Computerized Machine for Cutting Space Shuttle Thermal Tiles

Science.gov (United States)

Ramirez, Luis E.; Reuter, Lisa A.

2009-01-01

A report presents the concept of a machine aboard the space shuttle that would cut oversized thermal-tile blanks to precise sizes and shapes needed to replace tiles that were damaged or lost during ascent to orbit. The machine would include a computer-controlled jigsaw enclosed in a clear acrylic shell that would prevent escape of cutting debris. A vacuum motor would collect the debris into a reservoir and would hold a tile blank securely in place. A database stored in the computer would contain the unique shape and dimensions of every tile. Once a broken or missing tile was identified, its identification number would be entered into the computer, wherein the cutting pattern associated with that number would be retrieved from the database. A tile blank would be locked into a crib in the machine, the shell would be closed (proximity sensors would prevent activation of the machine while the shell was open), and a "cut" command would be sent from the computer. A blade would be moved around the crib like a plotter, cutting the tile to the required size and shape. Once the tile was cut, an astronaut would take a space walk for installation.

Investigations of Cutting Fluid Performance Using Different Machining Operations

DEFF Research Database (Denmark)

De Chiffre, Leonardo; Belluco, Walter

2002-01-01

An analysis of cutting fluid performance in dif-ferent metal cutting operations is presented based on performance criteria, work material and fluid type. Cutting fluid performance was evaluated in turning, drilling, reaming and tapping operations, with respect to tool life, cutting forces and prod...... will get the same performance ranking for different metalworking fluids no matter what machining test is used, when the fluids are of the same type. Results show that this is mostly true for the water-based fluids on austenitic stainless steel while ranking did change depending on the test with straight......-gated. In the case of austenitic stainless steel as the workpiece material, results using the different operations under different cutting conditions show that the performance of vegetable oil based prod-ucts is superior or equal to that of mineral oil based products. The hypothesis was investigated that one...

ANALYSIS OF PARAMETERS AFFECTING THE QUALITY OF A CUTTING MACHINE

Directory of Open Access Journals (Sweden)

Iveta Onderová

2014-02-01

Full Text Available The quality of cutting machines is affected by several factors that can be directly or indirectly influenced by manufacturers, technicians and users of machine tools. The most critical qualitative evaluation parameters of machine tools include accuracy and stability. Investigations of accuracy and repeatable positioning accuracy were essential for the research presented in this paper. The aim was to develop and experimentally verify the design of a methodology for cutting centers aimed at achieving the desired working precision. Before working on the topic described here, it was necessary to make several scientific analyses, which are summarized in this paper. We can build on the initial working hypothesis that by improving the technological parameters (e.g. by increasing the working speed of the machine, or by improving the precision of the positioning the quality of the cutting machine will also be improved. For the purposes of our study, several investigated parameters were set affecting positioning accuracy, such as rigidity, positioning speed, etc. First, the stiffness of the portal structure of the cutting machine was analyzed. FEM analysis was used to investigate several alternative structures of the cutting machine, and also an innovative solution for beam mounting. The second step was to integrate two types of drives into the design of the cutting machine. The first drive is a classic rack and pinion drive for cutting machines. To increase (improve the working speed of the machine, linear motors were designed as an alternative drive. The portal of the cutting machine was designed for a working speed of 260mmin−1 and acceleration of 25 m. s−2. The third step was based on the results of the analysis. In collaboration with Microstep, an experimental cutting machine in a portal version was produced using linear synchronous motors driving the portal on both sides, and with direct linear metering of its position. In the fourth step, an

Trim cut machining and surface integrity analysis of Nimonic 80A alloy using wire cut EDM

Directory of Open Access Journals (Sweden)

Amitesh Goswami

2017-02-01

Full Text Available This present work deals with the features of trim cut wire EDM machining of Nimonic 80A in terms of machining parameters, to predict material removal rate (MRR, surface roughness (Ra, wire wear ratio (WWR and microstructure analysis. Trim cut is performed after rough cut to remove the rough layer deposited after machining due to melting and re-solidification of the eroded metal from workpiece as well as from wire electrode. Taguchi’s design of experiments methodology has been used for planning and designing the experiments. The relative significance of various factors has also been evaluated and analyzed using ANOVA. The results clearly indicate trim cut potential for high surface finish compared to rough cut machining.

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.

Experimental improvement of the technology of cutting of high-pressure hoses with metal braid on hand cutting machine

OpenAIRE

Karpenko, Mykola; Bogdevicius, Marijonas; Prentkovskis, Olegas

2016-01-01

In the article the review of the problem of improvement of technology of high pressure hoses cutting on the hand cutting machines is analyzed. Different methods of cutting of high pressure hoses into the billets are overviewed and the quality of edge cuts of hoses is analyzed. The comparison of treatment on automatic cutting machines and on hand cutting machines is carried out. Different experimental techniques of improvement of the quality of edges cutting of high pressure hoses are prese...

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.

Machining of bone: Analysis of cutting force and surface roughness by turning process.

Science.gov (United States)

Noordin, M Y; Jiawkok, N; Ndaruhadi, P Y M W; Kurniawan, D

2015-11-01

There are millions of orthopedic surgeries and dental implantation procedures performed every year globally. Most of them involve machining of bones and cartilage. However, theoretical and analytical study on bone machining is lagging behind its practice and implementation. This study views bone machining as a machining process with bovine bone as the workpiece material. Turning process which makes the basis of the actually used drilling process was experimented. The focus is on evaluating the effects of three machining parameters, that is, cutting speed, feed, and depth of cut, to machining responses, that is, cutting forces and surface roughness resulted by the turning process. Response surface methodology was used to quantify the relation between the machining parameters and the machining responses. The turning process was done at various cutting speeds (29-156 m/min), depths of cut (0.03 -0.37 mm), and feeds (0.023-0.11 mm/rev). Empirical models of the resulted cutting force and surface roughness as the functions of cutting speed, depth of cut, and feed were developed. Observation using the developed empirical models found that within the range of machining parameters evaluated, the most influential machining parameter to the cutting force is depth of cut, followed by feed and cutting speed. The lowest cutting force was obtained at the lowest cutting speed, lowest depth of cut, and highest feed setting. For surface roughness, feed is the most significant machining condition, followed by cutting speed, and with depth of cut showed no effect. The finest surface finish was obtained at the lowest cutting speed and feed setting. © IMechE 2015.

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

The Cutting Process, Chips and Cutting Forces in Machining CFRP

DEFF Research Database (Denmark)

Koplev, A.; Lystrup, Aage; Vorm, T.

1983-01-01

The cutting of unidirectional CFRP, perpendicular as well as parallel to the fibre orientation, is examined. Shaping experiments, ‘quick-stop’ experiments, and a new chip preparation technique are used for the investigation. The formation of the chips, and the quality of the machined surface...... is discussed. The cutting forces parallel and perpendicular to the cutting direction are measured for various parameters, and the results correlated to the formation of chips and the wear of the tool....

Tool path strategy and cutting process monitoring in intelligent machining

Science.gov (United States)

Chen, Ming; Wang, Chengdong; An, Qinglong; Ming, Weiwei

2018-06-01

Intelligent machining is a current focus in advanced manufacturing technology, and is characterized by high accuracy and efficiency. A central technology of intelligent machining—the cutting process online monitoring and optimization—is urgently needed for mass production. In this research, the cutting process online monitoring and optimization in jet engine impeller machining, cranio-maxillofacial surgery, and hydraulic servo valve deburring are introduced as examples of intelligent machining. Results show that intelligent tool path optimization and cutting process online monitoring are efficient techniques for improving the efficiency, quality, and reliability of machining.

Development of the cutting machine for the biological shield wall

International Nuclear Information System (INIS)

Yokota, Mitsuo; Hasegawa, Tetsuo; Kohyama, Kazunori.

1987-01-01

22 years have passed since the first commercial nuclear power plant operation in Japan. At present, there were 33 commercial nuclear power plants in operation, supplying about 25 percent of total electricity. Some of them are going to be terminated in the near future and enter into the decommissioning stage. Therefore, it is now necessary to developed decommissioning technologies, including dismantling techniques of these power plants. The development of a concrete cutting machine is one of the most important items applicable to dismantling biological shield walls of the plants. This paper describes the outline of the cutting machine developed for the biological shield wall demolition of the Japan Power Demonstration Reactor (JPDR) including actual decommissioning works tested. (author)

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.

Test of remote control cutting equipment by Nd:YAG laser

Energy Technology Data Exchange (ETDEWEB)

Shimizu, Akio [Fuji Electric Corp. Research and Development Ltd., Yokosuka, Kanagawa (Japan); Hosoda, Hiroshi

1997-11-01

Technology of remote controlled cutting and reduction of generative secondary products have been required to the cutting system for decommissioning nuclear equipments. At a point of view that laser cutting technology by use of a Nd:YAG laser is effective, we have developed the laser cutting machine and carried out cutting tests for several stainless steel plates. This report is described the result of experiment by test equipment, about element technology of remote controlled cutting nuclear equipments. (author)

Test of remote control cutting equipment by Nd:YAG laser

International Nuclear Information System (INIS)

Shimizu, Akio; Hosoda, Hiroshi.

1997-01-01

Technology of remote controlled cutting and reduction of generative secondary products have been required to the cutting system for decommissioning nuclear equipments. At a point of view that laser cutting technology by use of a Nd:YAG laser is effective, we have developed the laser cutting machine and carried out cutting tests for several stainless steel plates. This report is described the result of experiment by test equipment, about element technology of remote controlled cutting nuclear equipments. (author)

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.

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.

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.

WATER-JET CUTTING MACHINE NOW AVAILABLE FROM THE CERN RAW MATERIALS STORES

CERN Multimedia

2007-01-01

The CERN Raw Materials Stores has recently acquired a new water-jet cutting machine. The machine is capable of cutting all types and shapes of materials up to 70 mm in thickness, with an accuracy of +/- 0.1mm/m. For the time being, users requiring materials to be cut should supply drawings in DXF, DWG or IGES (AutoCad) file format. The machine will be operational as of 1st October 2007. The Stores Team Paulo Dos Santos FI-LS-MM 72308

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

Directory of Open Access Journals (Sweden)

Qiaokang Liang

2016-11-01

Full Text Available Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing.

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining.

Science.gov (United States)

Liang, Qiaokang; Zhang, Dan; Wu, Wanneng; Zou, Kunlin

2016-11-16

Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing.

Design and analysis of gasket cutting machine

Directory of Open Access Journals (Sweden)

Vipin V. Gopal

2016-03-01

Full Text Available Paper is about the design and analysis of the optimized gasket cutting machine which can be provide to the companies where there is use of gaskets at a certain interval of time. The paper contain the cost optimized machine which is provide at a much lower cost as compared to the machines presently available in the market. This machine can be specifically used for the boiler and refrigeration companies where the gaskets are used to avoid the leakage due to the joining of two different diametric pipes. Inspite of giving a large order of gaskets, they can prepare the same at small rate whenever needed at the location.

Optimizing cutting conditions on sustainable machining of aluminum alloy to minimize power consumption

Science.gov (United States)

Nur, Rusdi; Suyuti, Muhammad Arsyad; Susanto, Tri Agus

2017-06-01

Aluminum is widely utilized in the industrial sector. There are several advantages of aluminum, i.e. good flexibility and formability, high corrosion resistance and electrical conductivity, and high heat. Despite of these characteristics, however, pure aluminum is rarely used because of its lacks of strength. Thus, most of the aluminum used in the industrial sectors was in the form of alloy form. Sustainable machining can be considered to link with the transformation of input materials and energy/power demand into finished goods. Machining processes are responsible for environmental effects accepting to their power consumption. The cutting conditions have been optimized to minimize the cutting power, which is the power consumed for cutting. This paper presents an experimental study of sustainable machining of Al-11%Si base alloy that was operated without any cooling system to assess the capacity in reducing power consumption. The cutting force was measured and the cutting power was calculated. Both of cutting force and cutting power were analyzed and modeled by using the central composite design (CCD). The result of this study indicated that the cutting speed has an effect on machining performance and that optimum cutting conditions have to be determined, while sustainable machining can be followed in terms of minimizing power consumption and cutting force. The model developed from this study can be used for evaluation process and optimization to determine optimal cutting conditions for the performance of the whole process.

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.

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.

Machinability baja AISI 1040 pada proses bubut dengan variasi cutting speed dan feed rate

Directory of Open Access Journals (Sweden)

AAIA Sri Komaladewi

2012-11-01

Full Text Available In order to obtain desired results of machining process (turning, parameter of process and material characteristic to be machined should be well known. This is due to different machining conditions and material yield different material machinability as well. It is needed to investigate of material machinability (AISI 1040 such as force, power and shear angle under different cutting speed (80, 160 and 240 m/min and feed rate (0.1, 0.2, and 0.3 mm/rev. The results of investigation show that; at the same cutting speed the higher feed rate the higher cutting force needed; the higher cutting speed and feed rate, the higher power needed; at feed rate 0.1 mm./rev and 0.3 mm/rev, the higher cutting speed the shear angles has a trend to incline; at feed rate 0.2 mm/rev, cutting speed from 80 to 160 m/min yield increasing of shear angle, however, from 160 to 240 m/min shear angle declines.

Parametric optimization during machining of AISI 304 Austenitic Stainless Steel using CVD coated DURATOMIC cutting insert

Directory of Open Access Journals (Sweden)

M. Kaladhar

2012-08-01

Full Text Available In this work, Taguchi method is applied to determine the optimum process parameters for turning of AISI 304 austenitic stainless steel on CNC lathe. A Chemical vapour deposition (CVD coated cemented carbide cutting insert is used which is produced by DuratomicTM technology of 0.4 and 0.8 mm nose radii. The tests are conducted at four levels of Cutting speed, feed and depth of cut. The influence of these parameters are investigated on the surface roughness and material removal rate (MRR. The Analysis Of Variance (ANOVA is also used to analyze the influence of cutting parameters during machining. The results revealed that cutting speed significantly (46.05% affected the machined surface roughness values followed by nose radius (23.7%. The influence of the depth of cut (61.31% in affecting material removal rate (MRR is significantly large. The cutting speed (20.40% is the next significant factor. Optimal range and optimal level of parameters are also predicted for responses.

Researches Regarding The Circular Interpolation Algorithms At CNC Laser Cutting Machines

Science.gov (United States)

Tîrnovean, Mircea Sorin

2015-09-01

This paper presents an integrated simulation approach for studying the circular interpolation regime of CNC laser cutting machines. The circular interpolation algorithm is studied, taking into consideration the numerical character of the system. A simulation diagram, which is able to generate the kinematic inputs for the feed drives of the CNC laser cutting machine is also presented.

Design and accuracy analysis of a metamorphic CNC flame cutting machine for ship manufacturing

Science.gov (United States)

Hu, Shenghai; Zhang, Manhui; Zhang, Baoping; Chen, Xi; Yu, Wei

2016-09-01

The current research of processing large size fabrication holes on complex spatial curved surface mainly focuses on the CNC flame cutting machines design for ship hull of ship manufacturing. However, the existing machines cannot meet the continuous cutting requirements with variable pass conditions through their fixed configuration, and cannot realize high-precision processing as the accuracy theory is not studied adequately. This paper deals with structure design and accuracy prediction technology of novel machine tools for solving the problem of continuous and high-precision cutting. The needed variable trajectory and variable pose kinematic characteristics of non-contact cutting tool are figured out and a metamorphic CNC flame cutting machine designed through metamorphic principle is presented. To analyze kinematic accuracy of the machine, models of joint clearances, manufacturing tolerances and errors in the input variables and error models considering the combined effects are derived based on screw theory after establishing ideal kinematic models. Numerical simulations, processing experiment and trajectory tracking experiment are conducted relative to an eccentric hole with bevels on cylindrical surface respectively. The results of cutting pass contour and kinematic error interval which the position error is from-0.975 mm to +0.628 mm and orientation error is from-0.01 rad to +0.01 rad indicate that the developed machine can complete cutting process continuously and effectively, and the established kinematic error models are effective although the interval is within a `large' range. It also shows the matching property between metamorphic principle and variable working tasks, and the mapping correlation between original designing parameters and kinematic errors of machines. This research develops a metamorphic CNC flame cutting machine and establishes kinematic error models for accuracy analysis of machine tools.

Development and verification test on remote plasma cutting of large metallic waste

International Nuclear Information System (INIS)

Ozawa, Tamotsu; Yamada, Kunitaka; Abe, Tadashi

1979-01-01

Plasma cutting is the cutting method to melt and scatter cut objects by generating arc between an electrode in a nozzle and the cut objects and making working gas fed to surround it into high temperature, high speed plasma jet. In case of remote plasma cutting, a torch for the plasma cutting is operated remotely with a manipulator from the outside of a cell. At the time of planning the method of breaking up solid wastes, the type of cutting machines and the method of remote operation of the cutting machines and cut objects were examined. It was decided to adopt plasma cutting machines, because their cutting capability such as materials, thickness and cutting speed is excellent, and the construction and handling are simple. The form of the solid wastes to be cut is not uniform, accordingly the method of manipulator operation was adopted to respond to various forms flexibly. Cut objects are placed on a turntable to change the position successively. In case of remote plasma cutting, the controls of torch speed and gap must be made with a manipulator. The use of light-shielding glasses reduces largely the watchability of cut objects and becomes hindrance in the operation. As for the safety aspect, the suitable gas for cutting, which does not contain hydrogen, must be selected. The tests carried out for two years since November, 1977, are reported in this paper, and most of the problems have been solved. (Kako, I.)

Testing of machinability of mould steel 40CrMnMo7 using genetic algorithm

OpenAIRE

Stoić, Antun; Cukor, Goran; Kopač, Janez

2015-01-01

This paper deals with testing of hard materials machinability by high speed turning process and influence of cutting parameters on machinability rates. Todetermine machinability rates, surface roughness, tool wear and cutting force components were measured. In accordance with expected influence of certain parameter on machinability, experiments were designed and performed todetermine mathematical models of the measured values over full response range. Obtained mathematical models were used fo...

Free-piston cutting machine

Science.gov (United States)

Ciccarelli, Gaby; Subudhi, Manomohan; Hall, Robert E.

2000-01-01

A cutting machine includes a gun barrel for receiving a projectile. A compression tube is disposed in flow communication with the barrel and includes a piston therein. A reservoir is disposed in flow communication with the tube and receives a first gas under pressure. A second gas fills the compression tube on a front face of the piston. And, the pressurized first gas is discharged into the tube on a back face of the piston to accelerate the piston through the tube for compressing the second gas, and in turn launching the projectile through the barrel to impact a workpiece.

Material testing of copper by extrusion-cutting

DEFF Research Database (Denmark)

Segalina, F.; De Chiffre, Leonardo

2017-01-01

was developed and implemented on a CNC lathe. An investigation was carried out extrusion-cutting copper discs using high-speed-steel cutting tools at 100 m/min cutting speed. Flow stress values for copper under machining-relevant conditions were obtained from measurement of the extrusion-cutting force...

Numerical controlled diamond fly cutting machine for grazing incidence X-ray reflection mirrors

International Nuclear Information System (INIS)

Uchida, Fumihiko; Moriyama, Shigeo; Seya, Eiiti

1992-01-01

Synchrotron radiation has reached the stage of practical use, and the application to the wide fields that support future advanced technologies such as spectroscopy, the structural analysis of matters, semiconductor lithography and medical light source is expected. For the optical system of the equipment utilizing synchrotron radiation, the total reflection mirrors of oblique incidence are used for collimating and collecting X-ray. In order to restrain their optical aberration, nonspherical shape is required, and as the manufacturing method with high precision for nonspherical mirrors, a numerically controlled diamond cutting machine was developed. As for the cutting of soft metals with diamond tools, the high precision machining of any form can be done by numerical control, the machining time can be reduced as compared with grinding, and the cooling effect is large in metals. The construction of the cutting machine, the principle of machining, the control system, the method of calculating numerical control data, the investigation of machinable forms and the result of evaluation are reported. (K.I.)

Machinability of magnesium and aluminium alloys. Part I: cutting resistance

International Nuclear Information System (INIS)

Balout, B.; Songmene, V.; Masounave, J.

2002-01-01

Aluminium (2.7 g/cm 3 ) and magnesium (1.7 g/cm 3 ) are two competing light metals with similar mechanical properties and excellent possibilities for recycling. The forming of magnesium is often seen as an impediment to its use. New forming techniques using magnesium shavings are being developed, particularly in Japan. The machining of magnesium alloys by removal of metal raises safety concerns (risk of fire), which limits many potential applications of magnesium. The purpose of this work is to clarify and compare the machining properties of these two types of metal and better understand the mechanisms that may explain the differences in behaviour. Such a comparison could eventually provide an estimate of the cost of producing shavings for the manufacture of aluminium and magnesium parts through forging and extrusion, which would limit environmental pollution. Based on an analysis of cutting resistance during machining, it was demonstrated that magnesium alloys are easier to machine than similar aluminium alloys. Magnesium shavings are shorter than those of 6061-T6, but are especially more regular than those of A356, and their size is independent of cutting speed. It was also demonstrated that the fragility of materials can be characterized based on the results of cutting resistance produced during drilling

The use of cutting temperature to evaluate the machinability of titanium alloys.

Science.gov (United States)

Kikuchi, Masafumi

2009-02-01

This study investigated the machinability of titanium, two commercial titanium alloys (Ti-6Al-4V and Ti-6Al-7Nb) and free-cutting brass using the cutting temperature. The cutting temperature was estimated by measuring the thermal electromotive force of the tool-workpiece thermocouple during cutting. The thermoelectric power of each metal relative to the tool had previously been determined. The metals were slotted using a milling machine and carbide square end mills under four cutting conditions. The cutting temperatures of Ti-6Al-4V and Ti-6Al-7Nb were significantly higher than that of the titanium, while that of the free-cutting brass was lower. This result coincided with the relationship of the magnitude of the cutting forces measured in a previous study. For each metal, the cutting temperature became higher when the depth of cut or the cutting speed and feed increased. The increase in the cutting speed and feed was more influential on the value than the increase in the depth of cut when two cutting conditions with the same removal rates were compared. The results demonstrated that cutting temperature measurement can be utilized to develop a new material for dental CAD/CAM applications and to optimize the cutting conditions.

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.

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)

Constant Cutting Force Control for CNC Machining Using Dynamic Characteristic-Based Fuzzy Controller

Directory of Open Access Journals (Sweden)

Hengli Liu

2015-01-01

Full Text Available This paper presents a dynamic characteristic-based fuzzy adaptive control algorithm (DCbFACA to avoid the influence of cutting force changing rapidly on the machining stability and precision. The cutting force is indirectly obtained in real time by monitoring and extraction of the motorized spindle current, the feed speed is fuzzy adjusted online, and the current was used as a feedback to control cutting force and maintain the machining process stable. Different from the traditional fuzzy control methods using the experience-based control rules, and according to the complex nonlinear characteristics of CNC machining, the power bond graph method is implemented to describe the dynamic characteristics of process, and then the appropriate variation relations are achieved between current and feed speed, and the control rules are optimized and established based on it. The numerical results indicated that DCbFACA can make the CNC machining process more stable and improve the machining precision.

Comparative study for different statistical models to optimize cutting parameters of CNC end milling machines

International Nuclear Information System (INIS)

El-Berry, A.; El-Berry, A.; Al-Bossly, A.

2010-01-01

In machining operation, the quality of surface finish is an important requirement for many work pieces. Thus, that is very important to optimize cutting parameters for controlling the required manufacturing quality. Surface roughness parameter (Ra) in mechanical parts depends on turning parameters during the turning process. In the development of predictive models, cutting parameters of feed, cutting speed, depth of cut, are considered as model variables. For this purpose, this study focuses on comparing various machining experiments which using CNC vertical machining center, work pieces was aluminum 6061. Multiple regression models are used to predict the surface roughness at different experiments.

Kinematics of the AM-50 heading machine cutting head

Energy Technology Data Exchange (ETDEWEB)

Sikora, W; Bak, K; Klich, R [Politechnika Slaska, Gliwice (Poland). Instytut Mechanizacji Gornictwa

1987-01-01

Analyzes motion of the cutter head of the AM-50 heading machine. Two types of head motion are comparatively evaluated: planar motion and spatial motion. The spatial motion consists of the head rotational motion and horizontal or vertical feed motion, while planar motion consists of rotational motion and vertical feed motion. Equations that describe head motion under conditions of cutter vertical or horizontal feed motion are derived. The angle between the cutting speed direction and working speed direction is defined. On the basis of these formulae variations of cutting speed depending on the cutting tool position on a cutter head are calculated. Calculations made for 2 extreme cutting tools show that the cutting speed ranges from 1,205 m/s to 3,512 m/s. 4 refs.

Experimental testing of exchangeable cutting inserts cutting ability

OpenAIRE

Čep, Robert; Janásek, Adam; Čepová, Lenka; Petrů, Jana; Hlavatý, Ivo; Car, Zlatan; Hatala, Michal

2013-01-01

The article deals with experimental testing of the cutting ability of exchangeable cutting inserts. Eleven types of exchangeable cutting inserts from five different manufacturers were tested. The tested cutting inserts were of the same shape and were different especially in material and coating types. The main aim was both to select a suitable test for determination of the cutting ability of exchangeable cutting inserts and to design such testing procedure that could make it possible...

Modeling of tool path for the CNC sheet cutting machines

Science.gov (United States)

Petunin, Aleksandr A.

2015-11-01

In the paper the problem of tool path optimization for CNC (Computer Numerical Control) cutting machines is considered. The classification of the cutting techniques is offered. We also propose a new classification of toll path problems. The tasks of cost minimization and time minimization for standard cutting technique (Continuous Cutting Problem, CCP) and for one of non-standard cutting techniques (Segment Continuous Cutting Problem, SCCP) are formalized. We show that the optimization tasks can be interpreted as discrete optimization problem (generalized travel salesman problem with additional constraints, GTSP). Formalization of some constraints for these tasks is described. For the solution GTSP we offer to use mathematical model of Prof. Chentsov based on concept of a megalopolis and dynamic programming.

Effect of microstructure and cutting speed on machining behavior of Ti6Al4V alloy

Energy Technology Data Exchange (ETDEWEB)

Telrandhe, Sagar V.; Mishra, Sushil; Saxena, Ashish K. [Indian Institute of Technology Bombay, Mumbai (India)

2017-05-15

Machining of aerospace and biomedical grade titanium alloys has always been a challenge because of their low conductivity and elastic modulus. Different machining methods and parameters have been adopted for high precision machining of titanium alloys. Machining of titanium alloys can be improved by microstructure optimization. The present study focuses on the effect of microstructure on ma- chinability of Ti6Al4V alloys at different cutting speeds. Samples were subjected to different annealing conditions resulting in different grain sizes and local micro-strains (misorientation). Cutting forces were significantly reduced after annealing; consequently, sub-surface residual stresses were reduced. Deformation twinning was also observed on samples annealed at a higher temperature due to larger grain size. Initial strain free grains and deformation twinning during machining reduces the cutting force at higher cutting speed.

EVALUATION OF MACHINABILITY OF DUCTILE IRONS ALLOYED WITH Ni AND Cu IN TERMS OF CUTTING FORCES AND SURFACE QUALITY

Directory of Open Access Journals (Sweden)

Yücel AŞKUN

2003-02-01

Full Text Available Due to the enhanced strength, ductility and thoughness of Ductile Iron (DI when compared to the other types cast iron, its machinability is relatively poor. When a steel part is replaced with ductile iron, however, better machinability is considered to be the most important gain. This study presents the results of machining tests of ductile irons alloyed with Ni and Cu at various contents to determine the effect of their microstructure and mechanical properties on cutting forces and surface roughness. Six different specimen groups of ductile iron alloyed with various amounts of nickel and copper were subjected to machining tests and their machinabilities were investigated based on cutting forces and surface roughness criteria. The results were evaluated according to microstructure and mechanical properties of specimens determined before. In terms of both criterion, the best result obtained was specimen added 0.7 % Ni and 0.7 % Cu. When the specimens were evaluated according to their mechanical properties, the specimens alloyed 1 % Ni and 0.65 % Cu seemed promising.

Laser beam machining of polycrystalline diamond for cutting tool manufacturing

Science.gov (United States)

Wyszyński, Dominik; Ostrowski, Robert; Zwolak, Marek; Bryk, Witold

2017-10-01

The paper concerns application of DPSS Nd: YAG 532nm pulse laser source for machining of polycrystalline WC based diamond inserts (PCD). The goal of the research was to determine optimal laser cutting parameters for cutting tool shaping. Basic criteria to reach the goal was cutting edge quality (minimalization of finishing operations), material removal rate (time and cost efficiency), choice of laser beam characteristics (polarization, power, focused beam diameter). The research was planned and realised and analysed according to design of experiment rules (DOE). The analysis of the cutting edge was prepared with use of Alicona Infinite Focus measurement system.

Process Damping and Cutting Tool Geometry in Machining

Science.gov (United States)

Taylor, C. M.; Sims, N. D.; Turner, S.

2011-12-01

Regenerative vibration, or chatter, limits the performance of machining processes. Consequences of chatter include tool wear and poor machined surface finish. Process damping by tool-workpiece contact can reduce chatter effects and improve productivity. Process damping occurs when the flank (also known as the relief face) of the cutting tool makes contact with waves on the workpiece surface, created by chatter motion. Tool edge features can act to increase the damping effect. This paper examines how a tool's edge condition combines with the relief angle to affect process damping. An analytical model of cutting with chatter leads to a two-section curve describing how process damped vibration amplitude changes with surface speed for radiussed tools. The tool edge dominates the process damping effect at the lowest surface speeds, with the flank dominating at higher speeds. A similar curve is then proposed regarding tools with worn edges. Experimental data supports the notion of the two-section curve. A rule of thumb is proposed which could be useful to machine operators, regarding tool wear and process damping. The question is addressed, should a tool of a given geometry, used for a given application, be considered as sharp, radiussed or worn regarding process damping.

Process Damping and Cutting Tool Geometry in Machining

International Nuclear Information System (INIS)

Taylor, C M; Sims, N D; Turner, S

2011-01-01

Regenerative vibration, or chatter, limits the performance of machining processes. Consequences of chatter include tool wear and poor machined surface finish. Process damping by tool-workpiece contact can reduce chatter effects and improve productivity. Process damping occurs when the flank (also known as the relief face) of the cutting tool makes contact with waves on the workpiece surface, created by chatter motion. Tool edge features can act to increase the damping effect. This paper examines how a tool's edge condition combines with the relief angle to affect process damping. An analytical model of cutting with chatter leads to a two-section curve describing how process damped vibration amplitude changes with surface speed for radiussed tools. The tool edge dominates the process damping effect at the lowest surface speeds, with the flank dominating at higher speeds. A similar curve is then proposed regarding tools with worn edges. Experimental data supports the notion of the two-section curve. A rule of thumb is proposed which could be useful to machine operators, regarding tool wear and process damping. The question is addressed, should a tool of a given geometry, used for a given application, be considered as sharp, radiussed or worn regarding process damping.

Real-time wavelet-based inline banknote-in-bundle counting for cut-and-bundle machines

Science.gov (United States)

Petker, Denis; Lohweg, Volker; Gillich, Eugen; Türke, Thomas; Willeke, Harald; Lochmüller, Jens; Schaede, Johannes

2011-03-01

Automatic banknote sheet cut-and-bundle machines are widely used within the scope of banknote production. Beside the cutting-and-bundling, which is a mature technology, image-processing-based quality inspection for this type of machine is attractive. We present in this work a new real-time Touchless Counting and perspective cutting blade quality insurance system, based on a Color-CCD-Camera and a dual-core Computer, for cut-and-bundle applications in banknote production. The system, which applies Wavelet-based multi-scale filtering is able to count banknotes inside a 100-bundle within 200-300 ms depending on the window size.

Combustion-assisted laser cutting of a difficult-to-machine superalloy

International Nuclear Information System (INIS)

Molian, P.A.

1992-01-01

In laser cutting, the largest single application of lasers in manufacturing, the assist gas plays an important role in affecting the cutting performance. The assist gas is usually oxygen or an inert gas. In this paper acetylene and oxygen was employed to create combustion reactions during CO 2 laser cutting that enabled an improvement in the cutting speed, and cut quality of a difficult-to-machine superalloy. A comparison with laser cutting of a plain carbon steel under identical conditions was also made to determine the usefulness of combustion energy. Results indicate that both cutting speed and quality are enhanced by the reduction in the viscosity of slag formed during cutting (which assisted in ejection of the slag through the bottom of the kerf) due to the heat released by the acetylene burning inside the kerf. Correlations of experimental data with a theoretical model provided the influence of combustion power and gas-flow power on the cutting phenomena

New Methodologies for Development of High Efficient Machining of Difficult to Cut Materials

International Nuclear Information System (INIS)

Durante, S; Comoglio, M; Rostagno, M

2011-01-01

The article focuses on the automotive and aerospace industries. In these industries the need for enhanced materials performance is necessary if they are to remain competitive in global terms. Unfortunately the material properties, which make them so attractive to the aerospace and automotive industry can also make them difficult to machine. This paper will discuss integrated developments in machining techniques and cutting tools, which are emerging to cope with difficult to cut materials.

Influence of cutting data on surface quality when machining 17-4 PH stainless steel

Science.gov (United States)

Popovici, T. D.; Dijmărescu, M. R.

2017-08-01

The aim of the research presented in this paper is to analyse the cutting data influence upon surface quality for 17-4 PH stainless steel milling machining. The cutting regime parameters considered for the experiments were established using cutting regimes from experimental researches or from industrial conditions as basis, within the recommended ranges. The experimental program structure was determined by taking into account compatibility and orthogonality conditions, minimal use of material and labour. The machined surface roughness was determined by measuring the Ra roughness parameter, followed by surface profile registration in the form of graphics which were saved on a computer with MarSurf PS1Explorer software. Based on Ra roughness parameter, maximum values were extracted from these graphics and the influence charts of the cutting regime parameters upon surface roughness were traced using Microsoft Excel software. After a thorough analysis of the resulting data, relevant conclusions were drawn, presenting the interdependence between the surface roughness of the machined 17-4 PH samples and the cutting data variation.

Manufacturing Methods for Cutting, Machining and Drilling Composites. Volume 1. Composites Machining Handbook

Science.gov (United States)

1978-08-01

12°±30’ 1180±2° OPTIONAL .0005 IN./IN. BACK TAPER 015 RAD LIPS TO BE WITHIN .002 OF TRUE ANGULAR POSITION NOTES: 1. LAND WIDTH: 28% ± .005... horoscope and dye-penetrant requirements. 79 PHASE 1 PHASE II PHASE III PHASE IV CUTTING DRILLING MACHINING NONDESTRUCTIVE EVALUATION METHOD MATERIAL

Characterization of cutting parameters in the minimum quantity lubricant (MQL) machining process of a gearbox

OpenAIRE

Travieso Rodriguez, Jose Antonio; Gómez Gras, David; García Vilana, Silvia; Mainau Noguer, Ferran; Jerez Mesa, Ramón

2015-01-01

This paper aims to find the key process parameters for machining different parts of an automobile gearbox, commissioned by a company that needs to replace with the MQL lubrication system their current machining process based on cutting fluids. It particularly focuses on the definition of appropriate cutting parameters for machining under the MQL condition through a statistical method of Design of Experiments (DOE). Using a combination of recommended parameters, significant improvements in the...

Cutting and machining energetic materials with a femtosecond laser

Energy Technology Data Exchange (ETDEWEB)

Roeske, Frank; Benterou, Jerry; Lee, Ronald; Roos, Edward [Energetic Materials Center, Lawrence Livermore National Laboratory, P. O. Box 808, Livermore, CA 94550 (United States)

2003-04-01

A femtosecond (fs) laser has been used as a tool for solving many problems involving access, machining, disassembly, inspection and avoidance of undesirable hazardous waste streams in systems containing energetic materials. Because of the unique properties of the interaction of ultrashort laser pulses with matter, the femtosecond laser can be used to safely cut these energetic materials in a precise manner without creating an unacceptable waste stream. Many types of secondary high explosives (HE) and propellants have been cut with the laser for a variety of applications ranging from disassembly of aging conventional weapons (demilitarization), inspection of energetic components of aging systems to creating unique shapes of HE for purposes of initiation and detonation physics studies. Hundreds of samples of energetic materials have been cut with the fs laser without ignition and, in most cases, without changing the surface morphology of the cut surfaces. The laser has also been useful in cutting nonenergetic components in close proximity to energetic materials. (Abstract Copyright [2003], Wiley Periodicals, Inc.)

Effects of machining conditions on the specific cutting energy of carbon fibre reinforced polymer composites

Science.gov (United States)

Azmi, A. I.; Syahmi, A. Z.; Naquib, M.; Lih, T. C.; Mansor, A. F.; Khalil, A. N. M.

2017-10-01

This article presents an approach to evaluate the effects of different machining conditions on the specific cutting energy of carbon fibre reinforced polymer composites (CFRP). Although research works in the machinability of CFRP composites have been very substantial, the present literature rarely discussed the topic of energy consumption and the specific cutting energy. A series of turning experiments were carried out on two different CFRP composites in order to determine the power and specific energy constants and eventually evaluate their effects due to the changes in machining conditions. A good agreement between the power and material removal rate using a simple linear relationship. Further analyses revealed that a power law function is best to describe the effect of feed rate on the changes in the specific cutting energy. At lower feed rate, the specific cutting energy increases exponentially due to the nature of finishing operation, whereas at higher feed rate, the changes in specific cutting energy is minimal due to the nature of roughing operation.

Application of CO2 laser cutting machine to shipbuilding; Zosen no setsudan eno CO2 laser no tekiyo

Energy Technology Data Exchange (ETDEWEB)

Fujimoto, Y. [Mitsui Engineering and Shipbuilding Co. Ltd., Tokyo (Japan)

1998-11-01

Carbon dioxide laser has been applied to cutting works in shipbuilding. As NC cutter was obsolete, CO2 laser cutting machine with a rated output 3 kW was introduced. According to the specifications of the machinable plate, the maximum thickness is 19 mm, and effective width and length are 5.4 m and 29.1 m, respectively. As the cutting width is wide and the running distance of laser beam is long, the error of light axis is expanded only by a small error of irradiation angle, which results in the inconvenience. Stable operation was realized by improving the fixation of reflecting mirror. Right angle cutting section with a cutting curve below 0.5 mm was obtained, and cutting time was reduced by the one-line cutting by which both sections can be available with a single cutting line. For the cutting of thin plate with a thickness less than 10 mm, strain was not formed, and remedy was not required. Block strain was remarkably reduced during the assembly process. Maintenance-free operation without monitoring can be performed for a long time. This machine is operated at night and lunch time, resulting in the reduced processes. The working environment is appropriate without noise and dust. Facility cost and maintenance cost were also reduced. Lower cutting speed is a weak point, when compared with the plasma cutting machine. The present machine is not applied to aluminum plates with high surface reflectivity. 13 figs.

Analysis of the Influence of the Use of Cutting Fluid in Hybrid Processes of Machining and Laser Metal Deposition (LMD

Directory of Open Access Journals (Sweden)

Magdalena Cortina

2018-02-01

Full Text Available Hybrid manufacturing processes that combine additive and machining operations are gaining relevance in modern industry thanks to the capability of building complex parts with minimal material and, many times, with process time reduction. Besides, as the additive and subtractive operations are carried out in the same machine, without moving the part, dead times are reduced and higher accuracies are achieved. However, it is not clear whether the direct material deposition after the machining operation is possible or intermediate cleaning stages are required because of the possible presence of residual cutting fluids. Therefore, different Laser Metal Deposition (LMD tests are performed on a part impregnated with cutting fluid, both directly and after the removal of the coolant by techniques such as laser vaporizing and air blasting. The present work studies the influence of the cutting fluid in the LMD process and the quality of the resulting part. Resulting porosity is evaluated and it is concluded that if the part surface is not properly clean after the machining operation, deficient clad quality can be obtained in the subsequent laser additive operation.

Machining of Some Difficult-to-Cut Materials with Rotary Cutting Tools

OpenAIRE

Stjernstoft, Tero

2004-01-01

Automobile and aero industries have an increasing interestin materials with improved mechanical properties. However, manyof these new materials are classified as difficult-to-cut withconventional tools. It is obvious that tools, cutting processesand cutting models has to be devel-oped parallel to materialsscience. In this thesis rotary cutting tools are tested as analternative toexpensive diamond or cubic bore nitridetools. Metal matrix composites mostly consist of a light metalalloy (such as...

Impact of Cutting Forces and Chip Microstructure in High Speed Machining of Carbon Fiber – Epoxy Composite Tube

Directory of Open Access Journals (Sweden)

Roy Y. Allwin

2017-09-01

Full Text Available Carbon fiber reinforced polymeric (CFRP composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure which offer vital inputs to the machinability and deformation characteristics of the material. In this work, the orthogonal machining of CFRP was conducted by varying the cutting parameters such as cutting speed and feed rate at high cutting speed/feed rate ranges up to 346 m/min/ 0.446 mm/rev. The impact of the cutting parameters on cutting forces (principal cutting, feed and thrust forces and chip microstructure were analyzed. A significant impact on thrust forces and chip segmentation pattern was seen at higher feed rates and low cutting speeds.

The effect of cutting conditions on power inputs when machining

Science.gov (United States)

Petrushin, S. I.; Gruby, S. V.; Nosirsoda, Sh C.

2016-08-01

Any technological process involving modification of material properties or product form necessitates consumption of a certain power amount. When developing new technologies one should take into account the benefits of their implementation vs. arising power inputs. It is revealed that procedures of edge cutting machining are the most energy-efficient amongst the present day forming procedures such as physical and technical methods including electrochemical, electroerosion, ultrasound, and laser processing, rapid prototyping technologies etc, such as physical and technical methods including electrochemical, electroerosion, ultrasound, and laser processing, rapid prototyping technologies etc. An expanded formula for calculation of power inputs is deduced, which takes into consideration the mode of cutting together with the tip radius, the form of the replaceable multifaceted insert and its wear. Having taken as an example cutting of graphite iron by the assembled cutting tools with replaceable multifaceted inserts the authors point at better power efficiency of high feeding cutting in comparison with high-speed cutting.

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.

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.

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.

Operational dynamics of the cutting head of the AM-50 heading machine

Energy Technology Data Exchange (ETDEWEB)

Sikora, W; Bak, K; Klich, R [Politechnika Slaska, Gliwice (Poland). Instytut Mechanizacji Gornictwa

1987-01-01

Operation of the cutter head of an AM-50 heading machine is influenced by a large number of factors, many of them of a random character. Forces acting on each of the cutting tools participating in coal or rock cutting are determined and summed up. The total cutting force is then calculated and on that basis the turning moment is derived. Cutting tool operation also is analyzed as a stochastic process. Cutting forces of each cutting tool change from 0 to maximum. However these forces are distributed in cutting time and the total cutting force is not the sum of the average cutting forces, nor is it the sum of maximum cutting forces. Using calculus of probability, the probable force distribution was determined. This distribution is compared to force distribution calculated on the basis of power consumption of the cutter motors. The differences between the two force distributions are, among others, caused by insufficient investigation into operation of conic cutters. 10 refs.

Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

Directory of Open Access Journals (Sweden)

A.K.M.N. Amin, M.A. Rizal, and M. Razman

2012-08-01

Full Text Available Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC, which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

Dry Machining Aeronautical Aluminum Alloy AA2024-T351: Analysis of Cutting Forces, Chip Segmentation and Built-Up Edge Formation

Directory of Open Access Journals (Sweden)

Badis Haddag

2016-08-01

Full Text Available In this paper, machining aeronautical aluminum alloy AA2024-T351 in dry conditions was investigated. Cutting forces, chip segmentation, and built-up edge formation were analyzed. Machining tests revealed that the chip formation process depends on cutting conditions and tool geometry. So continuous and segmented chips are generated. Under some cutting conditions, built-up edge formation occurs. A predictive machining theory, based on a finite elements method (FEM, was applied to reproduce and explain these phenomena. Thermomechanical behaviors of the work material and the tool-work material interface were considered. Results of the proposed modelling were compared to experimental data for a wide range of cutting speed. It was shown that the feed force is well reproduced by the ALE-FE (arbitrary lagrangian-eulerian finite element formulation and highly underestimated by the lagrangian finite element (LAG-FE one. While, the periodic localized shear band, leading to a chip segmentation, is well reproduced with the Lagrangian FE formulation. It was found that the chip segmentation can be correlated to the cutting force evolution using the defined chip segmentation intensity parameter. For the built-up edge (BUE phenomenon, it was shown that it depends on the contact/friction at the tool-chip interface, and this is possible to simulate by making the friction coefficient time-dependent.

INFLUENCE OF MACHINING TECHNOLOGIES ON VALUES OF RESIDUAL STRESSES OF OXIDE CUTTING CERAMICS

Directory of Open Access Journals (Sweden)

Jakub Němeček

2017-07-01

Full Text Available Currently, the intensive development of engineering ceramic and effort to replace sintered carbides as cutting materials are in progress. With the development of the sintering technology it is now possible to produce compact ceramic cutting samples with very good mechanical properties. The advantage of these materials is their easy accessibility and low purchase price. In this work, the influence of the finishing machine technology on the values of surface residual stresses of cutting ceramic samples Al2O3+TiC were studying. The samples were supplied by Moscow State University of Technology STANKIN. Measurements made in the X-ray diffraction laboratory at the Department of solid state engineering were performed for both the phases. The influence of the parameters of machining to residual stresses was studied and the resulting values were compared with each other.

Performance of Process Damping in Machining Titanium Alloys at Low Cutting Speed with Different Helix Tools

International Nuclear Information System (INIS)

Shaharun, M A; Yusoff, A R; Reza, M S; Jalal, K A

2012-01-01

Titanium is a strong, lustrous, corrosion-resistant and transition metal with a silver color to produce strong lightweight alloys for industrial process, automotive, medical instruments and other applications. However, it is very difficult to machine the titanium due to its poor machinability. When machining titanium alloys with the conventional tools, the wear rate of the tool is rapidly accelerate and it is generally difficult to achieve at high cutting speed. In order to get better understanding of machining titanium alloy, the interaction between machining structural system and the cutting process which result in machining instability will be studied. Process damping is a useful phenomenon that can be exploited to improve the limited productivity of low speed machining. In this study, experiments are performed to evaluate the performance of process damping of milling under different tool helix geometries. The results showed that the helix of 42° angle is significantly increase process damping performance in machining titanium alloy.

The influence of cooling techniques on cutting forces and surface roughness during cryogenic machining of titanium alloys

Directory of Open Access Journals (Sweden)

Wstawska Iwona

2016-12-01

Full Text Available Titanium alloys are one of the materials extensively used in the aerospace industry due to its excellent properties of high specific strength and corrosion resistance. On the other hand, they also present problems wherein titanium alloys are extremely difficult materials to machine. In addition, the cost associated with titanium machining is also high due to lower cutting velocities and shorter tool life. The main objective of this work is a comparison of different cooling techniques during cryogenic machining of titanium alloys. The analysis revealed that applied cooling technique has a significant influence on cutting force and surface roughness (Ra parameter values. Furthermore, in all cases observed a positive influence of cryogenic machining on selected aspects after turning and milling of titanium alloys. This work can be also the starting point to the further research, related to the analysis of cutting forces and surface roughness during cryogenic machining of titanium alloys.

Effects of cutting parameters and machining environments on surface roughness in hard turning using design of experiment

Science.gov (United States)

Mia, Mozammel; Bashir, Mahmood Al; Dhar, Nikhil Ranjan

2016-07-01

Hard turning is gradually replacing the time consuming conventional turning process, which is typically followed by grinding, by producing surface quality compatible to grinding. The hard turned surface roughness depends on the cutting parameters, machining environments and tool insert configurations. In this article the variation of the surface roughness of the produced surfaces with the changes in tool insert configuration, use of coolant and different cutting parameters (cutting speed, feed rate) has been investigated. This investigation was performed in machining AISI 1060 steel, hardened to 56 HRC by heat treatment, using coated carbide inserts under two different machining environments. The depth of cut, fluid pressure and material hardness were kept constant. The Design of Experiment (DOE) was performed to determine the number and combination sets of different cutting parameters. A full factorial analysis has been performed to examine the effect of main factors as well as interaction effect of factors on surface roughness. A statistical analysis of variance (ANOVA) was employed to determine the combined effect of cutting parameters, environment and tool configuration. The result of this analysis reveals that environment has the most significant impact on surface roughness followed by feed rate and tool configuration respectively.

Implementation of the geometrical problem in CNC metal cutting machine

Directory of Open Access Journals (Sweden)

Erokhin V.V.

2017-06-01

Full Text Available The article deals with the tasks of managing the production process (technological process and technological equip-ment, the most detailed analysis of the implementation of the geometric problem in CNC machines. The influence of the solution of the geometric CNC problem on the accuracy of workpiece machining is analyzed by implementing a certain interpolation algorithm and the values of the discreteness of the movements of the working bodies of the CNC machine. The technique of forming a given trajectory of motion of the machine's executive organ is given, by means of which it is required to ensure the coordinated movement of the shaping coordinates according to a certain law, depend-ing on the specified trajectory of the cutting edge of the tool. The advantages and disadvantages of the implementation of interpolation in CNC systems by various methods are considered, and particular attention is paid to combined meth-ods of realizing interpolation.

Prediction of 3D chip formation in the facing cutting with lathe machine using FEM

Science.gov (United States)

Prasetyo, Yudhi; Tauviqirrahman, Mohamad; Rusnaldy

2016-04-01

This paper presents the prediction of the chip formation at the machining process using a lathe machine in a more specific way focusing on facing cutting (face turning). The main purpose is to propose a new approach to predict the chip formation with the variation of the cutting directions i.e., the backward and forward direction. In addition, the interaction between stress analysis and chip formation on cutting process was also investigated. The simulations were conducted using three dimensional (3D) finite element method based on ABAQUS software with aluminum and high speed steel (HSS) as the workpiece and the tool materials, respectively. The simulation result showed that the chip resulted using a backward direction depicts a better formation than that using a conventional (forward) direction.

Effect of reinforcement on the cutting forces while machining metal matrix composites–An experimental approach

Directory of Open Access Journals (Sweden)

Ch. Shoba

2015-12-01

Full Text Available Hybrid metal matrix composites are of great interest for researchers in recent years, because of their attractive superior properties over traditional materials and single reinforced composites. The machinabilty of hybrid composites becomes vital for manufacturing industries. The need to study the influence of process parameters on the cutting forces in turning such hybrid composite under dry environment is essentially required. In the present study, the influence of machining parameters, e.g. cutting speed, feed and depth of cut on the cutting force components, namely feed force (Ff, cutting force (Fc, and radial force (Fd has been investigated. Investigations were performed on 0, 2, 4, 6 and 8 wt% Silicon carbide (SiC and rice husk ash (RHA reinforced composite specimens. A comparison was made between the reinforced and unreinforced composites. The results proved that all the cutting force components decrease with the increase in the weight percentage of the reinforcement: this was probably due to the dislocation densities generated from the thermal mismatch between the reinforcement and the matrix. Experimental evidence also showed that built-up edge (BUE is formed during machining of low percentage reinforced composites at high speed and high depth of cut. The formation of BUE was captured by SEM, therefore confirming the result. The decrease of cutting force components with lower cutting speed and higher feed and depth of cut was also highlighted. The related mechanisms are explained and presented.

Study of cutting speed on surface roughness and chip formation when machining nickel-based alloy

International Nuclear Information System (INIS)

Khidhir, Basim A.; Mohamed, Bashir

2010-01-01

Nickel- based alloy is difficult-to-machine because of its low thermal diffusive property and high strength at higher temperature. The machinability of nickel- based Hastelloy C-276 in turning operations has been carried out using different types of inserts under dry conditions on a computer numerical control (CNC) turning machine at different stages of cutting speed. The effects of cutting speed on surface roughness have been investigated. This study explores the types of wear caused by the effect of cutting speed on coated and uncoated carbide inserts. In addition, the effect of burr formation is investigated. The chip burr is found to have different shapes at lower speeds. Triangles and squares have been noticed for both coated and uncoated tips as well. The conclusion from this study is that the transition from thick continuous chip to wider discontinuous chip is caused by different types of inserts. The chip burr has a significant effect on tool damage starting in the line of depth-of-cut. For the coated insert tips, the burr disappears when the speed increases to above 150 m/min with the improvement of surface roughness; increasing the speed above the same limit for uncoated insert tips increases the chip burr size. The results of this study showed that the surface finish of nickel-based alloy is highly affected by the insert type with respect to cutting speed changes and its effect on chip burr formation and tool failure

HIGH PERFORMANCE TAPS FOR CUTTING THREADS IN DIFFICULT TO MACHINE MATERIALS

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M. R. Akhmedova

2016-01-01

Full Text Available Objectives. This article explores in detail questions of instrument operation function of tapping internal threads in hard materials. The existing relationship between vibration system amplitude and tool durability is indicated; on this basis, it is determined that the best course for improving the durability performance is increasing vibratory resistance. Based on a critical analysis of existing designs with consideration of their flaws, the development of new technological designs of taps is tasked with ensuring stable operation when handling hard materials. Methods. It is noteworthy that one of the main vibration resistance improvement methods of the tool is to reduce the contact area of the tool with the work piece in the cutting zone. Methods are proposed for improving the vibration resistance of taps, considering the correlation adjustment of tap teeth in order to completely eliminate friction at the sides of the thread cutting surface and uneven implementation flute cutting steps. Results. The idea of increasing vibration resistance has seen the new development of vibration-proof tap designs, heralded as innovations due to the accuracy of thread cutting and durability achieved by reducing the thread contact area with the work piece in the cutting zone. Increased vibration resistance is achieved in the modified taps through high correction by means of thread side downgrading of the coarse tap cone by an additional angle of 30º. In another design, the stylus provided with uneven angular spacing. Test results of designed taps machined in corrosion-resistant 1Kh18N9T steel. A manifold increase in tool durability was achieved due to its high vibration resistance. Conclusions. The redesigned taps have a number of advantages, characterised by a high resistance when processing difficult materials and an insignificant increase in the complexity of their manufacture compared with standard taps. Therefore they can be recommended for large

Determination of cut front position in laser cutting

Science.gov (United States)

Pereira, M.; Thombansen, U.

2016-07-01

Laser cutting has a huge importance to manufacturing industry. Laser cutting machines operate with fixed technological parameters and this does not guarantee the best productivity. The adjustment of the cutting parameters during operation can improve the machine performance. Based on a coaxial measuring device it is possible to identify the cut front position during the cutting process. This paper describes the data analysis approach used to determine the cut front position for different feed rates. The cut front position was determined with good resolution, but improvements are needed to make the whole process more stable.

Correlation of cutting fluid performance in different machining operations

DEFF Research Database (Denmark)

De Chiffre, Leonardo; Belluco, Walter

2001-01-01

An analysis of cutting fluid performance in different metal cutting operations is presented, based on experimental investigations in which type of operation, performance criteria, work material, and fluid type are considered. Cutting fluid performance was evaluated in turning, drilling, reaming...... investigated. Results show that correlation of cutting fluid performance in different operations exists, within the same group of cutting fluids, in the case of stainless steel as workpiece material. Under the tested conditions, the average correlation coefficients between efficiency parameters with different...... operations on austenitic stainless steel lied in the range 0.87-0.97 for waterbased fluids and 0.79-0.89 for straight oils. A similar correlation could not be found for the other workpiece materials investigated in this work. A rationalisation of cutting fluid performance tests is suggested....

Determination of cut front position in laser cutting

International Nuclear Information System (INIS)

Pereira, M; Thombansen, U

2016-01-01

Laser cutting has a huge importance to manufacturing industry. Laser cutting machines operate with fixed technological parameters and this does not guarantee the best productivity. The adjustment of the cutting parameters during operation can improve the machine performance. Based on a coaxial measuring device it is possible to identify the cut front position during the cutting process. This paper describes the data analysis approach used to determine the cut front position for different feed rates. The cut front position was determined with good resolution, but improvements are needed to make the whole process more stable. (paper)

Influence of Vegetable Oil-Based Controlled Cutting Fluid Impinging Supply System on Micro Hardness in Machining of Ti-6Al-4V

OpenAIRE

Salah Gariani; Islam Shyha; Fawad Inam; Dehong Huo

2017-01-01

A controlled cutting fluid impinging supply system (CUT-LIST) was developed to deliver an accurate amount of cutting fluid into the machining zone via well-positioned coherent nozzles based on a calculation of the heat generated. The performance of the CUT-LIST was evaluated against a conventional flood cutting fluid supply system during step shoulder milling of Ti-6Al-4V using vegetable oil-based cutting fluid. In this paper, the micro-hardness of the machined surface was used as the main cr...

On the Cutting Performance of Coated HSS Taps When Machining of Austenitic Steel

Science.gov (United States)

Sliwkova, Petra; Piska, Miroslav

2014-12-01

The paper deals with a quality of the PVD coated HSS taps when cutting the stainless austenitic chromiumnickel non-stabilized steel DIN 1.4301 (X5CrNi 18-10). The main attention is focused on the analysis of loading (cutting moment, specific energy) of the HSS taps by means of pieso-electrical dynamometer Kistler 9272 and the relation between the quality of duplex and triplex PVD coatings and their effects on the quality of machined thread surfaces and tool life of the taps. The results showed a safe and stabilized cutting with acceptable quality of threads for HSSE with the TiN+TiCN+DLC coating.

Test tube systems with cutting/recombination operations

Energy Technology Data Exchange (ETDEWEB)

Freund, R. [Technische Universitaet Wien (Austria); Csuhaj-Varju, E. [Computer and Automation Institute, Budapest (Hungary); Wachtler, F. [Universitaet Wien (Austria)

1996-12-31

We introduce test tube systems based on operations that are closely related to the splicing operations, i.e. we consider the operations of cutting a string at a specific site into two pieces with marking them at the cut ends and of recombining two strings with specifically marked endings. Whereas in the splicing of two strings these strings are cut at specific sites and the cut pieces are recombined immediately in a crosswise way, in CR(cutting/recombination)-schemes cutting can happen independently from recombining the cut pieces. Test tube systems based on these operations of cutting and recombination turn out to have maximal generative power even if only very restricted types of input filters for the test tubes are used for the redistribution of the contents of the test tubes after a period of cuttings and recombinations in the test tubes. 10 refs.

Method of vertically and horizontally cutting steel pipe piles and removing them based on the development of a steel pipe pile vertically cutting machine; Kokanko tatehoko setsudanki no kaihatsu ni yoru kochi chubu no juo setsudan tekkyo koho

Energy Technology Data Exchange (ETDEWEB)

Watanabe, S.; Takeshita, A.; Kobayashi, K.

1997-07-25

A machine for vertically cutting steel pipe piles has newly been developed for the purpose of removing the end portions the shore protection steel pipe piles which interfere with the shield tunneling work in the Ohokagawa River tunneling section on the Minato Mirai 21 Line. This paper reports the development of the machine for vertically cutting steel pipe piles, and a method of cutting the shield tunneling work hindering piles under the ground by using this machine. The obstacle-constituting portions of the piles are removed by destroying the copings, excavating the interior of the piles to make the same hollow so that a cutting machine can be inserted, and cutting the piles vertically and horizontally. The basic structure of the cutting machine comprises a lower cutting unit for making forward and backward and upward and downward movements of a cutter, and an upper movable unit for controlling the rotation of the cutting unit. The cutting of a pile is done by projecting the cutter by a cylinder the base of which is joined to a cutter driver, and then moving the rotating cutter upward. The amounts of movements of these parts are detected by sensors, and an arbitrary range of the underground portion of a pile can be cut by a remote control operation. 10 figs., 1 tab.

Application of wire sawing method to decommissioning of nuclear power plant. Cutting test with turbine pedestal of thermal power plant

International Nuclear Information System (INIS)

Hasegawa, Hideki; Uchiyama, Noriyuki; Sugiyama, Kazuya; Yamashita, Yoshitaka; Watanabe, Morishige

1995-01-01

It is very important to reduce radioactive waste volume, and to reduce radiation dose to workers and to the public during dismantling of the activated concrete in the decommissioning stage of a nuclear power plant. For the above, we studied a dismantling method which can separate activated concrete from non-activated concrete safely and effectively. Considering the state of legal regulation about radioactive waste disposal, and the state of developing of decommissioning technologies, we come to a conclusion that wire sawing method is feasible as a concrete cutting method. This study was carried out to evaluate the availability of the wire sawing method to dismantling of concrete structures of nuclear power plants. This study consists of concrete cutting rate test and concrete block cutting test. The former is to obtain data about cutting rate with various steel ratios while the latter is to obtain data about working time and man hour of the whole work with wire sawing. Thirty-six year old turbine pedestal of a thermal power plant was selected as a test piece to simulate actual decommissioning work of nuclear power plant, taking its massive concrete volume and age. Taking account of the handling in the building, the wire sawing machine with motor driven was used in this study considering that it did not produce exhaust gas. The concrete cutting rate test was performed with parameter of steel ratio in the concrete, wire tension and cutting direction. In the concrete block cutting test, imaging the actual cutting situation, cubic blocks which side was approximately 1 meter were taken out, and a large block to be cut and to be taken out is a section of 1m x 1.5m x 10m. Test results are shown below. The difference of cutting rate was mainly caused by the difference of reinforcement steel ratio. Working time data of installation, removal of machines and cutting were obtained. Data on secondary waste (dust, drainage and sludge) and environmental effect (noise and

Distinguishing butchery cut marks from crocodile bite marks through machine learning methods.

Science.gov (United States)

Domínguez-Rodrigo, Manuel; Baquedano, Enrique

2018-04-10

All models of evolution of human behaviour depend on the correct identification and interpretation of bone surface modifications (BSM) on archaeofaunal assemblages. Crucial evolutionary features, such as the origin of stone tool use, meat-eating, food-sharing, cooperation and sociality can only be addressed through confident identification and interpretation of BSM, and more specifically, cut marks. Recently, it has been argued that linear marks with the same properties as cut marks can be created by crocodiles, thereby questioning whether secure cut mark identifications can be made in the Early Pleistocene fossil record. Powerful classification methods based on multivariate statistics and machine learning (ML) algorithms have previously successfully discriminated cut marks from most other potentially confounding BSM. However, crocodile-made marks were marginal to or played no role in these comparative analyses. Here, for the first time, we apply state-of-the-art ML methods on crocodile linear BSM and experimental butchery cut marks, showing that the combination of multivariate taphonomy and ML methods provides accurate identification of BSM, including cut and crocodile bite marks. This enables empirically-supported hominin behavioural modelling, provided that these methods are applied to fossil assemblages.

Analysis of machining and machine tools

CERN Document Server

Liang, Steven Y

2016-01-01

This book delivers the fundamental science and mechanics of machining and machine tools by presenting systematic and quantitative knowledge in the form of process mechanics and physics. It gives readers a solid command of machining science and engineering, and familiarizes them with the geometry and functionality requirements of creating parts and components in today’s markets. The authors address traditional machining topics, such as: single and multiple point cutting processes grinding components accuracy and metrology shear stress in cutting cutting temperature and analysis chatter They also address non-traditional machining, such as: electrical discharge machining electrochemical machining laser and electron beam machining A chapter on biomedical machining is also included. This book is appropriate for advanced undergraduate and graduate mechani cal engineering students, manufacturing engineers, and researchers. Each chapter contains examples, exercises and their solutions, and homework problems that re...

Prediction of laser cutting heat affected zone by extreme learning machine

Science.gov (United States)

Anicic, Obrad; Jović, Srđan; Skrijelj, Hivzo; Nedić, Bogdan

2017-01-01

Heat affected zone (HAZ) of the laser cutting process may be developed based on combination of different factors. In this investigation the HAZ forecasting, based on the different laser cutting parameters, was analyzed. The main goal was to predict the HAZ according to three inputs. The purpose of this research was to develop and apply the Extreme Learning Machine (ELM) to predict the HAZ. The ELM results were compared with genetic programming (GP) and artificial neural network (ANN). The reliability of the computational models were accessed based on simulation results and by using several statistical indicators. Based upon simulation results, it was demonstrated that ELM can be utilized effectively in applications of HAZ forecasting.

Development of a semiautomatic cutting machine for the fabrication of 137Cs-brachytherapy sources

International Nuclear Information System (INIS)

Avhad, B.G.; Dutta, M.L.; Saxena, S.K.; Dash, A.

2004-01-01

Cesium-137 sources are used in brachytherapy for the treatment of gynaecological cancers.The process of source preparation entails the vitrification of radioactive glass, its conversion into glass spheres, subsequent filling of spheres into platinum moulds and cutting of sources into the tubular form of dimension 1.5 mm(OD) x 5 mm(l). The large scale production of these sources demands the remote cutting operations within 4 inch thick lead shielded processing plants. This paper describes the development of a semi-automatic cutting machine, which can be used in the large scale production of 137 Cs brachytherapy sources. (author)

Analysis of surface integrity in machining of AISI 304 stainless steel under various cooling and cutting conditions

Science.gov (United States)

Klocke, F.; Döbbeler, B.; Lung, S.; Seelbach, T.; Jawahir, I. S.

2018-05-01

Recent studies have shown that machining under specific cooling and cutting conditions can be used to induce a nanocrystalline surface layer in the workspiece. This layer has beneficial properties, such as improved fatigue strength, wear resistance and tribological behavior. In machining, a promising approach for achieving grain refinement in the surface layer is the application of cryogenic cooling. The aim is to use the last step of the machining operation to induce the desired surface quality to save time-consuming and expensive post machining surface treatments. The material used in this study was AISI 304 stainless steel. This austenitic steel suffers from low yield strength that limits its technological applications. In this paper, liquid nitrogen (LN2) as cryogenic coolant, as well as minimum quantity lubrication (MQL), was applied and investigated. As a reference, conventional flood cooling was examined. Besides the cooling conditions, the feed rate was varied in four steps. A large rounded cutting edge radius and finishing cutting parameters were chosen to increase the mechanical load on the machined surface. The surface integrity was evaluated at both, the microstructural and the topographical levels. After turning experiments, a detailed analysis of the microstructure was carried out including the imaging of the surface layer and hardness measurements at varying depths within the machined layer. Along with microstructural investigations, different topological aspects, e.g., the surface roughness, were analyzed. It was shown that the resulting microstructure strongly depends on the cooling condition. This study also shows that it was possible to increase the micro hardness in the top surface layer significantly.

Study on Ti-6Al-4V Alloy Machining Applying the Non-Resonant Three-Dimensional Elliptical Vibration Cutting

Directory of Open Access Journals (Sweden)

Mingming Lu

2017-10-01

Full Text Available The poor machinability of Ti-6Al-4V alloy makes it hard to process by conventional processing methods even though it has been widely used in military and civilian enterprise fields. Non-resonant three-dimensional elliptical vibration cutting (3D-EVC is a novel cutting technique which is a significant development potential for difficult-to-cut materials. However, few studies have been conducted on processing the Ti-6Al-4V alloy using the non-resonant 3D-EVC technique, the effect of surface quality, roughness, topography and freeform surface has not been clearly researched yet. Therefore, the machinability of Ti-6Al-4V alloy using the non-resonant 3D-EVC apparatus is studied in this paper. Firstly, the principle of non-resonant 3D-EVC technique and the model of cutter motion are introduced. Then the tool path is synthesized. The comparison experiments are carried out with traditional continuous cutting (TCC, two-dimension elliptical vibration cutting (2D-EVC, and the non-resonant 3D-EVC method. The experimental results shown that the excellent surface and lower roughness (77.3 nm could be obtained using the non-resonant 3D-EVC method; the shape and dimension of elliptical cutting mark also relates to the cutting speed and vibration frequency, and the concave/convex spherical surface topography are achieved by non-resonant 3D-EVC in the Ti-6Al-4V alloy. This proved that the non-resonant 3D-EVC technique has the better machinability compared with the TCC and 2D-EVC methods.

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.

Accuracy Enhancement with Processing Error Prediction and Compensation of a CNC Flame Cutting Machine Used in Spatial Surface Operating Conditions

Directory of Open Access Journals (Sweden)

Shenghai Hu

2017-04-01

Full Text Available This study deals with the precision performance of the CNC flame-cutting machine used in spatial surface operating conditions and presents an accuracy enhancement method based on processing error modeling prediction and real-time compensation. Machining coordinate systems and transformation matrix models were established for the CNC flame processing system considering both geometric errors and thermal deformation effects. Meanwhile, prediction and compensation models were constructed related to the actual cutting situation. Focusing on the thermal deformation elements, finite element analysis was used to measure the testing data of thermal errors, the grey system theory was applied to optimize the key thermal points, and related thermal dynamics models were carried out to achieve high-precision prediction values. Comparison experiments between the proposed method and the teaching method were conducted on the processing system after performing calibration. The results showed that the proposed method is valid and the cutting quality could be improved by more than 30% relative to the teaching method. Furthermore, the proposed method can be used under any working condition by making a few adjustments to the prediction and compensation models.

Using Machine Learning to Search for MSSM Higgs Bosons

CERN Document Server

Diesing, Rebecca

2016-01-01

This paper examines the performance of machine learning in the identification of Minimally Su- persymmetric Standard Model (MSSM) Higgs Bosons, and compares this performance to that of traditional cut strategies. Two boosted decision tree algorithms were tested, scikit-learn and XGBoost. These tests indicated that machine learning can perform significantly better than traditional cuts. However, since machine learning in this form cannot be directly implemented in a real MSSM Higgs analysis, this performance information was instead used to better understand the relationships between training variables. Further studies might use this information to construct an improved cut strategy.

Rotary ultrasonic machining of CFRP: a mechanistic predictive model for cutting force.

Science.gov (United States)

Cong, W L; Pei, Z J; Sun, X; Zhang, C L

2014-02-01

Cutting force is one of the most important output variables in rotary ultrasonic machining (RUM) of carbon fiber reinforced plastic (CFRP) composites. Many experimental investigations on cutting force in RUM of CFRP have been reported. However, in the literature, there are no cutting force models for RUM of CFRP. This paper develops a mechanistic predictive model for cutting force in RUM of CFRP. The material removal mechanism of CFRP in RUM has been analyzed first. The model is based on the assumption that brittle fracture is the dominant mode of material removal. CFRP micromechanical analysis has been conducted to represent CFRP as an equivalent homogeneous material to obtain the mechanical properties of CFRP from its components. Based on this model, relationships between input variables (including ultrasonic vibration amplitude, tool rotation speed, feedrate, abrasive size, and abrasive concentration) and cutting force can be predicted. The relationships between input variables and important intermediate variables (indentation depth, effective contact time, and maximum impact force of single abrasive grain) have been investigated to explain predicted trends of cutting force. Experiments are conducted to verify the model, and experimental results agree well with predicted trends from this model. Copyright © 2013 Elsevier B.V. All rights reserved.

DIAGNOSTICS OF WORKPIECE SURFACE CONDITION BASED ON CUTTING TOOL VIBRATIONS DURING MACHINING

Directory of Open Access Journals (Sweden)

Jerzy Józwik

2015-05-01

Full Text Available The paper presents functional relationships between surface geometry parameters, feed and vibrations level in the radial direction of the workpiece. Time characteristics of the acceleration of cutting tool vibration registered during C45 steel and stainless steel machining for separate axes (X, Y, Z were presented as a function of feedrate f. During the tests surface geometric accuracy assessment was performed and 3D surface roughness parameters were determined. The Sz parameter was selected for the analysis, which was then collated with RMS vibration acceleration and feedrate f. The Sz parameter indirectly provides information on peak to valley height and is characterised by high generalising potential i.e. it is highly correlated to other surface and volume parameters of surface roughness. Test results presented in this paper may constitute a valuable source of information considering the influence of vibrations on geometric accuracy of elements for engineers designing technological processes.

Performance tests of an abrasive cut-off systems for the finishing of high-precision casts

Directory of Open Access Journals (Sweden)

A. Fedoryszyn

2008-10-01

Full Text Available The paper summarizes the performance data of a newly designed and engineered grinding and cut-off system. The machine is used forseparation of models manufactured by the investment casting method. The machine comprises the following units:- base supporting other assemblies and elements: abrasive disc holder and drives; this solution enables an easy replacement and access toholding elements while a belt transmission allows the disc rpm to be varied,- mechanism moving the spindle in the horizontal, hence the abrasive disc position with respect to the batch can be precisely controlled,depending on the cast position and their shape,- holding and positioning-control of the batch to enable the fore and aft movements and rotations,- guide systems ensuring the travel of the batch in the specified direction and adjusting the travel speed to the required cutting rate,- centering, control, exhaust system, housing.Extensive tests were performed, including the tests of operating parameters of abrasive discs depending on the cast material, cyclograms ofthe applied treatment are obtained accordingly.

Performance tests of an abrasive cut-off systems for the finishing of high-precision casts

Directory of Open Access Journals (Sweden)

A. Fedoryszyn

2008-07-01

Full Text Available The paper summarizes the performance data of a newly designed and engineered grinding and cut-off system. The machine is used for separation of models manufactured by the investment casting method. The machine comprises the following units:- base supporting other assemblies and elements: abrasive disc holder and drives; this solution enables an easy replacement and access to holding elements while a belt transmission allows the disc rpm to be varied,- mechanism moving the spindle in the horizontal, hence the abrasive disc position with respect to the batch can be precisely controlled, depending on the cast position and their shape,- holding and positioning-control of the batch to enable the fore and aft movements and rotations,- guide systems ensuring the travel of the batch in the specified direction and adjusting the travel speed to the required cutting rate,- centering, control, exhaust system, housingExtensive tests were performed, including the tests of operating parameters of abrasive discs depending on the cast material, cyclograms of the applied treatment are obtained accordingly.

Machinability study of steels in precision orthogonal cutting

Directory of Open Access Journals (Sweden)

Leonardo Roberto Silva

2012-08-01

Full Text Available The miniaturization of components and systems is advancing steadily in many areas of engineering. Consequently, micro-machining is becoming an important manufacture technology due to the increasing demand for miniaturized products in recent years. Precision machining aims the production of advanced components with high dimensional accuracy and acceptable surface integrity. This work presents an experimental study based on Merchant and Lee & Shaffer theories applied to precision radial turning of AISI D2 cold work tool and AISI 1045 medium carbon steels with uncoated carbide tools ISO grade K15. The aim of this study is to evaluate the influence of feed rate on chip compression ratio (Rc, chip deformation (ε, friction angle (ρ, shear angle (Φ, normal stress (σ and shear stress (• for both work materials. The results indicated that the shear angle decreased and chip deformation increased as the chip compression ratio was elevated without significant differences between both materials. Additionally, higher cutting and thrust forces and normal and shear stresses were observed for the tool steel. Finally, the Lee & Shaffer model gave shear plane angle values closer to the experimental data.

GPK heading machine

Energy Technology Data Exchange (ETDEWEB)

Krmasek, J.; Novosad, K.

1981-01-01

This article evaluates performance tests of the Soviet made GPK heading machine carried out in 4 coal mines in Czechoslovakia (Ostrava-Karvina region and Kladno mines). GPK works in coal seams and rocks with compression strength of 40 to 50 MPa. Dimensions of the tunnel are height 1.8 to 3.8 m and width 2.6 to 4.7 m, tunnel gradient plus to minus 10 degrees. GPK weighs 16 t, its conical shaped cutting head equipped with RKS-1 cutting tools is driven by an electric motor with 55 kW capacity. Undercarriage of the GPK, gathering-arm loader, hydraulic system, electric system and dust supression system (water spraying or pneumatic section) are characterized. Specifications of GPK heading machines are compared with PK-3r and F8 heading machines. Reliability, number of failures, dust level, noise, productivity depending on compression strength of rocks, heading rate in coal and in rocks, energy consumption, performance in inclined tunnels, and cutting tool wear are evaluated. Tests show that GPK can be used to drive tunnels in coal with rock constituting up to 50% of the tunnel crosscut, as long as rock compression strength does not exceed 50 MPa. In rocks characterized by higher compression strength cutting tool wear sharply increases. GPK is characterized by higher productivity than that of the PK-3r heading machine. Among the weak points of the GPK are: unsatisfactory reliability and excessive wear of its elements. (4 refs.) (In Czech)

Machinability of IPS Empress 2 framework ceramic.

Science.gov (United States)

Schmidt, C; Weigl, P

2000-01-01

Using ceramic materials for an automatic production of ceramic dentures by CAD/CAM is a challenge, because many technological, medical, and optical demands must be considered. The IPS Empress 2 framework ceramic meets most of them. This study shows the possibilities for machining this ceramic with economical parameters. The long life-time requirement for ceramic dentures requires a ductile machined surface to avoid the well-known subsurface damages of brittle materials caused by machining. Slow and rapid damage propagation begins at break outs and cracks, and limits life-time significantly. Therefore, ductile machined surfaces are an important demand for machine dental ceramics. The machining tests were performed with various parameters such as tool grain size and feed speed. Denture ceramics were machined by jig grinding on a 5-axis CNC milling machine (Maho HGF 500) with a high-speed spindle up to 120,000 rpm. The results of the wear test indicate low tool wear. With one tool, you can machine eight occlusal surfaces including roughing and finishing. One occlusal surface takes about 60 min machining time. Recommended parameters for roughing are middle diamond grain size (D107), cutting speed v(c) = 4.7 m/s, feed speed v(ft) = 1000 mm/min, depth of cut a(e) = 0.06 mm, width of contact a(p) = 0.8 mm, and for finishing ultra fine diamond grain size (D46), cutting speed v(c) = 4.7 m/s, feed speed v(ft) = 100 mm/min, depth of cut a(e) = 0.02 mm, width of contact a(p) = 0.8 mm. The results of the machining tests give a reference for using IPS Empress(R) 2 framework ceramic in CAD/CAM systems. Copyright 2000 John Wiley & Sons, Inc.

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

Surface roughness and cutting force estimation in the CNC turning using artificial neural networks

Directory of Open Access Journals (Sweden)

Mohammad Ramezani

2015-04-01

Full Text Available Surface roughness and cutting forces are considered as important factors to determine machinability rate and the quality of product. A number of factors like cutting speed, feed rate, depth of cutting and tool noise radius influence the surface roughness and cutting forces in turning process. In this paper, an Artificial Neural Network (ANN model was used to forecast surface roughness and cutting forces with related inputs, including cutting speed, feed rate, depth of cut and tool noise radius. The machined surface roughness and cutting force parameters related to input parameters are the outputs of the ANN model. In this work, 24 samples of experimental data were used to train the network. Moreover, eight other experimental tests were implemented to test the network. The study concludes that ANN was a reliable and accurate method for predicting machining parameters in CNC turning operation.

Fast and intuitive programming of adaptive laser cutting of lace enabled by machine vision

Science.gov (United States)

Vaamonde, Iago; Souto-López, Álvaro; García-Díaz, Antón

2015-07-01

A machine vision system has been developed, validated, and integrated in a commercial laser robot cell. It permits an offline graphical programming of laser cutting of lace. The user interface allows loading CAD designs and aligning them with images of lace pieces. Different thread widths are discriminated to generate proper cutting program templates. During online operation, the system aligns CAD models of pieces and lace images, pre-checks quality of lace cuts and adapts laser parameters to thread widths. For pieces detected with the required quality, the program template is adjusted by transforming the coordinates of every trajectory point. A low-cost lace feeding system was also developed for demonstration of full process automation.

Diamond and cBN hybrid and nanomodified cutting tools with enhanced performance: Development, testing and modelling

DEFF Research Database (Denmark)

Loginov, Pavel; Mishnaevsky, Leon; Levashov, Evgeny

2015-01-01

with 25% of diamond replaced by cBN grains demonstrate 20% increased performance as compared with pure diamond machining tools, and more than two times higher performance as compared with pure cBN tools. Further, cast iron machining efficiency of the wheels modified by hBN particles was 80% more efficient......The potential of enhancement of superhard steel and cast iron cutting tool performance on the basis of microstuctural modifications of the tool materials is studied. Hybrid machining tools with mixed diamond and cBN grains, as well as machining tool with composite nanomodified metallic binder...... are developed, and tested experimentally and numerically. It is demonstrated that both combination of diamond and cBN (hybrid structure) and nanomodification of metallic binder (with hexagonal boron nitride/hBN platelets) lead to sufficient improvement of the cast iron machining performance. The superhard tools...

Operation of the AM-50 cutting head under different cutting conditions

Energy Technology Data Exchange (ETDEWEB)

Sikora, W; Kusz, F; Fels, M

1988-02-01

Presents results of investigations into operation of the AM-50 heading machine. About 50% of headings, i.e. about 800 km/a, are driven by about 400 heading machines. It has been found that energy consumption depends on compression strength of rock and is 6 times higher for sandstone than for clayey shale. Power consumed by cutting heads depends mainly on the web used (30-150 mm depending on rock strength). Wear of cutting tools is 1-30 pieces per meter of heading advance at a working cross-section area of 15 m/sup 2/. The AM-50 machine uses cutting speeds of 1.1-3.5 m/s. Higher speeds negatively affect the resistance to cutting. Nonuniform tool wear on the cutting head circumference is an indication of improper head design that requires remedying.

Experimental use of road header (AM-50) as face cutting machine for extraction of coal in longwall panel

Energy Technology Data Exchange (ETDEWEB)

Passi, K.K.; Kumar, C.R.; Prasad, P. [DGMS, Dhanbad (India)

2001-07-01

The scope of this paper has been limited to the use of available machines and techniques for attaining higher and more efficient production in underground coal mines. Under certain conditions of strata and higher degree of gassiness, the longwall method with hydraulic sand stowing is the only appropriate method of work for extraction of thick seam. In Moonidih Jitpur Colliery of M/S IISCO, No. 14 seam, Degree III gassy seam, 9.07 m thick, is extracted in multilift system with hydraulic sand stowing. In general, the bottom lift is extracted by Single Ended Ranging Arm Shearer and the middle and top lift are extracted by conventional method. However, in one of the panels spare road header machine was used as face cutting machine in bottom lift, on an experimental basis. This paper presents a successful case study of extraction of bottom lift coal by the longwall method with hydraulic sand stowing using road header (AM 50) as the face cutting machines. 9 figs.

Development and Testing of an Integrated Rotating Dynamometer Based on Fiber Bragg Grating for Four-Component Cutting Force Measurement.

Science.gov (United States)

Liu, Mingyao; Bing, Junjun; Xiao, Li; Yun, Kang; Wan, Liang

2018-04-18

Cutting force measurement is of great importance in machining processes. Hence, various methods of measuring the cutting force have been proposed by many researchers. In this work, a novel integrated rotating dynamometer based on fiber Bragg grating (FBG) was designed, constructed, and tested to measure four-component cutting force. The dynamometer consists of FBGs that are pasted on the newly designed elastic structure which is then mounted on the rotating spindle. The elastic structure is designed as two mutual-perpendicular semi-octagonal rings. The signals of the FBGs are transmitted to FBG interrogator via fiber optic rotary joints and optical fiber, and the wavelength values are displayed on a computer. In order to determine the static and dynamic characteristics, many tests have been done. The results show that it is suitable for measuring cutting force.

Machining of Machine Elements Made of Polymer Composite Materials

Science.gov (United States)

Baurova, N. I.; Makarov, K. A.

2017-12-01

The machining of the machine elements that are made of polymer composite materials (PCMs) or are repaired using them is considered. Turning, milling, and drilling are shown to be most widely used among all methods of cutting PCMs. Cutting conditions for the machining of PCMs are presented. The factors that most strongly affect the roughness parameters and the accuracy of cutting PCMs are considered.

Effect of cutting parameters on machinability characteristics in milling of magnesium alloy with carbide tool

Directory of Open Access Journals (Sweden)

Kaining Shi

2016-01-01

Full Text Available Magnesium alloy has attracted more attentions due to its excellent mechanical properties. However, in process of dry cutting operation, many problems restrict its further development. In this article, the effect of cutting parameters on machinabilities of magnesium alloy is explored under dry milling condition. This research is an attempt to investigate the impact of cutting speed at multiple feed rates on cutting force and surface roughness, while a statistical analysis is adopted to determine the influential intensities accurately. The results showed that cutting force is affected by the positively constant intensity from feed rate and the increasingly negative intensity from cutting speed. In contrast, surface roughness is determined by the gradually increasing negative tendency from feed rate and the positive effect with constant intensity from cutting speed. Within the range of the experiments, feed rate is the leading contribution for cutting force while the cutting speed is the dominant factor for surface roughness according to the absolute intensity values. Meanwhile, the trends of influencing intensities between cutting force and surface roughness are opposite. Besides, it is also found that in milling magnesium alloy, chip morphology is highly sensitive to cutting speed while the chip quality mainly depends on feed rate.

Demonstration of Laser Cutting System for Tube Specimen

Energy Technology Data Exchange (ETDEWEB)

Jin, Y. G.; Kim, G. S.; Heo, G. S.; Baik, S. J.; Kim, H. M.; Ahn, S. B. [KAERI, Daejeon (Korea, Republic of)

2016-05-15

The oxide layer removal system was also developed because the oxide layer on the surface of the irradiated fuel cladding and components interrupted the applying the electric current during the processing. However, it was found that the mechanical testing data of the irradiated specimens with removal of oxide layer was less reliable than the specimens with oxide layer . The laser cutting system using Nd:YAG with fiber optic beam delivery has great potential in material processing applications of the irradiated fuel cladding and components due to non-contact process. Thus, the oxide layer doesn't interrupt the fabrication process during the laser cutting system. In the present study, the laser cutting system was designed to fabricate the mechanical testing specimens from the unirradiated fuel cladding with and without oxide. The feasibility of the laser cutting system was demonstrated for the fabrication of various types of unirradiated specimens. The effect of surface oxide layer was also investigated for machining process of the zirlo fuel cladding and it was found that laser beam machining could be a useful tool to fabricate the specimens with surface oxide layer. Based on the feasibility studies and demonstration, the design of the laser cutting machine for fully or partially automatic and remotely operable system will be proposed and made.

Analyses of Effects of Cutting Parameters on Cutting Edge Temperature Using Inverse Heat Conduction Technique

Directory of Open Access Journals (Sweden)

Marcelo Ribeiro dos Santos

2014-01-01

Full Text Available During machining energy is transformed into heat due to plastic deformation of the workpiece surface and friction between tool and workpiece. High temperatures are generated in the region of the cutting edge, which have a very important influence on wear rate of the cutting tool and on tool life. This work proposes the estimation of heat flux at the chip-tool interface using inverse techniques. Factors which influence the temperature distribution at the AISI M32C high speed steel tool rake face during machining of a ABNT 12L14 steel workpiece were also investigated. The temperature distribution was predicted using finite volume elements. A transient 3D numerical code using irregular and nonstaggered mesh was developed to solve the nonlinear heat diffusion equation. To validate the software, experimental tests were made. The inverse problem was solved using the function specification method. Heat fluxes at the tool-workpiece interface were estimated using inverse problems techniques and experimental temperatures. Tests were performed to study the effect of cutting parameters on cutting edge temperature. The results were compared with those of the tool-work thermocouple technique and a fair agreement was obtained.

[A new machinability test machine and the machinability of composite resins for core built-up].

Science.gov (United States)

Iwasaki, N

2001-06-01

A new machinability test machine especially for dental materials was contrived. The purpose of this study was to evaluate the effects of grinding conditions on machinability of core built-up resins using this machine, and to confirm the relationship between machinability and other properties of composite resins. The experimental machinability test machine consisted of a dental air-turbine handpiece, a control weight unit, a driving unit of the stage fixing the test specimen, and so on. The machinability was evaluated as the change in volume after grinding using a diamond point. Five kinds of core built-up resins and human teeth were used in this study. The machinabilities of these composite resins increased with an increasing load during grinding, and decreased with repeated grinding. There was no obvious correlation between the machinability and Vickers' hardness; however, a negative correlation was observed between machinability and scratch width.

Prediction and Control of Cutting Tool Vibration in Cnc Lathe with Anova and Ann

Directory of Open Access Journals (Sweden)

S. S. Abuthakeer

2011-06-01

Full Text Available Machining is a complex process in which many variables can deleterious the desired results. Among them, cutting tool vibration is the most critical phenomenon which influences dimensional precision of the components machined, functional behavior of the machine tools and life of the cutting tool. In a machining operation, the cutting tool vibrations are mainly influenced by cutting parameters like cutting speed, depth of cut and tool feed rate. In this work, the cutting tool vibrations are controlled using a damping pad made of Neoprene. Experiments were conducted in a CNC lathe where the tool holder is supported with and without damping pad. The cutting tool vibration signals were collected through a data acquisition system supported by LabVIEW software. To increase the buoyancy and reliability of the experiments, a full factorial experimental design was used. Experimental data collected were tested with analysis of variance (ANOVA to understand the influences of the cutting parameters. Empirical models have been developed using analysis of variance (ANOVA. Experimental studies and data analysis have been performed to validate the proposed damping system. Multilayer perceptron neural network model has been constructed with feed forward back-propagation algorithm using the acquired data. On the completion of the experimental test ANN is used to validate the results obtained and also to predict the behavior of the system under any cutting condition within the operating range. The onsite tests show that the proposed system reduces the vibration of cutting tool to a greater extend.

A Study on Ultrasonic Elliptical Vibration Cutting of Inconel 718

Directory of Open Access Journals (Sweden)

Zhao Haidong

2016-01-01

Full Text Available Inconel 718 is a kind of nickel-based alloys that are widely used in the aerospace and nuclear industry owing to their high temperature mechanical properties. Cutting of Inconel 718 in conventional cutting (CC is a big challenge in modern industry. Few researches have been studied on cutting of Inconel 718 using single point diamond tool applying the UEVC method. This paper shows an experimental study on UEVC of Inconel 718 by using polycrystalline diamond (PCD coated tools. Firstly, cutting tests have been carried out to study the effect of machining parameters in the UEVC in terms of surface finish and flank wear during machining of Inconel 718. The tests have clearly shown that the PCD coated tools in cutting of Inconel 718 by the UEVC have better performance at 0.1 mm depth of cut as compared to the lower 0.05 mm depth of cut and the higher 0.12 or 0.15 mm depth of cut. Secondly, like CC method, the cutting performance in UEVC increases with the decrease of the feed rate and cutting speed. The CC tests have also been carried out to compare performance of CC with UEVC method.

Feasibility Study of Laser Cutting for Fabrication of Tensile Specimen

International Nuclear Information System (INIS)

Jin, Y. G.; Baik, S. J.; Kim, G. S.; Heo, G. S.; Yoo, B. O.; Ahn, S. B.; Chun, Y. B.

2015-01-01

The specimen fabrication technique was established to machine the specimen from the irradiated materials. The wire cut EDM(electric discharge machine) was modified to fabricate the mechanical testing specimens from irradiated components and fuel claddings. The oxide layer removal system was also developed because the oxide layer on the surface of the irradiated components and claddings interrupted the applying the electric current during the processing. However, zirconium oxide is protective against further corrosion as well as beneficial to mechanical strength for the tensile deformation of the cladding. Thus, it is important to fabricate the irradiated specimens without removal of oxide layer on the surface of the irradiated structural components and claddings. In the present study, laser cutting system was introduced to fabricate the various mechanical testing specimens from the unirradiated fuel cladding and the feasibility of the laser cutting system was studied for the fabrication of various types of irradiated specimens in a hot cell at IMEF (Irradiated Materials Examination Facility) of KAERI. Laser beam machining system was introduced to fabricate the various mechanical testing specimens from the unirradiated fuel cladding and the dimensions were compared for the feasibility of the laser cutting system. The effect of surface oxide layer was also investigated for machining process of the zircaloy-4 fuel cladding and it was found that laser beam machining could be a useful tool to fabricate the specimens with surface oxide layer

Feasibility Study of Laser Cutting for Fabrication of Tensile Specimen

Energy Technology Data Exchange (ETDEWEB)

Jin, Y. G.; Baik, S. J.; Kim, G. S.; Heo, G. S.; Yoo, B. O.; Ahn, S. B.; Chun, Y. B. [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

2015-05-15

The specimen fabrication technique was established to machine the specimen from the irradiated materials. The wire cut EDM(electric discharge machine) was modified to fabricate the mechanical testing specimens from irradiated components and fuel claddings. The oxide layer removal system was also developed because the oxide layer on the surface of the irradiated components and claddings interrupted the applying the electric current during the processing. However, zirconium oxide is protective against further corrosion as well as beneficial to mechanical strength for the tensile deformation of the cladding. Thus, it is important to fabricate the irradiated specimens without removal of oxide layer on the surface of the irradiated structural components and claddings. In the present study, laser cutting system was introduced to fabricate the various mechanical testing specimens from the unirradiated fuel cladding and the feasibility of the laser cutting system was studied for the fabrication of various types of irradiated specimens in a hot cell at IMEF (Irradiated Materials Examination Facility) of KAERI. Laser beam machining system was introduced to fabricate the various mechanical testing specimens from the unirradiated fuel cladding and the dimensions were compared for the feasibility of the laser cutting system. The effect of surface oxide layer was also investigated for machining process of the zircaloy-4 fuel cladding and it was found that laser beam machining could be a useful tool to fabricate the specimens with surface oxide layer.

Characteristics of laser assisted machining for silicon nitride ceramic according to machining parameters

International Nuclear Information System (INIS)

Kim, Jong Do; Lee, Su Jin; Suh, Jeong

2011-01-01

This paper describes the Laser Assisted Machining (LAM) that cuts and removes softened parts by locally heating the ceramic with laser. Silicon nitride ceramics can be machined with general machining tools as well, because YSiAlON, which was made up ceramics, is soften at about 1,000 .deg. C. In particular, the laser, which concentrates on highly dense energy, can locally heat materials and very effectively control the temperature of the heated part of specimen. Therefore, this paper intends to propose an efficient machining method of ceramic by deducing the machining governing factors of laser assisted machining and understanding its mechanism. While laser power is the machining factor that controls the temperature, the CBN cutting tool could cut the material more easily as the material gets deteriorated from the temperature increase by increasing the laser power, but excessive oxidation can negatively affect the quality of the material surface after machining. As the feed rate and cutting depth increase, the cutting force increases and tool lifespan decreases, but surface oxidation also decreases. In this experiment, the material can be cut to 3 mm of cutting depth. And based on the results of the experiment, the laser assisted machining mechanism is clarified

Mechanics of Cutting and Boring. Part 7. Dynamics and Energetics of Axial Rotation Machines,

Science.gov (United States)

1981-12-01

systematic analytical scheme that can be used to facilitate future work on the mechanics of cutting and boring machines. In the industrial sector, rock...Proceedings. Chapter 66, p. 1149-1158. Mellor, M. and I. Hawkes (1972) How to rate a hard-rock borer. World Construction, Sept, p. 21-23. (Also in Ingenieria

The effect of abrading and cutting instruments on machinability of dental ceramics.

Science.gov (United States)

Sakoda, Satoshi; Nakao, Noriko; Watanabe, Ikuya

2018-03-16

The aim was to investigate the effect of machining instruments on machinability of dental ceramics. Four dental ceramics, including two zirconia ceramics were machined by three types (SiC, diamond vitrified, and diamond sintered) of wheels with a hand-piece engine and two types (diamond and carbide) of burs with a high-speed air turbine. The machining conditions used were abrading speeds of 10,000 and 15,000 r.p.m. with abrading force of 100 gf for the hand-piece engine, and a pressure of 200 kPa and a cutting force of 80 gf for the air-turbine hand-piece. The machinability efficiency was evaluated by volume losses after machining the ceramics. A high-abrading speed had high-abrading efficiency (high-volume loss) compared to low-abrading speed in all abrading instruments used. The diamond vitrified wheels demonstrated higher volume loss for two zirconia ceramics than those of SiC and diamond sintered wheels. When the high-speed air-turbine instruments were used, the diamond points showed higher volume losses compared to the carbide burs for one ceramic and two zirconia ceramics with high-mechanical properties. The results of this study indicated that the machinability of dental ceramics depends on the mechanical and physical properties of dental ceramics and machining instruments. The abrading wheels show autogenous action of abrasive grains, in which ground abrasive grains drop out from the binder during abrasion, then the binder follow to wear out, subsequently new abrasive grains come out onto the instrument surface (autogenous action) and increase the grinding amount (volume loss) of grinding materials.

HTGR Metallic Reactor Internals Core Shell Cutting & Machining Antideformation Technique Study

International Nuclear Information System (INIS)

Xing Huiping; Xue Song

2014-01-01

The reactor shell assembly of HTGR nuclear power station demonstration project metallic reactor internals is key components of reactor, remains with high-precision large component with large-sized thin-walled straight cylinder-shaped structure, and is the first manufacture in China. As compared with other reactor shell, it has a larger ID (Φ5360mm), a longer length (19000mm), a smaller wall thickness (40mm) and a higher precision requirement. During the process of manufacture, the deformation due to cutting & machining will directly affect the final result of manufacture, the control of structural deformation and cutting deformation shall be throughout total manufacture process of such assembly. To realize the control of entire core shell assembly geometry, the key is to innovate and make breakthroughs on anti-deformation technique and then provide reliable technological foundations for the manufacture of HTGR metallic reactor internals. (author)

Wire electric-discharge machining and other fabrication techniques

Science.gov (United States)

Morgan, W. H.

1983-01-01

Wire electric discharge machining and extrude honing were used to fabricate a two dimensional wing for cryogenic wind tunnel testing. Electric-discharge cutting is done with a moving wire electrode. The cut track is controlled by means of a punched-tape program and the cutting feed is regulated according to the progress of the work. Electric-discharge machining involves no contact with the work piece, and no mechanical force is exerted. Extrude hone is a process for honing finish-machined surfaces by the extrusion of an abrasive material (silly putty), which is forced through a restrictive fixture. The fabrication steps are described and production times are given.

Spread of `Eco-vendor`, an energy-saving type automatic vending machine for beverages with a peak cut function; Shoenegata seiryo inryoyo jido hanbaiki (peak cut kino tsuki) `eko benda` no fukyu ni tsuite

Energy Technology Data Exchange (ETDEWEB)

NONE

1996-05-01

`Eco-vendor`, an energy-saving type automatic vending machine for beverages with a peak cut function has been developed in 1995 through cooperation by Tokyo Electric Power Company, Coca-Cola Japan, and Fuji Electric Co., Ltd. It can cut 90 percent of the power consumption during 13:00 to 16:00 on weekdays in summer, and can save 10 to 15 percent of annual power consumption. Since the heat insulation performance has been improved to keep beverages at the set temperature during the peak cut operation, the energy-saving effect for cold products in summer and for hot products in winter has been enhanced. For the manufacturing of `Eco-vendor`, Fuji Electric Co., Ltd. has offered its technical know-how to five manufacturers of automatic vending machine for beverages without compensation, and each manufacturer has accepted the offer. Electric power companies of Japan have cooperated to pay incident of 10,000 yen per an `Eco-vendor` to the manufacturers. Japan`s automatic vending machine industries and nationwide beverage industries have positively cooperated. Consequently, Tokyo Electric Power Company has successfully spread 2,600 machines up to the end of fiscal 1995, and aims at the spread of 16,000 machines in fiscal 1996. 2 figs.

Performance Enhancement of Abrasive Waterjet Cutting

NARCIS (Netherlands)

2008-01-01

Abrasive Waterjet (AWJ) Machining is a recent non-traditional machining process. This technology is widely used in industry for cutting difficult-to-machine-materials, milling slots, polishing hard materials etc. AWJ machining has many advantages, e.g. it can cut net-shape parts, no heat is

The Effect of Operational Cutting Parameters on Nitinol-60 in Wire Electrodischarge Machining

Directory of Open Access Journals (Sweden)

Ali Akbar LotfiNeyestanak

2013-01-01

Full Text Available Shape memory alloys are a kind of active materials, which have significant characteristics in comparison with other alloys. Since these materials are applicable in different fields such as aerospace, automobile industry, medicine, and dentistry, the effects of wire electrodischarge machining on the properties of these alloys have been studied. In this paper, changes in the shape recovery ability and microhardness of the machined surface of Nitonol-60 shape memory alloy have been studied considering recasting and formation of resolidificated layer on the shape memory alloy surface. XRD and EDXA analyses of the surface layer of the sample besides a microscopic study of the shape memory alloy layer by SEM and a study of the changes in mechanical properties of the surface layer were done by performing microhardness and tension tests on the work piece surface. Considering the surface layer, reversible strain has been studied according to the shape recovery percentage of Nitinol-60 shape memory alloy. Results show that the surface layer formed on the surface of the samples has caused changes in both physical and mechanical properties of the cut surface because of the penetration of the separated materials in comparison with deeper layers of the piece.

Cutting performance of TiCN–HSS cermet in dry machining

OpenAIRE

Canteli Fernández, José Antonio; Cantero Guisández, José Luis; Marín, N.C.; Gómez, B.; Gordo Odériz, Elena; Miguélez, Henar

2010-01-01

This work is focused on the cutting performance of a new cermet based on high-speed steel (HSS) matrix with hard phase TiCN. The processing route to manufacture the cermet M2+ 50 vol.% TiCN is described. Orthogonal cutting tests, carried out in a lathe showed the ability of the new cermet to achieve turning operations, showing reasonably wear resistance performing dry cutting operations. Tool life was significantly increased, when the cermet was compared with the reference materia...

Investigation of Coated Cutting Tool Performance during Machining of Super Duplex Stainless Steels through 3D Wear Evaluations

Directory of Open Access Journals (Sweden)

Yassmin Seid Ahmed

2017-08-01

Full Text Available In this study, the wear mechanisms and tribological performance of uncoated and coated carbide tools were investigated during the turning of super duplex stainless steel (SDSS—Grade UNS S32750, known commercially as SAF 2507. The tool wear was evaluated throughout the cutting tests and the wear mechanisms were investigated using an Alicona Infinite Focus microscope and a scanning electron microscope (SEM equipped with energy dispersive spectroscopy (EDS. Tribo-film formation on the worn rake surface of the tool was analyzed using X-ray Photoelectron Spectroscopy (XPS. In addition, tribological performance was evaluated by studying chip characteristics such as thickness, compression ratio, shear angle, and undersurface morphology. Finally, surface integrity of the machined surface was investigated using the Alicona microscope to measure surface roughness and SEM to reveal the surface distortions created during the cutting process, combined with cutting force analyses. The results obtained showed that the predominant wear mechanisms are adhesion and chipping for all tools investigated and that the AlTiN coating system exhibited better performance in all aspects when compared with CVD TiCN + Al2O3 coated cutting insert and uncoated carbide insert; in particular, built-up edge formation was significantly reduced.

Experimental Investigation on Tool Wear Behavior and Cutting Temperature during Dry Machining of Carbon Steel SAE 1030 Using KC810 and KC910 Coated Inserts

Directory of Open Access Journals (Sweden)

Y. Tamerabet

2018-03-01

Full Text Available The removal of cutting fluids and lubrication in dry machining operations requires a good knowledge and full control of all the mechanisms that lead to tool damage. In order to optimize dry machining operations, it is necessary to clearly identify the wear patterns, determine the contact conditions and define the relationship between the contact parameters and the operating conditions. The idea is to choose optimal cutting conditions which lead to the best contact conditions limiting the triggering or aggravation of wear phenomena. The purpose of this paper is to determine the impact multilayer coatings and cutting parameters on tool wear and temperature at the tool-chip interface for two types of coated carbides (KC810 and KC910 Commercialized inserts during dry turning operation of carbon steel SAE 1030, in order to determine the ideal parameters and guarantee the best performances of the cutting tools. Cutting temperature, Crater and Flank wear have been systematically recorded in order to determine their influence on tool life time. To ensure the optimum choice of machining conditions; the TAGUCHI method associated to multi-factorial method were applied to plan the experiments. It has been noted that cutting speed was the most influential factor on temperature and wear evolution. We noted also that the KC810 insert was more suitable for machining of SAE 1030 Carbon Steel; where The best life time was registered (T=228 min. The KC810 inserts offer 30 min of additional machining time for the same work conditions.

Experimental Investigation on Cutting Characteristics in Nanometric Plunge-Cutting of BK7 and Fused Silica Glasses.

Science.gov (United States)

An, Qinglong; Ming, Weiwei; Chen, Ming

2015-03-27

Ductile cutting are most widely used in fabricating high-quality optical glass components to achieve crack-free surfaces. For ultra-precision machining of brittle glass materials, critical undeformed chip thickness (CUCT) commonly plays a pivotal role in determining the transition point from ductile cutting to brittle cutting. In this research, cutting characteristics in nanometric cutting of BK7 and fused silica glasses, including machined surface morphology, surface roughness, cutting force and specific cutting energy, were investigated with nanometric plunge-cutting experiments. The same cutting speed of 300 mm/min was used in the experiments with single-crystal diamond tool. CUCT was determined according to the mentioned cutting characteristics. The results revealed that 320 nm was found as the CUCT in BK7 cutting and 50 nm was determined as the size effect of undeformed chip thickness. A high-quality machined surface could be obtained with the undeformed chip thickness between 50 and 320 nm at ductile cutting stage. Moreover, no CUCT was identified in fused silica cutting with the current cutting conditions, and brittle-fracture mechanism was confirmed as the predominant chip-separation mode throughout the nanometric cutting operation.

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.

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)

Effect of Machining Velocity in Nanoscale Machining Operations

International Nuclear Information System (INIS)

Islam, Sumaiya; Khondoker, Noman; Ibrahim, Raafat

2015-01-01

The aim of this study is to investigate the generated forces and deformations of single crystal Cu with (100), (110) and (111) crystallographic orientations at nanoscale machining operation. A nanoindenter equipped with nanoscratching attachment was used for machining operations and in-situ observation of a nano scale groove. As a machining parameter, the machining velocity was varied to measure the normal and cutting forces. At a fixed machining velocity, different levels of normal and cutting forces were generated due to different crystallographic orientations of the specimens. Moreover, after machining operation percentage of elastic recovery was measured and it was found that both the elastic and plastic deformations were responsible for producing a nano scale groove within the range of machining velocities from 250-1000 nm/s. (paper)

An FMS Dynamic Production Scheduling Algorithm Considering Cutting Tool Failure and Cutting Tool Life

International Nuclear Information System (INIS)

Setiawan, A; Wangsaputra, R; Halim, A H; Martawirya, Y Y

2016-01-01

This paper deals with Flexible Manufacturing System (FMS) production rescheduling due to unavailability of cutting tools caused either of cutting tool failure or life time limit. The FMS consists of parallel identical machines integrated with an automatic material handling system and it runs fully automatically. Each machine has a same cutting tool configuration that consists of different geometrical cutting tool types on each tool magazine. The job usually takes two stages. Each stage has sequential operations allocated to machines considering the cutting tool life. In the real situation, the cutting tool can fail before the cutting tool life is reached. The objective in this paper is to develop a dynamic scheduling algorithm when a cutting tool is broken during unmanned and a rescheduling needed. The algorithm consists of four steps. The first step is generating initial schedule, the second step is determination the cutting tool failure time, the third step is determination of system status at cutting tool failure time and the fourth step is the rescheduling for unfinished jobs. The approaches to solve the problem are complete-reactive scheduling and robust-proactive scheduling. The new schedules result differences starting time and completion time of each operations from the initial schedule. (paper)

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

Electric-Discharge Machining Techniques for Evaluating Tritium Effects on Materials

International Nuclear Information System (INIS)

Morgan, M.J.

2003-01-01

In this investigation, new ways to evaluate the long-term effects of tritium on the structural properties of components were developed. Electric-discharge machining (EDM) techniques for cutting tensile and fracture toughness samples from tritium exposed regions of returned reservoirs were demonstrated. An existing electric discharge machine was used to cut sub-size tensile and fracture toughness samples from the inside surfaces of reservoir mockups. Tensile properties from the EDM tensile samples were similar to those measured using full-size samples cut from similar stock. Although the existing equipment could not be used for machining tritium-exposed hardware, off-the shelf EDM units are available that could. With the right equipment and the required radiological controls in place, similar machining and testing techniques could be used to directly measure the effects of tritium on the properties of material cut from reservoir returns. Stress-strain properties from tritium-exposed reservoirs would improve finite element modeling of reservoir performance because the data would be representative of the true state of the reservoir material in the field. Tensile data from samples cut directly from reservoirs would also complement existing shelf storage and burst test data of the Life Storage Program and help answer questions about a specific reservoir's processing history and properties

ITER lip seal welding and cutting developments

Energy Technology Data Exchange (ETDEWEB)

Levesy, B.; Cordier, J.J.; Jokinen, T. [ITER Organization, Route de Vinon sur Verdon, 13115 Saint Paul Lez Durance (France); Kujanpää, V.; Karhu, M. [VTT Technical Research Centre of Finland (Finland); Le Barbier, R. [ITER Organization, Route de Vinon sur Verdon, 13115 Saint Paul Lez Durance (France); Määttä, T. [VTT Technical Research Centre of Finland (Finland); Martins, J.P.; Utin, Y. [ITER Organization, Route de Vinon sur Verdon, 13115 Saint Paul Lez Durance (France)

2015-10-15

Highlights: • Different TIG and Laser welding techniques are tested. • Twin spot laser welding techniques is the best. • Limited heat input gives a stable weld pool in all positions. • Penetrations is achieved. • Lip seal welding and cutting with a robotic arm is successfully performed on a representative mock-up. - Abstract: The welded lip seals form part of the torus primary vacuum boundary in between the port plugs and the vacuum vessel, and are classified as Protection Important Component. In order to refurbish the port plugs or the in-vessel components, port plugs have to be removed from the machine. The lip seal design must enable up to ten opening of the vacuum vessel during the life time operation of the ITER machine. Therefore proven, remote reliable cutting and re-welding are essential, as these operations need to be performed in the port cells in a nuclear environment, where human presence will be restricted. Moreover, the combination of size of the components to be welded (∼10 m long vacuum compatible thin welds) and the congested environment close to the core of the machine constraint the type and size of tools to be used. This paper describes the lip seal cutting and welding development programme performed at the VTT Technical Research Centre, Finland. Potential cutting and welding techniques are analyzed and compared. The development of the cutting, TIG and laser welding techniques on samples are presented. Effects of lip seal misalignments and optimization of the 2 welding processes are discussed. Finally, the manufacturing and test of the two 1.2 m × 1 m representative mock-ups are presented. The set-up and use of a robotic arm for the mock-up cutting and welding operations are also described.

ITER lip seal welding and cutting developments

International Nuclear Information System (INIS)

Levesy, B.; Cordier, J.J.; Jokinen, T.; Kujanpää, V.; Karhu, M.; Le Barbier, R.; Määttä, T.; Martins, J.P.; Utin, Y.

2015-01-01

Highlights: • Different TIG and Laser welding techniques are tested. • Twin spot laser welding techniques is the best. • Limited heat input gives a stable weld pool in all positions. • Penetrations is achieved. • Lip seal welding and cutting with a robotic arm is successfully performed on a representative mock-up. - Abstract: The welded lip seals form part of the torus primary vacuum boundary in between the port plugs and the vacuum vessel, and are classified as Protection Important Component. In order to refurbish the port plugs or the in-vessel components, port plugs have to be removed from the machine. The lip seal design must enable up to ten opening of the vacuum vessel during the life time operation of the ITER machine. Therefore proven, remote reliable cutting and re-welding are essential, as these operations need to be performed in the port cells in a nuclear environment, where human presence will be restricted. Moreover, the combination of size of the components to be welded (∼10 m long vacuum compatible thin welds) and the congested environment close to the core of the machine constraint the type and size of tools to be used. This paper describes the lip seal cutting and welding development programme performed at the VTT Technical Research Centre, Finland. Potential cutting and welding techniques are analyzed and compared. The development of the cutting, TIG and laser welding techniques on samples are presented. Effects of lip seal misalignments and optimization of the 2 welding processes are discussed. Finally, the manufacturing and test of the two 1.2 m × 1 m representative mock-ups are presented. The set-up and use of a robotic arm for the mock-up cutting and welding operations are also described.

Machinability of experimental Ti-Ag alloys.

Science.gov (United States)

Kikuchi, Masafumi; Takahashi, Masatoshi; Okuno, Osamu

2008-03-01

This study investigated the machinability of experimental Ti-Ag alloys (5, 10, 20, and 30 mass% Ag) as a new dental titanium alloy candidate for CAD/CAM use. The alloys were slotted with a vertical milling machine and carbide square end mills under two cutting conditions. Machinability was evaluated through cutting force using a three-component force transducer fixed on the table of the milling machine. The horizontal cutting force of the Ti-Ag alloys tended to decrease as the concentration of silver increased. Values of the component of the horizontal cutting force perpendicular to the feed direction for Ti-20% Ag and Ti-30% Ag were more than 20% lower than those for titanium under both cutting conditions. Alloying with silver significantly improved the machinability of titanium in terms of cutting force under the present cutting conditions.

Laser Cutting of Different Materials

Directory of Open Access Journals (Sweden)

Kadir ÇAVDAR

2013-08-01

Full Text Available In this paper; in general potential developments and trends of a particular machining field by extensively evaluating present studies of laser beam machining have been discussed. As it is indicated below, technical literatures have been subsumed under five major headlines: Experimental studies, reviews, optimization researches of the cutting parameters, theoretical modelling studies of laser beam cutting and academic studies relating to laser cutting

Effect of Moisture Content of Paper Material on Laser Cutting

Science.gov (United States)

Stepanov, Alexander; Saukkonen, Esa; Piili, Heidi; Salminen, Antti

Laser technology has been used in industrial processes for several decades. The most advanced development and implementation took place in laser welding and cutting of metals in automotive and ship building industries. However, there is high potential to apply laser processing to other materials in various industrial fields. One of these potential fields could be paper industry to fulfill the demand for high quality, fast and reliable cutting technology. Difficulties in industrial application of laser cutting for paper industry are associated to lack of basic information, awareness of technology and its application possibilities. Nowadays possibilities of using laser cutting for paper materials are widened and high automation level of equipment has made this technology more interesting for manufacturing processes. Promising area of laser cutting application at paper making machines is longitudinal cutting of paper web (edge trimming). There are few locations at a paper making machine where edge trimming is usually done: wet press section, calender or rewinder. Paper web is characterized with different moisture content at different points of the paper making machine. The objective of this study was to investigate the effect of moisture content of paper material on laser cutting parameters. Effect of moisture content on cellulose fibers, laser absorption and energy needed for cutting is described as well. Laser cutting tests were carried out using CO2 laser.

Detection of Cutting Tool Wear using Statistical Analysis and Regression Model

Science.gov (United States)

Ghani, Jaharah A.; Rizal, Muhammad; Nuawi, Mohd Zaki; Haron, Che Hassan Che; Ramli, Rizauddin

2010-10-01

This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals. A statistical-based method called Integrated Kurtosis-based Algorithm for Z-Filter technique, called I-kaz was used for developing a regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out using a CNC turning machine Colchester Master Tornado T4 in dry cutting condition. A Kistler 9255B dynamometer was used to measure the cutting force signals, which were transmitted, analyzed, and displayed in the DasyLab software. Various force signals from machining operation were analyzed, and each has its own I-kaz 3D coefficient. This coefficient was examined and its relationship with flank wear lands (VB) was determined. A regression model was developed due to this relationship, and results of the regression model shows that the I-kaz 3D coefficient value decreases as tool wear increases. The result then is used for real time tool wear monitoring.

In vitro assessment of cutting efficiency and durability of zirconia removal diamond rotary instruments.

Science.gov (United States)

Kim, Joon-Soo; Bae, Ji-Hyeon; Yun, Mi-Jung; Huh, Jung-Bo

2017-06-01

Recently, zirconia removal diamond rotary instruments have become commercially available for efficient cutting of zirconia. However, research of cutting efficiency and the cutting characteristics of zirconia removal diamond rotary instruments is limited. The purpose of this in vitro study was to assess and compare the cutting efficiency, durability, and diamond rotary instrument wear pattern of zirconia diamond removal rotary instruments with those of conventional diamond rotary instruments. In addition, the surface characteristics of the cut zirconia were assessed. Block specimens of 3 mol% yttrium cation-doped tetragonal zirconia polycrystal were machined 10 times for 1 minute each using a high-speed handpiece with 6 types of diamond rotary instrument from 2 manufacturers at a constant force of 2 N (n=5). An electronic scale was used to measure the lost weight after each cut in order to evaluate the cutting efficiency. Field emission scanning electron microscopy was used to evaluate diamond rotary instrument wear patterns and machined zirconia block surface characteristics. Data were statistically analyzed using the Kruskal-Wallis test, followed by the Mann-Whitney U test (α=.05). Zirconia removal fine grit diamond rotary instruments showed cutting efficiency that was reduced compared with conventional fine grit diamond rotary instruments. Diamond grit fracture was the most dominant diamond rotary instrument wear pattern in all groups. All machined zirconia surfaces were primarily subjected to plastic deformation, which is evidence of ductile cutting. Zirconia blocks machined with zirconia removal fine grit diamond rotary instruments showed the least incidence of surface flaws. Although zirconia removal diamond rotary instruments did not show improved cutting efficiency compared with conventional diamond rotary instruments, the machined zirconia surface showed smoother furrows of plastic deformation and fewer surface flaws. Copyright © 2016 Editorial Council

Experimental research on the machinability of Hardox steel by abrasive waterjet cutting

Directory of Open Access Journals (Sweden)

Filip Alexandru Catalin

2017-01-01

Full Text Available One of the main present industry challenges is finding the most efficient manufacturing process for a certain part. When parts are made of strong steels like Hardox, their fabrication method is usually difficult. Abrasive waterjet cutting (AWJ is one of the cutting processes which can be used in this case. This paper presents an experimental research on the machinability of Hardox steel by AWJ. The experiments were conducted using a factorial design model considering two of the main influence parameters like the traverse speed and the distance between the nozzle and the surface of the material. Based on the measurement of the dimensions and the roughness of the parts, the influence of the parameters was revealed and analyzed. The manufacturing time was also compared, as it directly influences the production cost. Further research is considered to develop a mathematical model which can be used for a proper choice of the process parameters depending on the initial requirements.

Study on Damage Evaluation and Machinability of UD-CFRP for the Orthogonal Cutting Operation Using Scanning Acoustic Microscopy and the Finite Element Method

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Dongyao Wang

2017-02-01

Full Text Available Owing to high specific strength and designability, unidirectional carbon fiber reinforced polymer (UD-CFRP has been utilized in numerous fields to replace conventional metal materials. Post machining processes are always required for UD-CFRP to achieve dimensional tolerance and assembly specifications. Due to inhomogeneity and anisotropy, UD-CFRP differs greatly from metal materials in machining and failure mechanism. To improve the efficiency and avoid machining-induced damage, this paper undertook to study the correlations between cutting parameters, fiber orientation angle, cutting forces, and cutting-induced damage for UD-CFRP laminate. Scanning acoustic microscopy (SAM was employed and one-/two-dimensional damage factors were then created to quantitatively characterize the damage of the laminate workpieces. According to the 3D Hashin’s criteria a numerical model was further proposed in terms of the finite element method (FEM. A good agreement between simulation and experimental results was validated for the prediction and structural optimization of the UD-CFRP.

Study on Damage Evaluation and Machinability of UD-CFRP for the Orthogonal Cutting Operation Using Scanning Acoustic Microscopy and the Finite Element Method.

Science.gov (United States)

Wang, Dongyao; He, Xiaodong; Xu, Zhonghai; Jiao, Weicheng; Yang, Fan; Jiang, Long; Li, Linlin; Liu, Wenbo; Wang, Rongguo

2017-02-20

Owing to high specific strength and designability, unidirectional carbon fiber reinforced polymer (UD-CFRP) has been utilized in numerous fields to replace conventional metal materials. Post machining processes are always required for UD-CFRP to achieve dimensional tolerance and assembly specifications. Due to inhomogeneity and anisotropy, UD-CFRP differs greatly from metal materials in machining and failure mechanism. To improve the efficiency and avoid machining-induced damage, this paper undertook to study the correlations between cutting parameters, fiber orientation angle, cutting forces, and cutting-induced damage for UD-CFRP laminate. Scanning acoustic microscopy (SAM) was employed and one-/two-dimensional damage factors were then created to quantitatively characterize the damage of the laminate workpieces. According to the 3D Hashin's criteria a numerical model was further proposed in terms of the finite element method (FEM). A good agreement between simulation and experimental results was validated for the prediction and structural optimization of the UD-CFRP.

OPTIMIZATION OF MACHINING PARAMETERS USING TAGUCHI APPROACH DURING HARD TURNING OF ALLOY STEEL WITH UNCOATED CARBIDE UNDER DRY CUTTING ENVIRONMENT

Directory of Open Access Journals (Sweden)

A. Das

2015-12-01

Full Text Available In today’s world of manufacturing by machining process two things are very important, one is productivity and the other one is quality. Quality of a product generally depends upon the surface finish and dimensional deviations. The productivity can be seen as a key economic indicator of innovation in terms of higher material removal rate with a less time and cost in machining industries. Taguchi method is a popular statistical technique for optimization of input parameters to get the best output results. Dry machining is a popular methodology for machining hard material and it has been accepted by many researchers to a great extent because of its low cost and safety. Many scientists have taken various input parameters and studied their effects on different output responses. In the present paper an attempt has been made to study the effect of input parameters such as cutting speed, feed rate and depth of cut on Surface roughness, Tool wear, Power consumption and Chip reduction co-efficient under dry condition using uncoated carbide insert. Signal to noise ratio has been used to select the optimal condition for various output responses. ANOVA table has been drawn for each output responses and finally mathematical model of multiple regression analysis has been prepared and authenticity of the statistical model have been checked by normal probability plot. It has been found from the experimental result that the power consumption and flank wear both were minimum at the cutting speed of 250 rpm and 400 rpm respectively. Chip reduction coefficient has been found minimum at a depth of cut of 0.3 mm and surface roughness was minimum at 0.1 mm/rev. feed rate.

Development and characterization of AlCrN coated Si3N4 ceramic cutting tool

International Nuclear Information System (INIS)

Souza, J.V.C.; Nono, M.C.A.; Machado, J.P.B.; Silva, O.M.M.; Sa, F.C.L.

2010-01-01

Ceramic cutting tools are showing a growing market perspective in terms of application on machining operations due to their high hardness, wear resistance, and machining without a cutting fluid, therefore are good candidates for cast iron and Nickel superalloys machining. The objective of the present paper was the development of Si 3 N 4 based ceramic cutting insert, characterization of its physical and mechanical properties, and subsequent coating with AlCrN using a PVD method. The characterization of the coating was made using an optical profiler, XRD, AFM and microhardness tester. The results showed that the tool presented a fracture toughness of 6,43 MPa.m 1/2 and hardness of 16 GPa. The hardness reached 31 GPa after coating. The machining tests showed an improvement on work piece roughness when machining with coated insert, in comparison with the uncoated cutting tool. Probably this fact is related to hardness, roughness and topography of AlCrN. (author)

High power YAG laser cutting; Koshutsuryoku YAG laser ni yoru setsudan gijutsu

Energy Technology Data Exchange (ETDEWEB)

Owaki, K. [Ishikawajima-Harima Heavy Industries Co. Ltd., Tokyo (Japan)

1998-08-01

This paper describes features of high power YAG cutting. The optical fiber transmission YAG laser machining system has some advantages in which optical path length compensation unit is not required and measures for low power loss and dust are not required, when compared with the CO2 laser system. Its application to the cutting of stainless steel plates has attracted attention. Cutting tests of SUS304 were conducted using high power YAG laser. Cutting of SUS304 plate with a thickness of 40 mm could be successfully done at the power of 3.5 kW. Cutting tests of SUS304 pipes with a thickness of 8 mm in water under the depth of 20 m were also conducted using air as assist gas at the power of 2.5 kW. Excellent results were obtained without scale deposition. For the tests by the composite beam using 3 kW and 4 kW systems, SUS304 plate with a thickness of 50 mm could be cut at the cutting speed of 0.1 m/min. Laser cutting of pipes from the internal surface was conducted using a newly developed small machining head which can rotate in the peripheral direction. Excellent quality for welding was confirmed. Cutting speed and plate thickness were improved by combining water jet cutter and YAG laser unit. 6 refs., 10 figs.

High precision tungsten cutting for optics

International Nuclear Information System (INIS)

Reglero, V.; Velasco, T.; Rodrigo, J.; Gasent, L.J.; Alamo, J.; Chato, R.; Ruiz Urien, I.; Santos, I.; Zarauz, J.; Clemente, G.; Sanz-Tudanca, C.; Lopez, J.L.

2001-01-01

The results obtained during the INTEGRAL masks development program an implementing the HURA and MURA codes on tungsten plates of different thickness are presented. Hard scientific requirements on pixels size and location tolerances (tenths of microns over large areas -1 m 2 - and thickness from 0.5 mm to 60 mm) required the set up of a dedicated program for testing cutting technologies: laser, photochemical milling, spark machining and electro discharge wire cutting. After a very intensive test campaign the wire cutting process was selected as the optimum technology for code manufacturing . Accuracies achieved an the code cutting fulfill scientific requirements. In fact, they are 5 times better than required. Pixel size and centroids location accuracies of 0.01 mm over a 1 m 2 area have been obtained for the 10,000 pixels on IBIS, 100 pixels on SPI and 24000 pixels on JEM-X masks. Comparative results among different cutting technologies are also discussed. (author)

Towards a durability test for washing-machines.

Science.gov (United States)

Stamminger, Rainer; Tecchio, Paolo; Ardente, Fulvio; Mathieux, Fabrice; Niestrath, Phoebe

2018-04-01

Durability plays a key role in enhancing resource conservation and contributing to waste minimization. The washing-machine product group represents a relevant case study for the development of a durability test and as a potential trigger to systematically address durability in the design of products. We developed a procedure to test the durability performance of washing-machines as a main objective of this research. The research method consisted of an analysis of available durability standards and procedures to test products and components, followed by an analysis of relevant references related to frequent failures. Finally, we defined the criteria and the conditions for a repeatable, relatively fast and relevant endurance test. The durability test considered the whole product tested under conditions of stress. A series of spinning cycles with fixed imbalanced loads was run on two washing-machines to observe failures and performance changes during the test. Even though no hard failures occurred, results clearly showed that not all washing-machines can sustain such a test without abrasion or performance deterioration. However, the attempt to reproduce the stress induced on a washing-machine by carrying out a high number of pure spinning cycles with fixed loads did not allow equal testing conditions: the actions of the control procedure regarding imbalanced loads differ from machine to machine. The outcomes of this research can be used as grounds to develop standardised durability tests and to, hence, contribute to the development of future product policy measures.

Development of YAG laser cutting system for decommissioning nuclear equipments

International Nuclear Information System (INIS)

Kasai, Takeshi; Nitta, Kazuhiko; Hosoda, Hiroshi.

1995-01-01

Technology of remote controlled cutting and reduction of generative secondary products have been required to the cutting system for decommissioning nuclear equipments. At a point of view that laser cutting technology by use of a Nd:YAG laser is effective, we have developed the laser cutting machine and carried out cutting tests for several stainless steel plates. As a result, the stainless steel plate with a thickness of 22mm could be cut by using an optical fiber which can flexibly propagate laser power, and possibility of application of this laser cutting system to decommissioning nuclear equipments was verified. (author)

Development of YAG laser cutting system for decommissioning nuclear equipments

Energy Technology Data Exchange (ETDEWEB)

Kasai, Takeshi [Fuji Electric Co. Research and Development Ltd., Yokosuka, Kanagawa (Japan); Nitta, Kazuhiko; Hosoda, Hiroshi

1995-07-01

Technology of remote controlled cutting and reduction of generative secondary products have been required to the cutting system for decommissioning nuclear equipments. At a point of view that laser cutting technology by use of a Nd:YAG laser is effective, we have developed the laser cutting machine and carried out cutting tests for several stainless steel plates. As a result, the stainless steel plate with a thickness of 22mm could be cut by using an optical fiber which can flexibly propagate laser power, and possibility of application of this laser cutting system to decommissioning nuclear equipments was verified. (author).

Evaluation of an air drilling cuttings containment system

Energy Technology Data Exchange (ETDEWEB)

Westmoreland, J.

1994-04-01

Drilling at hazardous waste sites for environmental remediation or monitoring requires containment of all drilling fluids and cuttings to protect personnel and the environment. At many sites, air drilling techniques have advantages over other drilling methods, requiring effective filtering and containment of the return air/cuttings stream. A study of. current containment methods indicated improvements could be made in the filtering of radionuclides and volatile organic compounds, and in equipment like alarms, instrumentation or pressure safety features. Sandia National Laboratories, Dept. 61 11 Environmental Drilling Projects Group, initiated this work to address these concerns. A look at the industry showed that asbestos abatement equipment could be adapted for containment and filtration of air drilling returns. An industry manufacturer was selected to build a prototype machine. The machine was leased and put through a six-month testing and evaluation period at Sandia National Laboratories. Various materials were vacuumed and filtered with the machine during this time. In addition, it was used in an actual air drive drilling operation. Results of these tests indicate that the vacuum/filter unit will meet or exceed our drilling requirements. This vacuum/filter unit could be employed at a hazardous waste site or any site where drilling operations require cuttings and air containment.

Machinability evaluation of titanium alloys.

Science.gov (United States)

Kikuchi, Masafumi; Okuno, Osamu

2004-03-01

In the present study, the machinability of titanium, Ti-6Al-4V, Ti-6A1-7Nb, and free-cutting brass was evaluated using a milling machine. The metals were slotted with square end mills under four cutting conditions. The cutting force and the rotational speed of the spindle were measured. The cutting forces for Ti-6Al-4V and Ti-6Al-7Nb were higher and that for brass was lower than that for titanium. The rotational speed of the spindle was barely affected by cutting. The cross sections of the Ti-6Al-4V and Ti-6Al-7Nb chips were more clearly serrated than those of titanium, which is an indication of difficult-to-cut metals. There was no marked difference in the surface roughness of the cut surfaces among the metals. Cutting force and the appearance of the metal chips were found to be useful as indices of machinability and will aid in the development of new alloys for dental CAD/CAM and the selection of suitable machining conditions.

Multi-channel mechanical test machine for HANARO (I)

International Nuclear Information System (INIS)

Song, M. S.; Choi, Y.; Cho, M. S.; Kim, B. G.; Kang, Y. H.

2004-01-01

Design and fabrication of multi-channel mechanical test machine is useful and important for the study of in-pile test of nuclear materials in HANARO. The dimension and shape of the multi-channel mechanical test machine should be fixed to a test reactor and their objectives. KAERI successfully developed a non-instrumented multi-channel mechanical test machine for material irradiation tests in a domestic research reactor, HANARO. This results in strongly stimulating and accelerating irradiation tests of materials in domestic industry and research fields with HANARO. Although various types of in-pile creep capsule were made for well installation in each test reactor, there is no in-pile creep multi-channel mechanical test machine for HANARO. Hence, the objectives of this study are to fabricate and test a multi-channel mechanical test machine of HANARO

ENVIRONMENTALLY REDUCING OF COOLANTS IN METAL CUTTING

Directory of Open Access Journals (Sweden)

Veijo KAUPPINEN

2012-11-01

Full Text Available Strained environment is a global problem. In metal industries the use of coolant has become more problematic in terms of both employee health and environmental pollution. It is said that the use of coolant forms approximately 8 - 16 % of the total production costs.The traditional methods that use coolants are now obviously becoming obsolete. Hence, it is clear that using a dry cutting system has great implications for resource preservation and waste reduction. For this purpose, a new cooling system is designed for dry cutting. This paper presents the new eco-friendly cooling innovation and the benefits gained by using this method. The new cooling system relies on a unit for ionising ejected air. In order to compare the performance of using this system, cutting experiments were carried out. A series of tests were performed on a horizontal turning machine and on a horizontal machining centre.

Predicting the Performance of Chain Saw Machines Based on Shore Scleroscope Hardness

Science.gov (United States)

Tumac, Deniz

2014-03-01

Shore hardness has been used to estimate several physical and mechanical properties of rocks over the last few decades. However, the number of researches correlating Shore hardness with rock cutting performance is quite limited. Also, rather limited researches have been carried out on predicting the performance of chain saw machines. This study differs from the previous investigations in the way that Shore hardness values (SH1, SH2, and deformation coefficient) are used to determine the field performance of chain saw machines. The measured Shore hardness values are correlated with the physical and mechanical properties of natural stone samples, cutting parameters (normal force, cutting force, and specific energy) obtained from linear cutting tests in unrelieved cutting mode, and areal net cutting rate of chain saw machines. Two empirical models developed previously are improved for the prediction of the areal net cutting rate of chain saw machines. The first model is based on a revised chain saw penetration index, which uses SH1, machine weight, and useful arm cutting depth as predictors. The second model is based on the power consumed for only cutting the stone, arm thickness, and specific energy as a function of the deformation coefficient. While cutting force has a strong relationship with Shore hardness values, the normal force has a weak or moderate correlation. Uniaxial compressive strength, Cerchar abrasivity index, and density can also be predicted by Shore hardness values.

Method of distilling machine-cut peat and other finely divided material

Energy Technology Data Exchange (ETDEWEB)

1942-03-03

Apparatus arrangement is given for dry distillation of machine-cut peat and similar materials in particle or powder form, consisting of a tunnel oven through which the material is led and in which it is heated by help of the gases generated in the process. These gases are brought to circulate through the interior of the oven and heat exchangers installed outside the oven, are flushed by hot combustion gases. Through the tunnel oven a mounted turnable shaft is provided with paddles which lift the material and let it fall to make the particles of material get good contact with the circulating gases without offering too much resistance to the flow of the gases.

Thrown object testing of forest machine operator protective structures

Science.gov (United States)

S.E. Taylor; M.W. Veal; R.B. Rummer

2003-01-01

High-speed chains or rotating disks are commonly used to cut and process trees during forest harvesting operations. Mechanical failure or fatigue of these tools can lead to a potentially hazardous situation where fragments of chain or sawteeth are thrown through the operator enclosures on forest machines. This poster presentation discusses the development and...

X-ray evaluation of residual stress distributions within surface machined layer generated by surface machining and sequential welding

International Nuclear Information System (INIS)

Taniguchi, Yuu; Okano, Shigetaka; Mochizuki, Masahito

2017-01-01

The excessive tensile residual stress generated by welding after surface machining may be an important factor to cause stress corrosion cracking (SCC) in nuclear power plants. Therefore we need to understand and control the residual stress distribution appropriately. In this study, residual stress distributions within surface machined layer generated by surface machining and sequential welding were evaluated by X-ray diffraction method. Depth directional distributions were also investigated by electrolytic polishing. In addition, to consider the effect of work hardened layer on the residual stress distributions, we also measured full width at half maximum (FWHM) obtained from X-ray diffraction. Testing material was a low-carbon austenitic stainless steel type SUS316L. Test specimens were prepared by surface machining with different cutting conditions. Then, bead-on-plate welding under the same welding condition was carried out on the test specimens with different surface machined layer. As a result, the tensile residual stress generated by surface machining increased with increasing cutting speed and showed nearly uniform distributions on the surface. Furthermore, the tensile residual stress drastically decreased with increasing measurement depth within surface machined layer. Then, the residual stress approached 0 MPa after the compressive value showed. FWHM also decreased drastically with increasing measurement depth and almost constant value from a certain depth, which was almost equal regardless of the machining condition, within surface machined layer in all specimens. After welding, the transverse distribution of the longitudinal residual stress varied in the area apart from the weld center according to machining conditions and had a maximum value in heat affected zone. The magnitude of the maximum residual stress was almost equal regardless of the machining condition and decreased with increasing measurement depth within surface machined layer. Finally, the

An Experimental Study of the Cutting Forces in Metal Turning

Directory of Open Access Journals (Sweden)

Zoltan Iosif Korka

2013-09-01

Full Text Available Cutting forces are classified among the most important technological parameters in machining process. Cutting forces are the background for the evaluation of the necessary machining power, as well as for dimensioning of the tools. Cutting forces are also having a major influence on the deformation of the work piece machined, its dimensional accuracy, and machining system stability.

SURFACE ROUGHNESS AND CUTTING FORCES IN CRYOGENIC TURNING OF CARBON STEEL

Directory of Open Access Journals (Sweden)

T. C. YAP

2015-07-01

Full Text Available The effect of cryogenic liquid nitrogen on surface roughness, cutting forces, and friction coefficient of the machined surface when machining of carbon steel S45C in wet, dry and cryogenic condition was studied through experiments. The experimental results show that machining with liquid nitrogen increases the cutting forces, reduces the friction coefficient, and improves the chips produced. Beside this, conventional machining with cutting fluid is still the most suitable method to produce good surface in high speed machining of carbon steel S45C whereas dry machining produced best surface roughness in low speed machining. Cryogenic machining is not able to replace conventional cutting fluid in turning carbon steel.

Research on cutting vibration characteristics of face-milling involute gear

Directory of Open Access Journals (Sweden)

Chengzhe JIN

2017-10-01

Full Text Available Traditional machining methods, such as gear hobbing, gear shaping and gear milling, etc, are commonly used for cutting machining of gear tooth profile, which cannot meet huge machining demand of gears to a certain extent. This article proposes to utilize a face-milling machining method in involute gear machining, which can be used to reduce production cost effectively. Cutting vibration generated during cutting machining has a direct effect on the machining accuracy and machined surface quality of workpiece. Therefore, it is desiderated to perform in-depth research regarding this issue. ADAMS software was used to establish a rigid-flexible coupling virtual prototyping model of face-milling gear milling system and a cutting vibration system model. Cutting vibration analysis was performed for face-milling gear by adopting quick sine frequency sweep method, so that the frequency response characteristics of workpiece in three directions X, Y and Z and space were acquired. The research results will provide reference and theoretical foundation for actual application of face-milling gear machining technology.

Magnetofluidic testing of rock cutting knives

International Nuclear Information System (INIS)

Buioca, C.D.; Iusan, Vasile; Pirlea, Remus

2002-01-01

The nondestructive testing of cutting knives consists in the determination of nonuniformity of a magnetic fluid layer applied on the horizontally placed surface of the magnetized cutting plate of the knife. A low constant magnetic field was applied perpendicular to the knife surface and a uniform magnetic fluid layer was applied. The defects as nonuniform brass layer, fissures or small cavities between the cutting plate and knife core determine the apparition of magnetic field gradients and therefore magnetic forces acting on the magnetic fluid which migrates to the zones with higher magnetic field intensity. After several minutes, a nonuniform layer of magnetic fluid was directly observed. Quantitative results, concerning the position and dimensions of the defect, were obtained by computer aided processing of the magnetic fluid layer image. Experimental data for several cutting knives are presented in the paper

Some possibilities for determining cutting data when using laser cutting:

OpenAIRE

Radovanović, Miroslav

2006-01-01

The technological problems faced in the field of the application of laser-cutting machines lie in insufficient knowledge of the laser technique and the absence of both sufficiently reliable practical data and knowledge about the parameters affecting the work process itself. A significant parameter that is necessary to determine and to enter in an NC-program is the cutting speed. Various authors analyze the laser-cutting process and give mathematical models where laser cutting is modeled by us...

Influence of non-edible vegetable based oil as cutting fluid on chip, surface roughness and cutting force during drilling operation of Mild Steel

Science.gov (United States)

Susmitha, M.; Sharan, P.; Jyothi, P. N.

2016-09-01

Friction between work piece-cutting tool-chip generates heat in the machining zone. The heat generated reduces the tool life, increases surface roughness and decreases the dimensional sensitiveness of work material. This can be overcome by using cutting fluids during machining. They are used to provide lubrication and cooling effects between cutting tool and work piece and cutting tool and chip during machining operation. As a result, important benefits would be achieved such longer tool life, easy chip flow and higher machining quality in the machining processes. Non-edible vegetable oils have received considerable research attention in the last decades owing to their remarkable improved tribological characteristics and due to increasing attention to environmental issues, have driven the lubricant industry toward eco friendly products from renewable sources. In the present work, different non-edible vegetable oils are used as cutting fluid during drilling of Mild steel work piece. Non-edible vegetable oils, used are Karanja oil (Honge), Neem oil and blend of these two oils. The effect of these cutting fluids on chip formation, surface roughness and cutting force are investigated and the results obtained are compared with results obtained with petroleum based cutting fluids and dry conditions.

Intermittent single point machining of brittle materials

Energy Technology Data Exchange (ETDEWEB)

Marsh, E

1999-12-07

A series of tests were undertaken to explore diamond tool wear in the intermittent cutting of brittle materials, specifically silicon. The tests were carried out on a plain way No. 3 Moore machine base equipped as a flycutter with a motorized Professional Instruments 4R air bearing spindle. The diamond tools were made by Edge Technologies with known crystal orientation and composition and sharpened with either an abrasive or chemical process, depending on the individual test. The flycutting machine configuration allowed precise control over the angle at which the tool engages the anisotropic silicon workpiece. In contrast, the crystallographic orientation of the silicon workpiece changes continuously during on-axis turning. As a result, it is possible to flycut a workpiece in cutting directions that are known to be easy or hard. All cuts were run in the 100 plane of the silicon, with a slight angle deliberately introduced to ensure that the 100 plane is engaged in ''up-cutting'' which lengthens the tool life. A Kistler 9256 dynamometer was used to measure the cutting forces in order to gain insight into the material removal process and tool wear during testing. The dynamometer provides high bandwidth force measurement with milli-Newton resolution and good thermal stability. After many successive passes over the workpiece, it was observed that the cutting forces grow at a rate that is roughly proportional to the degradation of the workpiece surface finish. The exact relationship between cutting force growth and surface finish degradation was not quantified because of the problems associated with measuring surface finish in situ. However, a series of witness marks were made during testing in an aluminum sample that clearly show the development of wear flats on the tool nose profile as the forces grow and the surface finish worsens. The test results show that workpieces requiring on the order of two miles of track length can be made with low tool

Experimental Investigation of Tensile Test on Connection of Cold-formed Cut-curved Steel Section

Science.gov (United States)

Sani, Mohd Syahrul Hisyam Mohd; Muftah, Fadhluhartini; Rahman, Nurul Farraheeda Abdul; Fakri Muda, Mohd

2017-08-01

Cold-formed steel (CFS) is widely used as structural and non-structural components such as roof trusses and purlin. A CFS channel section with double intermediate web stiffener and lipped is chosen based on the broader usage in roof truss construction. CFS section is cut to form cold-formed pre-cut-curved steel section and lastly strengthened by several types of method or likely known as connection to establish the cold-formed cut-curved steel (CFCCS) section. CFCCS is proposed to be used as a top chord section in the roof truss system. The CFCCS is to resist the buckling phenomena of the roof truss structure and reduced the compression effect on the top chord. The tensile test connection of CFCCS section, especially at the flange element with eight types of connection by welding, plate with self-drilling screw and combination is investigated. The flange element is the weakest part that must be solved first other than the web element because they are being cut totally, 100% of their length for curving process. The testing is done using a universal testing machine for a tensile load. From the experiment, specimen with full welding has shown as a good result with an ultimate load of 13.37 kN and reported having 35.41% when compared with normal specimen without any of connection methods. Furthermore, the experimental result is distinguished by using Eurocode 3. The failure of a full welding specimen is due to breaking at the welding location. Additionally, all specimens with either full weld or spot weld or combination failed due to breaking on weld connection, but specimen with flange plate and self-drilling screw failed due to tilting and bearing. Finally, the full welding specimen is chosen as a good connection to perform the strengthening method of CFCCS section.

High speed cutting of AZ31 magnesium alloy

Directory of Open Access Journals (Sweden)

Liwei Lu

2016-06-01

Full Text Available Using LBR-370 numerical control lathe, high speed cutting was applied to AZ31 magnesium alloy. The influence of cutting parameters on microstructure, surface roughness and machining hardening were investigated by using the methods of single factor and orthogonal experiment. The results show that the cutting parameters have an important effect on microstructure, surface roughness and machine hardening. The depth of stress layer, roughness and hardening present a declining tendency with the increase of the cutting speed and also increase with the augment of the cutting depth and feed rate. Moreover, we established a prediction model of the roughness, which has an important guidance on actual machining process of magnesium alloy.

EXPERIMENTAL INVESTIGATION OF THE EFFECT OF MACHINIG PARAMETERS OVER CUTTING FORCE AND SURFACE ROUGHNESS IN THE MACHINABILITY OF AA5052 ALLOY

Directory of Open Access Journals (Sweden)

Hasan GÖKKAYA

2006-03-01

Full Text Available In this study, the effects of different cutting and feed rates over average surface roughness and main cutting force during the machinability of AA5052 aluminum alloy with uncoated cemented carbide insert were evaluated. In the experiments, stable depth of cut (1.5 mm, four different cutting speeds (200, 300, 400, 500 m/min and five different feed rates (0.10, 0.15, 0.20, 0.25, 0.30 mm/rev were used. Based on cutting and feed rates, the lowest main cutting force was obtained as 113 in 500 m/min cutting speed and 0.10 mm/rev feed rate and the highest cutting force was obtained as 332 N in 200 m/min cutting speed and 0.30 mm/rev feed rate. The lowest average surface roughness was obtained as 0.95 µm in 200 m/min cutting speed and 0.10 mm/rev feed rate and the highest average surface roughness was obtained as 6.65 µm in 300 m/min cutting speed and 0.30 mm/rev feed rate.

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.

Failure Identification of Hacksaw Machine REMOR 400

International Nuclear Information System (INIS)

Paidjo; Abdul Hafid; Sagino

2007-01-01

REMOR 400 Hack sawing machine is one of machines type has been old age. For arrange of cutting pressure and repeat lifting load after cutting process by using the hydraulic system. Beside of worn-out of hacksaw blade, failure cutting earn also because of leakage from the hydraulic system of machine. Leakage of hydraulic system occurs because of over load factor using or aging. Base on inspection result, hacksaw machine REMOR 400 fault on hydraulic system in the 2006 year. This matter will be seen from its seal brittle from the machine. For activate to return machine so much replacement repeat the seals used by machine. (author)

Optimization of cutting parameters in CNC turning of stainless steel 304 with TiAlN nano coated carbide cutting tool

Science.gov (United States)

Durga Prasada Rao, V.; Harsha, N.; Raghu Ram, N. S.; Navya Geethika, V.

2018-02-01

In this work, turning was performed to optimize the surface finish or roughness (Ra) of stainless steel 304 with uncoated and coated carbide tools under dry conditions. The carbide tools were coated with Titanium Aluminium Nitride (TiAlN) nano coating using Physical Vapour Deposition (PVD) method. The machining parameters, viz., cutting speed, depth of cut and feed rate which show major impact on Ra are considered during turning. The experiments are designed as per Taguchi orthogonal array and machining process is done accordingly. Then second-order regression equations have been developed on the basis of experimental results for Ra in terms of machining parameters used. Regarding the effect of machining parameters, an upward trend is observed in Ra with respect to feed rate, and as cutting speed increases the Ra value increased slightly due to chatter and vibrations. The adequacy of response variable (Ra) is tested by conducting additional experiments. The predicted Ra values are found to be a close match of their corresponding experimental values of uncoated and coated tools. The corresponding average % errors are found to be within the acceptable limits. Then the surface roughness equations of uncoated and coated tools are set as the objectives of optimization problem and are solved by using Differential Evolution (DE) algorithm. Also the tool lives of uncoated and coated tools are predicted by using Taylor’s tool life equation.

Improvement of Drill Performance in Metal Cutting Using MoST Solid Lubricant Coatings

Institute of Scientific and Technical Information of China (English)

N.R. Thomas; D.G. Teer; S. Yang; S. Hickman

2004-01-01

Coated tools are widely used in today's metal cutting industries and have significantly improved machining productivity through reducing operation costs and time. This paper presents the results of a systematic study of the performance of HSS drills coated with CrTiAlN and drills with a top solid lubricant coating of MoSTTM. The tests were performed on a Haas vertical machining centre under wet and dry cutting conditions to machine through holes in medium carbon steel workpieces. The feed force and torque were recorded throughout some of the tests using a force dynamometer,while the tool wear was monitored and measured. It was found that MoSTTM coatings even under accelerated conditions improve the tool life significantly based on their unique properties and very low friction.

High pressure water jet mining machine

Science.gov (United States)

Barker, Clark R.

1981-05-05

A high pressure water jet mining machine for the longwall mining of coal is described. The machine is generally in the shape of a plowshare and is advanced in the direction in which the coal is cut. The machine has mounted thereon a plurality of nozzle modules each containing a high pressure water jet nozzle disposed to oscillate in a particular plane. The nozzle modules are oriented to cut in vertical and horizontal planes on the leading edge of the machine and the coal so cut is cleaved off by the wedge-shaped body.

Machinability of advanced materials

CERN Document Server

Davim, J Paulo

2014-01-01

Machinability of Advanced Materials addresses the level of difficulty involved in machining a material, or multiple materials, with the appropriate tooling and cutting parameters.  A variety of factors determine a material's machinability, including tool life rate, cutting forces and power consumption, surface integrity, limiting rate of metal removal, and chip shape. These topics, among others, and multiple examples comprise this research resource for engineering students, academics, and practitioners.

Effects of Cutting Edge Microgeometry on Residual Stress in Orthogonal Cutting of Inconel 718 by FEM.

Science.gov (United States)

Shen, Qi; Liu, Zhanqiang; Hua, Yang; Zhao, Jinfu; Lv, Woyun; Mohsan, Aziz Ul Hassan

2018-06-14

Service performance of components such as fatigue life are dramatically influenced by the machined surface and subsurface residual stresses. This paper aims at achieving a better understanding of the influence of cutting edge microgeometry on machined surface residual stresses during orthogonal dry cutting of Inconel 718. Numerical and experimental investigations have been conducted in this research. The cutting edge microgeometry factors of average cutting edge radius S¯, form-factor K , and chamfer were investigated. An increasing trend for the magnitudes of both tensile and compressive residual stresses was observed by using larger S¯ or introducing a chamfer on the cutting edges. The ploughing depth has been predicted based on the stagnation zone. The increase of ploughing depth means that more material was ironed on the workpiece subsurface, which resulted in an increase in the compressive residual stress. The thermal loads were leading factors that affected the surface tensile residual stress. For the unsymmetrical honed cutting edge with K = 2, the friction between tool and workpiece and tensile residual stress tended to be high, while for the unsymmetrical honed cutting edge with K = 0.5, the high ploughing depth led to a higher compressive residual stress. This paper provides guidance for regulating machine-induced residual stress by edge preparation.

Assessment of abrasiveness for research of rock cutting

Directory of Open Access Journals (Sweden)

Milan Labaš

2012-12-01

Full Text Available Rock abrasiveness is ability of rock to wear down the working tool during the mutual interaction between the working indentorand the rock in the mechanical rock cutting process. The cutting indentor is worn down during the interaction, which changes itsgeometric dimensions causing the enlargement of a contact area between the tool and the rock surface. The changes in these dimensionsconsequently alter the rate of advance of the drilling machine and the specific cutting energy. We have determined the abrasivenessaccording to the norm ON 44 1121 (1982 on the testing device constructed at the Institute of Geotechnics SAS.

Research of a smart cutting tool based on MEMS strain gauge

Science.gov (United States)

Zhao, Y.; Zhao, Y. L.; Shao, YW; Hu, T. J.; Zhang, Q.; Ge, X. H.

2018-03-01

Cutting force is an important factor that affects machining accuracy, cutting vibration and tool wear. Machining condition monitoring by cutting force measurement is a key technology for intelligent manufacture. Current cutting force sensors exist problems of large volume, complex structure and poor compatibility in practical application, for these problems, a smart cutting tool is proposed in this paper for cutting force measurement. Commercial MEMS (Micro-Electro-Mechanical System) strain gauges with high sensitivity and small size are adopted as transducing element of the smart tool, and a structure optimized cutting tool is fabricated for MEMS strain gauge bonding. Static calibration results show that the developed smart cutting tool is able to measure cutting forces in both X and Y directions, and the cross-interference error is within 3%. Its general accuracy is 3.35% and 3.27% in X and Y directions, and sensitivity is 0.1 mV/N, which is very suitable for measuring small cutting forces in high speed and precision machining. The smart cutting tool is portable and reliable for practical application in CNC machine tool.

Laser cutting of Kevlar laminates

Energy Technology Data Exchange (ETDEWEB)

VanCleave, R.A.

1977-09-01

An investigation has been conducted of the use of laser energy for cutting contours, diameters, and holes in flat and shaped Kevlar 49 fiber-reinforced epoxy laminates as an alternate to conventional machining. The investigation has shown that flat laminates 6.35 mm thick may be cut without backup by using a high-powered (1000-watt) continuous wave CO/sub 2/ laser at high feedrates (33.87 mm per second). The cut produced was free of the burrs and delaminations resulting from conventional machining methods without intimate contact backup. In addition, the process cycle time was greatly reduced.

A Study on The Development of Local Exhaust Ventilation System (LEV’s) for Installation of Laser Cutting Machine

Science.gov (United States)

Harun, S. I.; Idris, S. R. A.; Tamar Jaya, N.

2017-09-01

Local exhaust ventilation (LEV) is an engineering system frequently used in the workplace to protect operators from hazardous substances. The objective of this project is design and fabricate the ventilation system as installation for chamber room of laser cutting machine and to stimulate the air flow inside chamber room of laser cutting machine with the ventilation system that designed. LEV’s fabricated with rated voltage D.C 10.8V and 1.5 ampere. Its capacity 600 ml, continuously use limit approximately 12-15 minute, overall length LEV’s fabricated is 966 mm with net weight 0.88 kg and maximum airflow is 1.3 meter cubic per minute. Stimulate the air flow inside chamber room of laser cutting machine with the ventilation system that designed and fabricated overall result get 2 main gas vapor which air and carbon dioxide. For air gas which experimented by using anemometer, general duct velocity that produce is same with other gas produce, carbon dioxide which 5 m/s until 10 m/s. Overall result for 5 m/s and 10 m/s as minimum and maximum duct velocity produce for both air and carbon dioxide. The air gas flow velocity that captured by LEV’s fabricated, 3.998 m/s average velocity captured from 5 m/s duct velocity which it efficiency of 79.960% and 7.667 m/s average velocity captured from 10 m/s duct velocity with efficiency of 76.665%. For carbon dioxide gas flow velocity that captured by LEV’s fabricated, 3.674 m/s average velocity captured from 5 m/s duct velocity which it efficiency of 73.480% and 8.255 m/s average velocity captured from 10 m/s duct velocity with efficiency of 82.545%.

Assessment of the applicability of AWJ technique for dismantling the reactor of Fugen. Performance of underwater-cutting thick plate and testing of sound-based monitoring for underwater-cutting process

International Nuclear Information System (INIS)

Maruyama, Shin-ichiro; Nishio, Shin-ichi

2010-01-01

The reactor of Fugen is characterized by its double-walled pressure tube construction that is composed of pressure tubes and calandria tubes. The reactor dismantlement has been planning on dismantling it under water and the abrasive water jet (AWJ) underwater-cutting method is chosen as an option among simultaneous double tubes cutting technologies. For assessing the applicability of the AWJ cutting technology, a thick plate was cut under water by the small AWJ cutting machine. In addition, since cutting causes muddiness in water, cutting was monitored by the sound-based monitoring system which was adopted as a secondary cutting monitoring method. As a results, it was demonstrated that one-phase cutting was possible under water for a stainless-steel plate with 150mm thickness and that the relationship between cutting depth and capable cutting speed could be predictable. As for the sound-based cutting monitoring, the predictability whether or not cutting would be successful was verified by checking the change of sounds level. (author)

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.

Thirteen Year Loblolly Pine Growth Following Machine Application of Cut-Stump Treament Herbicides For Hardwood Stump-Sprout Control

Science.gov (United States)

Clyde G. Vidrine; John C. Adams

2002-01-01

Thirteen year growth results of 1-0 out-planted loblolly pine seedlings on nonintensively prepared up-land mixed pine-hardwood sites receiving machine applied cut-stump treatment (CST) herbicides onto hardwood stumps at the time of harvesting is presented. Plantation pine growth shows significantly higher growth for pine in the CST treated plots compared to non-CST...

Random non-proportional fatigue tests with planar tri-axial fatigue testing machine

OpenAIRE

Inoue, T.; Nagao, R.; Takeda, N.

2016-01-01

Complex stresses, which occur on the mechanical surfaces of transport machinery in service, bring a drastic degradation in fatigue life. However, it is hard to reproduce such complex stress states for evaluating the fatigue life with conventional multiaxial fatigue machines. We have developed a fatigue testing machine that enables reproduction of such complex stresses. The testing machine can reproduce arbitrary in-plane stress states by applying three independent loads to the test specimen u...

The Impact Of Surface Shape Of Chip-Breaker On Machined Surface

Science.gov (United States)

Šajgalík, Michal; Czán, Andrej; Martinček, Juraj; Varga, Daniel; Hemžský, Pavel; Pitela, David

2015-12-01

Machined surface is one of the most used indicators of workpiece quality. But machined surface is influenced by several factors such as cutting parameters, cutting material, shape of cutting tool or cutting insert, micro-structure of machined material and other known as technological parameters. By improving of these parameters, we can improve machined surface. In the machining, there is important to identify the characteristics of main product of these processes - workpiece, but also the byproduct - the chip. Size and shape of chip has impact on lifetime of cutting tools and its inappropriate form can influence the machine functionality and lifetime, too. This article deals with elimination of long chip created when machining of shaft in automotive industry and with impact of shape of chip-breaker on shape of chip in various cutting conditions based on production requirements.

Machine Tool Software

Science.gov (United States)

1988-01-01

A NASA-developed software package has played a part in technical education of students who major in Mechanical Engineering Technology at William Rainey Harper College. Professor Hack has been using (APT) Automatically Programmed Tool Software since 1969 in his CAD/CAM Computer Aided Design and Manufacturing curriculum. Professor Hack teaches the use of APT programming languages for control of metal cutting machines. Machine tool instructions are geometry definitions written in APT Language to constitute a "part program." The part program is processed by the machine tool. CAD/CAM students go from writing a program to cutting steel in the course of a semester.

Surface dimpling on rotating work piece using rotation cutting tool

Science.gov (United States)

Bhapkar, Rohit Arun; Larsen, Eric Richard

2015-03-31

A combined method of machining and applying a surface texture to a work piece and a tool assembly that is capable of machining and applying a surface texture to a work piece are disclosed. The disclosed method includes machining portions of an outer or inner surface of a work piece. The method also includes rotating the work piece in front of a rotating cutting tool and engaging the outer surface of the work piece with the rotating cutting tool to cut dimples in the outer surface of the work piece. The disclosed tool assembly includes a rotating cutting tool coupled to an end of a rotational machining device, such as a lathe. The same tool assembly can be used to both machine the work piece and apply a surface texture to the work piece without unloading the work piece from the tool assembly.

Development of flank wear model of cutting tool by using adaptive feedback linear control system on machining AISI D2 steel and AISI 4340 steel

Science.gov (United States)

Orra, Kashfull; Choudhury, Sounak K.

2016-12-01

The purpose of this paper is to build an adaptive feedback linear control system to check the variation of cutting force signal to improve the tool life. The paper discusses the use of transfer function approach in improving the mathematical modelling and adaptively controlling the process dynamics of the turning operation. The experimental results shows to be in agreement with the simulation model and error obtained is less than 3%. The state space approach model used in this paper successfully check the adequacy of the control system through controllability and observability test matrix and can be transferred from one state to another by appropriate input control in a finite time. The proposed system can be implemented to other machining process under varying range of cutting conditions to improve the efficiency and observability of the system.

Analysis and optimization of machining parameters of laser cutting for polypropylene composite

Science.gov (United States)

Deepa, A.; Padmanabhan, K.; Kuppan, P.

2017-11-01

Present works explains about machining of self-reinforced Polypropylene composite fabricated using hot compaction method. The objective of the experiment is to find optimum machining parameters for Polypropylene (PP). Laser power and Machining speed were the parameters considered in response to tensile test and Flexure test. Taguchi method is used for experimentation. Grey Relational Analysis (GRA) is used for multiple process parameter optimization. ANOVA (Analysis of Variance) is used to find impact for process parameter. Polypropylene has got the great application in various fields like, it is used in the form of foam in model aircraft and other radio-controlled vehicles, thin sheets (∼2-20μm) used as a dielectric, PP is also used in piping system, it is also been used in hernia and pelvic organ repair or protect new herrnis in the same location.

Impact of heat treatment on HSS cutting tool (ASTM A600) and its behaviour during machining of mild steel (ASTM A36)

Science.gov (United States)

Afolalu, S. A.; Abioye, O. P.; Salawu, E. Y.; Okokpujie, I. P.; Abioye, A. A.; Omotosho, O. A.; Ajayi., O. O.

2018-04-01

Carburization is one the best heat treatment that responded well to hardening with Palm Kernel Shell giving the best hardness value. This work studied the influence of carburization on HSStool(ASTM A600) and its behaviour during machining of mild steel (ASTM A36). Composition of the samples (12 pieces of 180 × 12 × 12 mm) HSS tools were checked using UV-VIS spectrometer and the tools were carburized with PKS at holding temperatures and time of 800, 850, 900, 950 °C and 60,90 120 minutes using muffle furnance. The micro structural analysis, surface and core hardnessof the treated samples gave better results than the untreated samples when checked withsoft driven and optical microscope. It wasalso observed that increase in the feed rate and depth for length of cut of 50 mm significantly reduces the wear progression and thereby gave best machining time at maximum carburizing temperature and time(950 °C / 120 minutes) when it was used to cut mild steelon the lathe machine.

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...

Performance tests of an abrasive cut-off systems for the finishing of high-precision casts

OpenAIRE

A. Fedoryszyn; W. T. Meksa; G. Woźnicki

2008-01-01

The paper summarizes the performance data of a newly designed and engineered grinding and cut-off system. The machine is used for separation of models manufactured by the investment casting method. The machine comprises the following units:- base supporting other assemblies and elements: abrasive disc holder and drives; this solution enables an easy replacement and access to holding elements while a belt transmission allows the disc rpm to be varied,- mechanism moving the spindle in the horiz...

Digital 3D reconstruction of Agustin de Betancourt's historical heritage: the machine for cutting grass in waterways

Directory of Open Access Journals (Sweden)

José Ignacio Rojas-Sola

2016-05-01

Full Text Available Agustín de Betancourt y Molina was one of the most distinguished engineers of the eighteenth and nineteenth centuries with numerous contributions to various fields of engineering, including civil engineering. This research shows the process followed in the documentation of the cultural heritage of that Canary engineer, especially in the geometric documentation of a machine for cutting grass in waterways presented in England in 1795 after three years researching on theory of machines. The baseline information has been recovered from the Canary Orotava Foundation of History of Science who has spent years collecting information about the Project Betancourt, in particular, planimetric information as well as a small report on its operation and description of parts of machine. From this information, we have constructed a three dimensional (3D model using CAD techniques with the use of Solid Edge ST7 parametric software, which has enabled the team to create the 3D model as well as different detail plans and exploded views.

Some aspects of precise laser machining - Part 1: Theory

Science.gov (United States)

Wyszynski, Dominik; Grabowski, Marcin; Lipiec, Piotr

2018-05-01

The paper describes the role of laser beam polarization and deflection on quality of laser beam machined parts made of difficult to cut materials (used for cutting tools). Application of efficient and precise cutting tool (laser beam) has significant impact on preparation and finishing operations of cutting tools for aviation part manufacturing. Understanding the phenomena occurring in the polarized light laser cutting gave possibility to design, build and test opto-mechanical instrumentation to control and maintain process parameters and conditions. The research was carried within INNOLOT program funded by Polish National Centre for Research and Development.

Laser circular cutting of Kevlar sheets: Analysis of thermal stress filed and assessment of cutting geometry

Science.gov (United States)

Yilbas, B. S.; Akhtar, S. S.; Karatas, C.

2017-11-01

A Kevlar laminate has negative thermal expansion coefficient, which makes it difficult to machine at room temperaures using the conventional cutting tools. Contararily, laser machining of a Kevlar laminate provides advantages over the conventional methods because of the non-mechanical contact between the cutting tool and the workpiece. In the present study, laser circular cutting of Kevlar laminate is considered. The experiment is carried out to examine and evaluate the cutting sections. Temperature and stress fields formed in the cutting section are simulated in line with the experimental study. The influence of hole diameters on temperature and stress fields are investigated incorporating two different hole diameters. It is found that the Kevlar laminate cutting section is free from large size asperities such as large scale sideways burnings and attachemnt of charred residues. The maximum temperature along the cutting circumference remains higher for the large diameter hole than that of the small diameter hole. Temperature decay is sharp around the cutting section in the region where the cutting terminates. This, in turn, results in high temperature gradients and the thermal strain in the cutting region. von Mises stress remains high in the region where temperature gradients are high. von Mises stress follows similar to the trend of temperature decay around the cutting edges.

Laser cutting system in bridge fabricating line; Kyoryo seisaku line ni okeru laser no setsudan system

Energy Technology Data Exchange (ETDEWEB)

Kitaguchi, Y.; Yokotani, K. [Hitachi Zosen Corp., Osaka (Japan)

1994-11-01

This paper describes the laser cutting system established at a new advanced plant that was constructed by Hitachi Shipbuilding and Engineering Co., Ltd. in 1993. At the plant, the cutting line consists of four NC cutting lines: the plasma cutting machine, gas cutting machine, frame planer, and laser cutting machine. The laser cutting machine is used to cut complex shapes of relatively thin (6 - 16 mm) materials with high accuracy. The machine consists of a 3 kW CO2 laser oscillator mounted gantry type NC cutter and a slat conveyor of about 30 m long, with the maximum cutting width of 3.6 m. The NC cutting machine is provided with the automatic printing function using NC data, marking function, scheduled operation function, steel plate detector, and coordinate rotation function, etc. These functions enable unattended operation of the machine to cut multiple materials. This NC laser cutting line has the same performance data collection function for data during the operating time as other production lines. Therefore, the NC laser cutting line can be subjected to the realtime centralized control together with the other lines. All these technologies have provided high accuracy and efficiency for production as well as an environment in which many female operators can successfully work. 10 figs., 4 tabs.

Testing and Modeling of Machine Properties in Resistance Welding

DEFF Research Database (Denmark)

Wu, Pei

The objective of this work has been to test and model the machine properties including the mechanical properties and the electrical properties in resistance welding. The results are used to simulate the welding process more accurately. The state of the art in testing and modeling machine properties...... as real projection welding tests, is easy to realize in industry, since tests may be performed in situ. In part II, an approach of characterizing the electrical properties of AC resistance welding machines is presented, involving testing and mathematical modelling of the weld current, the firing angle...... in resistance welding has been described based on a comprehensive literature study. The present thesis has been subdivided into two parts: Part I: Mechanical properties of resistance welding machines. Part II: Electrical properties of resistance welding machines. In part I, the electrode force in the squeeze...

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.

Reproducibility of a reaming test

DEFF Research Database (Denmark)

Pilny, Lukas; Müller, Pavel; De Chiffre, Leonardo

2012-01-01

The reproducibility of a reaming test was analysed to document its applicability as a performance test for cutting fluids. Reaming tests were carried out on a drilling machine using HSS reamers. Workpiece material was an austenitic stainless steel, machined using 4.75 m∙min-1 cutting speed and 0......). Process reproducibility was assessed as the ability of different operators to ensure a consistent rating of individual lubricants. Absolute average values as well as experimental standard deviations of the evaluation parameters were calculated, and uncertainty budgeting was performed. Results document...... a built-up edge occurrence hindering a robust evaluation of cutting fluid performance, if the data evaluation is based on surface finish only. Measurements of hole geometry provide documentation to recognize systematic error distorting the performance test....

Reproducibility of a reaming test

DEFF Research Database (Denmark)

Pilny, Lukas; Müller, Pavel; De Chiffre, Leonardo

2014-01-01

The reproducibility of a reaming test was analysed to document its applicability as a performance test for cutting fluids. Reaming tests were carried out on a drilling machine using HSS reamers. Workpiece material was an austenitic stainless steel, machined using 4.75 m•min−1 cutting speed and 0......). Process reproducibility was assessed as the ability of different operators to ensure a consistent rating of individual lubricants. Absolute average values as well as experimental standard deviations of the evaluation parameters were calculated, and uncertainty budgeting was performed. Results document...... a built–up edge occurrence hindering a robust evaluation of cutting fluid performance, if the data evaluation is based on surface finish only. Measurements of hole geometry provide documentation to recognise systematic error distorting the performance test....

Monitoring Method of Cutting Force by Using Additional Spindle Sensors

Science.gov (United States)

Sarhan, Ahmed Aly Diaa; Matsubara, Atsushi; Sugihara, Motoyuki; Saraie, Hidenori; Ibaraki, Soichi; Kakino, Yoshiaki

This paper describes a monitoring method of cutting forces for end milling process by using displacement sensors. Four eddy-current displacement sensors are installed on the spindle housing of a machining center so that they can detect the radial motion of the rotating spindle. Thermocouples are also attached to the spindle structure in order to examine the thermal effect in the displacement sensing. The change in the spindle stiffness due to the spindle temperature and the speed is investigated as well. Finally, the estimation performance of cutting forces using the spindle displacement sensors is experimentally investigated by machining tests on carbon steel in end milling operations under different cutting conditions. It is found that the monitoring errors are attributable to the thermal displacement of the spindle, the time lag of the sensing system, and the modeling error of the spindle stiffness. It is also shown that the root mean square errors between estimated and measured amplitudes of cutting forces are reduced to be less than 20N with proper selection of the linear stiffness.

A new device to test cutting efficiency of mechanical endodontic instruments

Science.gov (United States)

Rubini, Alessio Giansiracusa; Plotino, Gianluca; Al-Sudani, Dina; Grande, Nicola M.; Putorti, Ermanno; Sonnino, GianPaolo; Cotti, Elisabetta; Testarelli, Luca; Gambarini, Gianluca

2014-01-01

Background The purpose of the present study was to introduce a new device specifically designed to evaluate the cutting efficiency of mechanically driven endodontic instruments. Material/Methods Twenty new Reciproc R25 (VDW, Munich, Germany) files were used to be investigated in the new device developed to test the cutting ability of endodontic instruments. The device consists of a main frame to which a mobile plastic support for the hand-piece is connected and a stainless-steel block containing a Plexiglas block against which the cutting efficiency of the instruments was tested. The length of the block cut in 1 minute was measured in a computerized program with a precision of 0.1mm. The instruments were activated by using a torque-controlled motor (Silver Reciproc; VDW, Munich, Germany) in a reciprocating movement by the “Reciproc ALL” program (Group 1) and in counter-clockwise rotation at 300 rpm (Group 2). Mean and standard deviations of each group were calculated and data were statistically analyzed with a one-way ANOVA test (P0.05). Conclusions The cutting testing device evaluated in the present study was reliable and easy to use and may be effectively used to test cutting efficiency of both rotary and reciprocating mechanical endodontic instruments. PMID:24603777

Investigation of the Machining Stability of a Milling Machine with Hybrid Guideway Systems

Directory of Open Access Journals (Sweden)

Jui-Pin Hung

2016-03-01

Full Text Available This study was aimed to investigate the machining stability of a horizontal milling machine with hybrid guideway systems by finite element method. To this purpose, we first created finite element model of the milling machine with the introduction of the contact stiffness defined at the sliding and rolling interfaces, respectively. Also, the motorized built-in spindle model was created and implemented in the whole machine model. Results of finite element simulations reveal that linear guides with different preloads greatly affect the dynamic responses and machining stability of the horizontal milling machine. The critical cutting depth predicted at the vibration mode associated with the machine tool structure is about 10 mm and 25 mm in the X and Y direction, respectively, while the cutting depth predicted at the vibration mode associated with the spindle structure is about 6.0 mm. Also, the machining stability can be increased when the preload of linear roller guides of the feeding mechanism is changed from lower to higher amount.

Reducing the uncertainty in robotic machining by modal analysis

Science.gov (United States)

Alberdi, Iñigo; Pelegay, Jose Angel; Arrazola, Pedro Jose; Ørskov, Klaus Bonde

2017-10-01

The use of industrial robots for machining could lead to high cost and energy savings for the manufacturing industry. Machining robots offer several advantages respect to CNC machines such as flexibility, wide working space, adaptability and relatively low cost. However, there are some drawbacks that are preventing a widespread adoption of robotic solutions namely lower stiffness, vibration/chatter problems and lower accuracy and repeatability. Normally due to these issues conservative cutting parameters are chosen, resulting in a low material removal rate (MRR). In this article, an example of a modal analysis of a robot is presented. For that purpose the Tap-testing technology is introduced, which aims at maximizing productivity, reducing the uncertainty in the selection of cutting parameters and offering a stable process free from chatter vibrations.

Measuring Diagnostic Stand for Experimental Researches in Technology Machining

Directory of Open Access Journals (Sweden)

A. E. Dreval'

2014-01-01

Full Text Available The paper reviews applied techniques, methods, and structure of the control and measuring means to conduct experimental and scientific researches of cutting processes. Existing research methods in cutting the metals are divided by features, such as essence of methods, the number of records of physical indicators, the number of studied factors, duration of tests. The groups of methods are briefly characterized.The chair "Tool Engineering and Technologies" of BMSTU developed and made a diagnostic stand of control and measurements for conducting research activities in the field of materials processing technology by cutting to define rational technological decisions, when machining, and carry out an analysis of efficiency and economic feasibility of made decisions. The diagnostic stand contains modern the electronic equipment. Record of measuring parameters is made in real time with a possibility for visual representation of read results and mathematical and statistical processing of measurement results. The stand can be used in research laboratories of machine-building enterprises, laboratories of higher education institutions, and other scientific divisions.The paper presents a justification that the stand is reasonable to use for the following: completion and choice of rational cutting modes, workability assessment of new constructional materials, technical and operational characteristics of the processed surfaces, and operational properties of the cutting tools of various producers, choice of optimum geometrical parameters of the cutting tools and brands of the lubricant cooling technological means, as well as the energy consumption for the chosen machining process. The stand allows us to make an assessment of wear resistance and tribology-technical characteristics of tool materials, as well as an accuracy, rigidity, vibration stability of machines, both new and being in operation.

Application of laser cutting in shipbuilding factory. Improvement in cutting accuracy and drastic production capacity increase by night-time unmanned operation; Zosen kojo ni okeru laser setsudan no tekiyo. Setsudan seido kojo, yakan mujin unten de seisan noryoku ohaba up

Energy Technology Data Exchange (ETDEWEB)

NONE

1995-06-01

A shipbuilding factory which introduced the laser cutting machine is introduced. The laser cutting machine was selected to improve cutting accuracy, improve working environment, and achieve unmanned operation. In this factory, a thin plate with a plate thickness of approximately 10 mm is expected to be machined, and the cutting line consists of two plasma cutting machines, one laser cutting machine, and one gas cutting line and the NC rate is high (97 %). The laser cutting machine incorporates a CO2 laser oscillation machine with a maximum output of 3.5 kW. The following result was obtained as compared with the plasma cutting machine. The cutting accuracy was 0.5 mm or less of the calf margin and no upper edge did not melt down and the distortion was low. No dross adheres and the secondary treatment man-hour decreased. Since it was not necessary to replace an electrode by a new one, a continuous unmanned operation was enabled. The automatic power off function, etc. achieve safety measures against earthquake, etc. Neither fume nor noise was generated. Since the dust collector is not required, the initial cost is low and the running cost is inexpensive, namely 31 yen per meter (40 yen for the plasma cutting machine). 7 figs., 2 tabs.

Applied machining technology

CERN Document Server

Tschätsch, Heinz

2010-01-01

Machining and cutting technologies are still crucial for many manufacturing processes. This reference presents all important machining processes in a comprehensive and coherent way. It includes many examples of concrete calculations, problems and solutions.

Cutting NiTi with Femtosecond Laser

Directory of Open Access Journals (Sweden)

L. Quintino

2013-01-01

Full Text Available Superelastic shape memory alloys are difficult to machine by thermal processes due to the facility for Ti oxidation and by mechanical processes due to their superelastic behavior. In this study, femtosecond lasers were tested to analyze the potential for machining NiTi since femtosecond lasers allow nonthermal processing of materials by ablation. The effect of processing parameters on machining depth was studied, and material removal rates were computed. Surfaces produced were analyzed under SEM which shows a resolidified thin layer with minimal heat affected zones. However, for high cutting speeds, that is, for short interaction times, this layer was not observed. A depletion of Ni was seen which may be beneficial in biomedical applications since Ni is known to produce human tissue reactions in biophysical environments.

A Machine for Pulverizing and Sifting Gari Mash | Odigboh | Nigerian ...

African Journals Online (AJOL)

A prototype machine for pulverizing and sifting gari mash, designed as a companion to the gari frying machine developed by the authors, was built and tested. Driven by an electric motor, the prototype accepts lump3 of dewatered gari mash cuts them up into small pieces by a cake breaker and delivers the pieces by a belt ...

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.    

Philips high tension generator (x-ray machine) testing for baby ebm (electron beam machine) project

International Nuclear Information System (INIS)

Norman Awalludin; Leo Kwee Wah; Abu Bakar Mhd Ghazali

2005-01-01

This paper describes the test of the HT system (from X-ray machine) for usage of the mini EBM (Electron Beam Machine). It consists the procedures of the installation, the safety procedures when deals with HT, modification of the system for testing purpose and the technique/method for testing the HT system. As a result, the voltage for the HT system and the electron gun (filament) current can be measured. Based on the results, suitability of the machine for baby EBM could be confirmed. (Author)

PVD-Alumina Coatings on Cemented Carbide Cutting Tools: A Study About the Effect on Friction and Adhesion Mechanism

Directory of Open Access Journals (Sweden)

S.E. Cordes

2012-03-01

Full Text Available Crystalline PVD γ-alumina coatings are interesting for machining operations due to their outstanding characteristics, such as high hot hardness, high thermal stability and low tendency to adhesion. In the present work (Ti,AlN/γ-Al2O3-coatings are deposited on cemented carbide by means of MSIP. Objectives of this work are to study the effects of coating and cutting fluid regarding friction in tribological tests and to study the wear mechanisms and cutting performance of γ-Al2O3-based coated cemented carbide cutting tools in machining operations of austenitic stainless steels. Based on the remarkable properties of the coating system the performance of the cutting tools is increasing significantly.

Modeling of the integrity of machining surfaces: application to the case of 15-5 PH stainless steel finish turning

International Nuclear Information System (INIS)

Mondelin, A.

2012-01-01

During machining, extreme conditions of pressure, temperature and strain appear in the cutting zone. In this thermo-mechanical context, the link between the cutting conditions (cutting speed, lubrication, feed rate, wear, tool coating...) and the machining surface integrity represents a major scientific target. This PhD study is a part of a global project called MIFSU (Modeling of the Integrity and Fatigue resistance of Machining Surfaces) and it focuses on the finish turning of the 15-5PH (a martensitic stainless steel used for parts of helicopter rotor). Firstly, material behavior has been studied in order to provide data for machining simulations. Stress-free dilatometry tests were conducted to obtain the austenitization kinetics of 15-5PH steel for high heating rates (up to 11,000 degrees C/s). Then, parameters of Leblond metallurgical model have been calibrated. In addition, dynamic compression tests (de/dt ranging from 0.01 to 80/s and e ≥ 1) have been performed to calibrate a strain-rate dependent elasto-plasticity model (for high strains). These tests also helped to highlight the dynamic recrystallization phenomena and their influence on the flow stress of the material. Thus, recrystallization model has also been implemented.In parallel, a numerical model for the prediction of machined surface integrity has been constructed. This model is based on a methodology called 'hybrid' (developed during the PhD thesis of Frederic Valiorgue for the AISI 304L steel). The method consists in replacing tool and chip modeling by equivalent loadings (obtained experimentally). A calibration step of these loadings has been carried out using orthogonal cutting and friction tests (with sensitivity studies of machining forces, friction and heat partition coefficients to cutting parameters variations).Finally, numerical simulations predictions of microstructural changes (austenitization and dynamic recrystallization) and residual stresses have been successfully compared with

Si3N4 ceramic cutting tool sintered with CeO2 and Al2O3 additives with AlCrN coating

Directory of Open Access Journals (Sweden)

José Vitor Candido Souza

2011-12-01

Full Text Available Ceramic cutting tools are showing a growing market perspective in terms of application on machining operations due to their high hardness, wear resistance, and machining without a cutting fluid, therefore are good candidates for cast iron and Nickel superalloys machining. The objective of the present paper was the development of Si3N4 based ceramic cutting insert, characterization of its physical and mechanical properties, and subsequent coating with AlCrN using a PVD method. The characterization of the coating was made using an optical profiler, XRD, AFM and microhardness tester. The results showed that the tool presented a fracture toughness of 6.43 MPa.m½ and hardness of 16 GPa. The hardness reached 31 GPa after coating. The machining tests showed a decrease on workpiece roughness when machining with coated insert, in comparison with the uncoated cutting tool. Probably this fact is related to hardness, roughness and topography of AlCrN.

Wear mechanism of CBN cutting tool during high-speed machining of mold steel

International Nuclear Information System (INIS)

Farhat, Z.N.

2003-01-01

Wear behavior of cubic boron nitride (CBN) cutting tool when cutting P20 tool steel was investigated. Oblique cutting tests were performed on a CNC lathe using five speeds, namely, 240, 600 and 1000 m min -1 . The CBN cutting tools were found to be superior to tungsten carbide (WC) tools. Fourfold increase in productivity and significant reduction in chipping and cratering was achieved for CBN as compared to WC. Wear, as the width of the wear land (VB), was monitored at selected time intervals; furthermore, topography of worn surfaces was performed, using a profilometer. Wear characterization of the rake and the flank surfaces as well as of the collected chips was conducted using a scanning electron microscopy (SEM), backscattered electron imaging and energy depressive X-ray (EDX). It was found that deformation in the chips occurs by localized shear deformation and the dominant wear mechanism at all speeds used was identified to be diffusive wear. At a 1000 m min -1 cutting speed, a secondary wear mechanism was identified, which is melt wear, i.e., formation of low melting point Cr and Mn compounds with the tool material and the subsequent ejection from the cutting zone

Efficacy of Nanocutting Fluids in Machining-an Experimental Investigation

Directory of Open Access Journals (Sweden)

Vamsi Krishna Pasam

2018-01-01

Full Text Available This paper presents the experimental investigations on the performance of eco-friendly vegetable oil based nanofluids in turning operation. In order to assess the quality of nano cutting fluids used during machining, cutting temperatures, cutting forces, tool wear and surface roughness under constant cutting conditions are measured. The influence of two types of nanofluids prepared from nano boric acid (NBA and carbon nanotubes (CNT mixed separately with coconut oil (CC, on machining performance during turning operation is examined. Comparative analysis of the results obtained is done under dry, soluble oil (SL and lubricant environments at constant cutting conditions and 0.25% nano particle inclusions (NPI. To understand the influence of NPI experiments were conducted using CCNBA and CCCNT at varying NPI as well. Results obtained using cutting fluids prepared from vegetable oil based nanofluids are encouraging and more pronouncing by the application of CCCNT at machining zone. The extent of improvement in reduction of cutting temperatures, main cutting force, tool wear and surface roughness is tracked to be 13%, 37.5%, 44% and 40% respectively by the application of CCCNT compared to dry machining. It was found that application of CCNBA and CCCNT at 0.5% NPI is more effective in improving the machining performance.

The effects of cutting parameters on cutting forces and heat generation when drilling animal bone and biomechanical test materials.

Science.gov (United States)

Cseke, Akos; Heinemann, Robert

2018-01-01

The research presented in this paper investigated the effects of spindle speed and feed rate on the resultant cutting forces (thrust force and torque) and temperatures while drilling SawBones ® biomechanical test materials and cadaveric cortical bone (bovine and porcine femur) specimens. It also investigated cortical bone anisotropy on the cutting forces, when drilling in axial and radial directions. The cutting forces are only affected by the feed rate, whereas the cutting temperature in contrast is affected by both spindle speed and feed rate. The temperature distribution indicates friction as the primary heat source, which is caused by the rubbing of the tool margins and the already cut chips over the borehole wall. Cutting forces were considerably higher when drilling animal cortical bone, in comparison to cortical test material. Drilling direction, and therewith anisotropy, appears to have a negligible effect on the cutting forces. The results suggest that this can be attributed to the osteons being cut at an angle rather than in purely axial or radial direction, as a result of a twist drill's point angle. Copyright © 2017 IPEM. Published by Elsevier Ltd. All rights reserved.

Experimental Research and Mathematical Modeling of Parameters Effecting on Cutting Force and SurfaceRoughness in CNC Turning Process

Science.gov (United States)

Zeqiri, F.; Alkan, M.; Kaya, B.; Toros, S.

2018-01-01

In this paper, the effects of cutting parameters on cutting forces and surface roughness based on Taguchi experimental design method are determined. Taguchi L9 orthogonal array is used to investigate the effects of machining parameters. Optimal cutting conditions are determined using the signal/noise (S/N) ratio which is calculated by average surface roughness and cutting force. Using results of analysis, effects of parameters on both average surface roughness and cutting forces are calculated on Minitab 17 using ANOVA method. The material that was investigated is Inconel 625 steel for two cases with heat treatment and without heat treatment. The predicted and calculated values with measurement are very close to each other. Confirmation test of results showed that the Taguchi method was very successful in the optimization of machining parameters for maximum surface roughness and cutting forces in the CNC turning process.

Performance of 3KW laser in cutting industry. Yodan gyokai ni okeru 3KW reza no koyo

Energy Technology Data Exchange (ETDEWEB)

Kita, H.; Miyaji, T.

1993-11-01

Recently, as the CO2 laser oscillator requires bigger power output, steel plates to be cut with a laser cutting machine have become thick plates with thickness of 12mm or more and the size of the plate which can be cut has become from the standard size of 4 inch by 8 inch or 5 inch by 10 inch to a big size of more than several meters because of introduction of the gantry type. In this article, the CO2 laser cutting machine introduced to Komatsu Shearing Co. and its operating conditions are introduced and the trends of powerful laser cutting machines in the cutting industry in the future are predicted. Laser cutting makes high cutting quality, but its device and running costs becomes high. For adopting a laser cutting machine, such items have been individually examined that no bitter work is involved in cutting, no skill is needed, no strain is formed during the press work in the succeeding process and the yield is high (95%), and a Komatsu laser cutting machine has been introduced. As a result, it has been found that the machine can produce a product of higher quality than shearing. Hereafter, this machine will further be used for manufacturing parts of construction machines, etc. for which high accuracy and high quality are demanded. 7 figs., 8 tabs.

Setup and maintenance of manufacturing quality in CO2 laser cutting

OpenAIRE

Thombansen, U.; Hermanns, T.; Stoyanov, S.

2014-01-01

Manufacturing of parts by laser cutting is widely accepted in industry. In the market there are systems which are highly focused on special applications such as robot based 3D cutting in the automotive industry but also all-round machines which cut a diverse set of sheet steels at a variety of thicknesses. Most of these machines use a melt based cutting process where the molten material is ejected by an assist gas. Quality of the laser cut part is determined by a dross free cut with minimal r...

An innovative apparatus provided with a cutting auger for producing short logs for biomass energy from fast-growing tree species

Energy Technology Data Exchange (ETDEWEB)

Colorio, G.; Tomasone, R.; Cedrola, C.; Pagano, M.; Pochi, D.; Fanigliulo, R.; Sperandio, G. [Council for Research in Agriculture, Agricultural Engineering Research Unit, Rome (Italy)

2010-07-01

This paper reported on a new cutting mechanism that cuts fresh wood into small pieces instead of wood chips in order to avoid the problem of fermentation that occurs in storage. The prototype cutting device performs a gradual and oblique cut. It consists of a large auger in which a knife is inserted on the outer edge of the helicoid. Tree trunks up to 20 cm in diameter are fed perpendicularly into the machine and are pushed along the axis where slices are cut off against a fixed sharp-edged counter blade. The cylinder enclosing the auger is the main frame of the machine, and is closed at one end, where a heavy flywheel delivers the energy coming from the tractor's power take-off (PTO). The wood pieces ranging in length from 4 to 19 cm exit through the opposite end. The auger is 700 mm in diameter with a 300 mm pitch spacing. The logs are pushed into the machine by counter-rotating rollers placed in the feed funnel. Tests were conducted to determine the operative performance and power requirements of the machine. The cutting method requires less power compared to wood chipping machines. Work capacity is greater when producing slices instead of chips and the system produces less noise and fewer vibrations. The auger reaches a constant velocity of 200 RPM and can easily cut fresh wood of different species.

A Study of Resin as Master Jewellery Material, Surface Quality and Machining Time Improvement by Implementing Appropriate Cutting Strategy

Directory of Open Access Journals (Sweden)

Puspaputra Paryana

2017-01-01

Full Text Available This paper deals with a research about art and jewellery product machining that focused in the selection of appropriate material for jewellery master which is machined by CNC. CNC is used for better surface finish for no undercut design and more complex ornament. The need of production speed requires minimum process without reducing the quality of detail ornament significantly. Problems occur when high surface quality is required. In that condition high speed spindle is used with low feeding speed, as a result is high temperature in cutter-material area will melt the resin and build the build-up edge (BUE. Due to the existence of BUE, the cutting tool will no longer cut the resin, as a result the resin will then melt due to friction and the melt resin will then stuck on the relief and surface finish become worst and rework should be done. When required surface is achieved problem also occur in next going process, that is silicon mould making. Due to galvanization process for silicon at about 170°C, resin material may be broken or cracked. Research is then conducted to select appropriate resin type suitable for all production steps.

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

Melt Flow and Energy Limitation of Laser Cutting

Directory of Open Access Journals (Sweden)

Pavel Hudeček

2016-01-01

Full Text Available Laser technology is a convertible technology for plenty of parts in most materials. Laser material processing for industrial manufacturing applications is today a widespread procedure for welding, cutting, marking and micro machining of metal and plastic parts and components. Involvement and support this huge mass-production industry of laser cutting, new technology and dry-process using lasers were and are being actively developed. Fundamentally, industrial laser cutting or other applications on industry should satisfy the four key practical application issues including “Quality or Performance”, “Throughput or Speed”, “Cost or Total Ownership Cost”, and “Reliability”. Laser requires for examples several complicated physical factors to be resolved including die strength to be enable good wire-bonding and survival of severe cycling test, clean cutting wall surface, good cutting of direct attach film, and proper speed of cutting for achieving economy of throughput. Some example of maximum cutting rate, wherewith is normally limited laser energy, cutting speed is depend on type laser, different of cutting with one laser beam and beam pattern and applied laser power/material thickness will be introduced in this paper.

6kW class laser cutting equipment; 6kW daishutsuryoku laser setsudanki ni yoru atsuita setsudan

Energy Technology Data Exchange (ETDEWEB)

Nagata, Y.; Nagahori, M. [Tanaka Engineering Works Ltd., Saitama (Japan)

1994-11-01

Application of the laser cutting machine to the area of cutting steel plates of 5 mm thick or more was first enabled in 1990 by the 2 kW oscillator that was introduced in that year. The thick plate cutting industry has a short history. This paper describes the features and performance of the 6 kW laser cutting machine that was announced in April, 1994. The machine uses a newly developed high-speed axial flow type carbon dioxide laser oscillater with the rated output of 6 kW. As the discharge excitation method, the machine adopted the RF (radio frequency) method that causes low contamination in the discharge tube. The 6 kW laser cutting machine has a number of features such as a large cutting area provided by the oscillator contained in the cutting machine, cutting quality stabilized by the optical path length fixing unit, and automatic functions such as automatic setting of the cutting conditions and scheduled operation. The machine can cut mild steel plates of up to 40 mm thick (or up to 16 mm for stainless steel plates) at the cutting speed of 1600 mm/min for a 16 mm thick plate and 2200 mm/min for a 12 mm thick plate, with the good cut sectional surface. 5 figs., 1 tab.

The improvement of dynamic universal testing machine for hot cell usages

International Nuclear Information System (INIS)

Ahn, Sang Bok; Lee, Key Soon; Park, Dae Kyu; Hong, Kwon Pyo; Choo, Yong Sun

1998-01-01

Dynamic universal testing machine(UTM) were developed for hot cell usages, which can perform tensile, compression, bending, fracture toughness and fatigue crack growth tests. In this report, technical reviews in the course of developing machine were described. Detailed subjects are as follows; 1. Outline of testing method using dynamic UTM 2. Detailed testing system organizations 3. Technical specification to develop machine 4. Setting up load string 5. Inspection and pre-commissioning tests on machine. (author). 14 figs

The Effects of Operational Parameters on a Mono-wire Cutting System: Efficiency in Marble Processing

Science.gov (United States)

Yilmazkaya, Emre; Ozcelik, Yilmaz

2016-02-01

Mono-wire block cutting machines that cut with a diamond wire can be used for squaring natural stone blocks and the slab-cutting process. The efficient use of these machines reduces operating costs by ensuring less diamond wire wear and longer wire life at high speeds. The high investment costs of these machines will lead to their efficient use and reduce production costs by increasing plant efficiency. Therefore, there is a need to investigate the cutting performance parameters of mono-wire cutting machines in terms of rock properties and operating parameters. This study aims to investigate the effects of the wire rotational speed (peripheral speed) and wire descending speed (cutting speed), which are the operating parameters of a mono-wire cutting machine, on unit wear and unit energy, which are the performance parameters in mono-wire cutting. By using the obtained results, cuttability charts for each natural stone were created on the basis of unit wear and unit energy values, cutting optimizations were performed, and the relationships between some physical and mechanical properties of rocks and the optimum cutting parameters obtained as a result of the optimization were investigated.

Machine tool structures

CERN Document Server

Koenigsberger, F

1970-01-01

Machine Tool Structures, Volume 1 deals with fundamental theories and calculation methods for machine tool structures. Experimental investigations into stiffness are discussed, along with the application of the results to the design of machine tool structures. Topics covered range from static and dynamic stiffness to chatter in metal cutting, stability in machine tools, and deformations of machine tool structures. This volume is divided into three sections and opens with a discussion on stiffness specifications and the effect of stiffness on the behavior of the machine under forced vibration c

Making the cut for the contour method

OpenAIRE

Bouchard, P. John; Ledgard, Peter; Hiller, Stan; Hosseinzadh Torknezhad, Foroogh

2012-01-01

The contour method is becoming an increasingly popular measurement technique for mapping residual stress in engineering components. The accuracy of the technique is critically dependent on the quality of the cut performed. This paper presents results from blind cutting trials on austenitic stainless steel using electro-discharge machines made by three manufacturers. The suitability of the machines is assessed based on the surface finish achieved, risk of wire breakages and the nature of cutti...

Understanding and Writing G & M Code for CNC Machines

Science.gov (United States)

Loveland, Thomas

2012-01-01

In modern CAD and CAM manufacturing companies, engineers design parts for machines and consumable goods. Many of these parts are cut on CNC machines. Whether using a CNC lathe, milling machine, or router, the ideas and designs of engineers must be translated into a machine-readable form called G & M Code that can be used to cut parts to precise…

Simulation of rock fragmentation induced by a tunnel boring machine disk cutter

Directory of Open Access Journals (Sweden)

Huiyun Li

2016-05-01

Full Text Available A constitutive model based on the Johnson–Cook material model and the extended Drucker–Prager strength criterion was implemented in LS-DYNA to simulate the rock failure process induced by a single disk cutter of a tunnel boring machine. The normal, rolling, and side forces were determined by numerical tests. The simulation results showed that the normal and rolling forces increased with increasing penetration while the side force changed little. The normal force also increased under the conditions of confining pressures. The damage region of rock and cutting forces were also obtained by simulation of two disk cutters acting in tandem with different cutting spacings. The optimum ratio of cutter spacing to penetration depth determined from numerical modeling agrees well with that obtained by linear cutting machine tests. The average normal and rolling forces acting on the first cutter are slightly greater than those acting on the second when the cutting disk spacing is relatively small. The numerical modeling was verified to accurately capture the fragmentation of rock induced by disk cutter.

Desain dan Implementasi Sistem Kendali CNC Router Menggunakan PC untuk Flame Cutting Machine

Directory of Open Access Journals (Sweden)

Roni Permana Saputra

2012-03-01

Full Text Available This paper focuses on design of router control systems based on computer numerical control (CNC using personal computer (PC implemented in flame cutting machine (FCM. NC-Code entered into the computer translated to be a command signal sent by the PC to a microcontroller to control the end effector’s movement alongthe X and Y axis simultaneously based on linear and circular interpolations calculation on the PC. This control system is implemented on FCM by connecting the output control of the microcontroller with the driver actuator of the FCM in the form of a DC motor. The obtained result is in the form of a CNC router control system prototype to be implemented in the FCM which is capable to perform linear interpolation and circular interpolation. 

Shearer drums - the cutting edge

Energy Technology Data Exchange (ETDEWEB)

O' Neill, M.; Wright, C.

2004-09-15

The paper discusses continuous miner and shearer cutters. It claims cutting drum require the same level of engineering know-how and technical expertise as do the machines driving them, and that the cutting drum, whether on a longwall shearer or continuous miner, comprises, the steel, pedestals, bit holders and the bits.

Basic analysis of weldability and machinability of structural materials for ITER Toroidal Field coils

Energy Technology Data Exchange (ETDEWEB)

Onozuka, Masanori [Mitsubishi Heavy Industries Ltd., Konan 2-16-5, Minato-ku, Tokyo 108-8215 (Japan)], E-mail: masanori_onozuka@mnes-us.com; Shimizu, Katsusuke; Urata, Kazuhiro; Kimura, Masahiro; Kadowaki, Hirokazu; Okamoto, Mamoru [Mitsubishi Heavy Industries Ltd., Konan 2-16-5, Minato-ku, Tokyo 108-8215 (Japan); Nakajima, Hideo; Hamada, Kazuya; Okuno, Kiyoshi [Japan Atomic Energy Agency, Mukouyama 801-1, Naka-shi, Ibaraki 311-0193 (Japan)

2007-10-15

A manufacturing study has been conducted to examine the welding and machining capabilities for strengthened austenitic stainless steels with a high nitrogen content, JJ1 and ST-SS316LN, to be employed for ITER Toroidal Field (TF) coil structural components. It was found that the applicable EB welding condition for JJ1 was limited to up to 40 mm thick plates. A wider range of welding conditions was found in the vertical upward direction. Based on those results, a verification test up to 900 mm in length was successfully conducted. With respect to TIG welding, an average deposition rate of 26 g/min (i.e. the filler wire supplying speed of 3000 mm/min) was achieved. In addition to the welding tests, a series of machining tests has been conducted to examine the machinability of JJ1 and ST-SS316LN. Various types of machining tools were examined. In practical application, the cutting speed should be low to extend the tool life. At a cutting speed of 40 m/min, a tool life of more than 2 h (at a traveling distance of up to 9 m) was attained. The degree of cutter wear after 30 min of operation, at a cutting speed of 40 m/min, was found to be around 0.1 mm, which is within an acceptable range.

Determination of the cutting forces regression functions for milling machining of the X105CrMo17 material

Science.gov (United States)

Popovici, T. D.; Dijmărescu, M. R.

2017-08-01

The aim of the research presented in this paper is to determine a cutting force prediction model for milling machining of the X105CrMo17 stainless steel. The analysed material is a martensitic stainless steel which, due to the high Carbon content (∼1%) and Chromium (∼17%), has high hardness and good corrosion resistance characteristics. This material is used for the steel structures parts which are subject of wear in corrosive environments, for making valve seats, bearings, various types of cutters, high hardness bushings, casting shells and nozzles, measuring instruments, etc. The paper is structured into three main parts in accordance to the considered research program; they are preceded by an introduction and followed by relevant conclusions. In the first part, for a more detailed knowledge of the material characteristics, a quality and quantity micro-analysis X-ray and a spectral analysis were performed. The second part presents the physical experiment in terms of input, necessary means, process and registration of the experimental data. In the third part, the experimental data is analysed and the cutting force model is developed in terms of the cutting regime parameters such as cutting speed, feed rate, axial depth and radial depth.

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.

29 CFR 1910.254 - Arc welding and cutting.

Science.gov (United States)

2010-07-01

... 29 Labor 5 2010-07-01 2010-07-01 false Arc welding and cutting. 1910.254 Section 1910.254 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.254 Arc welding and cutting. (a... following limits shall not be exceeded: (i) Alternating-current machines (A) Manual arc welding and cutting...

High-precision micro/nano-scale machining system

Science.gov (United States)

Kapoor, Shiv G.; Bourne, Keith Allen; DeVor, Richard E.

2014-08-19

A high precision micro/nanoscale machining system. A multi-axis movement machine provides relative movement along multiple axes between a workpiece and a tool holder. A cutting tool is disposed on a flexible cantilever held by the tool holder, the tool holder being movable to provide at least two of the axes to set the angle and distance of the cutting tool relative to the workpiece. A feedback control system uses measurement of deflection of the cantilever during cutting to maintain a desired cantilever deflection and hence a desired load on the cutting tool.

Dynamic testing of adhesive joints using a shock testing machine

NARCIS (Netherlands)

Aanhold, J.E. van; Weersink, A.F.J.; Ludolphy, J.W.L.

1998-01-01

A light-weight shock testing machine, designed for type approval testing of naval equipment up to 300 kg mass, has been modified into a dynamic tensile test rig. This enables to test structural details for high rate dynamic tensile loadings such as occur during underwater shock. The maximum capacity

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.

Testing and Modeling of Mechanical Characteristics of Resistance Welding Machines

DEFF Research Database (Denmark)

Wu, Pei; Zhang, Wenqi; Bay, Niels

2003-01-01

for both upper and lower electrode systems. This has laid a foundation for modeling the welding process and selecting the welding parameters considering the machine factors. The method is straightforward and easy to be applied in industry since the whole procedure is based on tests with no requirements......The dynamic mechanical response of resistance welding machine is very important to the weld quality in resistance welding especially in projection welding when collapse or deformation of work piece occurs. It is mainly governed by the mechanical parameters of machine. In this paper, a mathematical...... model for characterizing the dynamic mechanical responses of machine and a special test set-up called breaking test set-up are developed. Based on the model and the test results, the mechanical parameters of machine are determined, including the equivalent mass, damping coefficient, and stiffness...

“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

A Study on Mechanical behavior of Tensile Specimen Fabricated by Laser Cutting

Energy Technology Data Exchange (ETDEWEB)

Jin, Y. G.; Kim, G. S.; Baik, S. J.; Baek, S. Y. [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

2016-10-15

The mechanical testing data are required for the assessment of dry storage of the spent nuclear fuel. Laser cutting system could be useful tools for material processing such as cutting in radioactive environment due to non-contact nature, ease in handling and the laser cutting process is most advantageous, offering the narrow kerf width and heat affected zone by using small beam spot diameter. The feasibility of the laser cutting system was demonstrated for the fabrication of various types of the unirradiated cladding with and without oxide layer on the specimens. In the present study, the dimensional measurement and tensile test were conducted to investigate the mechanical behavior of the axial tensile test specimens depending on the material processing methods in a hot cell at IMEF (Irradiated Materials Examination Facility) of KAERI. Laser cutting system was used to fabricate the tensile test specimens, and the mechanical behavior was investigated using the dimensional measurement and tensile test. It was shown that the laser beam machining could be a useful tool to fabricate the specimens and this technique will be developed for the fabrication of various types of irradiated specimens in a hotcell.

A Study on Mechanical behavior of Tensile Specimen Fabricated by Laser Cutting

International Nuclear Information System (INIS)

Jin, Y. G.; Kim, G. S.; Baik, S. J.; Baek, S. Y.

2016-01-01

The mechanical testing data are required for the assessment of dry storage of the spent nuclear fuel. Laser cutting system could be useful tools for material processing such as cutting in radioactive environment due to non-contact nature, ease in handling and the laser cutting process is most advantageous, offering the narrow kerf width and heat affected zone by using small beam spot diameter. The feasibility of the laser cutting system was demonstrated for the fabrication of various types of the unirradiated cladding with and without oxide layer on the specimens. In the present study, the dimensional measurement and tensile test were conducted to investigate the mechanical behavior of the axial tensile test specimens depending on the material processing methods in a hot cell at IMEF (Irradiated Materials Examination Facility) of KAERI. Laser cutting system was used to fabricate the tensile test specimens, and the mechanical behavior was investigated using the dimensional measurement and tensile test. It was shown that the laser beam machining could be a useful tool to fabricate the specimens and this technique will be developed for the fabrication of various types of irradiated specimens in a hotcell

State of the art of plasma cutting in the GDR

International Nuclear Information System (INIS)

Foerster, H.; Wiese, P.

1983-01-01

In the GDR plasma cutting equipment has been developed for the power range of 3 to 100 kW. Metallic materials can be cut by machine or by hand up to a thickness of 150 mm. The great cutting velocities are of advantage since they allow coupling with the most modern directing machines. Possibilities of reducing detrimental effects of light, noise, and toxic materials by protective measures are discussed on the basis of examples

Shroud cutting techniques and collection systems for secondary radioactivity release

International Nuclear Information System (INIS)

Yokoi, H.; Watanabe, A.; Uetake, N.; Shimura, T.; Omote, T.; Adachi, H.; Murakami, S.; Kobayashi, H.; Gotoh, M.

2001-01-01

Replacement of in-core shroud has been conducted as part of the preventive maintenance program in Tsuruga-1. The EDM (electric discharged machining) and plasma cutting methods were applied to in-core shroud cutting and secondary cutting in the DSP (dryer/separator pool), respectively. The cutting systems were improved in order to decrease radioactive secondary products. 1) Fundamental EDM cutting tests: fundamental EDM cutting tests were carried out in order to study secondary products. It could be presumed that volatile Co-carbonyl compound was generated by using a carbon electrode. The Ag/W electrode was effective as EDM electrode for in-core shroud cutting to prevent generation of Co-carbonyl compound and to decrease the total amount of secondary products. 2) In-core shroud cutting in RPV (reactor pressure vessel): EDM cutting system with the Ag/W electrode and collection system could keep a good environment during in-core shroud cutting in Tsuruga-1. Activity concentration was lower value than limitation of mask charge level, 4E-6 Bq/cm 3 , even near the water surface. 3) Secondary plasma cutting in DSP: the secondary cutting work was successful in the point of reduction of working period and radiation exposure. The amount of radiation exposure was reduced to 60% of the planned value, because of adequate decontamination of the working environment and reduction of number of torch maintenance tasks by improvements of the underwater cutting device

Methodes de compensation des erreurs d'usinage utilisant la mesure sur machines-outils

Science.gov (United States)

Guiassa, Rachid

On-machine measurement process is used to inspect the part immediately after the cut without part removal and additional setups. It detects the machining defects visible to the machine tool. The system machine-tool-part deflection and the cutting tool dimension inaccuracy are the most important sources of these defects. The machined part can be inspected, at the semi-finishing cut level to identify systematic defects that may occur later at the finishing cut. Therefore, corrective actions can be derived to anticipate the expected error in order to produce a part with acceptable accuracy. For industrial profitability, the measurement and the compensation tasks must be done under the closed door machining requirement without human interventions. This thesis aims to develop mathematical models that use the data inspection of previous cuts to formulate the compensation of the finishing-cut. The goal of the compensation is to anticipate the expected error which is identified under two components. One is independent on the depth of cut and is related to the cutting tool dimension such as the wear. The other is dependent on the cutting depth such as the deflection. A general model is presented which relies solely on-machine probing data from semi-finishing cuts to compensate the final cut. A variable cutting compliance coefficient relates the total system deflection to the depth of cut in multi-cut process. It is used to estimate the compensation of the tool path. The model is able to take into account the effect of the cutting depth variation and the material removal in the estimation of the error at the finishing-cut. In order to generate the continuous compensated tool path from discrete measurements, a B-Spline deformation technique is adapted to the available data and applied to compute the compensated tool path according to a restricted number of discrete compensation vectors. The results show that the on-machine probed errors can be significantly reduced using the

Laser cutting: influence on morphological and physicochemical properties of polyhydroxybutyrate.

Science.gov (United States)

Lootz, D; Behrend, D; Kramer, S; Freier, T; Haubold, A; Benkiesser, G; Schmitz, K P; Becher, B

2001-09-01

Polyhydroxybutyrate (PHB) is a biocompatible and resorbable implant material. For these reasons, it has been used for the fabrication of temporary stents, bone plates, nails and screws (Peng et al. Biomaterials 1996;17:685). In some cases, the brittle mechanical properties of PHB homopolymer limit its application. A typical plasticizer, triethylcitrate (TEC), was used to overcome such limitations by making the material more pliable. In the past few years, CO2-laser cutting of PHB was used in the manufacturing of small medical devices such as stents. Embrittlement of plasticized PHB tubes has been observed, after laser machining. Consequently, the physicochemical and morphological properties of laser-processed surfaces and cut edges of plasticized polymer samples were examined to determine the extent of changes in polymer properties as a result of laser machining. These studies included determination of the depth of the laser-induced heat affected zone by polariscopy of thin polymer sections. Molecular weight changes and changes in the TEC content as a function of distance from the laser-cut edge were determined. In a preliminary test, the cellular response to the processed material was investigated by cell culture study of L929 mouse fibroblasts on laser-machined surfaces. The heat-affected zone was readily classified into four different regions with a total depth of about 60 to 100 microm (Klamp, Master Thesis, University of Rostock, 1998). These results correspond well with the chemical analysis and molecular weight measurements. Furthermore, it was found that cells grew preferentially on the laser-machined area. These findings have significant implications for the manufacture of medical implants from PHB by laser machining.

Thermocouple and infrared sensor-based measurement of temperature distribution in metal cutting.

Science.gov (United States)

Kus, Abdil; Isik, Yahya; Cakir, M Cemal; Coşkun, Salih; Özdemir, Kadir

2015-01-12

In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR) pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining.

Engineered Surface Properties of Porous Tungsten from Cryogenic Machining

Science.gov (United States)

Schoop, Julius Malte

Porous tungsten is used to manufacture dispenser cathodes due to it refractory properties. Surface porosity is critical to functional performance of dispenser cathodes because it allows for an impregnated ceramic compound to migrate to the emitting surface, lowering its work function. Likewise, surface roughness is important because it is necessary to ensure uniform wetting of the molten impregnate during high temperature service. Current industry practice to achieve surface roughness and surface porosity requirements involves the use of a plastic infiltrant during machining. After machining, the infiltrant is baked and the cathode pellet is impregnated. In this context, cryogenic machining is investigated as a substitutionary process for the current plastic infiltration process. Along with significant reductions in cycle time and resource use, surface quality of cryogenically machined un-infiltrated (as-sintered) porous tungsten has been shown to significantly outperform dry machining. The present study is focused on examining the relationship between machining parameters and cooling condition on the as-machined surface integrity of porous tungsten. The effects of cryogenic pre-cooling, rake angle, cutting speed, depth of cut and feed are all taken into consideration with respect to machining-induced surface morphology. Cermet and Polycrystalline diamond (PCD) cutting tools are used to develop high performance cryogenic machining of porous tungsten. Dry and pre-heated machining were investigated as a means to allow for ductile mode machining, yet severe tool-wear and undesirable smearing limited the feasibility of these approaches. By using modified PCD cutting tools, high speed machining of porous tungsten at cutting speeds up to 400 m/min is achieved for the first time. Beyond a critical speed, brittle fracture and built-up edge are eliminated as the result of a brittle to ductile transition. A model of critical chip thickness ( hc ) effects based on cutting

The Knife Machine. Module 15.

Science.gov (United States)

South Carolina State Dept. of Education, Columbia. Office of Vocational Education.

This module on the knife machine, one in a series dealing with industrial sewing machines, their attachments, and operation, covers one topic: performing special operations on the knife machine (a single needle or multi-needle machine which sews and cuts at the same time). These components are provided: an introduction, directions, an objective,…

Performance Analysis of Abrasive Waterjet Machining Process at Low Pressure

Science.gov (United States)

Murugan, M.; Gebremariam, MA; Hamedon, Z.; Azhari, A.

2018-03-01

Normally, a commercial waterjet cutting machine can generate water pressure up to 600 MPa. This range of pressure is used to machine a wide variety of materials. Hence, the price of waterjet cutting machine is expensive. Therefore, there is a need to develop a low cost waterjet machine in order to make the technology more accessible for the masses. Due to its low cost, such machines may only be able to generate water pressure at a much reduced rate. The present study attempts to investigate the performance of abrasive water jet machining process at low cutting pressure using self-developed low cost waterjet machine. It aims to study the feasibility of machining various materials at low pressure which later can aid in further development of an effective low cost water jet machine. A total of three different materials were machined at a low pressure of 34 MPa. The materials are mild steel, aluminium alloy 6061 and plastics Delrin®. Furthermore, a traverse rate was varied between 1 to 3 mm/min. The study on cutting performance at low pressure for different materials was conducted in terms of depth penetration, kerf taper ratio and surface roughness. It was found that all samples were able to be machined at low cutting pressure with varied qualities. Also, the depth of penetration decreases with an increase in the traverse rate. Meanwhile, the surface roughness and kerf taper ratio increase with an increase in the traverse rate. It can be concluded that a low cost waterjet machine with a much reduced rate of water pressure can be successfully used for machining certain materials with acceptable qualities.

Finite element analysis when orthogonal cutting of hybrid composite CFRP/Ti

International Nuclear Information System (INIS)

Xu, Jinyang; Mansori, Mohamed El

2015-01-01

Hybrid composite, especially CFRP/Ti stack, is usually considered as an innovative structural configuration for manufacturing the key load-bearing components in modern aerospace industry. This paper originally proposed an FE model to simulate the total chip formation process dominated the hybrid cutting operation. The hybrid composite model was established based on three physical constituents, i.e., Ti constituent, interface and CFRP constituent. Different constitutive models and damage criteria were introduced to replicate the interrelated cutting behaviour of the stack material. The CFRP/Ti interface was modelled as a third phase through the concept of cohesive zone (CZ). Particular attention was made on the comparative studies of the influence of different cutting-sequence strategies on the machining responses induced in hybrid stack cutting. The numerical results emphasized the pivotal role of cutting-sequence strategy on the various machining induced responses including cutting-force generation, machined surface quality and induced interface damage. (paper)

Generation Mechanism of Work Hardened Surface Layer in Metal Cutting

Science.gov (United States)

Hikiji, Rikio; Kondo, Eiji; Kawagoishi, Norio; Arai, Minoru

Finish machining used to be carried out in grinding, but it is being replaced by cutting with very small undeformed chip thickness. In ultra precision process, the effects of the cutting conditions and the complicated factors on the machined surface integrity are the serious problems. In this research, work hardened surface layer was dealt with as an evaluation of the machined surface integrity and the effect of the mechanical factors on work hardening was investigated experimentally in orthogonal cutting. As a result, it was found that work hardened surface layer was affected not only by the shear angle varied under the cutting conditions and the thrust force of cutting resistance, but also by the thrust force acting point, the coefficient of the thrust force and the compressive stress equivalent to the bulk hardness. Furthermore, these mechanical factors acting on the depth of the work hardened surface layer were investigated with the calculation model.

Influence of edge radius of sintered-carbide tip on roughness of machined surface

Directory of Open Access Journals (Sweden)

Jiří Votava

2013-01-01

Full Text Available Increasing of cutting speed and thus increasing labour productivity is observed as a current trend in engineering production. This effort results to development of new cutting materials which are more capable to resist increased requirements on machined surface as well as operating life of the instrument. Nowadays, the most widely used materials used for cutting instruments are sintered carbides which are alloyed by other metals. The goal of this paper is to analyse change in quality of machined surface depending on the change of cutting conditions. For cutting operation, there were used a milling cutter high-speed steel 90 (HSS and removable sintered-carbide tips with different radius. Steel 12 050 hardened for 17 HRC was used as a machined material. Firstly, hardness of machined as well as machining materials was analysed. Further, metallographic analysis and measurement of microhardness of the individual structure phases was processed. Cutting conditions of both instruments were selected depending on the machined material. Surface roughness indicates the quality of machined surface.

Evaluation influence of machining parameters on shape form errors in turning of machine parts clamped in the chuck with adaptive jaws

Directory of Open Access Journals (Sweden)

I.V. Lutsiv

2017-12-01

Full Text Available The paper deals with the derivation problem of the dependence of machine part geometric form deviation in cross section area on clamping diameter as well as cutting speed, feed and cutting depth in semi finish machining. The analysis of single factor circular deviation dependences on machining conditions values is performed. Using the special software application package the laboratory conditions experiment results are analyzed. The dispersion analysis including options for main linear and quadratic effects evaluation is given and the simplification model of experiment results is obtained. It presents the evaluation empiric dependence of cutting conditions and clamping diameter influence on shape error forming (dynamic error. It is found that to obtain the necessary form accuracy in machining with lathe chuck equipped with the adaptive clamping jaws it is desirable to control the most statistically significant factors that actually are the cutting depth and feed.

Candu 600 fuelling machine testing, the romanian experience

International Nuclear Information System (INIS)

Valeca, S.; Doca, C.; Iorga, C.

2013-01-01

The Candu 600 Fuelling Machine is a complex mechanism which must run in safety conditions and with high reliability in the Candu Reactor. The testing and commissioning process of this nuclear equipment meets the high standards of NPPs requirements using special technological facilities, modern measurement instruments as well the appropriate IT resources for data acquisition and processing. The paper presents the experience of the Institute for Nuclear Research Pitesti, Romania, in testing Candu 600 Fuelling Machines, inclusive the implied facilities, and in development of four simulators: two dedicated for the training of the Candu 600 Fuelling Machine Operators, and another two to simulate some process signals and actions. (authors)

Laser cutting or water-jet cutting. Laser setsudan ka water-jet setsudan ka

Energy Technology Data Exchange (ETDEWEB)

Yamada, T. (Shibuya Kogyo Co. Ltd., Ishikawa (Japan))

1991-05-01

The recent spread of carbon oxide laser cutter is so startlingly fast, but at the same time, water jet cutting using ultra high pressure water stream is drawing attention as it has identical characteristics, and opens the way to cutting materials that have been hitherto difficult to cut. The authors, who are fabricators of cutters of both types, gave the comparisons and explanations on several examples referring to materials that can be cut, cutting accuracy, speed, shape and thermal effects to cut face, and running cost in detail. However, simple comparison is difficult. For instance, cutting 6 mm thick SUS sheet costs a running cost of 65 yen per meter in laser cutting, and 535 yen per meter in water jet cutting, but this situation is often reversed when other material or sheet thickness is selected. The actual situation in the sheet metal processing industry at the present time is that it uses by far more laser processing machines, and uses water jet cutters to supplement for cutting materials more difficult to cut. 10 figs., 3 tabs.

Experimental Research Using of MQL in Metal Cutting

Directory of Open Access Journals (Sweden)

G. Globočki Lakić

2013-12-01

Full Text Available In this paper an effect of using of minimal quantity lubrication (MQL technique in turning operations is presented. Experimental research was performed on carbon steel C45E. Technological parameters: depth of cut, feed rate and cutting speed were adjusted to semi-machining and roughing. Higher values ​​of feed and cutting speed were used, than recommended from literature and different types of cooling and lubrication in turning conditions were applied. As a conventional procedure and technology, lubrication with flooding was applied. As special lubrication the MQL technique was used. During research, monitoring of the cutting force, chip shape, tool wear and surface roughness was performed. Relations between parameters, material machinability and economy of process were analyzed.

A Quality Function Deployment-Based Model for Cutting Fluid Selection

Directory of Open Access Journals (Sweden)

Kanika Prasad

2016-01-01

Full Text Available Cutting fluid is applied for numerous reasons while machining a workpiece, like increasing tool life, minimizing workpiece thermal deformation, enhancing surface finish, flushing away chips from cutting surface, and so on. Hence, choosing a proper cutting fluid for a specific machining application becomes important for enhanced efficiency and effectiveness of a manufacturing process. Cutting fluid selection is a complex procedure as the decision depends on many complicated interactions, including work material’s machinability, rigorousness of operation, cutting tool material, metallurgical, chemical, and human compatibility, reliability and stability of fluid, and cost. In this paper, a decision making model is developed based on quality function deployment technique with a view to respond to the complex character of cutting fluid selection problem and facilitate judicious selection of cutting fluid from a comprehensive list of available alternatives. In the first example, HD-CUTSOL is recognized as the most suitable cutting fluid for drilling holes in titanium alloy with tungsten carbide tool and in the second example, for performing honing operation on stainless steel alloy with cubic boron nitride tool, CF5 emerges out as the best honing fluid. Implementation of this model would result in cost reduction through decreased manpower requirement, enhanced workforce efficiency, and efficient information exploitation.

Mineral mining machines

Energy Technology Data Exchange (ETDEWEB)

Mc Gaw, B H

1984-01-01

A machine for mining minerals is patented. It is a cutter loader with a drum actuating element of the worm type equipped with a multitude of cutting teeth reinforced with tungsten carbide. A feature of the patented machine is that all of the cutting teeth and holders on the drum have the identical design. This is achieved through selecting a slant angle for the cutting teeth which is the mean between the slant angle of the conventional radial teeth and the slant angle of the advance teeth. This, in turn, is provided thanks to the corresponding slant of the holders relative to the drum and (or) the slant of the cutting part of the teeth relative to their stems. Thus, the advance teeth projecting beyond the surface of the drum on the face side and providing upper and lateral clearances have the same angle of attack as the radial teeth, that is, from 20 to 35 degrees. A series of modifications of the cutting teeth is patented. One of the designs allows the cutting tooth to occupy a varying position relative to the drum, from the conventional vertical to an inverted, axially projecting position. In the last case the tooth in the extraction process provides the upper and lateral clearances for the drum on the face side. Among the different modifications of the cutting teeth, a design is proposed which provides for the presence of a stem which is shaped like a truncated cone. This particular stem is designed for use jointly with a wedge which unfastens the teeth and is placed in a holder. The latter is completed in a transverse slot thanks to which the rear end of the stem is compressed, which simplifies replacement of a tooth. Channels are provided in the patented machine for feeding water to the worm spiral, the holders and the cutting teeth themselves in order to deal with dust.

Deformation of products cut on AWJ x-y tables and its suppression

Science.gov (United States)

Hlaváč, L. M.; Hlaváčová, I. M.; Plančár, Š.; Krenický, T.; Geryk, V.

2018-02-01

The aim of this study is namely investigation of the abrasive water jet (AWJ) cutting of column pieces on commercial x-y cutting machines with AWJ. The shape deformation in curved and/or stepped parts of cutting trajectories caused by both the trailback (declination angle) and the taper (inclination of cut walls) can be calculated from submitted analytical model. Some of the results were compared with data measured on samples cut on two types of commercial tables. The main motivation of this investigation is determination of the percentage difference between predicted and real distortion of cutting product, i.e. accuracy of prepared analytical model. Subsequently, the possibility of reduction of the distortion can be studied through implementation of the theoretical model into the control systems of the cutting machines with the system for cutting head tilting. Despite some limitations of the used AWJ machines the comparison of calculated dimensions with the real ones shows very good correlation of model and experimental data lying within the range of measurement uncertainty. Results on special device demonstrated that the shape deformation in curved parts of the cutting trajectory can be substantially reduced through tilting of the cutting head.

A FLEXIBLE APPROACH TO THE BENEFICIAL USE OF MACHINING POWER IN MILLING PROCESS

Directory of Open Access Journals (Sweden)

Faruk MENDİ

2000-01-01

Full Text Available In this study, a computer program has been developed to calculate the cutting speed (Vc and depth of cut (a under certain cutting condition which will be determined by the user for making maximum use of the various milling machines used presently. In the scope of the study, data related to the cutting speed (Vc and depth of cut (a of St 37 Steel and powers of the machine have been obtained. The aim is to make maximum use of the machines by choosing cutting speed (Vc and depth of cut (a with the help data. The effect of changes in cutting speed (Vc and depth of cut (a on productivity has been studied.

Philosophy, design and testing of a uniform applied load flat plate testing machine

International Nuclear Information System (INIS)

Quirk, A.; Crook, C.

1976-08-01

The presence of a central crack, and its associated plastic zones may significantly affect distribution of the stress applied by a loading machine, to a test plate. As a result the fracture stress may be affected, usually optimistically. Examples of these effects are discussed. The design of a machine in which the load is uniformly applied to the test specimen is described and preliminary test data presented. (author)

An Adaptive Genetic Association Test Using Double Kernel Machines.

Science.gov (United States)

Zhan, Xiang; Epstein, Michael P; Ghosh, Debashis

2015-10-01

Recently, gene set-based approaches have become very popular in gene expression profiling studies for assessing how genetic variants are related to disease outcomes. Since most genes are not differentially expressed, existing pathway tests considering all genes within a pathway suffer from considerable noise and power loss. Moreover, for a differentially expressed pathway, it is of interest to select important genes that drive the effect of the pathway. In this article, we propose an adaptive association test using double kernel machines (DKM), which can both select important genes within the pathway as well as test for the overall genetic pathway effect. This DKM procedure first uses the garrote kernel machines (GKM) test for the purposes of subset selection and then the least squares kernel machine (LSKM) test for testing the effect of the subset of genes. An appealing feature of the kernel machine framework is that it can provide a flexible and unified method for multi-dimensional modeling of the genetic pathway effect allowing for both parametric and nonparametric components. This DKM approach is illustrated with application to simulated data as well as to data from a neuroimaging genetics study.

1000–ton testing machine for cyclic fatigue tests of materials at liquid nitrogen temperatures

Energy Technology Data Exchange (ETDEWEB)

Khitruk, A. A.; Klimchenko, Yu. A.; Kovalchuk, O. A.; Marushin, E. L.; Mednikov, A. A.; Nasluzov, S. N.; Privalova, E. K.; Rodin, I. Yu.; Stepanov, D. B.; Sukhanova, M. V. [The D.V. Efremov Scientific Research Institute of Electrophysical Apparatus (NIIEFA), 3 Doroga na Metallostroy, Metallostroy, Saint Petersburg 196641 (Russian Federation)

2014-01-29

One of the main tasks of superconductive magnets R and D is to determine the mechanical and fatigue properties of structural materials and the critical design elements in the cryogenic temperature range. This paper describes a new facility built based on the industrial 1000-ton (10 MN) testing machine Schenk PC10.0S. Special equipment was developed to provide the mechanical and cyclic tensile fatigue tests of large-scale samples at the liquid nitrogen temperature and in a given load range. The main feature of the developed testing machine is the cryostat, in which the device converting a standard compression force of the testing machine to the tensile force affected at the test object is placed. The control system provides the remote control of the test and obtaining, processing and presentation of test data. As an example of the testing machine operation the test program and test results of the cyclic tensile fatigue tests of fullscale helium inlet sample of the PF1 coil ITER are presented.

1000–ton testing machine for cyclic fatigue tests of materials at liquid nitrogen temperatures

International Nuclear Information System (INIS)

Khitruk, A. A.; Klimchenko, Yu. A.; Kovalchuk, O. A.; Marushin, E. L.; Mednikov, A. A.; Nasluzov, S. N.; Privalova, E. K.; Rodin, I. Yu.; Stepanov, D. B.; Sukhanova, M. V.

2014-01-01

One of the main tasks of superconductive magnets R and D is to determine the mechanical and fatigue properties of structural materials and the critical design elements in the cryogenic temperature range. This paper describes a new facility built based on the industrial 1000-ton (10 MN) testing machine Schenk PC10.0S. Special equipment was developed to provide the mechanical and cyclic tensile fatigue tests of large-scale samples at the liquid nitrogen temperature and in a given load range. The main feature of the developed testing machine is the cryostat, in which the device converting a standard compression force of the testing machine to the tensile force affected at the test object is placed. The control system provides the remote control of the test and obtaining, processing and presentation of test data. As an example of the testing machine operation the test program and test results of the cyclic tensile fatigue tests of fullscale helium inlet sample of the PF1 coil ITER are presented

Influence of Cutting Temperature on the Tensile Strength of a Carbon Fiber-Reinforced Polymer

Directory of Open Access Journals (Sweden)

Jérémy Delahaigue

2017-12-01

Full Text Available Carbon fiber-reinforced plastics (CFRP have seen a significant increase in use over the years thanks to their specific properties. Despite continuous improvements in the production methods of laminated parts, a trimming operation is still necessary to achieve the functional dimensions required by engineering specifications. Laminates made of carbon fibers are very abrasive and cause rapid tool wear, and require high cutting temperatures. This creates damage to the epoxy matrix, whose glass-transition temperature is often recognized to be about 180 °C. This study aims to highlight the influence of the cutting temperature generated by tool wear on the surface finish and mechanical properties obtained from tensile tests. Trimming operations were performed on a quasi-isotropic 24-ply carbon/epoxy laminate, of 3.6 mm thickness, with a 6 flutes diamond-coated (CVD cutter. The test specimens of 6 mm and 12 mm wide were obtained by trimming. The reduced width of the coupons allowed amplification of the effect of defects on the measured properties by increasing the proportion of coupon cross-section occupied by the defects. A new tool and a tool in an advanced state of wear were used to generate different cutting temperatures. Results showed a cutting temperature of 300 °C for the new tool and 475 °C for the worn tool. The analysis revealed that the specimens machined with the new tool have no thermal damage and the cut is clean. The plies oriented at −45° presented the worst surface finish according to the failure mode of the fiber. For the worn tool, the surface was degraded and the matrix was carbonized. After cutting, observations showed a degraded resin spread on the machined surface, which reduced the surface roughness and hid the cutting defects. In support of these observations, the tensile tests showed no variation of the mechanical properties for the 12 mm-wide specimens, but did show a 10% loss in mechanical properties for the 6 mm

Laser cutting: industrial relevance, process optimization, and laser safety

Science.gov (United States)

Haferkamp, Heinz; Goede, Martin; von Busse, Alexander; Thuerk, Oliver

1998-09-01

Compared to other technological relevant laser machining processes, up to now laser cutting is the application most frequently used. With respect to the large amount of possible fields of application and the variety of different materials that can be machined, this technology has reached a stable position within the world market of material processing. Reachable machining quality for laser beam cutting is influenced by various laser and process parameters. Process integrated quality techniques have to be applied to ensure high-quality products and a cost effective use of the laser manufacturing plant. Therefore, rugged and versatile online process monitoring techniques at an affordable price would be desirable. Methods for the characterization of single plant components (e.g. laser source and optical path) have to be substituted by an omnivalent control system, capable of process data acquisition and analysis as well as the automatic adaptation of machining and laser parameters to changes in process and ambient conditions. At the Laser Zentrum Hannover eV, locally highly resolved thermographic measurements of the temperature distribution within the processing zone using cost effective measuring devices are performed. Characteristic values for cutting quality and plunge control as well as for the optimization of the surface roughness at the cutting edges can be deducted from the spatial distribution of the temperature field and the measured temperature gradients. Main influencing parameters on the temperature characteristic within the cutting zone are the laser beam intensity and pulse duration in pulse operation mode. For continuous operation mode, the temperature distribution is mainly determined by the laser output power related to the cutting velocity. With higher cutting velocities temperatures at the cutting front increase, reaching their maximum at the optimum cutting velocity. Here absorption of the incident laser radiation is drastically increased due to

Thermocouple and Infrared Sensor-Based Measurement of Temperature Distribution in Metal Cutting

Directory of Open Access Journals (Sweden)

Abdil Kus

2015-01-01

Full Text Available In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining.

Thermocouple and Infrared Sensor-Based Measurement of Temperature Distribution in Metal Cutting

Science.gov (United States)

Kus, Abdil; Isik, Yahya; Cakir, M. Cemal; Coşkun, Salih; Özdemir, Kadir

2015-01-01

In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR) pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining. PMID:25587976

Thermal and thermo-mechanical simulation of laser assisted machining

International Nuclear Information System (INIS)

Germain, G.; Dal Santo, P.; Lebrun, J. L.; Bellett, D.; Robert, P.

2007-01-01

Laser Assisted Machining (LAM) improves the machinability of materials by locally heating the workpiece just prior to cutting. The heat input is provided by a high power laser focused several millimeters in front of the cutting tool. Experimental investigations have confirmed that the cutting force can be decreased, by as much as 40%, for various materials (tool steel, titanium alloys and nickel alloys). The laser heat input is essentially superficial and results in non-uniform temperature profiles within the depth of the workpiece. The temperature field in the cutting zone is therefore influenced by many parameters. In order to understand the effect of the laser on chip formation and on the temperature fields in the different deformation zones, thermo-mechanical simulation were undertaken. A thermo-mechanical model for chip formation with and without the laser was also undertaken for different cutting parameters. Experimental tests for the orthogonal cutting of 42CrMo4 steel were used to validate the simulation via the prediction of the cutting force with and without the laser. The thermo-mechanical model then allowed us to highlight the differences in the temperature fields in the cutting zone with and without the laser. In particular, it was shown that for LAM the auto-heating of the material in the primary shear zone is less important and that the friction between the tool and chip also generates less heat. The temperature fields allow us to explain the reduction in the cutting force and the resulting residual stress fields in the workpiece

Laser Cutting of Carbon Fiber Fabrics

Science.gov (United States)

Fuchs, A. N.; Schoeberl, M.; Tremmer, J.; Zaeh, M. F.

Due to their high weight-specific mechanical stiffness and strength, parts made from carbon fiber reinforced polymers (CFRP) are increasingly used as structural components in the aircraft and automotive industry. However, the cutting of preforms, as with most automated manufacturing processes for CFRP components, has not yet been fully optimized. This paper discusses laser cutting, an alternative method to the mechanical cutting of preforms. Experiments with remote laser cutting and gas assisted laser cutting were carried out in order to identify achievable machining speeds. The advantages of the two different processes as well as their fitness for use in mass production are discussed.

Automated Laser Cutting In Three Dimensions

Science.gov (United States)

Bird, Lisa T.; Yvanovich, Mark A.; Angell, Terry R.; Bishop, Patricia J.; Dai, Weimin; Dobbs, Robert D.; He, Mingli; Minardi, Antonio; Shelton, Bret A.

1995-01-01

Computer-controlled machine-tool system uses laser beam assisted by directed flow of air to cut refractory materials into complex three-dimensional shapes. Velocity, position, and angle of cut varied. In original application, materials in question were thermally insulating thick blankets and tiles used on space shuttle. System shapes tile to concave or convex contours and cuts beveled edges on blanket, without cutting through outer layer of quartz fabric part of blanket. For safety, system entirely enclosed to prevent escape of laser energy. No dust generated during cutting operation - all material vaporized; larger solid chips dislodged from workpiece easily removed later.

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)

The testing report of the development for the lithium grains and lithium rod automatic machine

International Nuclear Information System (INIS)

Qian Zongkui; Kong Xianghong; Huang Yong

2008-06-01

With the development of lithium industry, the lithium grains and lithium rod, as additive or catalyzer, having a big comparatively acreage and a strong activated feature, have a broad application. The lithium grains and lithium rod belong to the kind of final machining materials. The principle of the lithium grains and lithium rod that how to take shape through the procedures of extrusion, cutting, anti-conglutination, threshing and so on are analysed, A sort of lithium grains and lithium rod automatic machine is developed. (authors)

Test Rig for Valves of Digital Displacement Machines

DEFF Research Database (Denmark)

Nørgård, Christian; Christensen, Jeppe Haals; Bech, Michael Møller

2017-01-01

A test rig for the valves of digital displacement machines has been developed at Aalborg University. It is composed of a commercial radial piston machine, which has been modified to facilitate Digital Displacement operation for a single piston. Prototype valves have been optimized, designed and m...

Machine for development impact tests in sports seats and similar

International Nuclear Information System (INIS)

Gonçalves, R M

2015-01-01

This paper describes the stages of development of a machine to perform impact tests in sport seats, seats for spectators and multiple seats. This includes reviews and recommendations for testing laboratories that have needs similar to the laboratory where unfolded this process.The machine was originally developed seeking to meet certain impact tests in accordance with the NBR15925 standards; 15878 and 16031. The process initially included the study of the rules and the election of the tests for which the machine could be developed and yet all reports and outcome of interaction with service providers and raw materials.For operating facility, it was necessary to set entirely the machine control, which included the concept of dialogue with operator, the design of the menu screens and the procedures for submission and registration of results. To ensure reliability in the process, the machine has been successfully calibrated according to the requirements of the Brazilian network of calibration.The criticism to this enterprise covers the technical and economic aspects involved and points out the main obstacles that were needed to overcome. (paper)

Mechanical properties of JT-60 tokamak machine in power tests

International Nuclear Information System (INIS)

Takatsu, Hideyuki; Ohkubo, Minoru; Yamamoto, Masahiro; Ohta, Mitsuru

1986-01-01

JT-60 power tests were carried out from Dec. 10, 1984 to Feb. 20, 1985 to demonstrate, in advance of actual plasma operation, satisfactory performance of tokamak machine, power suppliers and control system in combination. The tests began with low power test of individual coil systems and progressed to full power tests. The coil current was raised step by step, monitoring the mechanical, thermal, electrical and vacuum data. Power tests were concluded with successful results. All of the coil systems were raised up to full power operation in combination and system performance was verified including the structural integrity of tokamak machine. Measured strain and deflection showed good agreements with those predicted in the design, which was an evidence that electromagnetic forces were supported as expected in the design. A few limitations to machine operation was made clear quantitatively. And it was found that existing detectors were insufficient to monitor machine integrity and two kinds of detector were proposed to be installed. (author)

Influence of shear cutting parameters on the electromagnetic properties of non-oriented electrical steel sheets

Energy Technology Data Exchange (ETDEWEB)

Weiss, H.A., E-mail: hw@utg.de [Institute of Metal Forming and Casting, Technical University of Munich, Garching, D-85748 Germany (Germany); Leuning, N.; Steentjes, S.; Hameyer, K. [Institute of Electrical Machines, RWTH Aachen University, Aachen, D-52062 Germany (Germany); Andorfer, T.; Jenner, S.; Volk, W. [Institute of Metal Forming and Casting, Technical University of Munich, Garching, D-85748 Germany (Germany)

2017-01-01

Mechanical stress occurring during the manufacturing process of electrical machines detrimentally alters the magnetic properties (iron losses and magnetizability). This affects the efficiency and performance of the machine. Improvement of the manufacturing process in terms of reduced magnetic property deterioration enables the full potential of the magnetic materials to be exploited, and as a result, the performance of the machine to be improved. A high quantity of electrical machine components is needed, with shear cutting (punching, blanking) being the most efficient manufacturing technology. The cutting process leads to residual stresses inside the non-oriented electrical sheet metal, resulting in increased iron losses. This paper studies the residual stresses induced by punching with different shear cutting parameters, taking a qualitative approach using finite element analysis. In order to calibrate the finite element analysis, shear cutting experiments are performed. A single sheet tester analysis of the cut blanks allows the correlation between residual stresses, micro hardness measurements, cutting surface parameters and magnetic properties to be studied.

An Investigation of Reaming Test Parameters Used for Cutting Fluid Evaluations

DEFF Research Database (Denmark)

De Chiffre, Leonardo; Zeng, Z.; Belluco, Walter

2001-01-01

It has been suggested that the lubricating efficiency of cutting fluids can be assessed using a reaming test that measures cutting forces and surface roughness. In the present work, an investigation was undertaken to ream austenitic stainless steel using water based fluids and to evaluate...

Machine Vision Tests for Spent Fuel Scrap Characteristics

International Nuclear Information System (INIS)

BERGER, W.W.

2000-01-01

The purpose of this work is to perform a feasibility test of a Machine Vision system for potential use at the Hanford K basins during spent nuclear fuel (SNF) operations. This report documents the testing performed to establish functionality of the system including quantitative assessment of results. Fauske and Associates, Inc., which has been intimately involved in development of the SNF safety basis, has teamed with Agris-Schoen Vision Systems, experts in robotics, tele-robotics, and Machine Vision, for this work

Features of energy impact on a billet material when cutting with outstripping plastic deformation

Directory of Open Access Journals (Sweden)

V. M. Yaroslavtsev

2014-01-01

Full Text Available In the last decades the so-called combined machining methods based on parallel, serial or parallelserial combination of different types of energy impacts on the billet are designed and developed. Combination of two or more sources of external energy in one method of machining can be directed to the solution of different technological tasks, such as: improvement of a basic method to enhance technicaland-economic and technological indicators of machining, expansion of technological capabilities of the method, increase of reliability and stability of technological process to produce details, etc. Besides, the combined methods of machining are considered as one of the means, which enables reducing the number of operations in technological process, allows the growth of workforce productivity.When developing the combined technologies, one of the main scientific tasks is to define the general regularities of interaction and mutual influence of the energy fluxes brought to the zone of machining. The result of such mutual influence becomes apparent from the forming technological parameters of machining and determines the most rational operating conditions of technological process.In the context of conducted in BMSTU researches on the combined cutting method with outstripping plastic deformation (OPD the mutual influence of the energetic components of machining has been quantitatively assessed. The paper shows a direct relationship between the rational ratio of the two types of the mechanical energy brought in the machining zone, the machining conditions, and the optimum operating conditions.The paper offers a physical model of chip formation when machining with OPD. The essence of model is that specific works spent on material deformation of a cut-off layer are quantitatively compared at usual cutting and at cutting with OPD. It is experimentally confirmed that the final strain-deformed material states of a cut-off layer, essentially, coincide in both

Predicting the surface roughness in the dry machining of duplex stainless steel (DSS

Directory of Open Access Journals (Sweden)

G. Krolczyk

2013-04-01

Full Text Available This paper examines the influence of cutting parameters, namely cutting speed, feed and depth of cut onto surface roughness after DSS turning process. The study included developing a mathematical model to determine the surface roughness. Verification research has been carried out on CNC lathe; hence the test plan has been adjusted to the possibility of programmable machines controlling GE Fanuc Series 0-T. The comparison of results obtained by given experimental plan was performed in industrial company.

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.

Drilling of metal matrix composites: cutting forces and chip formation

International Nuclear Information System (INIS)

Songmene, V.; Balout, B.; Masounave, J.

2002-01-01

Particulate metal matrix composites (MMCs) are known for their low weight and their high wear resistance, but also for the difficulties encountered during their machining. New aluminium MMCs containing with both soft lubricating graphite particles and hard particles (silicon carbide or alumina) with improved machinability were developed. This study investigates the drilling of these composites as compared to non-reinforced aluminium. The microstructure of chip, the cutting forces, the shear angles and the friction at tool-chip interface are used to compare the machinability of these composites. It was found that, during drilling of this new family of composites, the feed rate, and the nature of reinforcing particles govern the cutting forces. The mathematical models established by previous researchers for predicting the cutting forces when drilling metals were validated for these composites. The reinforcing particles within the composite help for chip segmentation, making the composite more brittle and easy to shear during the cutting process. (author)

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...

Tool wear and breakage monitoring in machining

International Nuclear Information System (INIS)

Madl, J.

1992-01-01

Risk minimization of metal cutting operations is one of the main problems of metal cutting technology. This paper describes some aspects in monitoring and control of machining processes. Tool monitoring is the fokus of machining process monitoring. Tool breakage and tool life recognition are the main problems of tool monitoring. All problems of this type of monitoring have not yet been fully solved. (orig.)

Test of fuel handling machine for Monju in sodium

International Nuclear Information System (INIS)

Ishii, Yoichiro; Masuda, Yoichi; Kataoka, Hajime

1980-01-01

Various types of fuel handling machines were studied, and under-the-plug method of fuel exchange and the fuel handling machine of single turning plug, fixed arm type were selected for the prototype reactor ''Monju'', because the turning plug is relatively small, and the rate of operation, safety, operational ability, maintainability and reliability required for the reactor are satisfied, moreover, the extrapolation to the demonstration reactor was considered. Attention must be paid to the points that the fuel handling machine is very long and invisible from outside, and the smooth operation and endurance in sodium are required for it. The full mock-up testing facility of single turning plug, fixed arm type was installed in 1974, and the full mock-up test has been carried out since 1975 in Oarai. Fuel exchange is carried out at about 6 months intervals in Monju, and about 20 to 30% of core and blanket fuels are exchanged for about one month period. The functions required for the fuel handling machine for Monju, the outline of the testing facility, the schedule of the testing, the items of testing and the results, and the matters to be specially written are described. The full mock-up test in sodium has been carried out for 5 years, and the functions and the endurance have been proved sufficiently. (Kako, I.)

Characterization of vibratory turning in cutting zone using a pneumatic quick-stop device

Directory of Open Access Journals (Sweden)

Saeid Amini

2017-04-01

Full Text Available Shear angle and sticking length are two crucial parameters in mechanics of metal cutting. These two parameters directly influence machinability factors such as cutting forces. Thus, shear angle and sticking length were investigated in vibratory turning process by using a pneumatic quick-stop device which was designed and fabricated, in this study. After preparation of ultrasonic assisted turning set-up, experimental tests have been carried out on two types of steel: AISI-1060 and AISI 304. Accordingly, the process of chip formation in each particular cutting test was quickly stopped when deformed chip was still in contact with workpiece. As a result, it was revealed that added linear vibration leads the turning operation to be improved by increase of shear angle and decrease of sticking length. Moreover, the effect of ultrasonic vibration on cutting force and chip micro-hardness is evaluated.

Crystal Orientation Effect on the Subsurface Deformation of Monocrystalline Germanium in Nanometric Cutting.

Science.gov (United States)

Lai, Min; Zhang, Xiaodong; Fang, Fengzhou

2017-12-01

Molecular dynamics simulations of nanometric cutting on monocrystalline germanium are conducted to investigate the subsurface deformation during and after nanometric cutting. The continuous random network model of amorphous germanium is established by molecular dynamics simulation, and its characteristic parameters are extracted to compare with those of the machined deformed layer. The coordination number distribution and radial distribution function (RDF) show that the machined surface presents the similar amorphous state. The anisotropic subsurface deformation is studied by nanometric cutting on the (010), (101), and (111) crystal planes of germanium, respectively. The deformed structures are prone to extend along the 110 slip system, which leads to the difference in the shape and thickness of the deformed layer on various directions and crystal planes. On machined surface, the greater thickness of subsurface deformed layer induces the greater surface recovery height. In order to get the critical thickness limit of deformed layer on machined surface of germanium, the optimized cutting direction on each crystal plane is suggested according to the relevance of the nanometric cutting to the nanoindentation.

Effect of micro-scale texturing on the cutting tool performance

Science.gov (United States)

Vasumathy, D.; Meena, Anil

2018-05-01

The present study is mainly focused on the cutting performance of the micro-scale textured carbide tools while turning AISI 304 austenitic stainless steel under dry cutting environment. The texture on the rake face of the carbide tools was fabricated by laser machining. The cutting performance of the textured tools was further compared with conventional tools in terms of cutting forces, tool wear, machined surface quality and chip curl radius. SEM and EDS analyses have been also performed to better understand the tool surface characteristics. Results show that the grooves help in breaking the tool-chip contact leading to a lesser tool-chip contact area which results in reduced iron (Fe) adhesion to the tool.

Investigation of Micro Square Structure Fabrication by Applying Textured Cutting Tool in WEDM

Directory of Open Access Journals (Sweden)

Jianguo Zhang

2015-09-01

Full Text Available This paper studies micro structure fabrication by means of a textured tool cutting edge, which is manufactured by applying the wire cut electrical discharge machining (WEDM. Machining performance of the square structure fabrication on the tool cutting edge is investigated in the WEDM process, and the machining accuracy is explored in experimental analyses. In this proposed method, undesired overcut comes from the discharge between the processing debris and the side wall of the target structure. Furthermore, by applying the textured cutting tool, the target square structure is directly fabricated on the alumina workpiece with just a simple turning process, which verifies the feasibility of the proposed tool cutting edge textured method by applying the WEDM. This technology is expected to become a potential method for the mass production of micro structure surfaces in the future.

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

Automatic testing in the integration phase of mobile work machine (TINAT) - MASIT31

Energy Technology Data Exchange (ETDEWEB)

Multanen, P.; Hyvoenen, M. (Tampere University of Technology, Department of Intelligent Hydraulics and Automation, Tampere (Finland)); Ellman, A. (Tampere University of Technology, Department of Mechanics and Design, Tampere (Finland)); Rantala, S.; Alanen, J. (VTT Technical Research Centre of Finland, Espoo (Finland))

2008-07-01

Abstract The performance and reliability of mobile work machines are significantly affected by control systems of machines and their characteristics. Currently the testing of control systems and verification of their properties is often carried out just in the integration phase of controls and mechanical structure of machine. This is very time consuming, requires a lot of test personnel and is not extensive enough. In TINAT project a test concept will be developed for the testing of entire control systems of work machines without real the mechanical structures of the machines by utilizing modelling and real-time hardware-in-the-loop simulation. The simulator system enables automatic generation of test scenarios and automatic analysis and reporting of test results. (orig.)

Investigation of the ElectroPuls E3000 Test Machine for Fatigue Testing of Structural Materials

Science.gov (United States)

2016-12-01

potential to use high frequencies to reduce test time significantly (at, for example, four times the maximum frequency possible on a servo- hydraulic ...crack growth rate data (at a frequency of 10 Hz) that was consistent with previous testing performed on servo- hydraulic testing machines (at a frequency...operate at frequencies "over 100 Hz" and has the potential to increase efficiency by decreasing test time, as compared with a servo- hydraulic test machine

Capacitive Sensing for Contact-less Proximity Detection in Industrial Marble Machines

Directory of Open Access Journals (Sweden)

Sergio Saponara

2010-02-01

Full Text Available The paper presents the design and experimental characterization of capacitive sensors, plus the relevant front-end acquisition circuitry, for process control in industrial marble machines. The new developed sensing system allows detecting, in real-time and without any contact, the presence of stone samples under the abrasive/cutting heads in an industrial machine. The obtained detection signal is needed as a feedback to improve the automatic control of the polishing/cutting process in marble industry. Different types of sensors are proposed whose performances are assessed through experimental test campaigns considering real industrial working conditions. Compared to state-of-art sensors the proposed solutions allow for a reliable detection while being of low complexity and robust to harsh environment conditions.

Design and development of Hoeken's structural dynamic linkage based agro-tiller machine

Science.gov (United States)

Hynes, N. Rajesh Jesudoss; Saran, K.; Pavithran, V.

2018-05-01

India is one of biggest exporters of medicinal plants, spices and other many agro products in the world. Owing to the special needs, an agricultural machine is designed using Hoeken linkage with Pantograph mechanism and developed that ensures safety digging to uproot the plant. Thus, the focus is to cut the plant by machine with proper care and shoot system is cut properly avoiding any damage to the upper part of the plant and rather be cut in the root area to use it. This is done by the agricultural cutting machine by the name "agricultural tiller machine" that can perform the action same as the objective needed for the effective production of raw materials for manufacturing of the agro products.

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.

Fundamental investigation on influence of external heat on chip formation during thermal assisted machining

Science.gov (United States)

Alkali, A. U.; Ginta, T. L.; Abdulrani, A. M.; Elsiti, N. M.

2018-04-01

Various heat sources have been investigated by numerous researchers to reveal machinability benefits of thermally assisted machining (TAM) process. Fewer engineering materials have been tested. In the same vein, those researches continue to demonstrate effective performance of TAM in terms of bulk material removal rate, improved surface finish, prolong tool life and reduction of cutting forces among others. Experimental investigation on the strain-hardenability and flow stress of material removed with respect to increase in temperature in TAM has not been given attention in previous studies. This study investigated the pattern of chip morphology and segmentation giving close attention to influence of external heat source responsible for strain – hardenability of the material removed during TAM and dry machining at room temperature. Full immersion down cut milling was used throughout the machining conditions. Machining was conducted on AISI 316L using uncoated tungsten carbide end mill insert at varying cutting speeds (V) of 50, 79, and 100 m/min, and feed rates (f) of 0.15, 0.25, and 0.4 mm/tooth while the depth of cut was maintained at 0.2mm throughout the machining trials. The analyses of chip formation, segmentations and stain hardenability were carried out by using LMU light microscope, field emission microscopy and micro indentation. The study observed that build up edge is formed when a stagnation zone develops in front of tool tip which give rise to poor thermal gradient for conduction heat to be transferred within the bulk material during dry machining. This promotes varying strain – hardening of the material removed with evident high chips hardness and thickness, whereas TAM circumvents such impairment by softening the shear zone through local preheat.

Experimental investigation and modelling of surface roughness and resultant cutting force in hard turning of AISI H13 Steel

Science.gov (United States)

Boy, M.; Yaşar, N.; Çiftçi, İ.

2016-11-01

In recent years, turning of hardened steels has replaced grinding for finishing operations. This process is compared to grinding operations; hard turning has higher material removal rates, the possibility of greater process flexibility, lower equipment costs, and shorter setup time. CBN or ceramic cutting tools are widely used hard part machining. For successful application of hard turning, selection of suitable cutting parameters for a given cutting tool is an important step. For this purpose, an experimental investigation was conducted to determine the effects of cutting tool edge geometry, feed rate and cutting speed on surface roughness and resultant cutting force in hard turning of AISI H13 steel with ceramic cutting tools. Machining experiments were conducted in a CNC lathe based on Taguchi experimental design (L16) in different levels of cutting parameters. In the experiments, a Kistler 9257 B, three cutting force components (Fc, Ff and Fr) piezoelectric dynamometer was used to measure cutting forces. Surface roughness measurements were performed by using a Mahrsurf PS1 device. For statistical analysis, analysis of variance has been performed and mathematical model have been developed for surface roughness and resultant cutting forces. The analysis of variance results showed that the cutting edge geometry, cutting speed and feed rate were the most significant factors on resultant cutting force while the cutting edge geometry and feed rate were the most significant factor for the surface roughness. The regression analysis was applied to predict the outcomes of the experiment. The predicted values and measured values were very close to each other. Afterwards a confirmation tests were performed to make a comparison between the predicted results and the measured results. According to the confirmation test results, measured values are within the 95% confidence interval.

Optimisation Of Cutting Parameters Of Composite Material Laser Cutting Process By Taguchi Method

Science.gov (United States)

Lokesh, S.; Niresh, J.; Neelakrishnan, S.; Rahul, S. P. Deepak

2018-03-01

The aim of this work is to develop a laser cutting process model that can predict the relationship between the process input parameters and resultant surface roughness, kerf width characteristics. The research conduct is based on the Design of Experiment (DOE) analysis. Response Surface Methodology (RSM) is used in this work. It is one of the most practical and most effective techniques to develop a process model. Even though RSM has been used for the optimization of the laser process, this research investigates laser cutting of materials like Composite wood (veneer)to be best circumstances of laser cutting using RSM process. The input parameters evaluated are focal length, power supply and cutting speed, the output responses being kerf width, surface roughness, temperature. To efficiently optimize and customize the kerf width and surface roughness characteristics, a machine laser cutting process model using Taguchi L9 orthogonal methodology was proposed.

Performance improvement studies for cutting tools with perforated surface in turning of titanium alloy

Directory of Open Access Journals (Sweden)

Charitha Rao

2018-01-01

Full Text Available In turning process, the cutting tool is essential for shaping materials. The cutting tools with various perforated surfaces help to increase the cutting tool life. Also, advances in CNC machining technologies have enhanced the productivity of machining process. One of the best or futuristic approaches in modern manufacturing engineering is the use of FEM Simulation for the metal cutting process. FEM simulation helps in understanding the metal deformation process and also helps in the reduction of experiments. The simulation helps the researchers to predict the major influencing cutting variable values without carrying out any experiment which is time-consuming and expensive. This research presents the simulation study of the performance of micro-hole patterned Polycrystalline Diamond cutting insert in machining Titanium alloy (Ti-6Al-4V. Micro-holes are drilled using Electrical Discharge Wire Drilling machine on the rake face of Polycrystalline Diamond (PCD cutting inserts. FEM analysis is carried out to evaluate the effect of perforations on the mechanical integrity of insert. The micro-hole patterned insert is modeled in PRO-E modeler and simulated using DEFORM-3D software. The effective stress, strain, and temperature distribution are analyzed and the results are compared with the normal insert.

Effect of Heat Treatment on Machining Properties of the AlSi9Cu3(Fe Alloy

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Wieroński P.

2016-09-01

Full Text Available Automation of machining operations, being result of mass volume production of components, imposes more restrictive requirements concerning mechanical properties of starting materials, inclusive of machinability mainly. In stage of preparation of material, the machinability is influenced by such factors as chemical composition, structure, mechanical properties, plastic working and heat treatment, as well as a factors present during machining operations, as machining type, cutting parameters, material and geometry of cutting tools, stiffness of the system: workpiece – machine tool – fixture and cutting tool.

Machining of glass fiber reinforced polyamide

Directory of Open Access Journals (Sweden)

2007-12-01

Full Text Available The machinability of a 30 wt% glass fiber reinforced polyamide (PA was investigated by means of drilling tests. A disk was cut from an extruded rod and drilled on the flat surface: thrust was acquired during drilling at different drilling speed, feed rate and drill diameter. Differential scanning calorimetry (DSC and indentation were used to characterize PA so as to evaluate the intrinsic lack of homogeneity of the extruded material. In conclusion, it was observed that the chip formation mechanism affects the thrust dependence on the machining parameters. A traditional modeling approach is able to predict thrust only in presence of a continuous chip. In some conditions, thrust increases as drilling speed increases and feed rate decreases; this evidence suggests not to consider the general scientific approach which deals the machining of plastics in analogy with metals. Moreover, the thrust can be significantly affected by the workpiece fabrication effect, as well as by the machining parameters; therefore, the fabrication effect is not negligible in the definition of an optimum for the machining process.

Investigation of wear land and rate of locally made HSS cutting tool

Science.gov (United States)

Afolalu, S. A.; Abioye, A. A.; Dirisu, J. O.; Okokpujie, I. P.; Ajayi, O. O.; Adetunji, O. R.

2018-04-01

Production technology and machining are inseparable with cutting operation playing important roles. Investigation of wear land and rate of cutting tool developed locally (C=0.56%) with an HSS cutting tool (C=0.65%) as a control was carried out. Wear rate test was carried out using Rotopol -V and Impact tester. The samples (12) of locally made cutting tools and one (1) sample of a control HSS cutting tool were weighed to get the initial weight and grit was fixed at a point for the sample to revolve at a specific time of 10 mins interval. Approach of macro transfer particles that involved mechanism of abrasion and adhesion which was termed as mechanical wear to handle abrasion adhesion processes was used in developing equation for growth wear at flank. It was observed from the wear test that best minimum wear rate of 1.09 × 10-8 and 2.053 × 10-8 for the tools developed and control were measured. MATLAB was used to simulate the wear land and rate under different conditions. Validated results of both the experimental and modeling showed that cutting speed has effect on wear rate while cutting time has predicted measure on wear land. Both experimental and modeling result showed best performances of tools developed over the control.

Gear cutting tools fundamentals of design and computation

CERN Document Server

Radzevich, Stephen P

2010-01-01

Presents the DG/K-based method of surface generation, a novel and practical mathematical method for designing gear cutting tools with optimal parameters. This book proposes a scientific classification for the various kinds of the gear machining meshes, discussing optimal designs of gear cutting tools.

An Axial Sliding Test for machine elements surfaces

DEFF Research Database (Denmark)

Godi, Alessandro; Grønbæk, J.; Mohaghegh, Kamran

2012-01-01

are necessary: a press to provide the normal pressure and a tensile machine to perform the axial movements. The test is calibrated so that the correspondence between the normal pressure and the container advancement is found. Finally, preliminary tests are carried out involving a multifunctional and a fine......Throughout the years, it has become more and more important to find new methods for reducing friction and wear occurrence in machine elements. A possible solution is found in texturing the surfaces under tribological contact, hence the development and spread of plateau-honed surface for cylinder...... liners. To prove the efficacy of a particular textured surface, it is paramount to perform experimental tests under controlled laboratory conditions. In this paper a new test rig simulating pure sliding conditions is presented, dubbed Axial Sliding Test. It presents four major components: a rod, a sleeve...

Side Flow Effect on Surface Generation in Nano Cutting.

Science.gov (United States)

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-12-01

The side flow of material in nano cutting is one of the most important factors that deteriorate the machined surface quality. The effects of the crystallographic orientation, feed, and the cutting tool geometry, including tool edge radius, rake angle and inclination angle, on the side flow are investigated employing molecular dynamics simulation. The results show that the stagnation region is formed in front of tool edge and it is characterized by the stagnation radius R s and stagnation height h s . The side flow is formed because the material at or under the stagnation region is extruded by the tool edge to flow to the side of the tool edge. Higher stagnation height would increase the size of the side flow. The anisotropic nature of the material which partly determines the stagnation region also influences the side flow due to the different deformation mechanism under the action of the tool edge. At different cutting directions, the size of the side flow has a great difference which would finally affect the machined surface quality. The cutting directions of {100} , {110} , and {110}  are beneficial to obtain a better surface quality with small side flow. Besides that, the side flow could be suppressed by reducing the feed and optimizing the cutting tool geometry. Cutting tool with small edge radius, large positive rake angle, and inclination angle would decrease the side flow and consequently improve the machined surface quality.

Cutting fluids and clean technologies; Los fluidos de corte y las tecnologias limpias (III)

Energy Technology Data Exchange (ETDEWEB)

Terradillos, J.; Arnaiz, A.

2003-07-01

Metalworking fluids are an essential constituent of manufacturing and represent an important part of machining cost and disposal charges. Practically all cutting fluids currently in use fall into four categories: straight oils, soluble oils, semi-synthetic fluids and synthetic oils. The composition of these fluids depends on the machining requirements and primary functions include improving tool life, reducing thermal deformation of parts and improving surface finish and flushing away chips from the cutting zone. To maintain cutting fluid quality in the long term and, at the same time, reduce its environmental impact, three strategies could be followed: Prevention, Minimization and Evaluation, Related to prevention, different approaches exist for reducing the impact of cutting fluids. They include dry cutting, machining using a minimum quantity of lubricant (MQL) and developing environmental friendly acceptable formulations or refrigerant gases. (Author)

ANN Surface Roughness Optimization of AZ61 Magnesium Alloy Finish Turning: Minimum Machining Times at Prime Machining Costs

Directory of Open Access Journals (Sweden)

Adel Taha Abbas

2018-05-01

Full Text Available Magnesium alloys are widely used in aerospace vehicles and modern cars, due to their rapid machinability at high cutting speeds. A novel Edgeworth–Pareto optimization of an artificial neural network (ANN is presented in this paper for surface roughness (Ra prediction of one component in computer numerical control (CNC turning over minimal machining time (Tm and at prime machining costs (C. An ANN is built in the Matlab programming environment, based on a 4-12-3 multi-layer perceptron (MLP, to predict Ra, Tm, and C, in relation to cutting speed, vc, depth of cut, ap, and feed per revolution, fr. For the first time, a profile of an AZ61 alloy workpiece after finish turning is constructed using an ANN for the range of experimental values vc, ap, and fr. The global minimum length of a three-dimensional estimation vector was defined with the following coordinates: Ra = 0.087 μm, Tm = 0.358 min/cm3, C = $8.2973. Likewise, the corresponding finish-turning parameters were also estimated: cutting speed vc = 250 m/min, cutting depth ap = 1.0 mm, and feed per revolution fr = 0.08 mm/rev. The ANN model achieved a reliable prediction accuracy of ±1.35% for surface roughness.

KrF excimer laser precision machining of hard and brittle ceramic biomaterials

International Nuclear Information System (INIS)

Huang, Yao-Xiong; Lu, Jian-Yi; Huang, Jin-Xia

2014-01-01

KrF excimer laser precision machining of porous hard–brittle ceramic biomaterials was studied to find a suitable way of machining the materials into various desired shapes and sizes without distorting their intrinsic structure and porosity. Calcium phosphate glass ceramics (CPGs) and hydroxyapatite (HA) were chosen for the study. It was found that KrF excimer laser can cut both CPGs and HA with high efficiency and precision. The ablation rates of CPGs and HA are respectively 0.081 µm/(pulse ⋅ J cm −2 ) and 0.048 µm/(pulse ⋅ J cm −2 ), while their threshold fluences are individually 0.72 and 1.5 J cm −2 . The cutting quality (smoothness of the cut surface) is a function of laser repetition rate and cutting speed. The higher the repetition rate and lower the cutting speed, the better the cutting quality. A comparison between the cross sections of CPGs and HA cut using the excimer laser and using a conventional diamond cutting blade indicates that those cut by the excimer laser could retain their intrinsic porosity and geometry without distortion. In contrast, those cut by conventional machining had distorted geometry and most of their surface porosities were lost. Therefore, when cutting hard–brittle ceramic biomaterials to prepare scaffold and implant or when sectioning them for porosity evaluation, it is better to choose KrF excimer laser machining. (paper)

Dynamic characterization of the cutting conditions in dry turning

Energy Technology Data Exchange (ETDEWEB)

Serra, R [ENI Val de Loire, Universite Francois Rabelais de Tours, Laboratoire de Mecanique et Rheologie, E.A. 2640, B.P. 3410, 41034 Blois Cedex (France); Chibane, H [Universite Francois Rabelais, Laboratoire de Mecanique et Rheologie, E.A. 2640, B.P. 3410, 41034 Blois Cedex (France); Leroy, R, E-mail: roger.serra@univ-tours.f [Universite Francois Rabelais, Polytech' Tours, Laboratoire de Mecanique et Rheologie, E.A. 2640, 7 Avenue Marcel Dassault, 37200 Tours (France)

2009-08-01

Machining instability in the form of violent vibrations or chatter is a physical process characterized by extreme cutting force at the cutting point. The process has very negative impact on machine integrity, tool life, surface quality and dimensional accuracy. Thus it could significantly compromise productivity and manufacturing quality. In the present paper, the importance of characterization and identification of dynamic instability in dry turning operation are shown. The stability behaviour of machine vibration or chatter has been examined and the various relevant parameters are studied and discuted. For chatter detection and identification of the transition between stable and unstable states, different methods are used. Results obtained proof the accuracy of these methods.

Design of an instrumented smart cutting tool and its implementation and application perspectives

International Nuclear Information System (INIS)

Wang, Chao; Cheng, Kai; Chen, Xun; Minton, Timothy; Rakowski, Richard

2014-01-01

This paper presents an innovative design of a smart cutting tool, using two surface acoustic wave (SAW) strain sensors mounted onto the top and the side surface of the tool shank respectively, and its implementation and application perspectives. This surface acoustic wave-based smart cutting tool is capable of measuring the cutting force and the feed force in a real machining environment, after a calibration process under known cutting conditions. A hybrid dissimilar workpiece is then machined using the SAW-based smart cutting tool. The hybrid dissimilar material is made of two different materials, NiCu alloy (Monel) and steel, welded together to form a single bar; this can be used to simulate an abrupt change in material properties. The property transition zone is successfully detected by the tool; the sensor feedback can then be used to initiate a change in the machining parameters to compensate for the altered material properties. (paper)

Quantitative assessment of the enamel machinability in tooth preparation with dental diamond burs.

Science.gov (United States)

Song, Xiao-Fei; Jin, Chen-Xin; Yin, Ling

2015-01-01

Enamel cutting using dental handpieces is a critical process in tooth preparation for dental restorations and treatment but the machinability of enamel is poorly understood. This paper reports on the first quantitative assessment of the enamel machinability using computer-assisted numerical control, high-speed data acquisition, and force sensing systems. The enamel machinability in terms of cutting forces, force ratio, cutting torque, cutting speed and specific cutting energy were characterized in relation to enamel surface orientation, specific material removal rate and diamond bur grit size. The results show that enamel surface orientation, specific material removal rate and diamond bur grit size critically affected the enamel cutting capability. Cutting buccal/lingual surfaces resulted in significantly higher tangential and normal forces, torques and specific energy (pmachinability for clinical dental practice. Copyright © 2014 Elsevier Ltd. All rights reserved.

CAD for cutting head exchange of roadheader

Energy Technology Data Exchange (ETDEWEB)

Tao, Z.; Wu, Z.; Qian, P. [China Coal Research Institute (China). Shanghai Branch

1999-08-01

Improving the cutting method according to the actual operating conditions is an effective way to raise production efficiency. A cutting head designed by means of computer and CAD software is characterized by short design cycle but high design quality. Taking the AM-50 road header as an example, this paper shows that it is feasible to design an interchangeable cutting head for the machine without interfering with the main technical parameters. 2 refs., 5 figs., 1 tab.

Experimental investigation into effect of cutting parameters on surface integrity of hardened tool steel

Science.gov (United States)

Bashir, K.; Alkali, A. U.; Elmunafi, M. H. S.; Yusof, N. M.

2018-04-01

Recent trend in turning hardened materials have gained popularity because of its immense machinability benefits. However, several machining processes like thermal assisted machining and cryogenic machining have reveal superior machinability benefits over conventional dry turning of hardened materials. Various engineering materials have been studied. However, investigations on AISI O1 tool steel have not been widely reported. In this paper, surface finish and surface integrity dominant when hard turning AISI O1 tool steel is analysed. The study is focused on the performance of wiper coated ceramic tool with respect to surface roughness and surface integrity of hardened tool steel. Hard turned tool steel was machined at varying cutting speed of 100, 155 and 210 m/min and feed rate of 0.05, 0.125 and 0.20mm/rev. The depth of cut of 0.2mm was maintained constant throughout the machining trials. Machining was conducted using dry turning on 200E-axis CNC lathe. The experimental study revealed that the surface finish is relatively superior at higher cutting speed of 210m/min. The surface finish increases when cutting speed increases whereas surface finish is generally better at lower feed rate of 0.05mm/rev. The experimental study conducted have revealed that phenomena such as work piece vibration due to poor or improper mounting on the spindle also contributed to higher surface roughness value of 0.66Ra during turning at 0.2mm/rev. Traces of white layer was observed when viewed with optical microscope which shows evidence of cutting effects on the turned work material at feed rate of 0.2 rev/min

Fractal characteristic study of shearer cutter cutting resistance curves

Energy Technology Data Exchange (ETDEWEB)

Liu, C. [Heilongjiang Scientific and Technical Institute, Haerbin (China). Dept of Mechanical Engineering

2004-02-01

The cutting resistance curve is the most useful tool for reflecting the overall cutting performance of a cutting machine. The cutting resistance curve is influenced by many factors such as the pick structure and arrangement, the cutter operation parameters, coal quality and geologic conditions. This paper discusses the use of fractal geometry to study the properties of the cutting resistance curve, and the use of fractal dimensions to evaluate cutting performance. On the basis of fractal theory, the general form and calculation method of fractal characteristics are given. 4 refs., 3 figs., 1 tab.

Random non-proportional fatigue tests with planar tri-axial fatigue testing machine

Directory of Open Access Journals (Sweden)

T. Inoue

2016-10-01

Full Text Available Complex stresses, which occur on the mechanical surfaces of transport machinery in service, bring a drastic degradation in fatigue life. However, it is hard to reproduce such complex stress states for evaluating the fatigue life with conventional multiaxial fatigue machines. We have developed a fatigue testing machine that enables reproduction of such complex stresses. The testing machine can reproduce arbitrary in-plane stress states by applying three independent loads to the test specimen using actuators which apply loads in the 0, 45, and 90 degree directions. The reproduction was tested with complex stress data obtained from the actual operation of transport machinery. As a result, it was found that the reproduced stress corresponded to the measured stress with an error range of less than 10 %. Then, we made a comparison between measured fatigue lives under random non-proportional loading conditions and predicted fatigue lives. It was found that predicted fatigue lives with cr, stress on critical plane, were over a factor of 10 against measured fatigue lives. On the other hand, predicted fatigue lives with ma, stress in consideration of a non-proportional level evaluated by using amplitude and direction of principal stress, were within a factor of 3 against measured fatigue lives

Surface texture generation during cylindrical milling in the aspect of cutting force variations

International Nuclear Information System (INIS)

Wojciechowski, S; Twardowski, P; Pelic, M

2014-01-01

The work presented here concentrates on surface texture analysis, after cylindrical milling of hardened steel. Cutting force variations occurring in the machining process have direct influence on the cutter displacements and thus on the generated surface texture. Therefore, in these experiments, the influence of active number of teeth (z c ) on the cutting force variations was investigated. Cutting forces and cutter displacements were measured during machining process (online) using, namely piezoelectric force dynamometer and 3D laser vibrometer. Surface roughness parameters were measured using stylus surface profiler. The surface roughness model including cutting parameters (f z , D) and cutting force variations was also developed. The research revealed that in cylindrical milling process, cutting force variations have immediate influence on surface texture generation

Composite Material Testing Data Reduction to Adjust for the Systematic 6-DOF Testing Machine Aberrations

Science.gov (United States)

Athanasios lliopoulos; John G. Michopoulos; John G. C. Hermanson

2012-01-01

This paper describes a data reduction methodology for eliminating the systematic aberrations introduced by the unwanted behavior of a multiaxial testing machine, into the massive amounts of experimental data collected from testing of composite material coupons. The machine in reference is a custom made 6-DoF system called NRL66.3 and developed at the NAval...

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.

Modification and Performance Evaluation of a Low Cost Electro-Mechanically Operated Creep Testing Machine

OpenAIRE

John J. MOMOH; Lanre Y. SHUAIB-BABATA; Gabriel O. ADELEGAN

2010-01-01

Existing mechanically operated tensile and creep testing machine was modified to a low cost, electro-mechanically operated creep testing machine capable of determining the creep properties of aluminum, lead and thermoplastic materials as a function of applied stress, time and temperature. The modification of the testing machine was necessitated by having an electro-mechanically operated creep testing machine as a demonstration model ideal for use and laboratory demonstrations, which will prov...

Testing a CANDU-fueling machine at the Institute for Nuclear Research Pitesti

International Nuclear Information System (INIS)

Cojocaru, Virgil

2006-01-01

In 2003, as a national and European premiere, the Fueling Machine Head no. 4 (F/M) for the Nuclear Power Plant Cernavoda Unit 2 (NPP) was successfully tested at the Institute for Nuclear Research Pitesti (INR). In 2005, the second Fueling Machine (no. 5) has tested for the Nuclear Power Plant Cernavoda Unit 2. The Institute's main objective is to develop scientific and technological support for the Romanian Nuclear Power Program. Testing the Fueling Machines at INR Pitesti is part of the overall program to assimilate the CANDU technology in Romania. To perform the tests of these machines at INR Pitesti, a special testing rig has built being available for this goal. Both the testing rig and staff had successfully assessed by the AECL representatives during two missions. There was a delivery contract between GEC Canada and Nuclear Power Plant Cernavoda - Unit 2 to provide the Fueling Machines no. 4 and no. 5 in Romania before testing activity. As a first conclusion, the Institute for Nuclear Research Pitesti has the facilities, the staff and the experience to perform possible co-operations with any CANDU Reactor owner

Effect of machining parameters on surface finish of Inconel 718 in end milling

Directory of Open Access Journals (Sweden)

Sarkar Bapi

2017-01-01

Full Text Available Surface finish is an important criteria in machining process and selection of proper machining parameters is important to obtain good surface finish. In the present work effects of the machining parameters in end milling of Inconel 718 were investigated. Central composite design was used to design the total number of experiments. A Mathematical model for surface roughness has been developed using response surface methodology. In this study, the influence of cutting parameters such as cutting speed, feed rate and depth of cut on surface roughness was analyzed. The study includes individual effect of cutting parameters on surface roughness as well as their interaction. The analysis of variance (ANOVA was employed to find the validity of the developed model. The results show that depth of cut mostly affected the surface roughness. It is also observed that surface roughness values are comparable in both dry and wet machining conditions.

Nonlinear dynamics of regenerative cutting processes-Comparison of two models

International Nuclear Information System (INIS)

Wang, X.S.; Hu, J.; Gao, J.B.

2006-01-01

Understanding the nonlinear dynamics of cutting processes is essential for the improvement of machining technology. We study machine cutting processes by two different models, one has been recently introduced by Litak [Litak G. Chaotic vibrations in a regenerative cutting process. Chaos, Solitons and Fractals 2002;13:1531-5] and the other is the classic delay differential equation model. Although chaotic solutions have been found in both models, well known routes to chaos, such as period-doubling or quasi-periodic motion to chaos are not observed in either model. Careful analysis shows that the chaotic motion from the Litak's model has sharper spectral peaks, a smaller correlation dimension and a smaller value for the largest positive Lyapunov exponent. Implications to the control of chaos in cutting processes are discussed

Cutting Performance of Low Stress Thick TiAlN PVD Coatings during Machining of Compacted Graphite Cast Iron (CGI

Directory of Open Access Journals (Sweden)

Kenji Yamamoto

2018-01-01

Full Text Available A new family of physical vapor deposited (PVD coatings is presented in this paper. These coatings are deposited by a superfine cathode (SFC using the arc method. They combine a smooth surface, high hardness, and low residual stresses. This allows the production of PVD coatings as thick as 15 µm. In some applications, in particular for machining of such hard to cut material as compacted graphite iron (CGI, such coatings have shown better tool life compared to the conventional PVD coatings that have a lower thickness in the range of up to 5 μm. Finite element modeling of the temperature/stress profiles was done for the SFC coatings to present the temperature/stress profiles during cutting. Comprehensive characterization of the coatings was performed using XRD, TEM, SEM/EDS studies, nano-hardness, nano-impact measurements, and residual stress measurements. Application of the coating with this set of characteristics reduces the intensity of buildup edge formation during turning of CGI, leading to longer tool life. Optimization of the TiAlN-based coatings composition (Ti/Al ratio, architecture (mono vs. multilayer, and thickness were performed. Application of the optimized coating resulted in a 40–60% improvement in the cutting tool life under finishing turning of CGI.

Strain-free polished channel-cut crystal monochromators: a new approach and results

Science.gov (United States)

Kasman, Elina; Montgomery, Jonathan; Huang, XianRong; Lerch, Jason; Assoufid, Lahsen

2017-08-01

The use of channel-cut crystal monochromators has been traditionally limited to applications that can tolerate the rough surface quality from wet etching without polishing. We have previously presented and discussed the motivation for producing channel cut crystals with strain-free polished surfaces [1]. Afterwards, we have undertaken an effort to design and implement an automated machine for polishing channel-cut crystals. The initial effort led to inefficient results. Since then, we conceptualized, designed, and implemented a new version of the channel-cut polishing machine, now called C-CHiRP (Channel-Cut High Resolution Polisher), also known as CCPM V2.0. The new machine design no longer utilizes Figure-8 motion that mimics manual polishing. Instead, the polishing is achieved by a combination of rotary and linear functions of two coordinated motion systems. Here we present the new design of C-CHiRP, its capabilities and features. Multiple channel-cut crystals polished using the C-CHiRP have been deployed into several beamlines at the Advanced Photon Source (APS). We present the measurements of surface finish, flatness, as well as topography results obtained at 1-BM of APS, as compared with results typically achieved when polishing flat-surface monochromator crystals using conventional polishing processes. Limitations of the current machine design, capabilities and considerations for strain-free polishing of highly complex crystals are also discussed, together with an outlook for future developments and improvements.

Development and characterization of AlCrN coated Si{sub 3}N{sub 4} ceramic cutting tool; Desenvolvimento e caracterizacao de ferramentas ceramicas de Si{sub 3}N{sub 4} revestidas com AlCrN

Energy Technology Data Exchange (ETDEWEB)

Souza, J.V.C.; Nono, M.C.A.; Machado, J.P.B., E-mail: vitor@las.inpe.b [Instituto Nacional de Pesquisas Espaciais (INPE), Sao Jose dos Campos, SP (Brazil); Silva, O.M.M. [Centro Tecnico de Aeronautica (CTA-IAE/AMR), Sao Jose dos Campos, SP (Brazil). Inst. de Aeronautica e Espaco. Div. de Materiais; Pimenta, M. [Balzers, Jundiai, SP (Brazil); Sa, F.C.L. [Centro Universitario de Volta Redonda (UNIFOA), RJ (Brazil)

2010-07-01

Ceramic cutting tools are showing a growing market perspective in terms of application on machining operations due to their high hardness, wear resistance, and machining without a cutting fluid, therefore are good candidates for cast iron and Nickel superalloys machining. The objective of the present paper was the development of Si{sub 3}N{sub 4} based ceramic cutting insert, characterization of its physical and mechanical properties, and subsequent coating with AlCrN using a PVD method. The characterization of the coating was made using an optical profiler, XRD, AFM and microhardness tester. The results showed that the tool presented a fracture toughness of 6,43 MPa.m{sup 1/2} and hardness of 16 GPa. The hardness reached 31 GPa after coating. The machining tests showed an improvement on work piece roughness when machining with coated insert, in comparison with the uncoated cutting tool. Probably this fact is related to hardness, roughness and topography of AlCrN. (author)

Modification and Performance Evaluation of a Low Cost Electro-Mechanically Operated Creep Testing Machine

Directory of Open Access Journals (Sweden)

John J. MOMOH

2010-12-01

Full Text Available Existing mechanically operated tensile and creep testing machine was modified to a low cost, electro-mechanically operated creep testing machine capable of determining the creep properties of aluminum, lead and thermoplastic materials as a function of applied stress, time and temperature. The modification of the testing machine was necessitated by having an electro-mechanically operated creep testing machine as a demonstration model ideal for use and laboratory demonstrations, which will provide an economical means of performing standard creep experiments. The experimental result is a more comprehensive understanding of the laboratory experience, as the technology behind the creep testing machine, the test methodology and the response of materials loaded during experiment are explored. The machine provides a low cost solution for Mechanics of Materials laboratories interested in creep testing experiment and demonstration but not capable of funding the acquisition of commercially available creep testing machines. Creep curves of strain versus time on a thermoplastic material were plotted at a stress level of 1.95MPa, 3.25MPa and 4.55MPa and temperature of 20oC, 40oC and 60oC respectively. The machine is satisfactory since it is always ready for operation at any given time.

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

Directory of Open Access Journals (Sweden)

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.

A new concept for the targeted cutting of concrete structures

International Nuclear Information System (INIS)

Reinhardt, Steffen; Gentes, Sascha; Weidemann, Roman; Geimer, Marcus

2011-01-01

The decontamination and crushing of reinforced concrete is a main part during deconstruction of nuclear facilities. The selective treatment of contaminated or activated material is of special interest, since the non-contaminated material can be transferred into the normal reprocessing cycle. In the frame of a project concerning the innovative cutting of massive reinforced concrete structures an all-purpose system for spatially restricted and defined cutting of strongly reinforced concrete including packaging suitable for final disposal was developed. Due to the remote handling of the machine the dose rate for personnel can be reduced significantly. Main part of the system is the tool that can cut highly reinforced concrete without system or component replacement. The authors describe preliminary tests of these tools, further experiments and process optimization are necessary before the tools can be integrated into the new system.

Machining of titanium alloys

CERN Document Server

2014-01-01

This book presents a collection of examples illustrating the resent research advances in the machining of titanium alloys. These materials have excellent strength and fracture toughness as well as low density and good corrosion resistance; however, machinability is still poor due to their low thermal conductivity and high chemical reactivity with cutting tool materials. This book presents solutions to enhance machinability in titanium-based alloys and serves as a useful reference to professionals and researchers in aerospace, automotive and biomedical fields.

Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in the hard turning of bearing steel using chamfer + hone cutting edge geometry

International Nuclear Information System (INIS)

Hua Jiang; Shivpuri, Rajiv; Cheng Xiaomin; Bedekar, Vikram; Matsumoto, Yoichi; Hashimoto, Fukuo; Watkins, Thomas R.

2005-01-01

Residual stress on the machined surface and the subsurface is known to influence the service quality of a component, such as fatigue life, tribological properties, and distortion. Therefore, it is essential to predict and control it for enhanced performance. In this paper, a newly proposed hardness based flow stress model is incorporated into an elastic-viscoplastic finite element model of hard turning to analyze process variables that affect the residual stress profile of the machined surface. The effects of cutting edge geometry and workpiece hardness as well as cutting conditions, such as feed rate and cutting speed, are investigated. Numerical analysis shows that hone edge plus chamfer cutting edge and aggressive feed rate help to increase both compressive residual stress and penetration depth. These predictions are validated by face turning experiments which were conducted using a chamfer with hone cutting edge for different material hardness and cutting parameters. The residual stresses under the machined surface are measured by X-ray diffraction/electropolishing method. A maximum circumferential residual stress of about 1700 MPa at a depth of 40 μm is reached for hardness of 62 HRc and feed rate of 0.56 mm/rev. This represents a significant increase from previously reported results in literatures. It is found from this analysis that using medium hone radius (0.02-0.05 mm) plus chamfer is good for keeping tool temperature and cutting force low, while obtaining desired residual stress profile

Application of the chain saw machine for underground quarry

Energy Technology Data Exchange (ETDEWEB)

Lim, Han-Uk; Baek, Hwan-Jo [Kangwon National University, Chuncheon(Korea); Kim, Chi-Hwan [Woosuk University, Wonju(Korea); Kim, Tae-Soo [Sungshin Mining Co., Jungseun(Korea)

2001-10-31

Many regulatory activities for preservation of the environment make it recently difficult for the stone industry in our country. To reduce environmental hazards and to conserve original surface and woods, some effective underground methods must be adopted. Some new techniques such as chain saw machine, diamond wire saw and water jet cutting can be considered. But application of chain saw machine for underground quarry is proposed in this study. Some technical adoptions with chain saw were carried out at Jungseun marble mine. It is proved that this machine can be effectively adopted to cut dimension stone. With chain saw and diamond wire saw, it can be expected to achieve more effectively cutting the dimension stone. (author). 6 refs., 3 tabs., 6 figs.

Effect of surface machining on corrosion behavior of SA182-304 in simulated

International Nuclear Information System (INIS)

Zhang Zhiming; Wang Jianqiu; Han Enhou; Ke Wei

2015-01-01

Different machining processes of mechanical parts can cause surface damage layers with different levels. The surface deformed layer can affect the corrosion behavior and service life of these mechanical parts a lot during the following service process. As a result, it is a key issue for the fabrication of the mechanical parts with long life that the selection of proper machining parameters and the removal of surface damage. The purpose of this study is to study the influence of different turning parameters on the corrosion behavior of nuclear grade SA182-304 stainless steel widely used in the advanced pressured water reactors (PWRs). 6 kinds of samples with different surface state are prepared by a lathe with different machining parameters, such as the feed, cutting speed and back engagement of the cutting edge. The high temperature and high pressure immersion test of these samples in the simulated PWR primary watershows that machining processes can affect the microstructure and chemical composition of the formed surface oxide scales a lot. According to the experimental results, the proper machining parameters for the studied SA182-304 are suggested. (authors)

Cutting device for a local power range monitor tube

International Nuclear Information System (INIS)

Watanabe, Shigeru; Tsuji, Teruaki.

1976-01-01

Object: To provide a combination of a lifting device for a local power range monitor (LPRM) tube, a cutter and a transfer machine to safely and securely cut the LPRM tube under water. Structure: An LPRM tube is gripped by an LPRM tube gripper, which is moved up and down by a chain drive, through a flexture corrector, and the tip of the LPRM tube is held and released from the LPRM tube gripper so as to be threaded into an LPRM tube cutter to grip it by a transfer gripper of an LPRM tube transfer machine, after which the LPRM tube cutter is operated under pressure water to cut the LPRM tube with a cutter edge so that a cut portion is closed. (Yoshino, Y.)

Influence of the surface layer characteristics on the regularities of the cutting process

Directory of Open Access Journals (Sweden)

Krainev Dmitriy V.

2017-01-01

Full Text Available The article considers the influence of the surface layer characteristics on the regularities of the cutting process and the formation of the quality of the surface machined. This effect has been confirmed by the study results of the combined cutting method with advanced plastic deformation (APD. The work estimates the impact of the change in the surface layer properties on the forces and temperature of cutting, stability of the chip formation and quality parameters of the surface machined.

Reduce, Reuse, Recycle: The Longitudinal Value of Local Cut Scores Using State Test Data

Science.gov (United States)

Nelson, Peter M.; Van Norman, Ethan R.; VanDerHeyden, Amanda

2017-01-01

We used existing reading (n = 1,498) and math (n = 2,260) data to evaluate state test scores for screening middle school students. In Phase 1, state test data were used to create a research-derived cut score that was optimal for predicting state test performance the following year. In Phase 2, those cut scores were applied with future cohorts.…

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.

Investigation of machining damage and tool wear resulting from drilling powder metal aluminum alloy

Energy Technology Data Exchange (ETDEWEB)

Fell, H.A. [Lockheed Martin Energy Systems, Inc., Oak Ridge, TN (United States)

1997-05-01

This report documents the cutting of aluminum powder metallurgy (PM) parts for the North Carolina Manufacturing Extension Partnership. The parts, an aluminum powder metal formulation, were supplied by Sinter Metals Inc., of Conover, North Carolina. The intended use of the alloy is for automotive components. Machining tests were conducted at Y-12 in the machine shop of the Skills Demonstration Center in Building 9737. Testing was done on June 2 and June 3, 1997. The powder metal alloy tested is very abrasive and tends to wear craters and produce erosion effects on the chip washed face of the drills used. It also resulted in huge amounts of flank wear and degraded performance on the part of most drills. Anti-wear coatings on drills seemed to have an effect. Drills with the coating showed less wear for the same amount of cutting. The usefulness of coolants and lubricants in reducing tool wear and chipping/breakout was not investigated.

Electronic vending machines for dispensing rapid HIV self-testing kits: a case study.

Science.gov (United States)

Young, Sean D; Klausner, Jeffrey; Fynn, Risa; Bolan, Robert

2014-02-01

This short report evaluates the feasibility of using electronic vending machines for dispensing oral, fluid, rapid HIV self-testing kits in Los Angeles County. Feasibility criteria that needed to be addressed were defined as: (1) ability to find a manufacturer who would allow dispensing of HIV testing kits and could fit them to the dimensions of a vending machine, (2) ability to identify and address potential initial obstacles, trade-offs in choosing a machine location, and (3) ability to gain community approval for implementing this approach in a community setting. To address these issues, we contracted a vending machine company who could supply a customized, Internet-enabled machine that could dispense HIV kits and partnered with a local health center available to host the machine onsite and provide counseling to participants, if needed. Vending machines appear to be feasible technologies that can be used to distribute HIV testing kits.

Instrumented Impact Testing: Influence of Machine Variables and Specimen Position

International Nuclear Information System (INIS)

Lucon, E.; McCowan, C. N.; Santoyo, R. A.

2008-01-01

An investigation has been conducted on the influence of impact machine variables and specimen positioning on characteristic forces and absorbed energies from instrumented Charpy tests. Brittle and ductile fracture behavior has been investigated by testing NIST reference samples of low, high and super-high energy levels. Test machine variables included tightness of foundation, anvil and striker bolts, and the position of the center of percussion with respect to the center of strike. For specimen positioning, we tested samples which had been moved away or sideways with respect to the anvils. In order to assess the influence of the various factors, we compared mean values in the reference (unaltered) and altered conditions; for machine variables, t-test analyses were also performed in order to evaluate the statistical significance of the observed differences. Our results indicate that the only circumstance which resulted in variations larger than 5 percent for both brittle and ductile specimens is when the sample is not in contact with the anvils. These findings should be taken into account in future revisions of instrumented Charpy test standards.