dose picked up by the workers because the need to have workers at the face of the Reactor during the SLARette operation is greatly reduced. This paper describes the design, development and manufacturing process utilized to produce the Advanced SLARette Delivery Machine and the experience gained during the Gentilly-2 NGS Spring outage. (author)

Nano Mechanical Machining Using AFM Probe

Science.gov (United States)

Mostofa, Md. Golam

Complex miniaturized components with high form accuracy will play key roles in the future development of many products, as they provide portability, disposability, lower material consumption in production, low power consumption during operation, lower sample requirements for testing, and higher heat transfer due to their very high surface-to-volume ratio. Given the high market demand for such micro and nano featured components, different manufacturing methods have been developed for their fabrication. Some of the common technologies in micro/nano fabrication are photolithography, electron beam lithography, X-ray lithography and other semiconductor processing techniques. Although these methods are capable of fabricating micro/nano structures with a resolution of less than a few nanometers, some of the shortcomings associated with these methods, such as high production costs for customized products, limited material choices, necessitate the development of other fabricating techniques. Micro/nano mechanical machining, such an atomic force microscope (AFM) probe based nano fabrication, has, therefore, been used to overcome some the major restrictions of the traditional processes. This technique removes material from the workpiece by engaging micro/nano size cutting tool (i.e. AFM probe) and is applicable on a wider range of materials compared to the photolithographic process. In spite of the unique benefits of nano mechanical machining, there are also some challenges with this technique, since the scale is reduced, such as size effects, burr formations, chip adhesions, fragility of tools and tool wear. Moreover, AFM based machining does not have any rotational movement, which makes fabrication of 3D features more difficult. Thus, vibration-assisted machining is introduced into AFM probe based nano mechanical machining to overcome the limitations associated with the conventional AFM probe based scratching method. Vibration-assisted machining reduced the cutting forces

IEEE International Workshop on Machine Learning for Signal Processing: Preface

DEFF Research Database (Denmark)

Tao, Jianhua

The 21st IEEE International Workshop on Machine Learning for Signal Processing will be held in Beijing, China, on September 18–21, 2011. The workshop series is the major annual technical event of the IEEE Signal Processing Society's Technical Committee on Machine Learning for Signal Processing...

Electromechanical model of machine for vibroabrasive treatment of machine parts

OpenAIRE

Gorbatiyk, Ruslan; Palamarchuk, Igor; Chubyk, Roman

2015-01-01

A lot of operations on trimming clean and finishing – stripping up treatment, first of all, removing of burrs, rounding and processing of borders, until recently time was carried out by hand, and hardly exposed to automation and became a serious obstacle in subsequent growth of the labor productivity. Machines with free kinematics connection between a tool and the treating parts is provided by the printing-down of all of the surface of the machine parts, that allows us to effectively treat bo...

Support Vector Machines as tools for mortality graduation

Directory of Open Access Journals (Sweden)

Alberto Olivares

2011-01-01

Full Text Available A topic of interest in demographic and biostatistical analysis as well as in actuarial practice,is the graduation of the age-specific mortality pattern. A classical graduation technique is to fit parametric models. Recently, particular emphasis has been given to graduation using nonparametric techniques. Support Vector Machines (SVM is an innovative methodology that could be utilized for mortality graduation purposes. This paper evaluates SVM techniques as tools for graduating mortality rates. We apply SVM to empirical death rates from a variety of populations and time periods. For comparison, we also apply standard graduation techniques to the same data.

Achieving precision in high density batch mode micro-electro-discharge machining

International Nuclear Information System (INIS)

Richardson, Mark T; Gianchandani, Yogesh B

2008-01-01

This paper reports a parametric study of batch mode micro-electro-discharge machining (µEDM) of high density features in stainless steel. Lithographically fabricated copper tools with single cross, parallel line and 8 × 8 circle/square array features of 5–100 µm width and 5–75 µm spacing were used to quantify trends in machining tolerance and the impact of debris accumulation. As the tool feature density is increased, debris accumulation effects begin to dominate, eventually degrading both tool and workpiece. Two independent techniques for mitigating this debris buildup are separately investigated. The first is a passivation coating which suppresses spurious discharges triggered from the sidewalls of the machining tool. By this method, the mean tool wear rate decreases from a typical of about 34% to 1.7% and machining non-uniformity reduces from 4.9 µm to 1.1 µm across the workpiece. The second technique involves a two-step machining process that enhances the hydrodynamic removal of machining debris compared to standard methods. This improves surface and edge finish, machining time and tool wear

Using machine-learning methods to analyze economic loss function of quality management processes

Science.gov (United States)

Dzedik, V. A.; Lontsikh, P. A.

2018-05-01

During analysis of quality management systems, their economic component is often analyzed insufficiently. To overcome this issue, it is necessary to withdraw the concept of economic loss functions from tolerance thinking and address it. Input data about economic losses in processes have a complex form, thus, using standard tools to solve this problem is complicated. Use of machine learning techniques allows one to obtain precise models of the economic loss function based on even the most complex input data. Results of such analysis contain data about the true efficiency of a process and can be used to make investment decisions.

Using internally cooled cutting tools in the machining of difficult-to-cut materials based on Waspaloy

Directory of Open Access Journals (Sweden)

Yahya Isik

2016-05-01

Full Text Available Nickel-based superalloys such as Waspaloy are used for engine components and in the nuclear industry, where considerable strength and corrosion resistance at high operating temperatures are called for. These characteristics of such alloys cause increases in cutting temperature and resultant tool damage, even at low cutting speeds and low feed rates. Thus, they are classified as difficult-to-cut materials. This article presents a cooling method to be used in metal cutting based on a tool holder with a closed internal cooling system with cooling fluid circulating inside. Hence, a green cooling method that does not harm the environment and is efficient in removing heat from the cutting zone was developed. A series of cutting experiments were conducted to investigate the practicality and effectiveness of the internally cooled tool model. The developed system achieved up to 13% better surface quality than with dry machining, and tool life was extended by 12%. The results clearly showed that with the reduced cutting temperature of the internal cooling, it was possible to control the temperature and thus prevent reaching the critical cutting temperature during the turning process, which is vitally important in extending tool life during the processing of Waspaloy.

Performance of Ti-multilayer coated tool during machining of MDN431 alloyed steel

Science.gov (United States)

Badiger, Pradeep V.; Desai, Vijay; Ramesh, M. R.

2018-04-01

Turbine forgings and other components are required to be high resistance to corrosion and oxidation because which they are highly alloyed with Ni and Cr. Midhani manufactures one of such material MDN431. It's a hard-to-machine steel with high hardness and strength. PVD coated insert provide an answer to problem with its state of art technique on the WC tool. Machinability studies is carried out on MDN431 steel using uncoated and Ti-multilayer coated WC tool insert using Taguchi optimisation technique. During the present investigation, speed (398-625rpm), feed (0.093-0.175mm/rev), and depth of cut (0.2-0.4mm) varied according to Taguchi L9 orthogonal array, subsequently cutting forces and surface roughness (Ra) were measured. Optimizations of the obtained results are done using Taguchi technique for cutting forces and surface roughness. Using Taguchi technique linear fit model regression analysis carried out for the combination of each input variable. Experimented results are compared and found the developed model is adequate which supported by proof trials. Speed, feed and depth of cut are linearly dependent on the cutting force and surface roughness for uncoated insert whereas Speed and depth of cut feed is inversely dependent in coated insert for both cutting force and surface roughness. Machined surface for coated and uncoated inserts during machining of MDN431 is studied using optical profilometer.

Reliability concepts applied to cutting tool change time

Energy Technology Data Exchange (ETDEWEB)

Patino Rodriguez, Carmen Elena, E-mail: cpatino@udea.edu.c [Department of Industrial Engineering, University of Antioquia, Medellin (Colombia); Department of Mechatronics and Mechanical Systems, Polytechnic School, University of Sao Paulo, Sao Paulo (Brazil); Francisco Martha de Souza, Gilberto [Department of Mechatronics and Mechanical Systems, Polytechnic School, University of Sao Paulo, Sao Paulo (Brazil)

2010-08-15

This paper presents a reliability-based analysis for calculating critical tool life in machining processes. It is possible to determine the running time for each tool involved in the process by obtaining the operations sequence for the machining procedure. Usually, the reliability of an operation depends on three independent factors: operator, machine-tool and cutting tool. The reliability of a part manufacturing process is mainly determined by the cutting time for each job and by the sequence of operations, defined by the series configuration. An algorithm is presented to define when the cutting tool must be changed. The proposed algorithm is used to evaluate the reliability of a manufacturing process composed of turning and drilling operations. The reliability of the turning operation is modeled based on data presented in the literature, and from experimental results, a statistical distribution of drilling tool wear was defined, and the reliability of the drilling process was modeled.

Reliability concepts applied to cutting tool change time

International Nuclear Information System (INIS)

Patino Rodriguez, Carmen Elena; Francisco Martha de Souza, Gilberto

2010-01-01

This paper presents a reliability-based analysis for calculating critical tool life in machining processes. It is possible to determine the running time for each tool involved in the process by obtaining the operations sequence for the machining procedure. Usually, the reliability of an operation depends on three independent factors: operator, machine-tool and cutting tool. The reliability of a part manufacturing process is mainly determined by the cutting time for each job and by the sequence of operations, defined by the series configuration. An algorithm is presented to define when the cutting tool must be changed. The proposed algorithm is used to evaluate the reliability of a manufacturing process composed of turning and drilling operations. The reliability of the turning operation is modeled based on data presented in the literature, and from experimental results, a statistical distribution of drilling tool wear was defined, and the reliability of the drilling process was modeled.

2015 International Conference on Machine Learning and Signal Processing

CERN Document Server

Woo, Wai; Sulaiman, Hamzah; Othman, Mohd; Saat, Mohd

2016-01-01

This book presents important research findings and recent innovations in the field of machine learning and signal processing. A wide range of topics relating to machine learning and signal processing techniques and their applications are addressed in order to provide both researchers and practitioners with a valuable resource documenting the latest advances and trends. The book comprises a careful selection of the papers submitted to the 2015 International Conference on Machine Learning and Signal Processing (MALSIP 2015), which was held on 15–17 December 2015 in Ho Chi Minh City, Vietnam with the aim of offering researchers, academicians, and practitioners an ideal opportunity to disseminate their findings and achievements. All of the included contributions were chosen by expert peer reviewers from across the world on the basis of their interest to the community. In addition to presenting the latest in design, development, and research, the book provides access to numerous new algorithms for machine learni...

Study on Surface Integrity of AISI 1045 Carbon Steel when machined by Carbide Cutting Tool under wet conditions

Directory of Open Access Journals (Sweden)

Tamin N. Fauzi

2017-01-01

Full Text Available This paper presents the evaluation of surface roughness and roughness profiles when machining carbon steel under wet conditions with low and high cutting speeds. The workpiece materials and cutting tools selected in this research were AISI 1045 carbon steel and canela carbide inserts graded PM25, respectively. The cutting tools undergo machining tests by CNC turning operations and their performances were evaluated by their surface roughness value and observation of the surface roughness profile. The machining tests were held at varied cutting speeds of 35 to 53 m/min, feed rate of 0.15 to 0.50 mm/rev and a constant depth of cut of 1 mm. From the analysis, it was found that surface roughness increased as the feed rate increased. Varian of surface roughness was suspected due to interaction between cutting speeds and feed rates as well as nose radius conditions; whether from tool wear or the formation of a built-up edge. This study helps us understand the effect of cutting speed and feed rate on surface integrity, when machining AISI 1045 carbon steel using carbide cutting tools, under wet cutting conditions.

MECHANISMS OF CUTTING BLADE WEAR AND THEIR INFLUENCE ON CUTTING ABILITY OF THE TOOL DURING MACHINING OF SPECIAL ALLOYS

Directory of Open Access Journals (Sweden)

Tomáš Zlámal

2016-09-01

Full Text Available With increased requirements for quality and shelf life of machined parts there is also a higher share of the use of material with specific properties that are identified by the term “superalloys”. These materials differ from common steels by mechanical and physical properties that cause their worse machinability. During machining of “superalloys” worse machinability has negative influence primarily on the amount of cutting edge wear, which shortens durability of the cutting tool. The goal of experimental activity shown in this contribution is to determine individual mechanisms of the cutting edge wear and their effects on the cutting ability during high speed machining of nickel superalloy. A specific exchangeable cutting insert made from cubic boric nitride was used for machining of the 625 material according to ASM 5666F. The criteria to evaluate cutting ability and durability of the cutting tool became selected parameters of surface integrity and quality of the machined surface.

The impact of process variables and wear characteristics on the cutting tool performance using Finite Element Analysis

OpenAIRE

Jiang, Xiaoheng

2016-01-01

The frequent failure of cutting tool in the cutting process may cause a huge loss of money and time especially for hard to machine materials such as titanium alloys. Thus this study is mainly focused on the impact of wear characteristics and process variables on the cutting tool which is ignored by most of researchers. A thermo-mechanical finite element model of orthogonal metal cutting with segment chip formation is presented. This model can be used to predict the process performance in the ...

Comparison between microfabrication technologies for metal tooling

DEFF Research Database (Denmark)

Uriarte, L.; Herrero, A.; Ivanov, A.

2006-01-01

microtechnologies for processing tooling inserts made of metal. The following technologies have been analysed: micromilling, micro-electrodischarge machining (EDM, including wire-EDM, sinking-EDM, and EDM-milling), laser micromachining, electroforming, and electrochemical milling (ECF) (an electrochemical machining...... innovative process proposed by HSG-IMAT). Considered tool-insert materials are nickel for electroforming, stainless steel for ECF, and tool steel (AISI H13) for all other processes. Typical features (ribs, channels, pins, and holes) required by micro-optics, microfluidics, and sensor and actuator...

Investigation of approximate models of experimental temperature characteristics of machines

Science.gov (United States)

Parfenov, I. V.; Polyakov, A. N.

2018-05-01

This work is devoted to the investigation of various approaches to the approximation of experimental data and the creation of simulation mathematical models of thermal processes in machines with the aim of finding ways to reduce the time of their field tests and reducing the temperature error of the treatments. The main methods of research which the authors used in this work are: the full-scale thermal testing of machines; realization of various approaches at approximation of experimental temperature characteristics of machine tools by polynomial models; analysis and evaluation of modelling results (model quality) of the temperature characteristics of machines and their derivatives up to the third order in time. As a result of the performed researches, rational methods, type, parameters and complexity of simulation mathematical models of thermal processes in machine tools are proposed.

MEASUREMENT OF INDOOR AIR EMISSIONS FROM DRY-PROCESS PHOTOCOPY MACHINES

Science.gov (United States)

The article provides background information on indoor air emissions from office equipment, with emphasis on dry-process photocopy machines. The test method is described in detail along with results of a study to evaluate the test method using four dry-process photocopy machines. ...

Influence of minimum quantity of lubricant (MQL on tool life of carbide cutting tools during milling process of steel AISI 1018

Directory of Open Access Journals (Sweden)

Diego Núñez

2017-03-01

Full Text Available Nowadays, high productivity of machining is an important issue to obtain economic benefits in the industry. This purpose could be reached with high cutting velocity and feed rate. However, the inherently behavior produce high temperatures in the interface of couple cutting tool/workpiece. Many cutting fluids have been developed to control temperature in process and increase tool life. The objective of this paper is to compare the carbide milling tool wear using different systems cutting fluids: flood and minimum quantity of lubrication (MQL. The values of carbide milling cutting tool wear was evaluate according with the standard ISO 8688-1 1989. The experimental results showed that using MQL reduces significantly (about 40% tool wear in milling AISI 1018 steel at industrial cutting conditions.

Obtainment, machining and wear of metal matrix composites processed by powder metallurgy

International Nuclear Information System (INIS)

Jesus, Edilson Rosa Barbosa de.

1998-01-01

The aim of this investigation was the obtainment of metal matrix composites (MMC) by the route of powder metallurgy, and the valuation of these materials with relation to their machining and wear characteristics. Firstly, were obtained pure commercial aluminium matrix composites materials, with 5, 10 and 15% volumetric fraction of silicon carbide particles. Was also obtained a material without reinforcement particles in order to verify by comparison, the influence of addition of reinforcement particles. The obtained materials were characterized physics (hydrostatic density), mechanics (hardness and tensile tests) and microstructurally (optical microscopy and scanning electron microscopy). The results showed a homogeneous distribution of reinforcement particles in the composite, and improvement in the mechanical properties, mainly tensile strength (UTS) in comparison to the unreinforced material. After, tests were made to verify the materials behavior during machining and to check the performance of several tool materials (cemented carbide, ceramics and polycrystalline diamond). In these tests, values of the cutting force were measured by instrumented tool-holders. Phenomena such as tool wear, built-up edge formation and mechanism of chip formation were also observed and evaluated. The results from the cemented carbide tool tests, were utilised for the machinability index determination of each material. These results were applied to the Taylor equation and the equation constants for each material and test conditions were determined. The results showed that the inclusion of silicon carbide particles made extremely difficult the machining of the composites, and only with diamond tool, satisfactory results were obtained. At last, wear tests were performed to verify the influence of the reinforcement particles in the characteristics of wear resistance of the materials. The results obtained were utilized in the wear coefficient determination for each material. The

A novel framework for diagnosing automatic tool changer and tool life based on cloud computing

Directory of Open Access Journals (Sweden)

Shang-Liang Chen

2016-03-01

Full Text Available Tool change is one among the most frequently performed machining processes, and if there is improper percussion as the tool’s position is changed, the spindle bearing can be damaged. A spindle malfunction can cause problems, such as a knife being dropped or bias in a machined hole. The measures currently taken to avoid such issues, which arose from the available machine tools, only involve determining whether the clapping knife’s state is correct using a spindle and the air adhesion method, which is also used to satisfy the high precision required from mechanical components. Therefore, it cannot be used with any type of machine tool; in addition, improper tapping of the spindle during an automatic tool change cannot be detected. Therefore, this study proposes a new type of diagnostic framework that combines cloud computing and vibration sensors, among of which, tool change is automatically diagnosed using an architecture to identify abnormalities and thereby enhances the reliability and productivity of the machine and equipment.

Study of Tool Wear Mechanisms and Mathematical Modeling of Flank Wear During Machining of Ti Alloy (Ti6Al4V)

Science.gov (United States)

Chetan; Narasimhulu, A.; Ghosh, S.; Rao, P. V.

2015-07-01

Machinability of titanium is poor due to its low thermal conductivity and high chemical affinity. Lower thermal conductivity of titanium alloy is undesirable on the part of cutting tool causing extensive tool wear. The main task of this work is to predict the various wear mechanisms involved during machining of Ti alloy (Ti6Al4V) and to formulate an analytical mathematical tool wear model for the same. It has been found from various experiments that adhesive and diffusion wear are the dominating wear during machining of Ti alloy with PVD coated tungsten carbide tool. It is also clear from the experiments that the tool wear increases with the increase in cutting parameters like speed, feed and depth of cut. The wear model was validated by carrying out dry machining of Ti alloy at suitable cutting conditions. It has been found that the wear model is able to predict the flank wear suitably under gentle cutting conditions.

Application of three dimensional finite element modeling for the simulation of machining processes

International Nuclear Information System (INIS)

Fischer, C.E.; Wu, W.T.; Chigurupati, P.; Jinn, J.T.

2004-01-01

For many years, metal cutting simulations have been performed using two dimensional approximations of the actual process. Factors such as chip morphology, cutting force, temperature, and tool wear can all be predicted on the computer. However, two dimensional simulation is limited to processes which are orthogonal, or which can be closely approximated as orthogonal.Advances in finite element technology, coupled with continuing improvement in the availability of low cost, high performance computer hardware, have made the three dimensional simulation of a large variety of metal cutting processes practical. Specific improvements include efficient FEM solvers, and robust adaptive remeshing. As researchers continue to gain an improved understanding of wear, material representation, tool coatings, fracture, and other such phenomena, the machining simulation system also must adapt to incorporate these evolving models.To demonstrate the capabilities of the 3D simulation system, a variety of drilling, milling, and turning processes have been simulated and will be presented in this paper. Issues related to computation time and simulation accuracy will also be addressed

Tuning of tool dynamics for increased stability of parallel (simultaneous) turning processes

Science.gov (United States)

Ozturk, E.; Comak, A.; Budak, E.

2016-01-01

Parallel (simultaneous) turning operations make use of more than one cutting tool acting on a common workpiece offering potential for higher productivity. However, dynamic interaction between the tools and workpiece and resulting chatter vibrations may create quality problems on machined surfaces. In order to determine chatter free cutting process parameters, stability models can be employed. In this paper, stability of parallel turning processes is formulated in frequency and time domain for two different parallel turning cases. Predictions of frequency and time domain methods demonstrated reasonable agreement with each other. In addition, the predicted stability limits are also verified experimentally. Simulation and experimental results show multi regional stability diagrams which can be used to select most favorable set of process parameters for higher stable material removal rates. In addition to parameter selection, developed models can be used to determine the best natural frequency ratio of tools resulting in the highest stable depth of cuts. It is concluded that the most stable operations are obtained when natural frequency of the tools are slightly off each other and worst stability occurs when the natural frequency of the tools are exactly the same.

Surface structuring of boron doped CVD diamond by micro electrical discharge machining

Science.gov (United States)

Schubert, A.; Berger, T.; Martin, A.; Hackert-Oschätzchen, M.; Treffkorn, N.; Kühn, R.

2018-05-01

Boron doped diamond materials, which are generated by Chemical Vapor Deposition (CVD), offer a great potential for the application on highly stressed tools, e. g. in cutting or forming processes. As a result of the CVD process rough surfaces arise, which require a finishing treatment in particular for the application in forming tools. Cutting techniques such as milling and grinding are hardly applicable for the finish machining because of the high strength of diamond. Due to its process principle of ablating material by melting and evaporating, Electrical Discharge Machining (EDM) is independent of hardness, brittleness or toughness of the workpiece material. EDM is a suitable technology for machining and structuring CVD diamond, since boron doped CVD diamond is electrically conductive. In this study the ablation characteristics of boron doped CVD diamond by micro electrical discharge machining are investigated. Experiments were carried out to investigate the influence of different process parameters on the machining result. The impact of tool-polarity, voltage and discharge energy on the resulting erosion geometry and the tool wear was analyzed. A variation in path overlapping during the erosion of planar areas leads to different microstructures. The results show that micro EDM is a suitable technology for finishing of boron doped CVD diamond.

4th Machining Innovations Conference

CERN Document Server

2014-01-01

This contributed volume contains the research results presented at the 4th Machining Innovations Conference, Hannover, September 2013. The topic of the conference are new production technologies in aerospace industry and the focus is on energy efficient machine tools as well as sustainable process planning. The target audience primarily comprises researchers and experts in the field but the book may also be beneficial for graduate students.

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part.

Science.gov (United States)

Ahmed, Yassmin Seid; Fox-Rabinovich, German; Paiva, Jose Mario; Wagg, Terry; Veldhuis, Stephen Clarence

2017-10-25

During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool-chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iron and Steel Institute (AISI) 304 stainless steel has a high tendency to form an unstable BUE, leading to deterioration of the surface quality. Therefore, it is necessary to understand the nature of the surface integrity induced during machining operations. Although many reports have been published on the effect of tool wear during machining of AISI 304 stainless steel on surface integrity, studies on the influence of the BUE phenomenon in the stable state of wear have not been investigated so far. The main goal of the present work is to investigate the close link between the BUE formation, surface integrity and cutting forces in the stable sate of wear for uncoated cutting tool during the cutting tests of AISI 304 stainless steel. The cutting parameters were chosen to induce BUE formation during machining. X-ray diffraction (XRD) method was used for measuring superficial residual stresses of the machined surface through the stable state of wear in the cutting and feed directions. In addition, surface roughness of the machined surface was investigated using the Alicona microscope and Scanning Electron Microscopy (SEM) was used to reveal the surface distortions created during the cutting process, combined with chip undersurface analyses. The investigated BUE formation during the stable state of wear showed that the BUE can cause a significant improvement in the surface integrity and cutting forces. Moreover, it can be used to compensate for tool wear through changing the tool geometry, leading to the protection of the cutting tool from wear.

FEM-DEM coupling simulations of the tool wear characteristics in prestressed machining superalloy

Directory of Open Access Journals (Sweden)

Ruitao Peng

2016-01-01

Full Text Available Due to the complicated contact loading at the tool-chip interface, ceramic tool wear in prestressed machining superalloy is rare difficult to evaluate only by experimental approaches. This study aims to develop a methodology to predict the tool wear evolution by using combined FEM and DEM numerical simulations. Firstly, a finite element model for prestressed cutting is established, subsequently a discrete element model to describe the tool-chip behaviour is established based on the obtained boundary conditions by FEM simulations, finally, simulated results are experimentally validated. The predicted tool wear results show nice agreement with experiments, the simulation indicates that, within a certain range, higher cutting speed effectively results in slighter wear of Sialon ceramic tools, and deeper depth of cut leads to more serious tool wear.

A chord error conforming tool path B-spline fitting method for NC machining based on energy minimization and LSPIA

OpenAIRE

He, Shanshan; Ou, Daojiang; Yan, Changya; Lee, Chen-Han

2015-01-01

Piecewise linear (G01-based) tool paths generated by CAM systems lack G1 and G2 continuity. The discontinuity causes vibration and unnecessary hesitation during machining. To ensure efficient high-speed machining, a method to improve the continuity of the tool paths is required, such as B-spline fitting that approximates G01 paths with B-spline curves. Conventional B-spline fitting approaches cannot be directly used for tool path B-spline fitting, because they have shortages such as numerical...

Machinability of hypereutectic cast Al–Si alloys processed by SSM ...

Indian Academy of Sciences (India)

P K Sood

Changing the shape of intermetallic phases from plate type to Chinese script will ... carry out machining, diamond tools of complex geometry are used due to their ... minium in a graphite crucible using an induction furnace. To avoid oxidation ...

Selection of parameters for advanced machining processes using firefly algorithm

Directory of Open Access Journals (Sweden)

Rajkamal Shukla

2017-02-01

Full Text Available Advanced machining processes (AMPs are widely utilized in industries for machining complex geometries and intricate profiles. In this paper, two significant processes such as electric discharge machining (EDM and abrasive water jet machining (AWJM are considered to get the optimum values of responses for the given range of process parameters. The firefly algorithm (FA is attempted to the considered processes to obtain optimized parameters and the results obtained are compared with the results given by previous researchers. The variation of process parameters with respect to the responses are plotted to confirm the optimum results obtained using FA. In EDM process, the performance parameter “MRR” is increased from 159.70 gm/min to 181.6723 gm/min, while “Ra” and “REWR” are decreased from 6.21 μm to 3.6767 μm and 6.21% to 6.324 × 10−5% respectively. In AWJM process, the value of the “kerf” and “Ra” are decreased from 0.858 mm to 0.3704 mm and 5.41 mm to 4.443 mm respectively. In both the processes, the obtained results show a significant improvement in the responses.

Testing of new banknotes for machines that process currency

Science.gov (United States)

Foster, Eugenie E.

2000-04-01

Banknotes are now frequently use din machines. The Federal Reserve Board and the US Department of the Treasury have identified a need to produce notes that are reliably accepted in a variety of machine applications. This paper describes the steps that led to identifying requirements of manufacturers of machines that process banknotes for test notes, and the program developed for the Bureau of Engraving and Printing to address those requirements.

Proceedings of IEEE Machine Learning for Signal Processing Workshop XV

DEFF Research Database (Denmark)

Larsen, Jan

These proceedings contains refereed papers presented at the Fifteenth IEEE Workshop on Machine Learning for Signal Processing (MLSP’2005), held in Mystic, Connecticut, USA, September 28-30, 2005. This is a continuation of the IEEE Workshops on Neural Networks for Signal Processing (NNSP) organized...... by the NNSP Technical Committee of the IEEE Signal Processing Society. The name of the Technical Committee, hence of the Workshop, was changed to Machine Learning for Signal Processing in September 2003 to better reflect the areas represented by the Technical Committee. The conference is organized...... by the Machine Learning for Signal Processing Technical Committee with sponsorship of the IEEE Signal Processing Society. Following the practice started two years ago, the bound volume of the proceedings is going to be published by IEEE following the Workshop, and we are pleased to offer to conference attendees...

Agile machining and inspection thrust area team-on-machine probing / compatibility assessment of Parametric Technology Corporation (PTC) pro/CMM DMIS with Zeiss DMISEngine.

Energy Technology Data Exchange (ETDEWEB)

Wade, James Rokwel; Tomlinson, Kurt; Bryce, Edwin Anthony

2008-09-01

The charter goal of the Agile Machining and Inspection Thrust Area Team is to identify technical requirements, within the nuclear weapons complex (NWC), for Agile Machining and Inspection capabilities. During FY 2008, the team identified Parametric Technology Corporation (PTC) Pro/CMM as a software tool for use in off-line programming of probing routines--used for measurement--for machining and turning centers. The probing routine would be used for in-process verification of part geometry. The same Pro/CMM program used on the machine tool could also be employed for program validation / part verification using a coordinate measuring machine (CMM). Funding was provided to determine the compatibility of the Pro/CMM probing program with CMM software (Zeiss DMISEngine).

Process capability improvement through DMAIC for aluminum alloy wheel machining

Science.gov (United States)

Sharma, G. V. S. S.; Rao, P. Srinivasa; Babu, B. Surendra

2017-07-01

This paper first enlists the generic problems of alloy wheel machining and subsequently details on the process improvement of the identified critical-to-quality machining characteristic of A356 aluminum alloy wheel machining process. The causal factors are traced using the Ishikawa diagram and prioritization of corrective actions is done through process failure modes and effects analysis. Process monitoring charts are employed for improving the process capability index of the process, at the industrial benchmark of four sigma level, which is equal to the value of 1.33. The procedure adopted for improving the process capability levels is the define-measure-analyze-improve-control (DMAIC) approach. By following the DMAIC approach, the C p, C pk and C pm showed signs of improvement from an initial value of 0.66, -0.24 and 0.27, to a final value of 4.19, 3.24 and 1.41, respectively.

Optimization of paper machine heat recovery system; Paperikoneen laemmoentalteenottosysteemin optimointi - PMSY 02

Energy Technology Data Exchange (ETDEWEB)

Pettersson, H. [Valmet Oyj Pansio, Turku (Finland)

1998-12-31

Conventionally the energy content of paper and board machine dryer section exhaust air is recovered in the heat recovery tower. This has had a major contribution to the overall energy economy of a paper machine. Modern paper machines have already reached momentary record speeds above 1700 m/min, and speeds above 2000 m/min will be strived to. This is possible by developing new efficient drying technologies. These will require new solutions for the heat recovery systems. At the same time requirements for new heat recovery solutions come from the gradually closing of paper mill water circulation systems. In this project a discrete tool based on optimization is developed, a tool for analyzing, optimizing and dimensioning of paper machine heat recovery systems for different process conditions. Delivery of a paper machine process requires more and more transferring of process knowledge into calculation model parameters. The overall target of the tool is to decrease the energy consumption considering new drying technologies and the gradually closing of water circulation systems. (orig.)

Optimization of paper machine heat recovery system; Paperikoneen laemmoentalteenottosysteemin optimointi - PMSY 02

Energy Technology Data Exchange (ETDEWEB)

Pettersson, H [Valmet Oyj Pansio, Turku (Finland)

1999-12-31

Conventionally the energy content of paper and board machine dryer section exhaust air is recovered in the heat recovery tower. This has had a major contribution to the overall energy economy of a paper machine. Modern paper machines have already reached momentary record speeds above 1700 m/min, and speeds above 2000 m/min will be strived to. This is possible by developing new efficient drying technologies. These will require new solutions for the heat recovery systems. At the same time requirements for new heat recovery solutions come from the gradually closing of paper mill water circulation systems. In this project a discrete tool based on optimization is developed, a tool for analyzing, optimizing and dimensioning of paper machine heat recovery systems for different process conditions. Delivery of a paper machine process requires more and more transferring of process knowledge into calculation model parameters. The overall target of the tool is to decrease the energy consumption considering new drying technologies and the gradually closing of water circulation systems. (orig.)

Study on the machinability characteristics of superalloy Inconel 718 during high speed turning

International Nuclear Information System (INIS)

Thakur, D.G.; Ramamoorthy, B.; Vijayaraghavan, L.

2009-01-01

The present paper is an attempt of an experimental investigation on the machinability of superalloy, Inconel 718 during high speed turning using tungsten carbide insert (K20) tool. The effect of machining parameters on the cutting force, specific cutting pressure, cutting temperature, tool wear and surface finish criteria were investigated during the experimentation. The machining parameters have been optimized by measuring forces. The effect of machining parameters on the tool wear was examined through SEM micrographs. During high speed turning acoustic emission signal were collected and analyzed to understand the effect of cutting parameters during online. The research work findings will also provide useful economic machining solution by utilizing economical tungsten carbide tooling during high speed processing of Inconel 718, which is otherwise usually machined by costly PCD or CBN tools. The present approach and results will be helpful for understanding the machinability of Inconel 718 during high speed turning for the manufacturing engineers

Study on lean thinking among MSMEs in the Machine tool sector in India

Science.gov (United States)

Priyaadarshini, R. G.; Sathish Kumar, V. R.; Aishwarya Rajlakshmi, S.

2018-02-01

In the era of stiff competition and customer expectations, manufacturing organizations across the world are struggling hard to minimize their costs and maximise their performance. Micro, Small and Medium enterprises (MSMEs), who are dependent on large corporate for business and support have a tall task of keeping pace quality in processes and output. They are in the constant vigil to adopt new systems and practices so that they can minimise their cost and maximize the productivity. This study has been conducted in the machine tool sector of Coimbatore, India; which houses more than 9000 companies and offers employment to over one lakh employees. They have a tremendous pressure to use scientific processes to increase their product quality and productivity. While Lean manufacturing has been the thrust to improve the competitiveness among MSMEs in India, this study has attempted to understand their attitude towards lean management and understand the extent to which companies practice lean tools and practices. It has been found that most of the organizations in the study possess a culture of lean thinking and possess the support of top management and employees also towards the initiative. It is also seen that the organizations that incorporated lean in their daily operations have been able to scale up their productivity.

Dynamic Modal Analysis of Vertical Machining Centre Components

OpenAIRE

Anayet U. Patwari; Waleed F. Faris; A. K. M. Nurul Amin; S. K. Loh

2009-01-01

The paper presents a systematic procedure and details of the use of experimental and analytical modal analysis technique for structural dynamic evaluation processes of a vertical machining centre. The main results deal with assessment of the mode shape of the different components of the vertical machining centre. The simplified experimental modal analysis of different components of milling machine was carried out. This model of the different machine tool's structure is made by design software...

Numerical Control Machine Tool Fault Diagnosis Using Hybrid Stationary Subspace Analysis and Least Squares Support Vector Machine with a Single Sensor

Directory of Open Access Journals (Sweden)

Chen Gao

2017-03-01

Full Text Available Tool fault diagnosis in numerical control (NC machines plays a significant role in ensuring manufacturing quality. However, current methods of tool fault diagnosis lack accuracy. Therefore, in the present paper, a fault diagnosis method was proposed based on stationary subspace analysis (SSA and least squares support vector machine (LS-SVM using only a single sensor. First, SSA was used to extract stationary and non-stationary sources from multi-dimensional signals without the need for independency and without prior information of the source signals, after the dimensionality of the vibration signal observed by a single sensor was expanded by phase space reconstruction technique. Subsequently, 10 dimensionless parameters in the time-frequency domain for non-stationary sources were calculated to generate samples to train the LS-SVM. Finally, the measured vibration signals from tools of an unknown state and their non-stationary sources were separated by SSA to serve as test samples for the trained SVM. The experimental validation demonstrated that the proposed method has better diagnosis accuracy than three previous methods based on LS-SVM alone, Principal component analysis and LS-SVM or on SSA and Linear discriminant analysis.

Technology of high-speed combined machining with brush electrode

Science.gov (United States)

Kirillov, O. N.; Smolentsev, V. P.; Yukhnevich, S. S.

2018-03-01

The new method was proposed for high-precision dimensional machining with a brush electrode when the true position of bundles of metal wire is adjusted by means of creating controlled centrifugal forces appeared due to the increased frequency of rotation of a tool. There are the ultimate values of circumferential velocity at which the bundles are pressed against a machined area of a workpiece in a stable manner despite the profile of the machined surface and variable stock of the workpiece. The special aspects of design of processing procedures for finishing standard parts, including components of products with low rigidity, are disclosed. The methodology of calculation and selection of processing modes which allow one to produce high-precision details and to provide corresponding surface roughness required to perform finishing operations (including the preparation of a surface for metal deposition) is presented. The production experience concerned with the use of high-speed combined machining with an unshaped tool electrode in knowledge-intensive branches of the machine-building industry for different types of production is analyzed. It is shown that the implementation of high-speed dimensional machining with an unshaped brush electrode allows one to expand the field of use of the considered process due to the application of a multipurpose tool in the form of a metal brush, as well as to obtain stable results of finishing and to provide the opportunities for long-term operation of the equipment without its changeover and readjustment.

The Influence of Tool Geometry towards Cutting Performance in Machining Aluminium 7075

Directory of Open Access Journals (Sweden)

Muhammad Syafik Jumali

2017-01-01

Full Text Available Aerospace industries often use Computer Numerical Control (CNC machining in manufacturing aerospace parts. Aluminium 7075 is the most common material used as aircraft components. This research aims to produce end mill with optimum geometry in terms of the helix angle, primary radial relief angle and secondary relief angle. End mills with different geometry parameters are tested on Aluminium 7075 and data on surface roughness and tool wear were collected. The results were then analysed to determine which parameters brought the optimum result with regards to surface roughness and tool wear.

Development of lathe tool dynamometer and finding cutting forces using negative and positive rake angle cutting tool

International Nuclear Information System (INIS)

Zeb, M.A.; Irfan, M.A.

2005-01-01

Most output parameters in machining, such as cutting forces, temperatures, strains and the work-hardening of the chip material, are directly related to the chip formation process. The characteristics of machining processes can be well understood if the forces and strains during chip formation are known. In this research a lathe tool dynamometer was used to measure cutting forces involved in machining of Steel 1045 and Aluminum 2219 T62. High Speed Steel (HSS), cutting tools with positive and negative rake angles were used. It was observed that more cutting forces are experienced by the cutting tool with positive rake angle as compared to the forces experienced by the cutting tool with negative rake angle. For steel 1045 the cutting forces using positive rake angle cutting tool were much higher. This suggested that for harder materials using a negative rake angle is more suitable for cutting. (author)

Electrical Discharge Machining (EDM: A Review

Directory of Open Access Journals (Sweden)

Asfana Banu

2016-09-01

Full Text Available Electro discharge machining (EDM process is a non-conventional and non-contact machining operation which is used in industry for high precision products. EDM is known for machining hard and brittle conductivematerials since it can melt any electrically conductive material regardless of its hardness. The workpiece machined by EDM depends on thermal conductivity, electrical resistivity, and melting points of the materials. The tool and the workpiece are adequately both immersed in a dielectric medium, such as, kerosene, deionised water or any other suitable fluid. This paper is reviewed comprehensively on types of EDM operation. A brief discussion is also done on the machining responses and mathematical modelling.

Monitoring machining conditions by infrared images

Science.gov (United States)

Borelli, Joao E.; Gonzaga Trabasso, Luis; Gonzaga, Adilson; Coelho, Reginaldo T.

2001-03-01

During machining process the knowledge of the temperature is the most important factor in tool analysis. It allows to control main factors that influence tool use, life time and waste. The temperature in the contact area between the piece and the tool is resulting from the material removal in cutting operation and it is too difficult to be obtained because the tool and the work piece are in motion. One way to measure the temperature in this situation is detecting the infrared radiation. This work presents a new methodology for diagnosis and monitoring of machining processes with the use of infrared images. The infrared image provides a map in gray tones of the elements in the process: tool, work piece and chips. Each gray tone in the image corresponds to a certain temperature for each one of those materials and the relationship between the gray tones and the temperature is gotten by the previous of infrared camera calibration. The system developed in this work uses an infrared camera, a frame grabber board and a software composed of three modules. The first module makes the image acquisition and processing. The second module makes the feature image extraction and performs the feature vector. Finally, the third module uses fuzzy logic to evaluate the feature vector and supplies the tool state diagnostic as output.

Tool grinding machine

Science.gov (United States)

Dial, Sr., Charles E.

1980-01-01

The present invention relates to an improved tool grinding mechanism for grinding single point diamond cutting tools to precise roundness and radius specifications. The present invention utilizes a tool holder which is longitudinally displaced with respect to the remainder of the grinding system due to contact of the tool with the grinding surface with this displacement being monitored so that any variation in the grinding of the cutting surface such as caused by crystal orientation or tool thickness may be compensated for during the grinding operation to assure the attainment of the desired cutting tool face specifications.

GAPscreener: An automatic tool for screening human genetic association literature in PubMed using the support vector machine technique

Directory of Open Access Journals (Sweden)

Khoury Muin J

2008-04-01

Full Text Available Abstract Background Synthesis of data from published human genetic association studies is a critical step in the translation of human genome discoveries into health applications. Although genetic association studies account for a substantial proportion of the abstracts in PubMed, identifying them with standard queries is not always accurate or efficient. Further automating the literature-screening process can reduce the burden of a labor-intensive and time-consuming traditional literature search. The Support Vector Machine (SVM, a well-established machine learning technique, has been successful in classifying text, including biomedical literature. The GAPscreener, a free SVM-based software tool, can be used to assist in screening PubMed abstracts for human genetic association studies. Results The data source for this research was the HuGE Navigator, formerly known as the HuGE Pub Lit database. Weighted SVM feature selection based on a keyword list obtained by the two-way z score method demonstrated the best screening performance, achieving 97.5% recall, 98.3% specificity and 31.9% precision in performance testing. Compared with the traditional screening process based on a complex PubMed query, the SVM tool reduced by about 90% the number of abstracts requiring individual review by the database curator. The tool also ascertained 47 articles that were missed by the traditional literature screening process during the 4-week test period. We examined the literature on genetic associations with preterm birth as an example. Compared with the traditional, manual process, the GAPscreener both reduced effort and improved accuracy. Conclusion GAPscreener is the first free SVM-based application available for screening the human genetic association literature in PubMed with high recall and specificity. The user-friendly graphical user interface makes this a practical, stand-alone application. The software can be downloaded at no charge.

Cutting temperature measurement and material machinability

Directory of Open Access Journals (Sweden)

Nedić Bogdan P.

2014-01-01

Full Text Available Cutting temperature is very important parameter of cutting process. Around 90% of heat generated during cutting process is then away by sawdust, and the rest is transferred to the tool and workpiece. In this research cutting temperature was measured with artificial thermocouples and question of investigation of metal machinability from aspect of cutting temperature was analyzed. For investigation of material machinability during turning artificial thermocouple was placed just below the cutting top of insert, and for drilling thermocouples were placed through screw holes on the face surface. In this way was obtained simple, reliable, economic and accurate method for investigation of cutting machinability.

Residual stresses generated in F-522 steel by different machining processes

International Nuclear Information System (INIS)

Gracia-Navas, V.; Ferreres, I.; Maranon, J. A.; Garcia-Rosales, C.; Gil-Sevillano, J.

2005-01-01

Machining operations induce plastic deformation and heat generation in the near surface area of the machined part, giving rise to residual stresses. Depending on their magnitude and sign, these stresses can be detrimental or beneficial to the service life of the part. The final stress state depends on the machining process applied, as well as on the machining parameters. Therefore, the establishment of adequate machining guidelines requires the measurement of the residual stresses generated both at the surface and inside the material. in this work, the residual stresses generated in F-522 steel by two hard turning (conventional and laser assisted) and two grinding (production and finishing) processes were measured by X-ray diffraction. Additionally, depth profiles of the volume fraction of retained austenite, microstructure and nano hardness were obtained in order to correlate those results with the residual stress state obtained for each machining process. It has been observed that turning generates tensile stresses in the surface while grinding causes compressive stresses. Below the surface grinding generates weak tensile or nearly null stresses whereas turning generates strong compressive stresses. These results show that the optimum mechanising process (disregarding economical considerations) implies the combination of turning plus elimination of a small thickness by final grinding. (Author) 19 refs

SOFTWARE TOOL FOR LASER CUTTING PROCESS CONTROL – SOLVING REAL INDUSTRIAL CASE STUDIES

Directory of Open Access Journals (Sweden)

Miloš Madić

2016-08-01

Full Text Available Laser cutting is one of the leading non-conventional machining technologies with a wide spectrum of application in modern industry. It order to exploit a number of advantages that this technology offers for contour cutting of materials, it is necessary to carefully select laser cutting conditions for each given workpiece material, thickness and desired cut qualities. In other words, there is a need for process control of laser cutting. After a comprehensive analysis of the main laser cutting parameters and process performance characteristics, the application of the developed software tool “BRUTOMIZER” for off-line control of CO2 laser cutting process of three different workpiece materials (mild steel, stainless steel and aluminum is illustrated. Advantages and abilities of the developed software tool are also illustrated.

Managing the Virtual Machine Lifecycle of the CernVM Project

International Nuclear Information System (INIS)

Charalampidis, I; Blomer, J; Buncic, P; Harutyunyan, A; Larsen, D

2012-01-01

CernVM is a virtual software appliance designed to support the development cycle and provide a runtime environment for LHC applications. It consists of a minimal Linux distribution, a specially tuned file system designed to deliver application software on demand, and contextualization tools. The maintenance of these components involves a variety of different procedures and tools that cannot always connect with each other. Additionally, most of these procedures need to be performed frequently. Currently, in the CernVM project, every time we build a new virtual machine image, we have to perform the whole process manually, because of the heterogeneity of the tools involved. The overall process is error-prone and time-consuming. Therefore, to simplify and aid this continuous maintenance process, we are developing a framework that combines these virtually unrelated tools with a single, coherent interface. To do so, we identified all the involved procedures and their tools, tracked their dependencies and organized them into logical groups (e.g. build, test, instantiate). These groups define the procedures that are performed throughout the lifetime of a virtual machine. In this paper we describe the Virtual Machine Lifecycle and the framework we developed (iAgent) in order to simplify the maintenance process.

On the development of a dual-layered diamond-coated tool for the effective machining of titanium Ti-6Al-4V alloy

International Nuclear Information System (INIS)

Srinivasan, Balaji; Rao, Balkrishna C; Ramachandra Rao, M S

2017-01-01

This work is focused on the development of a dual-layered diamond-coated tungsten carbide tool for machining titanium Ti-6Al-4V alloy. A hot-filament chemical vapor deposition technique was used to synthesize diamond films on tungsten carbide tools. A boron-doped diamond interlayer was added to a microcrystalline diamond layer in an attempt to improve the interface adhesion strength. The dual-layered diamond-coated tool was employed in machining at cutting speeds in the range of 70 to 150 m min −1 with a lower feed and a lower depth of cut of 0.5 mm rev −1 and 0.5 mm, respectively, to operate in the transition from adhesion- to diffusion-tool-wear and thereby arrive at suitable conditions for enhancing tool life. The proposed tool was then compared, on the basis of performance under real-time cutting conditions, with commercially available microcrystalline diamond, nanocrystalline diamond, titanium nitride and uncoated tungsten carbide tools. The life and surface finish of the proposed dual-layered tool and uncoated tungsten carbide were also investigated in interrupted cutting such as milling. The results of this study show a significant improvement in tool life and finish of Ti-6Al-4V parts machined with the dual-layered diamond-coated tool when compared with its uncoated counterpart. These results pave the way for the use of a low-cost tool, with respect to, polycrystalline diamond for enhancing both tool life and machining productivity in critical sectors fabricating parts out of titanium Ti-6Al-4V alloy. The application of this coating technology can also be extended to the machining of non-ferrous alloys owing to its better adhesion strength. (paper)

Machine Shop Fundamentals: Part I.

Science.gov (United States)

Kelly, Michael G.; And Others

These instructional materials were developed and designed for secondary and adult limited English proficient students enrolled in machine tool technology courses. Part 1 includes 24 lessons covering introduction, safety and shop rules, basic machine tools, basic machine operations, measurement, basic blueprint reading, layout, and bench tools.…

Image-Based Single Cell Profiling: High-Throughput Processing of Mother Machine Experiments.

Directory of Open Access Journals (Sweden)

Christian Carsten Sachs

Full Text Available Microfluidic lab-on-chip technology combined with live-cell imaging has enabled the observation of single cells in their spatio-temporal context. The mother machine (MM cultivation system is particularly attractive for the long-term investigation of rod-shaped bacteria since it facilitates continuous cultivation and observation of individual cells over many generations in a highly parallelized manner. To date, the lack of fully automated image analysis software limits the practical applicability of the MM as a phenotypic screening tool.We present an image analysis pipeline for the automated processing of MM time lapse image stacks. The pipeline supports all analysis steps, i.e., image registration, orientation correction, channel/cell detection, cell tracking, and result visualization. Tailored algorithms account for the specialized MM layout to enable a robust automated analysis. Image data generated in a two-day growth study (≈ 90 GB is analyzed in ≈ 30 min with negligible differences in growth rate between automated and manual evaluation quality. The proposed methods are implemented in the software molyso (MOther machine AnaLYsis SOftware that provides a new profiling tool to analyze unbiasedly hitherto inaccessible large-scale MM image stacks.Presented is the software molyso, a ready-to-use open source software (BSD-licensed for the unsupervised analysis of MM time-lapse image stacks. molyso source code and user manual are available at https://github.com/modsim/molyso.

Machine terms dictionary

Energy Technology Data Exchange (ETDEWEB)

NONE

1979-04-15

This book gives descriptions of machine terms which includes machine design, drawing, the method of machine, machine tools, machine materials, automobile, measuring and controlling, electricity, basic of electron, information technology, quality assurance, Auto CAD and FA terms and important formula of mechanical engineering.

Numerical study on the splitting of a vapor bubble in the ultrasonic assisted EDM process with the curved tool and workpiece.

Science.gov (United States)

Shervani-Tabar, M T; Seyed-Sadjadi, M H; Shabgard, M R

2013-01-01

Electrical discharge machining (EDM) is a powerful and modern method of machining. In the EDM process, a vapor bubble is generated between the tool and the workpiece in the dielectric liquid due to an electrical discharge. In this process dynamic behavior of the vapor bubble affects machining process. Vibration of the tool surface affects bubble behavior and consequently affects material removal rate (MRR). In this paper, dynamic behavior of the vapor bubble in an ultrasonic assisted EDM process after the appearance of the necking phenomenon is investigated. It is noteworthy that necking phenomenon occurs when the bubble takes the shape of an hour-glass. After the appearance of the necking phenomenon, the vapor bubble splits into two parts and two liquid jets are developed on the boundaries of the upper and lower parts of the vapor bubble. The liquid jet developed on the upper part of the bubble impinges to the tool and the liquid jet developed on the lower part of the bubble impinges to the workpiece. These liquid jets cause evacuation of debris from the gap between the tool and the workpiece and also cause erosion of the workpiece and the tool. Curved tool and workpiece affect the shape and the velocity of the liquid jets during splitting of the vapor bubble. In this paper dynamics of the vapor bubble after its splitting near the curved tool and workpiece is investigated in three cases. In the first case surfaces of the tool and the workpiece are flat, in the second case surfaces of the tool and the workpiece are convex and in the third case surfaces of the tool and workpiece are concave. Numerical results show that in the third case, the velocity of liquid jets which are developed on the boundaries of the upper and lower parts of the vapor bubble after its splitting have the highest magnitude and their shape are broader than the other cases. Copyright © 2012 Elsevier B.V. All rights reserved.