Experimental investigations of the effects of cutting angle on chattering of a flexible manipulator

NASA Technical Reports Server (NTRS)

Lew, J.; Huggins, J.; Magee, D.; Book, W.

1991-01-01

When a machine tool is mounted at the tip of a robotic manipulator, the manipulator becomes more flexible (the natural frequencies are lowered). Moreover, for a given flexible manipulator, its compliance will be different depending on feedback gains, configurations, and direction of interest. Here, the compliance of a manipulator is derived analytically, and its magnitude is represented as a compliance ellipsoid. Then, using a two-link flexible manipulator with an abrasive cut off saw, the experimental investigation shows that the chattering varies with the saw cutting angle due to different compliance. The main work is devoted to finding a desirable cutting angle which reduces the chattering.

Distribution of contact loads over the flank-land of the cutter with a rounded cutting edge

NASA Astrophysics Data System (ADS)

Kozlov, V.; Gerasimov, A.; Kim, A.

2016-04-01

In this paper, contact conditions between a tool and a workpiece material for wear-simulating turning by a cutter with a sharp-cornered edge and with a rounded cutting edge are analysed. The results of the experimental study of specific contact load distribution over the artificial flank wear-land of the cutter in free orthogonal turning of the disk from titanium alloy (Ti6Al2Mo2Cr), ductile (63Cu) and brittle (57Cu1Al3Mn) brasses are described. Investigations were carried out by the method of ‘split cutter’ and by the method of the artificial flank-land of variable width. The experiments with a variable feed rate and a cutting speed show that in titanium alloy machining with a sharp-cornered cutting edge the highest normal contact load (σh max = 3400…2200 MPa) is observed immediately at the cutting edge, and the curve has a horizontal region with the length of 0.2… 0.6 mm. At a distance from the cutting edge, the value of specific normal contact load is dramatically reduced to 1100…500 MPa. The character of normal contact load for a rounded cutting edge is different -it is uniform, and its value is approximately 2 times smaller compared to machining with a sharp-cornered cutting edge. In author’s opinion it is connected with generation of a seizure zone in a chip formation region and explains the capacity of highly worn-out cutting tools for titanium alloys machining. The paper analyses the distribution of tangential contact loads over the flank land, which pattern differs considerably for machining with a sharp-cornered edge and with a rounded cutting edge. Abbreviation and symbols: m/s - meter per second (cutting speed v); mm/r - millimeter per revolution (feed rate f); MPa - mega Pascal (specific contact load as a stress σ or τ) hf - the width of the flank wear land (chamfer) of the cutting tool, flank wear land can be natural or artificial like the one in this paper [mm]; xh - distance from the cutting edge on the surface of the flank-land [mm]; σh - normal specific contact load on the flank land [MPa]; τh - tangential (shear) specific contact load on the flank land [MPa]; HSS - high speed steel (material of cutting tool); Py - radial component of cutting force [N]; Py r - radial component of cutting force on the rake face [N]; Pz - tangential component of cutting force [N]; γ - rake angle of the cutting tool [°] α - clearance angle of the sharp cutting tool [°] αh - clearance angle of the flank wear land [°] ρ - rounding off radius of the cutting edge [mm]; b - width of the machined disk [mm].

Cutting process simulation of flat drill

NASA Astrophysics Data System (ADS)

Tamura, Shoichi; Matsumura, Takashi

2018-05-01

Flat drills at a point angle of 180 deg. have recently been developed for drilling of automobile parts with the inclination of the workpiece surfaces. The paper studies the cutting processes of the flat drills in the analytical simulation. A predictive force model is applied to simulation of the cutting force with the chip flow direction. The chip flow model is piled up with orthogonal cuttings in the plane containing the cutting velocities and the chip flow velocities, in which the chip flow direction is determined to minimize the cutting energy. Then, the cutting force is predicted in the determined in the chip flow model. The typical cutting force of the flat drill is discussed with comparing to that of the standard drill. The typical differences are confirmed in the cutting force change during the tool engagement and disengagement. The cutting force, then, is simulated in drilling for an inclined workpiece with a flat drill. The horizontal components in the cutting forces are simulated with changing the inclination angle of the plate. The horizontal force component in the flat drilling is stable to be controlled in terms of the machining accuracy and the tool breakage.

Lathe tool bit and holder for machining fiberglass materials

NASA Technical Reports Server (NTRS)

Winn, L. E. (Inventor)

1972-01-01

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

Experimental investigation of piercing of high-strength steels within a critical range of slant angle

NASA Astrophysics Data System (ADS)

Senn, S.; Liewald, M.

2017-09-01

Deep drawn parts often do have complex designs and, therefore, must be trimmed or punched subsequently in a second stage. Due to the complex part geometry, most punching areas do reveal critical slant angle (angle between part surface and ram movement direction) different to perpendicular direction. Piercing within a critical range of slant angle may lead to severe damage of the cutting tool. Consequently, expensive cam units are required to transform the ram moving direction in order to perform the piercing process perpendicularly to the local part surface. For modern sheet metals, however, the described critical angle of attack has not been investigated adequately until now. Therefore, cam units are used in cases in which regular piercing with high slant angle wouldn’t be possible. Purpose of this study is to investigate influencing factors and their effect on punch damage during piercing of high strength steels with slant angles. Therefore, a modular shearing tool was designed, which allows to simply switch die parts to vary cutting clearance and cutting angle. The target size of the study is to measure the lateral deviation of the punch which is monitored by an eddy current sensor. The sensor is located in the downholder and measures the lateral punch deviation in-line during manufacturing. The deviation is mainly influenced by slant angle of workpiece surface. In relation to slang angle and sheet thickness the clearance has a small influence on the measured punch deflection.

An Analysis of the Effects of Chip-groove Geometry on Machining Performance Using Finite Element Methods

NASA Astrophysics Data System (ADS)

Ee, K. C.; Dillon, O. W.; Jawahir, I. S.

2004-06-01

This paper discusses the influence of major chip-groove parameters of a cutting tool on the chip formation process in orthogonal machining using finite element (FE) methods. In the FE formulation, a thermal elastic-viscoplastic material model is used together with a modified Johnson-Cook material law for the flow stress. The chip back-flow angle and the chip up-curl radius are calculated for a range of cutting conditions by varying the chip-groove parameters. The analysis provides greater understanding of the effectiveness of chip-groove configurations and points a way to correlate cutting conditions with tool-wear when machining with a grooved cutting tool.

Ductile-regime turning of germanium and silicon

NASA Technical Reports Server (NTRS)

Blake, Peter N.; Scattergood, Ronald O.

1989-01-01

Single-point diamond turning of silicon and germanium was investigated in order to clarify the role of cutting depth in coaxing a ductile chip formation in normally brittle substances. Experiments based on the rapid withdrawal of the tool from the workpiece have shown that microfracture damage is a function of the effective depth of cut (as opposed to the nominal cutting depth). In essence, damage created by the leading edge of the tool is removed several revolutions later by lower sections of the tool edge, where the effective cutting depth is less. It appears that a truly ductile cutting response can be achieved only when the effective cutting depth, or critical chip thickness, is less than about 20 nm. Factors such as tool rake angle are significant in that they will affect the actual value of the critical chip thickness for transition from brittle to ductile response. It is concluded that the critical chip thickness is an excellent parameter for measuring the effects of machining conditions on the ductility of the cut and for designing tool-workpiece geometry in both turning and grinding.

Tool geometry and damage mechanisms influencing CNC turning efficiency of Ti6Al4V

NASA Astrophysics Data System (ADS)

Suresh, Sangeeth; Hamid, Darulihsan Abdul; Yazid, M. Z. A.; Nasuha, Nurdiyanah; Ain, Siti Nurul

2017-12-01

Ti6Al4V or Grade 5 titanium alloy is widely used in the aerospace, medical, automotive and fabrication industries, due to its distinctive combination of mechanical and physical properties. Ti6Al4V has always been perverse during its machining, strangely due to the same mix of properties mentioned earlier. Ti6Al4V machining has resulted in shorter cutting tool life which has led to objectionable surface integrity and rapid failure of the parts machined. However, the proven functional relevance of this material has prompted extensive research in the optimization of machine parameters and cutting tool characteristics. Cutting tool geometry plays a vital role in ensuring dimensional and geometric accuracy in machined parts. In this study, an experimental investigation is actualized to optimize the nose radius and relief angles of the cutting tools and their interaction to different levels of machining parameters. Low elastic modulus and thermal conductivity of Ti6Al4V contribute to the rapid tool damage. The impact of these properties over the tool tips damage is studied. An experimental design approach is utilized in the CNC turning process of Ti6Al4V to statistically analyze and propose optimum levels of input parameters to lengthen the tool life and enhance surface characteristics of the machined parts. A greater tool nose radius with a straight flank, combined with low feed rates have resulted in a desirable surface integrity. The presence of relief angle has proven to aggravate tool damage and also dimensional instability in the CNC turning of Ti6Al4V.

Investigation of the Effect of Tool Edge Geometry upon Cutting Variables, Tool Wear and Burr Formation Using Finite Element Simulation — A Progress Report

NASA Astrophysics Data System (ADS)

Sartkulvanich, Partchapol; Al-Zkeri, Ibrahim; Yen, Yung-Chang; Altan, Taylan

2004-06-01

This paper summarizes some of the progress made on FEM simulations of metal cutting processes conducted at the Engineering Research Center (ERC/NSM). Presented research focuses on the performance of various cutting edge geometries (hone and chamfer edges) for different tool materials and specifically on: 1) the effect of round and chamfer edge geometries on the cutting variables in machining carbon steels and 2) the effect of the edge hone size upon the flank wear and burr formation behavior in face milling of A356-T6 aluminum alloy. In the second task, an innovative design of edge preparation with varying hone size around the tool nose is also explored using FEM. In order to model three-dimensional conventional turning and face milling with two-dimensional orthogonal cutting simulations, 2D simulation cross-sections consisting of the cutting speed direction and chip flow direction are selected at different locations along the tool nose radius. Then the geometries of the hone and chamfer edges and their associated tool angles as well as uncut chip thickness are determined on these planes and employed in cutting simulations. The chip flow direction on the tool rake face are obtained by examining the wear grooves on the experimental inserts or estimated by using Oxley's approximation theory of oblique cutting. Simulation results are compared with the available experimental results (e.g. cutting forces) both qualitatively and quantitatively.

Experimental evaluation of tool run-out in micro milling

NASA Astrophysics Data System (ADS)

Attanasio, Aldo; Ceretti, Elisabetta

2018-05-01

This paper deals with micro milling cutting process focusing the attention on tool run-out measurement. In fact, among the effects of the scale reduction from macro to micro (i.e., size effects) tool run-out plays an important role. This research is aimed at developing an easy and reliable method to measure tool run-out in micro milling based on experimental tests and an analytical model. From an Industry 4.0 perspective this measuring strategy can be integrated into an adaptive system for controlling cutting forces, with the objective of improving the production quality, the process stability, reducing at the same time the tool wear and the machining costs. The proposed procedure estimates the tool run-out parameters from the tool diameter, the channel width, and the phase angle between the cutting edges. The cutting edge phase measurement is based on the force signal analysis. The developed procedure has been tested on data coming from micro milling experimental tests performed on a Ti6Al4V sample. The results showed that the developed procedure can be successfully used for tool run-out estimation.

Tool Forces and Chip Types In Orthogonal Cutting Of Southern Hardwoods

Treesearch

G.E. Woodson

1979-01-01

Specimens (l/8 to l/4 inch thick) from 5 trees of each of 22 hardwood species were cut orthogonally at 5 inches per minute. Average parallel and normal cutting forces for various rake angles (50, 60, and 70 degrees for veneer; 10, 20, and 30 degrees for planing; 20, 30, and 40 degrees for crosscutting) were measured at three moisture contents (10 percent, 20 percent,...

Automated Laser Cutting In Three Dimensions

NASA Technical Reports Server (NTRS)

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.

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

NASA Astrophysics Data System (ADS)

Khidhir, Basim A.; Mohamed, Bashir

2011-02-01

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.

Investigating the Effect of Approach Angle and Nose Radius on Surface Quality of Inconel 718

NASA Astrophysics Data System (ADS)

Kumar, Sunil; Singh, Dilbag; Kalsi, Nirmal S.

2017-11-01

This experimental work presents a surface quality evaluation of a Nickel-Cr-Fe based Inconel 718 superalloy, which has many applications in the aero engine and turbine components. However, during machining, the early wear of tool leads to decrease in surface quality. The coating on cutting tool plays a significant role in increasing the wear resistance and life of the tool. In this work, the aim is to study the surface quality of Inconel 718 with TiAlN-coated carbide tools. Influence of various geometrical parameters (tool nose radius, approach angle) and machining variables (cutting velocity, feed rate) on the quality of machined surface (surface roughness) was determined by using central composite design (CCD) matrix. The mathematical model of the same was developed. Analysis of variance was used to find the significance of the parameters. Results showed that the tool nose radius and feed were the main active factors. The present experiment accomplished that TiAlN-coated carbide inserts result in better surface quality as compared with uncoated carbide inserts.

Nanometric edge profile measurement of cutting tools on a diamond turning machine

NASA Astrophysics Data System (ADS)

Asai, Takemi; Arai, Yoshikazu; Cui, Yuguo; Gao, Wei

2008-10-01

Single crystal diamond tools are used for fabrication of precision parts [1-5]. Although there are many types of tools that are supplied, the tools with round nose are popular for machining very smooth surfaces. Tools with small nose radii, small wedge angles and included angles are also being utilized for fabrication of micro structured surfaces such as microlens arrays [6], diffractive optical elements and so on. In ultra precision machining, tools are very important as a part of the machining equipment. The roughness or profile of machined surface may become out of desired tolerance. It is thus necessary to know the state of the tool edge accurately. To meet these requirements, an atomic force microscope (AFM) for measuring the 3D edge profiles of tools having nanometer-scale cutting edge radii with high resolution has been developed [7-8]. Although the AFM probe unit is combined with an optical sensor for aligning the measurement probe with the tools edge top to be measured in short time in this system, this time only the AFM probe unit was used. During the measurement time, that was attached onto the ultra precision turning machine to confirm the possibility of profile measurement system.

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

PubMed

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.

Computer-aided analysis of cutting processes for brittle materials

NASA Astrophysics Data System (ADS)

Ogorodnikov, A. I.; Tikhonov, I. N.

2017-12-01

This paper is focused on 3D computer simulation of cutting processes for brittle materials and silicon wafers. Computer-aided analysis of wafer scribing and dicing is carried out with the use of the ANSYS CAE (computer-aided engineering) software, and a parametric model of the processes is created by means of the internal ANSYS APDL programming language. Different types of tool tip geometry are analyzed to obtain internal stresses, such as a four-sided pyramid with an included angle of 120° and a tool inclination angle to the normal axis of 15°. The quality of the workpieces after cutting is studied by optical microscopy to verify the FE (finite-element) model. The disruption of the material structure during scribing occurs near the scratch and propagates into the wafer or over its surface at a short range. The deformation area along the scratch looks like a ragged band, but the stress width is rather low. The theory of cutting brittle semiconductor and optical materials is developed on the basis of the advanced theory of metal turning. The fall of stress intensity along the normal on the way from the tip point to the scribe line can be predicted using the developed theory and with the verified FE model. The crystal quality and dimensions of defects are determined by the mechanics of scratching, which depends on the shape of the diamond tip, the scratching direction, the velocity of the cutting tool and applied force loads. The disunity is a rate-sensitive process, and it depends on the cutting thickness. The application of numerical techniques, such as FE analysis, to cutting problems enhances understanding and promotes the further development of existing machining technologies.

Ductile cutting of silicon microstructures with surface inclination measurement and compensation by using a force sensor integrated single point diamond tool

NASA Astrophysics Data System (ADS)

Chen, Yuan-Liu; Cai, Yindi; Shimizu, Yuki; Ito, So; Gao, Wei; Ju, Bing-Feng

2016-02-01

This paper presents a measurement and compensation method of surface inclination for ductile cutting of silicon microstructures by using a diamond tool with a force sensor based on a four-axis ultra-precision lathe. The X- and Y-directional inclinations of a single crystal silicon workpiece with respect to the X- and Y-motion axes of the lathe slides were measured respectively by employing the diamond tool as a touch-trigger probe, in which the tool-workpiece contact is sensitively detected by monitoring the force sensor output. Based on the measurement results, fabrication of silicon microstructures can be thus carried out directly along the tilted silicon workpiece by compensating the cutting motion axis to be parallel to the silicon surface without time-consuming pre-adjustment of the surface inclination or turning of a flat surface. A diamond tool with a negative rake angle was used in the experiment for superior ductile cutting performance. The measurement precision by using the diamond tool as a touch-trigger probe was investigated. Experiments of surface inclination measurement and ultra-precision ductile cutting of a micro-pillar array and a micro-pyramid array with inclination compensation were carried out respectively to demonstrate the feasibility of the proposed method.

Combination of Ultrasonic Vibration and Cryogenic Cooling for Cutting Performance Improvement of Inconel 718 Turning

NASA Astrophysics Data System (ADS)

Lin, S. Y.; Chung, C. T.; Cheng, Y. Y.

2011-01-01

The main objective of this study is to develop a thermo-elastic-plastic coupling model, based on a combination skill of ultrasonically assisted cutting and cryogenic cooling, under large deformation for Inconel 718 alloy machining process. The improvement extent on cutting performance and tool life promotion may be examined from this investigation. The critical value of the strain energy density of the workpiece will be utilized as the chip separation and the discontinuous chip segmentation criteria. The forced convection cooling and a hydrodynamic lubrication model will be considered and formulated in the model. Finite element method will be applied to create a complete numerical solution for this ultrasonic vibration cutting model. During the analysis, the cutting tool is incrementally advanced forward with superimposed ultrasonic vibration in a back and forth step-by-step manner, from an incipient stage of tool-workpiece engagement to a steady state of chip formation, a whole simulation of orthogonal cutting process under plane strain deformation is thus undertaken. High shear strength induces a fluctuation phenomenon of shear angle, high shear strain rate, variation of chip types and chip morphology, tool-chip contact length variation, the temperature distributions within the workpiece, chip and tool, periodic fluctuation in cutting forces can be determined from the developed model. A complete comparison of machining characteristics between some different combinations of ultrasonically assisted cutting and cryogenic cooling with conventional cutting operation can be acquired. Finally, the high-speed turning experiment for Inconel 718 alloy will be taken in the laboratory to validate the accuracy of the model, and the progressive flank wear, crater wear, notching and chipping of the tool edge can also be measured in the experiments.

Process Damping and Cutting Tool Geometry in Machining

NASA Astrophysics Data System (ADS)

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.

Sharper angle, higher risk? The effect of cutting angle on knee mechanics in invasion sport athletes.

PubMed

Schreurs, Mervin J; Benjaminse, Anne; Lemmink, Koen A P M

2017-10-03

Cutting is an important skill in team-sports, but unfortunately is also related to non-contact ACL injuries. The purpose was to examine knee kinetics and kinematics at different cutting angles. 13 males and 16 females performed cuts at different angles (45°, 90°, 135° and 180°) at maximum speed. 3D kinematics and kinetics were collected. To determine differences across cutting angles (45°, 90°, 135° and 180°) and sex (female, male), a 4×2 repeated measures ANOVA was conducted followed by post hoc comparisons (Bonferroni) with alpha level set at α≤0.05a priori. At all cutting angles, males showed greater knee flexion angles than females (p<0.01). Also, where males performed all cutting angles with no differences in the amount of knee flexion -42.53°±8.95°, females decreased their knee flexion angle from -40.6°±7.2° when cutting at 45° to -36.81°±9.10° when cutting at 90°, 135° and 180° (p<0.01). Knee flexion moment decreased for both sexes when cutting towards sharper angles (p<0.05). At 90°, 135° and 180°, males showed greater knee valgus moments than females. For both sexes, knee valgus moment increased towards the sharper cutting angles and then stabilized compared to the 45° cutting angle (p<0.01). Both females and males showed smaller vGRF when cutting to sharper angles (p<0.01). It can be concluded that different cutting angles demand different knee kinematics and kinetics. Sharper cutting angles place the knee more at risk. However, females and males handle this differently, which has implications for injury prevention. Copyright © 2017 Elsevier Ltd. All rights reserved.

The effect of workstation and task variables on forces applied during simulated meat cutting.

PubMed

McGorry, Raymond W; Dempsey, Patrick G; O'Brien, Niall V

2004-12-01

The purpose of the study was to investigate factors related to force and postural exposure during a simulated meat cutting task. The hypothesis was that workstation, tool and task variables would affect the dependent kinetic variables of gripping force, cutting moment and the dependent kinematic variables of elbow elevation and wrist angular displacement in the flexion/extension and radial/ulnar deviation planes. To evaluate this hypothesis a 3 x 3 x 2 x 2 x 2 (surface orientation by surface height by blade angle by cut complexity by work pace) within-subject factorial design was conducted with 12 participants. The results indicated that the variables can act and interact to modify the kinematics and kinetics of a cutting task. Participants used greater grip force and cutting moment when working at a pace based on productivity. The interactions of the work surface height and orientation indicated that the use of an adjustable workstation could minimize wrist deviation from neutral and improve shoulder posture during cutting operations. Angling the knife blade also interacted with workstation variables to improve wrist and upper extremity posture, but this benefit must be weighed against the potential for small increases in force exposure.

The cutting edge - Micro-CT for quantitative toolmark analysis of sharp force trauma to bone.

PubMed

Norman, D G; Watson, D G; Burnett, B; Fenne, P M; Williams, M A

2018-02-01

Toolmark analysis involves examining marks created on an object to identify the likely tool responsible for creating those marks (e.g., a knife). Although a potentially powerful forensic tool, knife mark analysis is still in its infancy and the validation of imaging techniques as well as quantitative approaches is ongoing. This study builds on previous work by simulating real-world stabbings experimentally and statistically exploring quantitative toolmark properties, such as cut mark angle captured by micro-CT imaging, to predict the knife responsible. In Experiment 1 a mechanical stab rig and two knives were used to create 14 knife cut marks on dry pig ribs. The toolmarks were laser and micro-CT scanned to allow for quantitative measurements of numerous toolmark properties. The findings from Experiment 1 demonstrated that both knives produced statistically different cut mark widths, wall angle and shapes. Experiment 2 examined knife marks created on fleshed pig torsos with conditions designed to better simulate real-world stabbings. Eight knives were used to generate 64 incision cut marks that were also micro-CT scanned. Statistical exploration of these cut marks suggested that knife type, serrated or plain, can be predicted from cut mark width and wall angle. Preliminary results suggest that knives type can be predicted from cut mark width, and that knife edge thickness correlates with cut mark width. An additional 16 cut marks walls were imaged for striation marks using scanning electron microscopy with results suggesting that this approach might not be useful for knife mark analysis. Results also indicated that observer judgements of cut mark shape were more consistent when rated from micro-CT images than light microscopy images. The potential to combine micro-CT data, medical grade CT data and photographs to develop highly realistic virtual models for visualisation and 3D printing is also demonstrated. This is the first study to statistically explore simulated real-world knife marks imaged by micro-CT to demonstrate the potential of quantitative approaches in knife mark analysis. Findings and methods presented in this study are relevant to both forensic toolmark researchers as well as practitioners. Limitations of the experimental methodologies and imaging techniques are discussed, and further work is recommended. Copyright © 2017 Elsevier B.V. All rights reserved.

Impact of novel shift handle laparoscopic tool on wrist ergonomics and task performance

PubMed Central

Yu, Denny; Lowndes, Bethany; Morrow, Missy; Kaufman, Kenton; Bingener, Juliane; Hallbeck, Susan

2015-01-01

Background Laparoscopic tool handles causing wrist flexion and extension more than 15° from neutral are considered “at-risk” for musculoskeletal strain. Therefore this study measured the impact of laparoscopic tool handle angles on wrist postures and task performance. Methods Eight surgeons performed standard and modified Fundamentals of Laparoscopic Surgery (FLS) tasks with laparoscopic tools. Tool A had three adjustable handle angle configurations, i.e., in-line 0° (A0), 30° (A30), and pistol-grip 70° (A70). Tool B was a fixed pistol-grip grasper. Participants performed FLS peg transfer, inverted peg transfer, and inverted circle-cut with each tool and handle angle. Inverted tasks were adapted from standard FLS tasks to simulate advanced tasks observed during abdominal wall surgeries, e.g., ventral hernia. Motion tracking, video-analysis, and modified NASA-TLX workload questionnaires were used to measure postures, performance (e.g., completion time and errors), and workload. Results Task performance did not differ among tools. For FLS peg transfer, self-reported physical workload was lower for B than A70, and mean wrist postures showed significantly higher flexion for in-line than pistol-grip tools (B and A70). For inverted peg transfer, workload was higher for all configurations. However, less time was spent in at-risk wrist postures for in-line (47%) than pistol-grip (93-94%), and most participants preferred Tool A. For inverted circle cut, workload did not vary across configurations, mean wrist posture was 10° closer to neutral for A0 than B, and median time in at-risk wrist postures was significantly less for A0 (43%) than B (87%). Conclusion The best ergonomic wrist positions for FLS (floor) tasks are provided by pistol-grip tools and for tasks on the abdominal wall (ventral surface) by in-line handles. Adjustable handle angle laparoscopic tools can reduce ergonomic risks for musculoskeletal strain and allow versatility for tasks alternating between the floor and ceiling positions in a surgical trainer without impacting performance. PMID:26541720

Impact of novel shift handle laparoscopic tool on wrist ergonomics and task performance.

PubMed

Yu, Denny; Lowndes, Bethany; Morrow, Missy; Kaufman, Kenton; Bingener, Juliane; Hallbeck, Susan

2016-08-01

Laparoscopic tool handles causing wrist flexion and extension more than 15° from neutral are considered "at risk" for musculoskeletal strain. Therefore, this study measured the impact of laparoscopic tool handle angles on wrist postures and task performance. Eight surgeons performed standard and modified Fundamentals of Laparoscopic Surgery (FLS) tasks with laparoscopic tools. Tool A had three adjustable handle angle configurations, i.e., in-line 0° (A0), 30° (A30), and pistol-grip 70° (A70). Tool B was a fixed pistol-grip grasper. Participants performed FLS peg transfer, inverted peg transfer, and inverted circle cut with each tool and handle angle. Inverted tasks were adapted from standard FLS tasks to simulate advanced tasks observed during abdominal wall surgeries, e.g., ventral hernia. Motion tracking, video analysis, and modified NASA-TLX workload questionnaires were used to measure postures, performance (e.g., completion time and errors), and workload. Task performance did not differ between tools. For FLS peg transfer, self-reported physical workload was lower for B than for A70, and mean wrist postures showed significantly higher flexion for in-line than for pistol-grip tools (B and A70). For inverted peg transfer, workload was higher for all configurations. However, less time was spent in at-risk wrist postures for in-line (47 %) than for pistol-grip (93-94 %), and most participants preferred Tool A. For inverted circle cut, workload did not vary across configurations, mean wrist posture was 10° closer to neutral for A0 than B, and median time in at-risk wrist postures was significantly less for A0 (43 %) than for B (87 %). The best ergonomic wrist positions for FLS (floor) tasks are provided by pistol-grip tools and for tasks on the abdominal wall (ventral surface) by in-line handles. Adjustable handle angle laparoscopic tools can reduce ergonomic risks of musculoskeletal strain and allow versatility for tasks alternating between the floor and ceiling positions in a surgical trainer without impacting performance.

On the closed form mechanistic modeling of milling: Specific cutting energy, torque, and power

NASA Astrophysics Data System (ADS)

Bayoumi, A. E.; Yücesan, G.; Hutton, D. V.

1994-02-01

Specific energy in metal cutting, defined as the energy expended in removing a unit volume of workpiece material, is formulated and determined using a previously developed closed form mechanistic force model for milling operations. Cutting power is computed from the cutting torque, cutting force, kinematics of the cutter, and the volumetric material removal rate. Closed form expressions for specific cutting energy were formulated and found to be functions of the process parameters: pressure and friction for both rake and flank surfaces and chip flow angle at the rake face of the tool. Friction is found to play a very important role in cutting torque and power. Experiments were carried out to determine the effects of feedrate, cutting speed, workpiece material, and flank wear land width on specific cutting energy. It was found that the specific cutting energy increases with a decrease in the chip thickness and with an increase in flank wear land.

Development of a computer controlled underbody plow.

DOT National Transportation Integrated Search

2007-01-01

Underbody plows can be very useful tools in winter maintenance, especially when compacted snow or hard ice must be removed from the roadway. By the application of significant down-force, and the use of an appropriate cutting edge angle, compacted sno...

Fundamentals of cutting.

PubMed

Williams, J G; Patel, Y

2016-06-06

The process of cutting is analysed in fracture mechanics terms with a view to quantifying the various parameters involved. The model used is that of orthogonal cutting with a wedge removing a layer of material or chip. The behaviour of the chip is governed by its thickness and for large radii of curvature the chip is elastic and smooth cutting occurs. For smaller thicknesses, there is a transition, first to plastic bending and then to plastic shear for small thicknesses and smooth chips are formed. The governing parameters are tool geometry, which is principally the wedge angle, and the material properties of elastic modulus, yield stress and fracture toughness. Friction can also be important. It is demonstrated that the cutting process may be quantified via these parameters, which could be useful in the study of cutting in biology.

Knee joint kinematics and kinetics during the hop and cut after soft tissue artifact suppression: Time to reconsider ACL injury mechanisms?

PubMed

Smale, Kenneth B; Potvin, Brigitte M; Shourijeh, Mohammad S; Benoit, Daniel L

2017-09-06

The recent development of a soft tissue artifact (STA) suppression method allows us to re-evaluate the tibiofemoral kinematics currently linked to non-contact knee injuries. The purpose of this study was therefore to evaluate knee joint kinematics and kinetics in six degrees of freedom (DoF) during the loading phases of a jump lunge and side cut using this in silico method. Thirty-five healthy adults completed these movements and their surface marker trajectories were then scaled and processed with OpenSim's inverse kinematics (IK) and inverse dynamics tools. Knee flexion angle-dependent kinematic constraints defined based on previous bone pin (BP) marker trajectories were then applied to the OpenSim model during IK and these constrained results were then processed with the standard inverse dynamics tool. Significant differences for all hip, knee, and ankle DoF were observed after STA suppression for both the jump lunge and side cut. Using clinically relevant effect size estimates, we conclude that STA contamination had led to misclassifications in hip transverse plane angles, knee frontal and transverse plane angles, medial/lateral and distractive/compressive knee translations, and knee frontal plane moments between the NoBP and the BP IK solutions. Our results have substantial clinical implications since past research has used joint kinematics and kinetics contaminated by STA to identify risk factors for musculoskeletal injuries. Copyright © 2017 Elsevier Ltd. All rights reserved.

Study of the performances of nano-case treatment cutting tools on carbon steel work material during turning operation

NASA Astrophysics Data System (ADS)

Afolalu, S. A.; Okokpujie, I. P.; Salawu, E. Y.; Abioye, A. A.; Abioye, O. P.; Ikumapayi, O. M.

2018-04-01

The degree of holding temperature and time play a major role in nano-case treatment of cutting tools which immensely contributed to its performance during machining operation. The objective of this research work is to carryout comparative study of performance of nano-case treatment tools developed using low and medium carbon steel as work piece. Turning operation was carried out under two different categories with specific work piece on universal lathe machine using HSS cutting tools 100 mm × 12mm × 12mm that has been nano-case treated under varying conditions of temperatures and timeof 800,850, 900, 950°C and 60, 90, 120 mins respectively. The turning parameters used in evaluating this experiment were cutting speed of 270, 380 and 560mm/min, feed rate of 0.15, 0.20 and 0.25 mm/min, depth of cut of 2mm, work piece diameter of 25mm and rake angle of 7° each at three levels. The results of comparative study of their performances revealed that the timespent in the machining of low carbon steel material at a minimum temperature and time of 800°C, 60 mins were1.50, 2.17 mins while at maximum temperature and time of 950°C, 120 mins were 1.19, 2.02 mins. It was also observed that at a corresponding constant speed of 270,380 and 560mm/min at higher temperature and time, a relative increased in the length of cut were observed. Critical observation of the result showed that at higher case hardening temperature and time (950°C/120mins), the HSS cutting tool gave a better performance as lesser time was consumed during the turning operation.

Influence of the cutting edge angle of a titanium instrument on chip formation in the machining of trabecular and cortical bone.

PubMed

von See, Constantin; Stoetzer, Marcus; Ruecker, Martin; Wagner, Max; Schumann, Paul; Gellrich, Nils-Claudius

2014-01-01

The placement of self-tapping implants is associated with microfractures and the formation of bone chips along the cutting flutes. This study was conducted to investigate the effect of different cutting edge angles on chip formation during the machining of trabecular and cortical bone using instruments with a rough titanium surface. Mandibular cortical and trabecular bone specimens were obtained from freshly slaughtered domestic pigs. A predefined thrust force was applied to the specimens. Four specially designed cutting instruments that simulated dental implants and had a rough titanium surface were allowed to complete one full revolution at cutting edge angles of 55, 65, 75, and 85 degrees, respectively. Torque and thrust were measured during the cutting process. Bone chips were measured and weighed under a microscope. Different cutting edge angles did not lead to significant differences in torque. The lowest torque values were measured when the cutting edges were positioned at 65 degrees in trabecular bone and at 85 degrees in cortical bone. Bone chips were significantly larger and heavier at angles of 55 and 65 degrees than at angles of 75 and 85 degrees in trabecular bone. Instruments with a rough titanium surface show considerable angle-dependent differences in chip formation. In addition to bone density, the angle of the cutting edges should be taken into consideration during the placement of dental implants. Good results were obtained when the cutting edges were positioned at an angle of 65 degrees. This angle can have positive effects on osseointegration.

Tool holder for preparation and inspection of a radiused edge cutting tool

DOEpatents

Asmanes, Charles

1979-01-01

A tool holding fixture is provided for removably holding a radiused edge cutting tool in a tool edge lapping apparatus. The fixture allows the operator to preset the lapping radius and angle before the tool holder is placed in the fixture and the holder may be removed from the lapping apparatus to inspect the tool and simply replaced in the fixture to continue lapping in accordance with a precise alignment without realignment of the tool relative to the lap. The tool holder includes a pair of self aligning bearings in the form of precision formed steel balls connected together by a rigid shaft. The tool is held by an arm extending from the shaft and the balls set in fixed position bearing cups and the holder is oscillated back and forth about a fixed axis of rotation to lap the tool radius by means of a reversibly driven belt-pulley arrangement coupled to the shaft between the bearings. To temporarily remove the holder, the drive belt is slipped over the rearward end of the holder and the holder is lifted out of the bearing cups.

Mining planer with pivotal tool holder

DOE Office of Scientific and Technical Information (OSTI.GOV)

Braun, E.; Braun, G.

1983-10-04

A planer assembly is disclosed for winning minerals from a mineral face comprising, a planer guide member, at least two planers slidably engaged on the guide member for movement in a travel direction along the face, a hinge interconnecting the two planers for transferring rotational moment applied to the planers and a planer tool holder mounted on each planer which carries a tool. The planer tool holder is positionable at an angle to make a cut of a selected depth with the depth increasing from planer to planer in a direction opposite the travel direction.

Effect of Cutting Angle and Depth of Cut on the Occurrence of Chipped Grain on Sycamore

Treesearch

Harold A. Stewart

1970-01-01

Sycamore specimens were planned with various combinations of depths of cut and rake angles. Depths of cut up to 1/16 inch had no significant effect on the occurrence of chipped grain in sycamore but rake angle did.

Effect of Forefoot Strike on Lower Extremity Muscle Activity and Knee Joint Angle During Cutting in Female Team Handball Players.

PubMed

Yoshida, Naruto; Kunugi, Shun; Mashimo, Sonoko; Okuma, Yoshihiro; Masunari, Akihiko; Miyazaki, Shogo; Hisajima, Tatsuya; Miyakawa, Shumpei

2015-06-01

The purpose of this study is to examine the effects of different strike forms, during cutting, on knee joint angle and lower limb muscle activity. Surface electromyography was used to measure muscle activity in individuals performing cutting manoeuvres involving either rearfoot strikes (RFS) or forefoot strikes (FFS). Three-dimensional motion analysis was used to calculate changes in knee angles, during cutting, and to determine the relationship between muscle activity and knee joint angle. Force plates were synchronized with electromyography measurements to compare muscle activity immediately before and after foot strike. The valgus angle tends to be smaller during FFS cutting than during RFS cutting. Just prior to ground contact, biceps femoris, semitendinosus, and lateral head of the gastrocnemius muscle activities were significantly greater during FFS cutting than during RFS cutting; tibialis anterior muscle activity was greater during RFS cutting. Immediately after ground contact, biceps femoris and lateral head of the gastrocnemius muscle activities were significantly greater during FFS cutting than during RFS cutting; tibialis anterior muscle activity was significantly lower during FFS cutting. The results of the present study suggest that the hamstrings demonstrate greater activity, immediately after foot strike, during FFS cutting than during RFS cutting. Thus, FFS cutting may involve a lower risk of anterior cruciate ligament injury than does RFS cutting.

Predictors of Frontal Plane Knee Moments During Side-Step Cutting to 45 and 110 Degrees in Men and Women: Implications for Anterior Cruciate Ligament Injury.

PubMed

Sigward, Susan M; Cesar, Guilherme M; Havens, Kathryn L

2015-11-01

To compare frontal plane knee moments, and kinematics and kinetics associated with knee valgus moments between cutting to 45 and 110 degrees, and to determine the predictive value of kinematics and ground reaction forces (GRFs) on knee valgus moments when cutting to these angles. Also, to determine whether sex differences exist in kinematics and kinetics when cutting to 45 and 110 degrees. Cross-sectional study. Laboratory setting. Forty-five (20 females) healthy young adult soccer athletes aged 16 to 23 years. Kinematic and kinetic variables were compared between randomly cued side-step cutting maneuvers to 45 and 110 degrees. Predictors of knee valgus moment were determined for each task. Kinematic variables: knee valgus angle, hip abduction, and internal rotation angles. Kinetic variables: vertical, posterior, and lateral GRFs, and knee valgus moment. Knee valgus moments were greater when cutting to 110 degrees compared with 45 degrees, and females exhibited greater moments than males. Vertical and lateral GRFs, hip internal rotation angle, and knee valgus angle explained 63% of the variance in knee valgus moment during cutting to 45 degrees. During cutting to 110 degrees, posterior GRF, hip internal rotation angle, and knee valgus angle explained 41% of the variance in knee valgus moment. Cutting tasks with larger redirection demands result in greater knee valgus moments. Similar factors, including shear GRFs, hip internal rotation, and knee valgus position contribute to knee valgus loading during cuts performed to smaller (45 degrees) and larger (110 degrees) angles. Reducing vertical and shear GRFs during cutting maneuvers may reduce knee valgus moments and thereby potentially reduce risk for anterior cruciate ligament injury.

Application of Taguchi-grey method to optimize drilling of EMS 45 steel using minimum quantity lubrication (MQL) with multiple performance characteristics

NASA Astrophysics Data System (ADS)

Soepangkat, Bobby O. P.; Suhardjono, Pramujati, Bambang

2017-06-01

Machining under minimum quantity lubrication (MQL) has drawn the attention of researchers as an alternative to the traditionally used wet and dry machining conditions with the purpose to minimize the cooling and lubricating cost, as well as to reduce cutting zone temperature, tool wear, and hole surface roughness. Drilling is one of the important operations to assemble machine components. The objective of this study was to optimize drilling parameters such as cutting feed and cutting speed, drill type and drill point angle on the thrust force, torque, hole surface roughness and tool flank wear in drilling EMS 45 tool steel using MQL. In this study, experiments were carried out as per Taguchi design of experiments while an L18 orthogonal array was used to study the influence of various combinations of drilling parameters and tool geometries on the thrust force, torque, hole surface roughness and tool flank wear. The optimum drilling parameters was determined by using grey relational grade obtained from grey relational analysis for multiple-performance characteristics. The drilling experiments were carried out by using twist drill and CNC machining center. This work is useful for optimum values selection of various drilling parameters and tool geometries that would not only minimize the thrust force and torque, but also reduce hole surface roughness and tool flank wear.

Strategies for single-point diamond machining a large format germanium blazed immersion grating

NASA Astrophysics Data System (ADS)

Montesanti, R. C.; Little, S. L.; Kuzmenko, P. J.; Bixler, J. V.; Jackson, J. L.; Lown, J. G.; Priest, R. E.; Yoxall, B. E.

2016-07-01

A large format germanium immersion grating was flycut with a single-point diamond tool on the Precision Engineering Research Lathe (PERL) at the Lawrence Livermore National Laboratory (LLNL) in November - December 2015. The grating, referred to as 002u, has an area of 59 mm x 67 mm (along-groove and cross-groove directions), line pitch of 88 line/mm, and blaze angle of 32 degree. Based on total groove length, the 002u grating is five times larger than the previous largest grating (ZnSe) cut on PERL, and forty-five times larger than the previous largest germanium grating cut on PERL. The key risks associated with cutting the 002u grating were tool wear and keeping the PERL machine running uninterrupted in a stable machining environment. This paper presents the strategies employed to mitigate these risks, introduces pre-machining of the as-etched grating substrate to produce a smooth, flat, damage-free surface into which the grooves are cut, and reports on trade-offs that drove decisions and experimental results.

Exploring the influence of constitutive models and associated parameters for the orthogonal machining of Ti6Al4V

NASA Astrophysics Data System (ADS)

Pervaiz, S.; Anwar, S.; Kannan, S.; Almarfadi, A.

2018-04-01

Ti6Al4V is known as difficult-to-cut material due to its inherent properties such as high hot hardness, low thermal conductivity and high chemical reactivity. Though, Ti6Al4V is utilized by industrial sectors such as aeronautics, energy generation, petrochemical and bio-medical etc. For the metal cutting community, competent and cost-effective machining of Ti6Al4V is a challenging task. To optimize cost and machining performance for the machining of Ti6Al4V, finite element based cutting simulation can be a very useful tool. The aim of this paper is to develop a finite element machining model for the simulation of Ti6Al4V machining process. The study incorporates material constitutive models namely Power Law (PL) and Johnson – Cook (JC) material models to mimic the mechanical behaviour of Ti6Al4V. The study investigates cutting temperatures, cutting forces, stresses, and plastic strains with respect to different PL and JC material models with associated parameters. In addition, the numerical study also integrates different cutting tool rake angles in the machining simulations. The simulated results will be beneficial to draw conclusions for improving the overall machining performance of Ti6Al4V.

Study of Effect of Impacting Direction on Abrasive Nanometric Cutting Process with Molecular Dynamics

NASA Astrophysics Data System (ADS)

Li, Junye; Meng, Wenqing; Dong, Kun; Zhang, Xinming; Zhao, Weihong

2018-01-01

Abrasive flow polishing plays an important part in modern ultra-precision machining. Ultrafine particles suspended in the medium of abrasive flow removes the material in nanoscale. In this paper, three-dimensional molecular dynamics (MD) simulations are performed to investigate the effect of impacting direction on abrasive cutting process during abrasive flow polishing. The molecular dynamics simulation software Lammps was used to simulate the cutting of single crystal copper with SiC abrasive grains at different cutting angles (0o-45o). At a constant friction coefficient, we found a direct relation between cutting angle and cutting force, which ultimately increases the number of dislocation during abrasive flow machining. Our theoretical study reveal that a small cutting angle is beneficial for improving surface quality and reducing internal defects in the workpiece. However, there is no obvious relationship between cutting angle and friction coefficient.

Study of Effect of Impacting Direction on Abrasive Nanometric Cutting Process with Molecular Dynamics.

PubMed

Li, Junye; Meng, Wenqing; Dong, Kun; Zhang, Xinming; Zhao, Weihong

2018-01-11

Abrasive flow polishing plays an important part in modern ultra-precision machining. Ultrafine particles suspended in the medium of abrasive flow removes the material in nanoscale. In this paper, three-dimensional molecular dynamics (MD) simulations are performed to investigate the effect of impacting direction on abrasive cutting process during abrasive flow polishing. The molecular dynamics simulation software Lammps was used to simulate the cutting of single crystal copper with SiC abrasive grains at different cutting angles (0 o -45 o ). At a constant friction coefficient, we found a direct relation between cutting angle and cutting force, which ultimately increases the number of dislocation during abrasive flow machining. Our theoretical study reveal that a small cutting angle is beneficial for improving surface quality and reducing internal defects in the workpiece. However, there is no obvious relationship between cutting angle and friction coefficient.

Comparison of Accuracy between Side-Cutting Instruments and Front-Cutting Instruments in Minimally Invasive Total Knee Arthroplasty.

PubMed

Pinsornsak, Piya; Harnroongroj, Thos

2016-11-01

The specialized instrument system used in minimally invasive surgery (MIS) has been developed for reducing soft tissue trauma in total knee arthroplasty (TKA). Compared with front-cutting MIS instruments, side-cutting quadriceps sparing MIS instruments have the advantage of creating a smaller incision and causing fewer traumas to the quadriceps tendon. However, the accuracy of side-cutting instruments concerns surgeons in prosthesis malalignment. To compare the accuracy of side-cutting quadriceps sparing instruments versus front-cutting instruments in MIS-TKA. In this prospective randomized controlled study, we compared the accuracy of side-cutting quadriceps sparing instruments versus the front-cutting instruments used in MIS-TKA. Sixty knees were included in the study, with 30 knees in each group. All the operations were performed by single surgeon. Coronal alignment (tibiofemoral angle, lateral distal femoral angle, and medial proximal tibial angle), and sagittal alignment (femoral component flexion and tibial posterior slope) were measured and compared. Tibiofemoral angle, lateral distal femoral angle, and medial proximal tibial angle, all of which are considered in the assessment of acceptable coronal radiographic alignment, were not different between groups (p = 0.353, 0.500, and 0.177, respectively). However, side-cutting quadriceps sparing instruments produced less acceptable sagittal radiographic alignment, femoral component flexion (63% vs. 93%, p = 0.005), and tibial posterior slope (73% vs. 93%, p = 0.04). Side-cutting quadriceps sparing MIS-TKA instruments had similar accuracy to front-cutting MIS-TKA instruments for coronal alignment but is less accurate for sagittal alignment.

Optimum angle-cut of collimator for dense objects in high-energy proton radiography

NASA Astrophysics Data System (ADS)

Xu, Hai-Bo; Zheng, Na

2016-02-01

The use of minus identity lenses with an angle-cut collimator can achieve high contrast images in high-energy proton radiography. This article presents the principles of choosing the angle-cut aperture of the collimator for different energies and objects. Numerical simulation using the Monte Carlo code Geant4 has been implemented to investigate the entire radiography for the French test object. The optimum angle-cut apertures of the collimators are also obtained for different energies. Supported by NSAF (11176001) and Science and Technology Developing Foundation of China Academy of Engineering Physics (2012A0202006)

AN Fitting Reconditioning Tool

NASA Technical Reports Server (NTRS)

Lopez, Jason

2011-01-01

A tool was developed to repair or replace AN fittings on the shuttle external tank (ET). (The AN thread is a type of fitting used to connect flexible hoses and rigid metal tubing that carry fluid. It is a U.S. military-derived specification agreed upon by the Army and Navy, hence AN.) The tool is used on a drill and is guided by a pilot shaft that follows the inside bore. The cutting edge of the tool is a standard-size replaceable insert. In the typical Post Launch Maintenance/Repair process for the AN fittings, the six fittings are removed from the ET's GUCP (ground umbilical carrier plate) for reconditioning. The fittings are inspected for damage to the sealing surface per standard operations maintenance instructions. When damage is found on the sealing surface, the condition is documented. A new AN reconditioning tool is set up to cut and remove the surface damage. It is then inspected to verify the fitting still meets drawing requirements. The tool features a cone-shaped interior at 36.5 , and may be adjusted at a precise angle with go-no-go gauges to insure that the cutting edge could be adjusted as it wore down. One tool, one setting block, and one go-no-go gauge were fabricated. At the time of this reporting, the tool has reconditioned/returned to spec 36 AN fittings with 100-percent success of no leakage. This tool provides a quick solution to repair a leaky AN fitting. The tool could easily be modified with different-sized pilot shafts to different-sized fittings.

Measuring Contours of Coal-Seam Cuts

NASA Technical Reports Server (NTRS)

1983-01-01

Angle transducers measure angle between track sections as longwall shearer proceeds along coal face. Distance transducer functions in conjunction with angle transducers to obtain relative angles at known positions. When cut is complete, accumulated data are stored on cassette tape, and track profile is computed and displayed. Micro-processor-based instrument integrates small changes in angle and distance.

Experimental test of theory for the stability of partially saturated vertical cut slopes

USGS Publications Warehouse

Morse, Michael M.; Lu, N.; Wayllace, Alexandra; Godt, Jonathan W.; Take, W.A.

2014-01-01

This paper extends Culmann's vertical-cut analysis to unsaturated soils. To test the extended theory, unsaturated sand was compacted to a uniform porosity and moisture content in a laboratory apparatus. A sliding door that extended the height of the free face of the slope was lowered until the vertical cut failed. Digital images of the slope cross section and upper surface were acquired concurrently. A recently developed particle image velocimetry (PIV) tool was used to quantify soil displacement. The PIV analysis showed strain localization at varying distances from the sliding door prior to failure. The areas of localized strain were coincident with the location of the slope crest after failure. Shear-strength and soil-water-characteristic parameters of the sand were independently tested for use in extended analyses of the vertical-cut stability and of the failure plane angle. Experimental failure heights were within 22.3% of the heights predicted using the extended theory.

Survival and Growth of Cottonwood Clones After Angle Planting and Base Angle Treatments

Treesearch

W.K. Randall; Harvey E. Kennedy

1976-01-01

Presently, commercial cottonwood plantations in the lower Mississippi Valley are established using vertically planted, unrooted cuttings with a flat (90°) base. Neither survival nor first-year growth of a group of six Stoneville clones was improved by angle planting or cutting base angles diagonally. For one clone, survival was significantly better when base angle was...

Real time computer controlled weld skate

NASA Technical Reports Server (NTRS)

Wall, W. A., Jr.

1977-01-01

A real time, adaptive control, automatic welding system was developed. This system utilizes the general case geometrical relationships between a weldment and a weld skate to precisely maintain constant weld speed and torch angle along a contoured workplace. The system is compatible with the gas tungsten arc weld process or can be adapted to other weld processes. Heli-arc cutting and machine tool routing operations are possible applications.

The Constant Intensity Cut Method applied to the KASCADE-Grande muon data

NASA Astrophysics Data System (ADS)

Arteaga-Velázquez, J. C.; Apel, W. D.; Badea, F.; Bekk, K.; Bertaina, M.; Blümer, J.; Bozdog, H.; Brancus, I. M.; Brüggemann, M.; Buchholz, P.; Cantoni, E.; Chiavassa, A.; Cossavella, F.; Daumiller, K.; de Souza, V.; Di Pierro, F.; Doll, P.; Engel, R.; Engler, J.; Finger, M.; Fuhrmann, D.; Ghia, P. L.; Gils, H. J.; Glasstetter, R.; Grupen, C.; Haungs, A.; Heck, D.; Hörandel, J. R.; Huege, T.; Isar, P. G.; Kampert, K.-H.; Kang, D.; Kickelbick, D.; Klages, H. O.; Kolotaev, Y.; Łuczak, P.; Mathes, H. J.; Mayer, H. J.; Milke, J.; Mitrica, B.; Morello, C.; Navarra, G.; Nehls, S.; Oehlschläger, J.; Ostapchenko, S.; Over, S.; Petcu, M.; Pierog, T.; Rebel, H.; Roth, M.; Schieler, H.; Schröder, F.; Sima, O.; Stümpert, M.; Toma, G.; Trinchero, G.; Ulrich, H.; Walkowiak, W.; Weindl, A.; Wochele, J.; Wommer, M.; Zabierowski, J.

2009-12-01

The constant intensity cut method is a very useful tool to reconstruct the cosmic ray energy spectrum in order to combine or compare extensive air shower data measured for different attenuation depths independently of the MC model. In this contribution the method is used to explore the muon data of the KASCADE-Grande experiment. In particular, with this technique, the measured muon number spectra for different zenith angle ranges are compared and summed up to obtain a single muon spectrum for the measured showers. Preliminary results are presented, along with estimations of the systematic uncertainties associated with the analysis technique.

Pre-Finishing of SiC for Optical Applications

NASA Technical Reports Server (NTRS)

Rozzi, Jay; Clavier, Odile; Gagne, John

2011-01-01

13 Manufacturing & Prototyping A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process. DRM is a deterministic machining process associated with conditions under high hydrostatic pressures and very small depths of cut. Under such conditions, using high negative-rake angle cutting tools, the high-pressure region near the tool corresponds to a plastic zone, where even a brittle material will behave in a ductile manner. In the high-MRR processing step, the objective is to remove material with a sufficiently high rate such that the process is economical, without inducing large-scale subsurface damage. A laser-assisted machining approach was evaluated whereby a CO2 laser was focused in advance of the cutting tool. While CVD (chemical vapor deposition) SiC was successfully machined with this approach, the cutting forces were substantially higher than cuts at room temperature under the same machining conditions. During the experiments, the expansion of the part and the tool due to the heating was carefully accounted for. The higher cutting forces are most likely due to a small reduction in the shear strength of the material compared with a larger increase in friction forces due to the thermal softening effect. The key advantage is that the hybrid machine approach has the potential to achieve optical quality without the need for a separate optical finishing step. Also, this method is scalable, so one can easily progress from machining 50-mm-diameter samples to the 250-mm-diameter mirror that NASA desires.

Shaping Cutter Original Profile for Fine-module Ratchet Teeth Cutting

NASA Astrophysics Data System (ADS)

Sharkov, O. V.; Koryagin, S. I.; Velikanov, N. L.

2018-03-01

The methods for determining geometric characteristics of a theoretical original profile of the cutter for cutting ratchet teeth with a module of 0.3–1.0 mm are considered in the article. Design models describing the shaping process of cutting edges of cutter teeth are developed. Systems of expressions for determining coordinates of the points of front and back edges of cutter teeth; the workpiece angles of rotation during the cutting process; the minimum cutter radius are received. The basic data when using the proposed technique are: radii of circumferences passing through cavities of cutter teeth and external cut teeth; the gradient angle and length of straight section of the front edge of a cut tooth; angles of rotation of the cutter and the workpiece at the moment of shaping.

A data base approach for prediction of deforestation-induced mass wasting events

NASA Technical Reports Server (NTRS)

Logan, T. L.

1981-01-01

A major topic of concern in timber management is determining the impact of clear-cutting on slope stability. Deforestation treatments on steep mountain slopes have often resulted in a high frequency of major mass wasting events. The Geographic Information System (GIS) is a potentially useful tool for predicting the location of mass wasting sites. With a raster-based GIS, digitally encoded maps of slide hazard parameters can be overlayed and modeled to produce new maps depicting high probability slide areas. The present investigation has the objective to examine the raster-based information system as a tool for predicting the location of the clear-cut mountain slopes which are most likely to experience shallow soil debris avalanches. A literature overview is conducted, taking into account vegetation, roads, precipitation, soil type, slope-angle and aspect, and models predicting mass soil movements. Attention is given to a data base approach and aspects of slide prediction.

Optimization design and analysis of the pavement planer scraper structure

NASA Astrophysics Data System (ADS)

Fang, Yuanbin; Sha, Hongwei; Yuan, Dajun; Xie, Xiaobing; Yang, Shibo

2018-03-01

By LS-DYNA, it establishes the finite element model of road milling machine scraper, and analyses the dynamic simulation. Through the optimization of the scraper structure and scraper angle, obtain the optimal structure of milling machine scraper. At the same time, the simulation results are verified. The results show that the scraper structure is improved that cemented carbide is located in the front part of the scraper substrate. Compared with the working resistance before improvement, it tends to be gentle and the peak value is smaller. The cutting front angle and the cutting back angle are optimized. The cutting front angle is 6 degrees and the cutting back angle is 9 degrees. The resultant of forces which contains the working resistance and the impact force is the least. It proves accuracy of the simulation results and provides guidance for further optimization work.

Problems And Their Solutions When Thin-Walled Turned Parts Of High Precision With Quasi-Optical Surfaces Are Manufactured On A CNC Automatic Lathe Under Workshop Conditions

NASA Astrophysics Data System (ADS)

Jaeger, Valentin E.

1989-04-01

The geometrical accuracy and surface roughness of diamond-turned workpieces is influenced by several parameters: the properties of the machine tool, the cutting process and the environmental conditions. A thin-walled electrode made from an aluminium alloy (wall thickness: 1 mm, length: 169 mm, outer diameter: 126 mm) and intended for an electrostatic measuring instrument, serves as an example to show how quasi-optical surfaces with a surface roughness Rα < 10 nm and deviations from roundness of <= 5 μm can be achieved when some of these influence quantities are optimized. The cylindrical part of the electrode was turned by means of a rounded mirror-finish diamond tool, the width of the cutting edge being 2 mm, the rake angle -6° and the clearance angle 2°. Compliance with the tolerances of geometrical accuracy was particularly difficult. As age-hardened wrought aluminium alloys cannot be stress-relieved by annealing, or only insufficiently, the geometrical accuracy - in particular the roundness - of thin-walled, rotationally symmetric bodies decisively depends on the state of stress of the workpiece material, on the clamping fixture and on the balanced condition of this clamping fixture.

Parametric effects of turning Ti-6Al-4V alloys with aluminum oxide nanolubricants with SDBS

NASA Astrophysics Data System (ADS)

Ali, M. A. M.; Azmi, A. I.; Khalil, A. N. M.

2017-09-01

Applications of nanolubricants have been claimed to improve machinability of aerospace metals due to reduction of friction as a results of the rolling action of billions of nanoparticles at the tool-chip interface. In addition, the need to pursue for an eco-friendly machining has pushed researchers toward implementing alternative lubrication methods through minimal quantity lubrication (MQL). However, the gap in the current literature regarding the performance of nanolubricants via MQL has restricted the widespread use of this lubricant and technique in industries. The present work aims to understand the parametric effects of nanoparticles concentration, cutting speed, feed rate and nozzle angle during machining of titanium alloy, Ti-6AL-4V. Multiple performance of machinability outputs such as surface roughness, tool wear and power consumption were simultaneously determined via Taguchi orthogonal array and grey relational analyses. Prior to machining tests, the nanolubricants stabilities were investigated through the addition of surfactant; sodium dodecyl benzene sulfonate (SDBS). The results clearly indicated that inclusion of SDBS surfactant managed to reduce agglomeration in the base lubricant. Meanwhile, grey relational analyses revealed that the combination of 0.6 % nanoparticles concentration, cutting speed of 85 m/min, feed rate of 0.1 mm/rev and nozzle angle of 60o as desired setting for all the three machining outputs.

Utilization of physicochemical variables developed from changes in sensory attributes and consumer acceptability to predict the shelf life of fresh-cut mango fruit.

PubMed

Salinas-Hernández, Rosa María; González-Aguilar, Gustavo A; Tiznado-Hernández, Martín Ernesto

2015-01-01

Sensory evaluation is the ideal tool for shelf-life determination. With the objective to develop an easy shelf-life indicator, color (L*, a*, b*, chroma and hue angle), total soluble solids (TSS), firmness (F), pH, acidity, and the sensory attributes of appearance, brightness, browning, odor, flavor, texture, color, acidity and sweetness were evaluated in fresh cut mangoes (FCM) stored at 5, 10, 15 and 20 °C. Overall acceptability was evaluated by consumers. Correlation analysis between sensory attributes and physicochemical variables was carried out. Physicochemical cut-off points based on sensory attributes and consumer acceptability was obtained by regression analysis and utilized to estimate FCM shelf-life by kinetic models fitted to each variable. The validation of the model was done by comparing the shelf life estimated by kinetic models and consumers. It was recorded large correlations between appearance, brightness, and color with L*; appearance and color with chroma and hue angle; sweetness and flavor with TSS, and between F and texture. The shelf life estimated based on consumer using a 9 point hedonic scale was in the range of 10-12, 2.3-2.6, 1.3-1.5 and 1.0-1.1 days for 5, 10, 15 and 20 °C. It was recorded large correlation coefficients between the shelf life estimated by consumer acceptability scores and physicochemical variables. Kinetic models based on physicochemical variables showed a tendency to overestimate the shelf life as compared with the models bases on the sensory attributes. It was concluded that physicochemical variables can be used as a tool to estimate the FCM shelf life.

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

NASA Astrophysics Data System (ADS)

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

2016-02-01

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.

Effects of footwear on lead limb knee and ankle joint kinematics in a fast bowler with a history of posterior ankle joint impingement-a case report.

PubMed

Bishop, Chris; Bartold, Simon; Thewlis, Dominic

2013-11-01

This case study reports the kinematic effect of 2 different cricket shoes on a fast bowler who reports a history of posterior ankle joint impingement. The participant bowled 6 trials in 2 pairs of cricket shoes. The 3-dimensional kinematics of the joints of the front leg was quantified during stance phase of the delivery stride. Wearing the high-cut shoe resulted in the ankle being 7.7-degree angle more plantarflexed at initial contact compared with the low-cut shoe. Again, when wearing the high-cut shoe compared with the low-cut shoe, the ankle joint was 15.5-degree angle more adducted and the knee was 4.1-degree angle less externally rotated at initial contact. This case study identifies the bowler's preferred shoe (high-cut shoe) as a potential contributing factor to the symptoms he was experiencing.

Three-dimensional tool radius compensation for multi-axis peripheral milling

NASA Astrophysics Data System (ADS)

Chen, Youdong; Wang, Tianmiao

2013-05-01

Few function about 3D tool radius compensation is applied to generating executable motion control commands in the existing computer numerical control (CNC) systems. Once the tool radius is changed, especially in the case of tool size changing with tool wear in machining, a new NC program has to be recreated. A generic 3D tool radius compensation method for multi-axis peripheral milling in CNC systems is presented. The offset path is calculated by offsetting the tool path along the direction of the offset vector with a given distance. The offset vector is perpendicular to both the tangent vector of the tool path and the orientation vector of the tool axis relative to the workpiece. The orientation vector equations of the tool axis relative to the workpiece are obtained through homogeneous coordinate transformation matrix and forward kinematics of generalized kinematics model of multi-axis machine tools. To avoid cutting into the corner formed by the two adjacent tool paths, the coordinates of offset path at the intersection point have been calculated according to the transition type that is determined by the angle between the two tool path tangent vectors at the corner. Through the verification by the solid cutting simulation software VERICUT® with different tool radiuses on a table-tilting type five-axis machine tool, and by the real machining experiment of machining a soup spoon on a five-axis machine tool with the developed CNC system, the effectiveness of the proposed 3D tool radius compensation method is confirmed. The proposed compensation method can be suitable for all kinds of three- to five-axis machine tools as a general form.

X-Z-Theta cutting method

DOEpatents

Bieg, Lothar F.

1993-01-12

A method for machining a workpiece. The method includes the use of a rotary cutting tool mounted on the end of a movable arm. The arm is adapted to move in a plane perpendicular to the axis of rotation of the cutting tool. The cutting tool has cutting teeth to cut chips of material off of the workpiece in a predetermined size and shape to facilitate better removal of the chips from the workpiece. The teeth can be of different type and length to permit the tool to both rough cut and finish cut the workpiece during machining. The total depth of cut is divided by the number of tool teeth, so that the longest tool always performs the finishing cut.

Effect of laser incidence angle on cut quality of 4 mm thick stainless steel sheet using fiber laser

NASA Astrophysics Data System (ADS)

Mullick, Suvradip; Agrawal, Arpit Kumar; Nath, Ashish Kumar

2016-07-01

Fiber laser has potential to outperform the more traditionally used CO2 lasers in sheet metal cutting applications due to its higher efficiency, better beam quality, reliability and ease of beam delivery through optical fiber. It has been however, reported that the higher focusability and shorter wavelength are advantageous for cutting thin metal sheets up to about 2 mm only. Better focasability results in narrower kerf-width, which leads to an earlier flow separation in the flow of assist gas within the kerf, resulting in uncontrolled material removal and poor cut quality. However, the advarse effect of tight focusability can be taken care by shifting the focal point position towards the bottom surface of work-piece, which results in a wider kerf size. This results in a more stable flow within the kerf for a longer depth, which improves the cut quality. It has also been reported that fiber laser has an unfavourable angle of incidence during cutting of thick sections, resulting in poor absorption at the metal surface. Therefore, the effect of laser incidence angle, along with other process parameters, viz. cutting speed and assist gas pressure on the cut quality of 4 mm thick steel sheet has been investigated. The change in laser incidence angle has been incorporated by inclining the beam towards and away from the cut front, and the quality factors are taken as the ratio of kerf width and the striation depth. Besides the absorption of laser radiation, beam inclination is also expected to influence the gas flow characteristics inside the kerf, shear force phenomena on the molten pool, laser beam coupling and laser power distribution at the inclined cut surface. Design of experiment has been used by implementing response surface methodology (RSM) to study the parametric dependence of cut quality, as well as to find out the optimum cut quality. An improvement in quality has been observed for both the inclination due to the combined effect of multiple phenomena.

Robot based deposition of WC-Co HVOF coatings on HSS cutting tools as a substitution for solid cemented carbide cutting tools

NASA Astrophysics Data System (ADS)

Tillmann, W.; Schaak, C.; Biermann, D.; Aßmuth, R.; Goeke, S.

2017-03-01

Cemented carbide (hard metal) cutting tools are the first choice to machine hard materials or to conduct high performance cutting processes. Main advantages of cemented carbide cutting tools are their high wear resistance (hardness) and good high temperature strength. In contrast, cemented carbide cutting tools are characterized by a low toughness and generate higher production costs, especially due to limited resources. Usually, cemented carbide cutting tools are produced by means of powder metallurgical processes. Compared to conventional manufacturing routes, these processes are more expensive and only a limited number of geometries can be realized. Furthermore, post-processing and preparing the cutting edges in order to achieve high performance tools is often required. In the present paper, an alternative method to substitute solid cemented carbide cutting tools is presented. Cutting tools made of conventional high speed steels (HSS) were coated with thick WC-Co (88/12) layers by means of thermal spraying (HVOF). The challenge is to obtain a dense, homogenous, and near-net-shape coating on the flanks and the cutting edge. For this purpose, different coating strategies were realized using an industrial robot. The coating properties were subsequently investigated. After this initial step, the surfaces of the cutting tools were ground and selected cutting edges were prepared by means of wet abrasive jet machining to achieve a smooth and round micro shape. Machining tests were conducted with these coated, ground and prepared cutting tools. The occurring wear phenomena were analyzed and compared to conventional HSS cutting tools. Overall, the results of the experiments proved that the coating withstands mechanical stresses during machining. In the conducted experiments, the coated cutting tools showed less wear than conventional HSS cutting tools. With respect to the initial wear resistance, additional benefits can be obtained by preparing the cutting edge by means of wet abrasive jet machining.

Shaping of Rack Cutter Original Profile for Fine-module Ratchet Teeth Cutting

NASA Astrophysics Data System (ADS)

Sharkov, O. V.; Koryagin, S. I.; Velikanov, N. L.

2018-05-01

The design models and the process of shaping the cutting edges of the rack cutter for cutting fine-module ratchet teeth are considered in the article. The use of fine-module ratchet teeth can reduce the noise and impact loads during operation of the freewheel mechanisms. Mathematical dependencies for calculating the coordinates determining the geometric position of the points of the front and back edges of the cutting profile of the rack cutter, the workpiece angle of rotation during cutting the ratchet teeth were obtained. When applying the developed method, the initial data are: the radii of the workpiece circumferences passing through the dedendum of the external and internal cut teeth; gradient angles of the front and back edges of the rail.

Method and apparatus for suppressing regenerative instability and related chatter in machine tools

DOEpatents

Segalman, Daniel J.; Redmond, James M.

2001-01-01

Methods of and apparatuses for mitigating chatter vibrations in machine tools or components thereof. Chatter therein is suppressed by periodically or continuously varying the stiffness of the cutting tool (or some component of the cutting tool), and hence the resonant frequency of the cutting tool (or some component thereof). The varying of resonant frequency of the cutting tool can be accomplished by modulating the stiffness of the cutting tool, the cutting tool holder, or any other component of the support for the cutting tool. By periodically altering the impedance of the cutting tool assembly, chatter is mitigated. In one embodiment, a cyclic electric (or magnetic) field is applied to the spindle quill which contains an electro-rheological (or magneto-rheological) fluid. The variable yield stress in the fluid affects the coupling of the spindle to the machine tool structure, changing the natural frequency of oscillation. Altering the modal characteristics in this fashion disrupts the modulation of current tool vibrations with previous tool vibrations recorded on the workpiece surface.

Method and apparatus for suppressing regenerative instability and related chatter in machine tools

DOEpatents

Segalman, Daniel J.; Redmond, James M.

1999-01-01

Methods of and apparatuses for mitigating chatter vibrations in machine tools or components thereof. Chatter therein is suppressed by periodically or continuously varying the stiffness of the cutting tool (or some component of the cutting tool), and hence the resonant frequency of the cutting tool (or some component thereof). The varying of resonant frequency of the cutting tool can be accomplished by modulating the stiffness of the cutting tool, the cutting tool holder, or any other component of the support for the cutting tool. By periodically altering the impedance of the cutting tool assembly, chatter is mitigated. In one embodiment, a cyclic electric (or magnetic) field is applied to the spindle quill which contains an electro-rheological (or magneto-rheological) fluid. The variable yield stress in the fluid affects the coupling of the spindle to the machine tool structure, changing the natural frequency of oscillation. Altering the modal characteristics in this fashion disrupts the modulation of current tool vibrations with previous tool vibrations recorded on the workpiece surface.

Research of a smart cutting tool based on MEMS strain gauge

NASA Astrophysics Data System (ADS)

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.

Cosmic Rays In The Magnetosphere, 2. Apparent Cut-off Rigidities and Coupling Functions

NASA Astrophysics Data System (ADS)

Dorman, L. I.; Danilova, O. A.; Iucci, N.; Parisi, M.; Ptitsyna, N. G.; Tyasto, M. I.; Villoresi, G.

We calculate the apparent cut-off rigidities along the survey Italy-Antarctica-Italy** on the basis of results of Danilova et al. (2001) on trajectory calculations for inclined cut- off rigidities at eight azimuths (through 45?) and five zeniths angles (through 15?) along the survey. For calculations of apparent cut-off rigidities we use also the infor- mation on integral multiplicities of secondary neutrons in dependence of zenith angle of incident primary cosmic ray particles, as theoretically computed. This information is based on the theoretical calculations of meson-nuclear cascades for primary protons with different rigidities arriving to the EarthSs atmosphere at different zenith angles (Dorman and Pakhomov, 1979). These results have been checked and normalized by using coupling functions obtained in the same survey [Dorman et al. (2000)]. The determined apparent cut-off rigidities have been compared with results obtained by Clem et al. (1997) and with those used by Dorman et al. (2000) computed by using vertical cut-off rigidities, for trajectories especially calculated for the survey. On the basis of the apparent cut-off rigidities along the latitude survey, the coupling functions for neutron monitor and bare neutron counters found by Dorman et al. (2000) are now determined more accurately. **Survey realized with logistic and financial support of the Italian Antarctic Program (PNRA) and with the co-operation of IFSI-CNR. REFERENCES: Clem, J.M., et al. J. Geophys. Res., 102, 26,919 (1997). Danilova, O.A., et al., Latitude survey in December 1996-March 1997, 1. Cut-off rigidities for different azimuth and zenith angles, Paper ST13, This issue (2001) Dorman L.I. and Pakhomov N.I., "The dependence of the integral generation multiplicity of neutron component at various depths in the atmosphere on zenith angle on primary particle in- cidence". Proc. 16-th ICRC, Kyoto, 4, 416-420 (1979) Dorman, L.I., et al., J. Geophys. Res. 105 , 21,047 (2000).

Influence of water-miscible cutting fluid on tool wear behavior of various coated high-speed steel tools in hobbing

NASA Astrophysics Data System (ADS)

Sato, Yuta; Matsuoka, Hironori; Kubo, Akio; Ono, Hajime; Ryu, Takahiro; Qiu, Hua; Nakae, Takashi; Shuto, Shuichi; Watanabe, Suguru; Anan, Ruito

2017-04-01

This paper deals with the influence of water-miscible cutting fluid on tool life (flank wear) compared with that with dry cutting and water-insoluble cutting oil in hobbing. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The following results were clarified. (1) The water-miscible cutting fluid used in the test prolongs the tool life for TiN-, TiAlN-, TiSiN- and AlCrSiN-coated tools in comparison with that obtained by dry cutting and water-insoluble cutting oil. (2) It was presumed that the tool wear decreases and the tool life is improved by the lubrication effect of the synthetic lubrication additive, mineral oil and sulfuric EP additive contained in the water-miscible cutting fluid, and also by the cooling effect.

Diamond tool wear detection method using cutting force and its power spectrum analysis in ultra-precision fly cutting

NASA Astrophysics Data System (ADS)

Zhang, G. Q.; To, S.

2014-08-01

Cutting force and its power spectrum analysis was thought to be an effective method monitoring tool wear in many cutting processes and a significant body of research has been conducted on this research area. However, relative little similar research was found in ultra-precision fly cutting. In this paper, a group of experiments were carried out to investigate the cutting forces and its power spectrum characteristics under different tool wear stages. Result reveals that the cutting force increases with the progress of tool wear. The cutting force signals under different tool wear stages were analyzed using power spectrum analysis. The analysis indicates that a characteristic frequency does exist in the power spectrum of the cutting force, whose power spectral density increases with the increasing of tool wear level, this characteristic frequency could be adopted to monitor diamond tool wear in ultra-precision fly cutting.

Implementation Analysis of Cutting Tool Carbide with Cast Iron Material S45 C on Universal Lathe

NASA Astrophysics Data System (ADS)

Junaidi; hestukoro, Soni; yanie, Ahmad; Jumadi; Eddy

2017-12-01

Cutting tool is the tools lathe. Cutting process tool CARBIDE with Cast Iron Material Universal Lathe which is commonly found at Analysiscutting Process by some aspects numely Cutting force, Cutting Speed, Cutting Power, Cutting Indication Power, Temperature Zone 1 and Temperatur Zone 2. Purpose of this Study was to determine how big the cutting Speed, Cutting Power, electromotor Power,Temperatur Zone 1 and Temperatur Zone 2 that drives the chisel cutting CARBIDE in the Process of tur ning Cast Iron Material. Cutting force obtained from image analysis relationship between the recommended Component Cuting Force with plane of the cut and Cutting Speed obtained from image analysis of relationships between the recommended Cutting Speed Feed rate.

Artificial Intelligence Based Selection of Optimal Cutting Tool and Process Parameters for Effective Turning and Milling Operations

NASA Astrophysics Data System (ADS)

Saranya, Kunaparaju; John Rozario Jegaraj, J.; Ramesh Kumar, Katta; Venkateshwara Rao, Ghanta

2016-06-01

With the increased trend in automation of modern manufacturing industry, the human intervention in routine, repetitive and data specific activities of manufacturing is greatly reduced. In this paper, an attempt has been made to reduce the human intervention in selection of optimal cutting tool and process parameters for metal cutting applications, using Artificial Intelligence techniques. Generally, the selection of appropriate cutting tool and parameters in metal cutting is carried out by experienced technician/cutting tool expert based on his knowledge base or extensive search from huge cutting tool database. The present proposed approach replaces the existing practice of physical search for tools from the databooks/tool catalogues with intelligent knowledge-based selection system. This system employs artificial intelligence based techniques such as artificial neural networks, fuzzy logic and genetic algorithm for decision making and optimization. This intelligence based optimal tool selection strategy is developed using Mathworks Matlab Version 7.11.0 and implemented. The cutting tool database was obtained from the tool catalogues of different tool manufacturers. This paper discusses in detail, the methodology and strategies employed for selection of appropriate cutting tool and optimization of process parameters based on multi-objective optimization criteria considering material removal rate, tool life and tool cost.

Experimental and numerical investigations on the temperature distribution in PVD AlTiN coated and uncoated Al2O3/TiCN mixed ceramic cutting tools in hard turning of AISI 52100 steel

NASA Astrophysics Data System (ADS)

Sateesh Kumar, Ch; Patel, Saroj Kumar; Das, Anshuman

2018-03-01

Temperature generation in cutting tools is one of the major causes of tool failure especially during hard machining where machining forces are quite high resulting in elevated temperatures. Thus, the present work investigates the temperature generation during hard machining of AISI 52100 steel (62 HRC hardness) with uncoated and PVD AlTiN coated Al2O3/TiCN mixed ceramic cutting tools. The experiments were performed on a heavy duty lathe machine with both coated and uncoated cutting tools under dry cutting environment. The temperature of the cutting zone was measured using an infrared thermometer and a finite element model has been adopted to predict the temperature distribution in cutting tools during machining for comparative assessment with the measured temperature. The experimental and numerical results revealed a significant reduction of cutting zone temperature during machining with PVD AlTiN coated cutting tools when compared to uncoated cutting tools during each experimental run. The main reason for decrease in temperature for AlTiN coated tools is the lower coefficient of friction offered by the coating material which allows the free flow of the chips on the rake surface when compared with uncoated cutting tools. Further, the superior wear behaviour of AlTiN coating resulted in reduction of cutting temperature.

The Effects of Cryogenic Treatment on Cutting Tools

NASA Astrophysics Data System (ADS)

Kumar, Satish; Khedkar, Nitin K.; Jagtap, Bhushan; Singh, T. P.

2017-08-01

Enhancing the cutting tool life is important and economic factor to reduce the tooling as well as manufacturing cost. The tool life is improved considerably by 92 % after cryogenic treatment. The cryogenic treatment is a one-time permanent, sub-zero heat treatment that entirely changes cross-section of cutting tool. The cryogenic treatment is carried out with deep freezing of cutting tool materials to enhance physical and mechanical properties. The cryogenic treatment improves mechanical such as hardness, toughness and tribological properties such as wear resistance, coefficient of friction, surface finish, dimensional stability and stress relief. The deep cryogenic treatment is the most beneficial treatment applied on cutting tools. The cryogenic treatment is the most advanced heat treatment and popular to improve performance of the cutting tool. The optimization of cryogenic treatment variables is necessary to improve tool life. This study reviews the effects of cryogenic treatment on microstructure, tribological properties of tool steels and machining applications of cutting tool by investigating the surface and performing the surface characterization test like SEM. The economy of cutting tool can be achieved by deep cryogenic treatment.

A Generalized Maxwell Model for Creep Behavior of Artery Opening Angle

PubMed Central

Zhang, W.; Guo, X.; Kassab, G. S.

2009-01-01

An artery ring springs open into a sector after a radial cut. The opening angle characterizes the residual strain in the unloaded state, which is fundamental to understanding stress and strain in the vessel wall. A recent study revealed that the opening angle decreases with time if the artery is cut from the loaded state, while it increases if the cut is made from the no-load state due to viscoelasticity. In both cases, the opening angle approaches the same value in 3 hours. This implies that the characteristic relaxation time is about 10,000 sec. Here, the creep function of a generalized Maxwell model (a spring in series with six Voigt bodies) is used to predict the temporal change of opening angle in multiple time scales. It is demonstrated that the theoretical model captures the salient features of the experimental results. The proposed creep function may be extended to study the viscoelastic response of blood vessels under various loading conditions. PMID:19045526

Engineered Surface Properties of Porous Tungsten from Cryogenic Machining

NASA Astrophysics Data System (ADS)

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 force, temperature and surface roughness data is developed and used to study the deformation mechanisms of porous tungsten under different machining conditions. It is found that when hmax = hc, ductile mode machining of otherwise highly brittle porous tungsten is possible. The value of hc is approximately the same as the average ligament size of the 80% density porous tungsten workpiece.

The role of the implementation angle of cuttings of Phyllanthus sellowianus as a reference for a soil protection measure against surface erosion

NASA Astrophysics Data System (ADS)

Rauch, H. P.; Sutili, F. J.; Aschbacher, M.; Müller, B.

2009-04-01

Cutting plantation is a very common method of soil bioengineering techniques. The potential of vegetative reproduction is used to install a vegetation cover on eroded slopes to prevent surface erosion. The development of above and below biomass from parts of the stock plant in a very short time and the fast and easy propagation are one of the most important advantages of this soil bioengineering type. Several handbooks (Schiechtl, 1992; Florineth, 2004 and Zeh, 2007) suggest potential plants for vegetative reproduction and describe the procedure of plantation in detail. It is recommended that the cuttings are not driven vertically into the ground. A flat implementation angle guarantees a more uniform rooting of the cutting part driven into the soil, however there are no systematically investigations of the impact of the implementation angle on the biomass performance and consequently on the performance as a surface erosion protection measure. This paper shows results from field investigations focusing on the problem of the impact of the implementation angle of cuttings. In sum 75 specimens of the species of Phyllanthus sellowianus. The plant species was recommended as a native potential soil bioengineering plant by Sutili (s. Sutili, 2006). The cuttings were planted with an average length of 50 cm and diameter of 2 cm. The implementation angle differences between 90 (vertical) 45 and 10 degree. Two months after plantation all plants were excavated and the relevant plant data sets were collected in order to analyse the biomass performance. The field investigations are part of an integrated research project of the University of Natural Resources and Applied Life Sciences, Vienna and the Federal University of Santa Maria, Rio Grande do Sul - Brazil.

Instrument and method for focusing X-rays, gamma rays and neutrons

DOEpatents

Smither, Robert K.

1984-01-01

A crystal diffraction instrument or diffraction grating instrument with an improved crystalline structure or grating spacing structure having a face for receiving a beam of photons or neutrons and diffraction planar spacing or grating spacing along that face with the spacing increasing progressively along the face to provide a decreasing Bragg diffraction angle for a monochromatic radiation and thereby increasing the usable area and acceptance angle. The increased planar spacing for the diffraction crystal is provided by the use of a temperature differential across the crystalline structure, by assembling a plurality of crystalline structures with different compositions, by an individual crystalline structure with a varying composition and thereby a changing planar spacing along its face, and by combinations of these techniques. The increased diffraction grating element spacing is generated during the fabrication of the diffraction grating by controlling the cutting tool that is cutting the grooves or controlling the laser beam, electron beam or ion beam that is exposing the resist layer, etc. It is also possible to vary this variation in grating spacing by applying a thermal gradient to the diffraction grating in much the same manner as is done in the crystal diffraction case.

Instrument and method for focusing x rays, gamma rays, and neutrons

DOEpatents

Smither, R.K.

1982-03-25

A crystal-diffraction instrument or diffraction-grating instrument is described with an improved crystalline structure or grating spacing structure having a face for receiving a beam of photons or neutrons and diffraction planar spacing or grating spacing along that face with the spacing increasing progressively along the face to provide a decreasing Bragg diffraction angle for a monochromatic radiation and thereby increasing the usable area and acceptance angle. The increased planar spacing for the diffraction crystal is provided by the use of a temperature differential across the line structures with different compositions, by an individual crystalline structure with a varying composition and thereby a changing planar spacing along its face, and by combinations of these techniques. The increased diffraction grating element spacing is generated during the fabrication of the diffraction grating by controlling the cutting tool that is cutting the grooves or controlling the laser beam, electron beam, or ion beam that is exposing the resist layer, etc. It is also possible to vary this variation in grating spacing by applying a thermal gradient to the diffraction grating in much the same manner as is done in the crystal-diffraction case.

Study on fibre laser machining quality of plain woven CFRP laminates

NASA Astrophysics Data System (ADS)

Li, Maojun; Li, Shuo; Yang, Xujing; Zhang, Yi; Liang, Zhichao

2018-03-01

Laser cutting is suitable for large-scale and high-efficiency production with relatively high cutting speed, while machining of CFRP composite using lasers is challenging with severe thermal damage due to different material properties and sensitivity to heat. In this paper, surface morphology of cutting plain woven carbon fibre-reinforced plastics (CFRP) by fibre laser and the influence of cutting parameters on machined quality were investigated. A full factorial experimental design was employed involving three variable factors, which included laser pulse frequency at three levels together with laser power and cutting speed at two levels. Heat-affected zone (HAZ), kerf depth and kerf angle were quantified to understand the interactions with cutting parameters. Observations of machined surface were analysed relating to various damages using optical microscope and scanning electron microscopy (SEM), which included HAZ, matrix recession, fibre protruding, striations, fibre-end swelling, collapses, cavities and delamination. Based on ANOVA analysis, it was found that both cutting speed and laser power were significant factors for HAZ and kerf depth, while laser power was the only significant factor for kerf angle. Besides, HAZ and the kerf depth showed similar sensitivity to the pulse energy and energy per unit length, which was opposite for kerf angle. This paper presented the feasibility and experimental results of cutting CFRP laminates using fibre laser, which is possibly the efficient and high-quality process to promote the development of CFRPs.

Numerical modelling of tool wear in turning with cemented carbide cutting tools

NASA Astrophysics Data System (ADS)

Franco, P.; Estrems, M.; Faura, F.

2007-04-01

A numerical model is proposed for analysing the flank and crater wear resulting from the loss of material on cutting tool surface in turning processes due to wear mechanisms of adhesion, abrasion and fracture. By means of this model, the material loss along cutting tool surface can be analysed, and the worn surface shape during the workpiece machining can be determined. The proposed model analyses the gradual degradation of cutting tool during turning operation, and tool wear can be estimated as a function of cutting time. Wear-land width (VB) and crater depth (KT) can be obtained for description of material loss on cutting tool surface, and the effects of the distinct wear mechanisms on surface shape can be studied. The parameters required for the tool wear model are obtained from bibliography and experimental observation for AISI 4340 steel turning with WC-Co cutting tools.

Analysis of Minimum Quantity Lubrication (MQL) for Different Coating Tools during Turning of TC11 Titanium Alloy.

PubMed

Qin, Sheng; Li, Zhongquan; Guo, Guoqiang; An, Qinglong; Chen, Ming; Ming, Weiwei

2016-09-28

The tool coating and cooling strategy are two key factors when machining difficult-to-cut materials such as titanium alloy. In this paper, diamond coating was deposited on a commercial carbide insert as an attempt to increase the machinability of TC11 alloy during the turning process. An uncoated carbide insert and a commercial Al₂O₃/TiAlN-coated tool were also tested as a comparison. Furthermore, MQL was applied to improve the cutting condition. Cutting performances were analyzed by cutting force, cutting temperate and surface roughness measurements. Tool wears and tool lives were evaluated to find a good matchup between the tool coating and cooling strategy. According to the results, using MQL can slightly reduce the cutting force. By applying MQL, cutting temperatures and tool wears were reduced by a great amount. Besides, MQL can affect the tool wear mechanism and tool failure modes. The tool life of an Al₂O₃/TiAlN-coated tool can be prolonged by 88.4% under the MQL condition. Diamond-coated tools can obtain a good surface finish when cutting parameters and lubrication strategies are properly chosen.

Analysis of Minimum Quantity Lubrication (MQL) for Different Coating Tools during Turning of TC11 Titanium Alloy

PubMed Central

Qin, Sheng; Li, Zhongquan; Guo, Guoqiang; An, Qinglong; Chen, Ming; Ming, Weiwei

2016-01-01

The tool coating and cooling strategy are two key factors when machining difficult-to-cut materials such as titanium alloy. In this paper, diamond coating was deposited on a commercial carbide insert as an attempt to increase the machinability of TC11 alloy during the turning process. An uncoated carbide insert and a commercial Al2O3/TiAlN-coated tool were also tested as a comparison. Furthermore, MQL was applied to improve the cutting condition. Cutting performances were analyzed by cutting force, cutting temperate and surface roughness measurements. Tool wears and tool lives were evaluated to find a good matchup between the tool coating and cooling strategy. According to the results, using MQL can slightly reduce the cutting force. By applying MQL, cutting temperatures and tool wears were reduced by a great amount. Besides, MQL can affect the tool wear mechanism and tool failure modes. The tool life of an Al2O3/TiAlN-coated tool can be prolonged by 88.4% under the MQL condition. Diamond-coated tools can obtain a good surface finish when cutting parameters and lubrication strategies are properly chosen. PMID:28773926

Igneous Sheet Intrusions as a Record of Paleostress States

NASA Astrophysics Data System (ADS)

Stephens, T. L.; Walker, R. J.; Healy, D.; Bubeck, A.; England, R. W.; McCaffrey, K. J. W.

2017-12-01

The architecture of igneous sheet intrusion networks provides useful constraints on paleostress during emplacement. Several models for sill emplacement have used the close spatial relationships between sills and dikes in layered (sedimentary) host rocks to propose that dike-sill transitions are driven by layering. Such models require a stress rotation - from horizontal extension for dikes, to horizontal compression for sills - which is assumed to reflect a near-hydrostatic stress state, facilitating the dilation and intrusion of pre-existing structures (e.g. faults, joints, and bedding). Here, we present case examples of sills for which layering is not the main control on emplacement: Isle of Mull (UK), Faroe Islands (European Atlantic margin) and the San Rafael Subvolcanic Field (Utah, USA). In each case, dikes cut, or are cut by, sills; indicating that dikes were not the feeders to sills in the same section. The sills consist of linked, flat and shallowly-dipping segments that always show near-vertical opening directions. Sills cut bedding and formation contacts with consistent low-angle dips, and cut or abut against vertical faults, fractures, and tectonic foliations. From this, we infer that magma pressure during emplacement did not exceed the horizontal stress. To constrain the stress state during emplacement we present a novel approach that combines analysis of local and overall sill geometry data with mechanical models for slip tendency, dilation tendency, and fracture susceptibility. We also present a new depth-independent mechanical model, which estimates paleostress ratio and driving fluid pressure ratio using the opening angles of dilated fluid-filled fractures. Our results show that the studied sills record previously unrecognised local fluctuations in the far-field stress state, during magmatic supply. Sills, therefore, present an important tool for determining paleostress in areas where few brittle deformation structures (e.g. faults), other than intrusions, are present.

Effect of micro-scale texturing on the cutting tool performance

NASA Astrophysics Data System (ADS)

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.

The use of water-jetting technology in prostheses revision surgery-first results of parameter studies on bone and bone cement.

PubMed

Honl, M; Rentzsch, R; Müller, G; Brandt, C; Bluhm, A; Hille, E; Louis, H; Morlock, M

2000-01-01

Water-jet cutting techniques have been used in industrial applications for many different materials. Recently these techniques have been developed into a revolutionary cutting tool for soft tissues in visceral surgery. The present study investigates the usage of this cutting technology for the revision surgery of endoprostheses. In the first part of the study, samples of bovine bone and acrylic bone cement (PMMA) were cut using an industrial jet cutting device with pure water. Below 400 bar, only PMMA was cut; above 400 bar, bone was also cut, but only pressures above 800 bar resulted in clinically useful rates of material removal (cut depth 2. 4 mm at 10 mm/min traverse speed). In the second part of the study, the effect of adding biocompatible abrasives to the water in order to reduce the required pressure was investigated, resulting in a significantly higher removal of material. At 600 bar, PMMA was cut 5. 2 mm deep with plain water and 15.2 mm deep with added abrasives. The quality of the cuts was increased by the abrasive. Though there was no clear selectivity between bone and PMMA any more, the rate of material removal at similar pressures was significantly higher for PMMA than for bone (600 bar: 1.6 mm cut depth for bone samples, 15.2 mm for PMMA). The measured cut depths with either method were not influenced by a change of the cutting direction with respect to the main direction of the osteons in the bone. However, a reduction of the jet surface angle (90 degrees to 23 degrees ) resulted for bone in a significantly lower cut depth at 600 bar (plain water: 0.62 mm vs. 0.06 mm; abrasive: 1.61 mm vs. 0.60 mm). The laboratory experiments indicate that abrasive water jets may be suitable for cutting biomaterials like bone and bone cement. Copyright 2000 John Wiley & Sons, Inc.

Performance analysis of cutting graphite-epoxy composite using a 90,000psi abrasive waterjet

NASA Astrophysics Data System (ADS)

Choppali, Aiswarya

Graphite-epoxy composites are being widely used in many aerospace and structural applications because of their properties: which include lighter weight, higher strength to weight ratio and a greater flexibility in design. However, the inherent anisotropy of these composites makes it difficult to machine them using conventional methods. To overcome the major issues that develop with conventional machining such as fiber pull out, delamination, heat generation and high tooling costs, an effort is herein made to study abrasive waterjet machining of composites. An abrasive waterjet is used to cut 1" thick graphite epoxy composites based on baseline data obtained from the cutting of ¼" thick material. The objective of this project is to study the surface roughness of the cut surface with a focus on demonstrating the benefits of using higher pressures for cutting composites. The effects of major cutting parameters: jet pressure, traverse speed, abrasive feed rate and cutting head size are studied at different levels. Statistical analysis of the experimental data provides an understanding of the effect of the process parameters on surface roughness. Additionally, the effect of these parameters on the taper angle of the cut is studied. The data is analyzed to obtain a set of process parameters that optimize the cutting of 1" thick graphite-epoxy composite. The statistical analysis is used to validate the experimental data. Costs involved in the cutting process are investigated in term of abrasive consumed to better understand and illustrate the practical benefits of using higher pressures. It is demonstrated that, as pressure increased, ultra-high pressure waterjets produced a better surface quality at a faster traverse rate with lower costs.

An ultra-precision tool nanoindentation instrument for replication of single point diamond tool cutting edges

NASA Astrophysics Data System (ADS)

Cai, Yindi; Chen, Yuan-Liu; Xu, Malu; Shimizu, Yuki; Ito, So; Matsukuma, Hiraku; Gao, Wei

2018-05-01

Precision replication of the diamond tool cutting edge is required for non-destructive tool metrology. This paper presents an ultra-precision tool nanoindentation instrument designed and constructed for replication of the cutting edge of a single point diamond tool onto a selected soft metal workpiece by precisely indenting the tool cutting edge into the workpiece surface. The instrument has the ability to control the indentation depth with a nanometric resolution, enabling the replication of tool cutting edges with high precision. The motion of the diamond tool along the indentation direction is controlled by the piezoelectric actuator of a fast tool servo (FTS). An integrated capacitive sensor of the FTS is employed to detect the displacement of the diamond tool. The soft metal workpiece is attached to an aluminum cantilever whose deflection is monitored by another capacitive sensor, referred to as an outside capacitive sensor. The indentation force and depth can be accurately evaluated from the diamond tool displacement, the cantilever deflection and the cantilever spring constant. Experiments were carried out by replicating the cutting edge of a single point diamond tool with a nose radius of 2.0 mm on a copper workpiece surface. The profile of the replicated tool cutting edge was measured using an atomic force microscope (AFM). The effectiveness of the instrument in precision replication of diamond tool cutting edges is well-verified by the experimental results.

Novel tool wear monitoring method in milling difficult-to-machine materials using cutting chip formation

NASA Astrophysics Data System (ADS)

Zhang, P. P.; Guo, Y.; Wang, B.

2017-05-01

The main problems in milling difficult-to-machine materials are the high cutting temperature and rapid tool wear. However it is impossible to investigate tool wear in machining. Tool wear and cutting chip formation are two of the most important representations for machining efficiency and quality. The purpose of this paper is to develop the model of tool wear with cutting chip formation (width of chip and radian of chip) on difficult-to-machine materials. Thereby tool wear is monitored by cutting chip formation. A milling experiment on the machining centre with three sets cutting parameters was performed to obtain chip formation and tool wear. The experimental results show that tool wear increases gradually along with cutting process. In contrast, width of chip and radian of chip decrease. The model is developed by fitting the experimental data and formula transformations. The most of monitored errors of tool wear by the chip formation are less than 10%. The smallest error is 0.2%. Overall errors by the radian of chip are less than the ones by the width of chip. It is new way to monitor and detect tool wear by cutting chip formation in milling difficult-to-machine materials.

Cutting tool form compensation system and method

DOEpatents

Barkman, W.E.; Babelay, E.F. Jr.; Klages, E.J.

1993-10-19

A compensation system for a computer-controlled machining apparatus having a controller and including a cutting tool and a workpiece holder which are movable relative to one another along a preprogrammed path during a machining operation utilizes a camera and a vision computer for gathering information at a preselected stage of a machining operation relating to the actual shape and size of the cutting edge of the cutting tool and for altering the preprogrammed path in accordance with detected variations between the actual size and shape of the cutting edge and an assumed size and shape of the cutting edge. The camera obtains an image of the cutting tool against a background so that the cutting tool and background possess contrasting light intensities, and the vision computer utilizes the contrasting light intensities of the image to locate points therein which correspond to points along the actual cutting edge. Following a series of computations involving the determining of a tool center from the points identified along the tool edge, the results of the computations are fed to the controller where the preprogrammed path is altered as aforedescribed. 9 figures.

Cutting tool form compensaton system and method

DOEpatents

Barkman, William E.; Babelay, Jr., Edwin F.; Klages, Edward J.

1993-01-01

A compensation system for a computer-controlled machining apparatus having a controller and including a cutting tool and a workpiece holder which are movable relative to one another along a preprogrammed path during a machining operation utilizes a camera and a vision computer for gathering information at a preselected stage of a machining operation relating to the actual shape and size of the cutting edge of the cutting tool and for altering the preprogrammed path in accordance with detected variations between the actual size and shape of the cutting edge and an assumed size and shape of the cutting edge. The camera obtains an image of the cutting tool against a background so that the cutting tool and background possess contrasting light intensities, and the vision computer utilizes the contrasting light intensities of the image to locate points therein which correspond to points along the actual cutting edge. Following a series of computations involving the determining of a tool center from the points identified along the tool edge, the results of the computations are fed to the controller where the preprogrammed path is altered as aforedescribed.

A PFC3D-based numerical simulation of cutting load for lunar rock simulant and experimental validation

NASA Astrophysics Data System (ADS)

Li, Peng; Jiang, Shengyuan; Tang, Dewei; Xu, Bo

2017-05-01

For sake of striking a balance between the need of drilling efficiency and the constrains of power budget on the moon, the penetrations per revolution of drill bit are generally limited in the range around 0.1 mm, and besides the geometric angle of the cutting blade need to be well designed. This paper introduces a simulation approach based on PFC3D (particle flow code 3 dimensions) for analyzing the cutting load feature on lunar rock simulant, which is derived from different geometric-angle blades with a small cutting depth. The mean values of the cutting force of five blades in the survey region (four on the boundary points and one on the center point) are selected as the macroscopic responses of model. The method of experimental design which includes Plackett-Burman (PB) design and central composite design (CCD) method is adopted in the matching procedure of microparameters in PFC model. Using the optimization method of enumeration, the optimum set of microparameters is acquired. Then, the experimental validation is implemented by using other twenty-five blades with different geometric angles, and the results from both simulations and laboratory tests give fair agreements. Additionally, the rock breaking process cut by different blades are quantified from simulation analysis. This research provides the theoretical support for the refinement of the rock cutting load prediction and the geometric design of cutting blade on the drill bit.

Usefulness of the "grand-piano sign" for determining femoral rotational alignment in total knee arthroplasty.

PubMed

Ohmori, Takaaki; Kabata, Tamon; Kajino, Yoshitomo; Taga, Tadashi; Inoue, Daisuke; Yamamoto, Takashi; Takagi, Tomoharu; Yoshitani, Junya; Ueno, Takuro; Tsuchiya, Hiroyuki

2018-01-01

The "grand-piano sign" is a well-known indicator of proper rotational femoral alignment. We investigated changes in the shape of the femoral anterior cutting plane by changing the rotational alignment, anterior portion depth, and cutting plane flexion angle. We simulated various cutting planes after cutting the anterior portion of the femur next to the distal femoral osteotomy in 50 patients with varus knee and also a femoral anterior osteotomy with four degree (S group) and seven degree (T group) flexion angles regarding the mechanical axis. We defined the final cutting plane as the farthest position that we could reach without making a notch and the precutting plane as two millimeters anterior from the final cutting plane. The simulated resection plane was rotated to produce external and internal rotation angles of 0°, three degrees, and five degrees relative to the surgical transepicondylar axis (SEA). We investigated medial and lateral portions of the femoral anterior cutting plane length ratio (M/L). When we cut parallel to SEA, M/L was 0.67±0.09 and 0.62±0.12 in the T and S groups, respectively. M/L was approximately 0.8 and 0.5 with five degree internal and external rotations, respectively (P<0.01). On comparing final cutting and precutting planes, there were no significant differences in M/L without five degree external rotation in the T group and no significant difference in any case in the S group (P>0.01). The ideal M/L of the femoral anterior cutting plane was 0.62-0.67. M/L did not change with a precutting plane in almost all rotational patterns. Copyright © 2017. Published by Elsevier B.V.

Experimental study on internal cooling system in hard turning of HCWCI using CBN tools

NASA Astrophysics Data System (ADS)

Ravi, A. M.; Murigendrappa, S. M.

2018-04-01

In recent times, hard turning became most emerging technique in manufacturing processes, especially to cut high hard materials like high chrome white cast iron (HCWCI). Use of Cubic boron nitride (CBN), pCBN and Carbide tools are most appropriate to shear the metals but are uneconomical. Since hard turning carried out in dry condition, lowering the tool wear by minimizing tool temperature is the only solution. Study reveals, no effective cooling systems are available so for in order to enhance the tool life of the cutting tools and to improve machinability characteristics. The detrimental effect of cutting parameters on cutting temperature is generally controlled by proper selections. The objective of this paper is to develop a new cooling system to control tool tip temperature, thereby minimizing the cutting forces and the tool wear rates. The materials chosen for this work was HCWCI and cutting tools are CBN inserts. Intricate cavities were made on the periphery of the tool holder for easy flow of cold water. Taguchi techniques were adopted to carry out the experimentations. The experimental results confirm considerable reduction in the cutting forces and tool wear rates.

The optimization study on the tool wear of carbide cutting tool during milling Carbon Fibre Reinforced (CFRP) using Response Surface Methodology (RSM)

NASA Astrophysics Data System (ADS)

Nor Khairusshima, M. K.; Hafiz Zakwan, B. Muhammad; Suhaily, M.; Sharifah, I. S. S.; Shaffiar, N. M.; Rashid, M. A. N.

2018-01-01

Carbon Fibre Reinforced Plastic (CFRP) composite has become one of famous materials in industry, such as automotive, aeronautics, aerospace and aircraft. CFRP is attractive due to its properties, which promising better strength and high specification of mechanical properties other than its high resistance to corrosion. Other than being abrasive material due to the carbon nature, CFRP is an anisotropic material, which the knowledge of machining metal and steel cannot be applied during machining CFRP. The improper technique and parameters used to machine CFRP may result in high tool wear. This paper is to study the tool wear of 8 mm diameter carbide cutting tool during milling CFRP. To predict the suitable cutting parameters within range of 3500-6220 (rev/min), 200-245 (mm/min), and 0.4-1.8 (mm) for cutting speed, speed, feed rate and depth of cut respectively, which produce optimized result (less tool wear), Response Surface Methodology (RSM) has been used. Based on the developed mathematical model, feed rate was identified as the primary significant item that influenced tool wear. The optimized cutting parameters are cutting speed, feed and depth of cut of 3500 rev/min, 200 mm/min and 0.5 mm, respectively, with tool wear of 0.0267 mm. It is also can be observed that as the cutting speed and feed rate increased the tool wear is increasing.

More About Cutting Tool For Shaving Weld Beads

NASA Technical Reports Server (NTRS)

Oelgoetz, Peter A.; Davis, William M.

1996-01-01

Report describes modification and testing of proposed tool discussed in "Cutting Tool For Shaving Weld Beads" (MFS-30056). Modified version of commercial pneumatically driven rotary cutting tool removes such hard metals as nickel alloys, titanium, and stainless steels.

Use of piezosurgery for internal auditory canal drilling in acoustic neuroma surgery.

PubMed

Grauvogel, Juergen; Scheiwe, Christian; Kaminsky, Jan

2011-10-01

Piezosurgery is based on microvibrations generated by the piezoelectrical effect and has a selective bone-cutting ability with preservation of soft tissue. This study examined the applicability of Piezosurgery compared to rotating drills (RD) for internal auditory canal (IAC) opening in acoustic neuroma (AN) surgery. Piezosurgery was used in eight patients for IAC drilling in AN surgery. After exposition of the IAC and tumor, the posterior wall of the IAC was drilled using Piezosurgery instead of RD. Piezosurgery was evaluated with respect to practicability, safety, preciseness of bone cutting, preservation of cranial nerves, influences on neurophysiological monitoring, and facial nerve and hearing outcome. Piezosurgery was successfully used for selective bone cutting, while cranial nerves were structurally and functionally preserved, which could be measured by means of neuromonitoring. Piezosurgery guaranteed a safe and precise cut by removing bone layer by layer in a shaping way. Compared to RD, limited influence on neurophysiological monitoring attributable to Piezosurgery was noted, allowing for continuous neuromonitoring. No disadvantage due to microvibrations was noticed concerning hearing function. The angled tip showed better handling in right-sided than in left-sided tumors in the hands of a right-handed surgeon. The short, thick handpiece may be improved for more convenient handling. Piezosurgery is a safe tool for selective bone cutting for opening of the IAC with preservation of facial nerve and hearing function in AN surgery. Piezosurgery has the potential to replace RD for this indication because of its safe and precise bone-cutting properties.

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

NASA Astrophysics Data System (ADS)

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.

The machined surface of magnesium AZ31 after rotary turning at air cooling condition

NASA Astrophysics Data System (ADS)

Akhyar, G.; Purnomo, B.; Hamni, A.; Harun, S.; Burhanuddin, Y.

2018-04-01

Magnesium is a lightweight metal that is widely used as an alternative to iron and steel. Magnesium has been applied in the automotive industry to reduce the weight of a component, but the machining process has the disadvantage that magnesium is highly flammable because it has a low flash point. High temperature can cause the cutting tool wear and contributes to the quality of the surface roughness. The purpose of this study is to obtain the value of surface roughness and implement methods of rotary cutting tool and air cooling output vortex tube cooler to minimize the surface roughness values. Machining parameters that is turning using rotary cutting tool at speed the workpiece of (Vw) 50, 120, 160 m/min, cutting speed of rotary tool of (Vt) 25, 50, 75 m/min, feed rate of (f) 0.1, 0.15, 0.2 mm/rev, and depth of cut of 0.3 mm. Type of tool used is a carbide tool diameter of 16 mm and air cooling pressure of 6 bar. The results show the average value of the lowest surface roughness on the speed the workpiece of 80 m/min, cutting speed of rotary tool of 50 m/min, feed rate of 0.2 mm/rev, and depth of cut of 0.3 mm. While the average value of the highest surface roughness on the speed the workpiece of 160 m/min, cutting speed of rotary tool of 50 m/min, feed rate of 0.2 mm/rev, and depth of cut of 0.3 mm. The influence of machining parameters concluded the higher the speed of the workpiece the surface roughness value higher. Otherwise the higher cutting speed of rotary tool then the lower the surface roughness value. The observation on the surface of the rotary tool, it was found that no uniform tool wear which causes non-uniform surface roughness. The use of rotary cutting tool contributing to lower surface roughness values generated.

Force-frequency effect of Y-cut langanite and Y-cut langatate.

PubMed

Kim, Yoonkee; Ballato, Arthur

2003-12-01

Most recently, langasite and its isomorphs (LGX) have been advanced as potential substitutes for quartz, owing to their extremely high-quality (Q) factors. At least twice higher Q value of LGX than that of quartz has been reported. High Q translates into potentially greater stability. In order to make such materials practical, the environmental sensitivities must be addressed. One of such sensitivities is the force-frequency effect, which relates the sensitiveness of a resonator to shock and vibration via the third-order (non-Hookean) elastic constants. In this paper, we report measured force-frequency coefficients of a Y-cut langanite (LGN) resonator and a Y-cut langatate (LGT) resonator as a function of the azimuthal angle, which is the angle between the crystalline x-axis of a resonator plate and the direction of in-plane diametric force applied to the periphery of the resonator. It was found that the LGN and the LGT behave like AT-cut quartz in the polarity of the frequency changes and the existence of zero-coefficient angle. The maximum magnitudes of the coefficients of the LGN and the LGT are five and seven times smaller than that of stress-compensated cut (SC-cut) quartz, respectively (or, 7 and 10 times smaller comparing to AT-cut quartz). The coefficients of planar-stress, which represent the superposition of a continuous distribution of periphery stresses, also were obtained as 0.52 X 10(-15) m x s/N and 0.38 X 10(-15) m x s/N for the LGN and the LGT, respectively.

[Measurement and analysis of hand-transmitted vibration of vibration tools in workplace for automobile casting and assembly].

PubMed

Xie, X S; Qi, C; Du, X Y; Shi, W W; Zhang, M

2016-02-20

To investigate the features of hand-transmitted vibration of common vibration tools in the workplace for automobile casting and assembly. From September to October, 2014, measurement and spectral analysis were performed for 16 typical hand tools(including percussion drill, pneumatic wrench, grinding machine, internal grinder, and arc welding machine) in 6 workplaces for automobile casting and assembly according to ISO 5349-1-2001 Mechanical vibration-Measurement and evaluation of human exposure to hand-transmitted vibration-part 1: General requirements and ISO 5349-2-2001 Mechanical vibration-Measurement and evaluation of human exposure to hand-transmitted vibration-Part 2: Practical guidance for measurement in the workplace. The vibration acceleration waveforms of shearing machine, arc welding machine, and pneumatic wrench were mainly impact wave and random wave, while those of internal grinder, angle grinder, percussion drill, and grinding machine were mainly long-and short-period waves. The daily exposure duration to vibration of electric wrench, pneumatic wrench, shearing machine, percussion drill, and internal grinder was about 150 minutes, while that of plasma cutting machine, angle grinder, grinding machine, bench grinder, and arc welding machine was about 400 minutes. The range of vibration total value(ahv) was as follows: pneumatic wrench 0.30~11.04 m/s(2), grinding wheel 1.61~8.97 m/s(2), internal grinder 1.46~8.70 m/s(2), percussion drill 11.10~14.50 m/s(2), and arc welding machine 0.21~2.18 m/s(2). The workers engaged in cleaning had the longest daily exposure duration to vibration, and the effective value of 8-hour energy-equivalent frequency-weighted acceleration for them[A(8)] was 8.03 m/s(2), while this value for workers engaged in assembly was 4.78 m/s(2). The frequency spectrogram with an 1/3-time frequency interval showed that grinding machine, angle grinder, and percussion drill had a high vibration acceleration, and the vibration limit curve was recommended for those with a frequency higher than 400 min/d. The workers who are engaged in cleaning, grinding, and a few positions of assembly and use grinding machine, angle grinder, internal grinder, and percussion drill are exposed to vibrations with a high vibration acceleration and at a high position of the frequency spectrum. The hand-transmitted vibration in the positions of cutting, polishing, and cleaning in automobile casting has great harm, and the harm caused by pneumatic wrench in automobile assembly should be taken seriously.

Microcutting characteristics on the single crystal diamond tool with edge radius using molecular dynamics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kim, Jeong-Du; Moon, Chan-Hong

1995-12-31

Ultraprecision metal cutting (UPMC) technology which makes possible submicrometer form accuracy and manometer roughness is developed to reach the 1nm nominal (undeformed) thickness of cut. At this thickness level, a few of atom`s layers should be considered. In this paper using the Molecuar Dynamics simulation, the phenomena of microcutting with a subnanometer chip thickness, the cutting mechanism for tool edge configuration to consider the sharp edge and round edge tool, the cut material and cutting speed are evaluated. Cutting mechanism of subnanometer depth of cut is evaluated.

Double diameter boring tool

DOEpatents

Ashbaugh, Fred N.; Murry, Kenneth R.

1988-12-27

A boring tool and a method of operation are provided for boring two concentric holes of precision diameters and depths in a single operation. The boring tool includes an elongated tool body, a shank for attachment to a standard adjustable boring head which is used on a manual or numerical control milling machine and first and second diametrically opposed cutting edges formed for cutting in opposite directions. The diameter of the elongated tool body is substantially equal to the distance from the first cutting edge tip to the axis of rotation plus the distance from the second cutting edge tip to the axis of rotation. The axis of rotation of the tool is spaced from the tool centerline a distance substantially equal to one-half the distance from the second cutting edge tip to the axis of rotation minus one-half the distance from the first cutting edge tip to the axis of rotation. The method includes the step of inserting the boring tool into the boring head, adjusting the distance between the tool centerline and the tool axis of rotation as described above and boring the two concentric holes.

High-Speed Edge Trimming of CFRP and Online Monitoring of Performance of Router Tools Using Acoustic Emission

PubMed Central

Prakash, Rangasamy; Krishnaraj, Vijayan; Zitoune, Redouane; Sheikh-Ahmad, Jamal

2016-01-01

Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industrial fields such as aerospace, automotive, and shipping industries due to their excellent mechanical properties that lead to enhanced functional performance. In this paper, an experimental study on edge trimming of CFRP was done with various cutting conditions and different geometry of tools such as helical-, fluted-, and burr-type tools. The investigation involves the measurement of cutting forces for the different machining conditions and its effect on the surface quality of the trimmed edges. The modern cutting tools (router tools or burr tools) selected for machining CFRPs, have complex geometries in cutting edges and surfaces, and therefore a traditional method of direct tool wear evaluation is not applicable. An acoustic emission (AE) sensing was employed for on-line monitoring of the performance of router tools to determine the relationship between AE signal and length of machining for different kinds of geometry of tools. The investigation showed that the router tool with a flat cutting edge has better performance by generating lower cutting force and better surface finish with no delamination on trimmed edges. The mathematical modeling for the prediction of cutting forces was also done using Artificial Neural Network and Regression Analysis. PMID:28773919

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

PubMed Central

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

2016-01-01

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. PMID:27854322

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

PubMed

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.

Double diameter boring tool

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ashbaugh, F.N.; Murry, K.R.

A method of boring two concentric holes of different depths is described utilizing an elongated boring tool having a tool axis of rotation, a longitudinally disposed tool centerline axis, and first and second transverse cutting edges at one end thereof extending across the boring tool, the second cutting edge being longitudinally rearwardly recessed with respect to the first cutting edge. The method consists of inserting the boring tool into an adjustable boring head, adjusting a distance B between the tool centerline axis and the tool axis of rotation such that the tool axis of rotation intersects a first boring areamore » of the first cutting edge; and boring the concentric holes having respectively larger and smaller diameters.« less

A study examining the effects of water-miscible cutting fluids for end milling process of carbon fiber reinforced plastic

NASA Astrophysics Data System (ADS)

Anan, Ruito; Matsuoka, Hironori; Ono, Hajime; Ryu, Takahiro; Nakae, Takashi; Shuto, Schuichi; Watanabe, Suguru; Sato, Yuta

2017-04-01

This study examined the improvements to the tool life and finished surface roughness by using water-miscible cutting fluids in carbon fiber reinforced plastics end milling. In cutting tests, it was found that the use of emulsion type, soluble type, and solution type cutting fluids improved tool life compared with the case of dry cutting. Specifically, significant differences in tool life were observed at a high cutting speed of 171 m/min. In addition, the finished surface exhibited a low level of roughness when the solution type cutting fluid was used, regardless of the cutting speed.

Measurement of W + bb and a search for MSSM Higgs bosons with the CMS detector at the LHC

NASA Astrophysics Data System (ADS)

O'Connor, Alexander Pinpin

Tooling used to cure composite laminates in the aerospace and automotive industries must provide a dimensionally stable geometry throughout the thermal cycle applied during the part curing process. This requires that the Coefficient of Thermal Expansion (CTE) of the tooling materials match that of the composite being cured. The traditional tooling material for production applications is a nickel alloy. Poor machinability and high material costs increase the expense of metallic tooling made from nickel alloys such as 'Invar 36' or 'Invar 42'. Currently, metallic tooling is unable to meet the needs of applications requiring rapid affordable tooling solutions. In applications where the tooling is not required to have the durability provided by metals, such as for small area repair, an opportunity exists for non-metallic tooling materials like graphite, carbon foams, composites, or ceramics and machinable glasses. Nevertheless, efficient machining of brittle, non-metallic materials is challenging due to low ductility, porosity, and high hardness. The machining of a layup tool comprises a large portion of the final cost. Achieving maximum process economy requires optimization of the machining process in the given tooling material. Therefore, machinability of the tooling material is a critical aspect of the overall cost of the tool. In this work, three commercially available, brittle/porous, non-metallic candidate tooling materials were selected, namely: (AAC) Autoclaved Aerated Concrete, CB1100 ceramic block and Cfoam carbon foam. Machining tests were conducted in order to evaluate the machinability of these materials using end milling. Chip formation, cutting forces, cutting tool wear, machining induced damage, surface quality and surface integrity were investigated using High Speed Steel (HSS), carbide, diamond abrasive and Polycrystalline Diamond (PCD) cutting tools. Cutting forces were found to be random in magnitude, which was a result of material porosity. The abrasive nature of Cfoam produced rapid tool wear when using HSS and PCD type cutting tools. However, tool wear was not significant in AAC or CB1100 regardless of the type of cutting edge. Machining induced damage was observed in the form of macro-scale chipping and fracture in combination with micro-scale cracking. Transverse rupture test results revealed significant reductions in residual strength and damage tolerance in CB1100. In contrast, AAC and Cfoam showed no correlation between machining induced damage and a reduction in surface integrity. Cutting forces in machining were modeled for all materials. Cutting force regression models were developed based on Design of Experiment and Analysis of Variance. A mechanistic cutting force model was proposed based upon conventional end milling force models and statistical distributions of material porosity. In order to validate the model, predicted cutting forces were compared to experimental results. Predicted cutting forces agreed well with experimental measurements. Furthermore, over the range of cutting conditions tested, the proposed model was shown to have comparable predictive accuracy to empirically produced regression models; greatly reducing the number of cutting tests required to simulate cutting forces. Further, this work demonstrates a key adaptation of metallic cutting force models to brittle porous material; a vital step in the research into the machining of these materials using end milling.

Preset pivotal tool holder

DOEpatents

Asmanes, Charles

1979-01-01

A tool fixture is provided for precise pre-alignment of a radiused edge cutting tool in a tool holder relative to a fixed reference pivot point established on said holder about which the tool holder may be selectively pivoted relative to the fixture base member to change the contact point of the tool cutting edge with a workpiece while maintaining the precise same tool cutting radius relative to the reference pivot point.

Effects of drilling variables on burr properties

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gillespie, L.K.

1976-09-01

An investigation utilizing 303Se stainless steel, 17-4PH stainless steel, 1018 steel, and 6061-T6 aluminum was conducted to determine the influence of drilling variables in controlling burr size to minimize burr-removal cost and improve the quality and reliability of parts for small precision mechanisms. Burr thickness can be minimized by reducing feedrate and cutting velocity, and by using drills having high helix angles. High helix angles reduce burr thickness, length, and radius, while most other variables reduce only one of these properties. Radial-lip drills minimize burrs from 303Se stainless steel when large numbers of holes are drilled; this material stretches 10more » percent before drill-breakthrough. Entrance burrs can be minimized by the use of subland drills at a greatly increased tool cost. Backup-rods used in cross-drilled holes may be difficult to remove and may scratch the hole walls.« less

AK-cut crystal resonators

NASA Technical Reports Server (NTRS)

Kahan, A.; Euler, F. K.

1983-01-01

Calculations have predicted the existence of crystallographically doubly rotated quartz orientations with turnover temperatures which are considerably less sensitive to angular misorientation then comparable AT- or BT-cuts. These crystals are arbitrarily designated as the AK-cut. Experimental data is given for seven orientations, phi-angle variations between 30-46 deg and theta-angle variations between 21-28 deg measured on 3.3-3.4 MHz fundamental mode resonators vibrating in the thickness shear c-mode. The experimental turnover temperatures of these resonators are between 80 C and 150 C, in general agreement with calculated values. The normalized frequency change as a function of temperature has been fitted with a cubic equation.

Shock synthesized and static sintered boron nitride cutting tool

NASA Astrophysics Data System (ADS)

Araki, M.; Kuroyama, Y.

1986-05-01

Shock synthesis of wBN (wurtzite phase boron nitride) on an industrial scale was achieved by Nippon Oil & Fats and Showa Denko in 1971. It seemed that the resultant wBN powder might display excellent qualities as a cutting tool material when it was sintered under very high static pressure and temperature because of its polycrystalline nature. Attempts to produce a wBN cutting tool material were commenced by the Tokyo Institute of Technology and Nippon Oil & Fats in 1976 and commercially available wBN cutting tools were first sold in 1980. Meanwhile, a new type of explosion chamber designed to eliminate explosion sound and earth vibration problems, novel high pressure vessels and other peripheral apparatuses have been developed. Now, WURZIN (trademark for the wBN cutting tool) is used in many aspects of the steel cutting field because it is durable when cutting various steels from mild steels to superalloys under high speed, interrupt and precision cutting conditions.

Muscle Fiber Orientation Angle Dependence of the Tensile Fracture Behavior of Frozen Fish Muscle

NASA Astrophysics Data System (ADS)

Hagura, Yoshio; Okamoto, Kiyoshi; Suzuki, Kanichi; Kubota, Kiyoshi

We have proposed a new cutting method for frozen fish named "cryo-cutting". This method applied tensile fracture force or bending fracture force to the frozen fish at appropriate low temperatures. In this paper, to clarify cryo-cutting mechanism, we analyzed tensile fracture behavior of the frozen fish muscle. In the analysis, the frozen fish muscle was considered unidirectionally fiber-reinforced composite material which consisted of fiber (muscle fiber) and matrix (connective tissue). Fracture criteria (maximum stress criterion, Tsai-Hill criterion) for the unidirectionally fiber-reinforced composite material were used. The following results were obtained: (1) By using Tsai-Hill criterion, muscle fiber orientation angle dependence of the tensile fracture stress could be calculated. (2) By using the maximum stress theory jointly with Tsai-Hill criterion, muscle fiber orientation angle dependence of the fracture mode of the frozen fish muscle could be estimated.

High Speed Metal Removal

DTIC Science & Technology

1982-10-01

AISI 1340, 4140 , 4340, and HF-1) which are commonly used in large caliber projectile manufacture were machined at...Tool Load Data for AISI 1340 "finishing" cuts Life-Line Data for AISI 4140 "roughing" cuts Tool Wear-Land Chart Data for AISI 4140 - "roughing...34 cuts; 570 Ceramic Coated Carbide Tool Wear-Land Chart Data for AISI 4140 - "roughing" cuts; G-10 Ceramic- Tool Wear-Land Chart Data for AISI 4140

Cutting Tool For Shaving Weld Beads

NASA Technical Reports Server (NTRS)

Hoffman, David S.; Mcferrin, David C.; Daniel, Ronald L., Jr.; Coby, John B., Jr.; Dawson, Sidney G.

1995-01-01

Cutting tool proposed for use in shaving weld beads flush with adjacent surfaces of weldments. Modified version of commercial pneumatically driven rotary cutting tool, cutting wheel of which turns at speeds sufficient for machining nickel alloys, titanium, and stainless steels. Equipped with forward-mounted handle and rear-mounted skid plate to maximize control and reduce dependence on skill of technician.

Surface dimpling on rotating work piece using rotation cutting tool

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bhapkar, Rohit Arun; Larsen, Eric Richard

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 coupledmore » 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.« less

Effect of cutting fluids and cutting conditions on surface integrity and tool wear in turning of Inconel 713C

NASA Astrophysics Data System (ADS)

Hikiji, R.

2018-01-01

The trend toward downsizing of engines helps to increase the number of turbochargers around Europe. As for the turbocharger, the temperature of the exhaust gas is so high that the parts made of nickel base super alloy Inconel 713C are used as high temperature strength metals. External turning of Inconel 713C which is used as the actual automotive parts was carried out. The effect of the cutting fluids and cutting conditions on the surface integrity and tool wear was investigated, considering global environment and cost performance. As a result, in the range of the cutting conditions used this time, when the depth of cut was small, the good surface integrity and tool life were obtained. However, in the case of the large corner radius, it was found that the more the cutting length increased, the more the tool wear increased. When the cutting length is so large, the surface integrity and tool life got worse. As for the cutting fluids, it was found that the synthetic type showed better performance in the surface integrity and tool life than the conventional emulsion. However, it was clear that the large corner radius made the surface roughness and tool life good, but it affected the size error etc. in machining the workpiece held in a cantilever style.

CHARACTERIZATION OF AORTIC TISSUE CUTTING PROCESS: EXPERIMENTAL INVESTIGATION USING PORCINE ASCENDING AORTA

PubMed Central

Hu, Zhongwei; Sun, Wei; Zhang, Bi

2012-01-01

Understanding biomechanical responses during soft tissue cutting is important for developing surgical simulators and robot-assisted surgery with haptic feedback. The biomechanics involved in the aortic tissue cutting process is largely unknown. In this study, porcine ascending aorta was selected as a representative aortic tissue, and tissue cutting experiments were performed using a novel tissue cutting apparatus. The tissue cutting responses under various cutting conditions were investigated, including differing initial tissue lateral holding force and distance, cutting speed, cutter inclination angle, tissue anatomical orientation and thickness. The results from this study suggest that a “break-in” cutting force of about 4 – 12 N, a cutter “break-in” distance of 5 – 15 mm, and a continuous cutting force of 2 – 4 N were needed to cut through the porcine ascending aorta tissue. For all testing conditions investigated in this study, the cutting force vs. the cutter displacement curves exhibited similar characteristics. More importantly, this study demonstrated that tissue cutting involving one or more of the following conditions: a larger lateral holding force, a smaller lateral hold distance, a higher cutting speed or a larger inclination angle, could result in a smaller “break in” cutting force and a smaller “break-in” distance. In addition, it was found that the cutting force in the vessel longitudinal direction was larger than that in the circumferential direction. There was a strong correlation between the tissue thickness and the cutting force. The experimental results reported in this study could provide a basis for understanding the characteristic response of aortic tissue to scalpel cutting, and offer insight into the development of surgical simulators. PMID:23262306

Differences in Neuromuscular Strategies Between Landing and Cutting Tasks in Female Basketball and Soccer Athletes

PubMed Central

Cowley, Hanni R; Ford, Kevin R; Myer, Gregory D; Kernozek, Thomas W; Hewett, Timothy E

2006-01-01

Context: High school female athletes are most likely to sustain a serious knee injury during soccer or basketball, 2 sports that often involve a rapid deceleration before a change of direction or while landing from a jump. Objective: To determine if female high school basketball and soccer players show neuromuscular differences during landing and cutting tasks and to examine neuromuscular differences between tasks and between dominant and nondominant sides. Design: A 3-way mixed factorial design investigating the effects of sport (basketball, soccer), task (jumping, cutting), and side (dominant, nondominant). Setting: Laboratory. Patients or Other Participants: Thirty high school female athletes who listed either basketball or soccer as their only sport of participation (basketball: n = 15, age = 15.1 ± 1.7 years, experience = 6.9 ± 2.2 years, height = 165.3 ± 7.9 cm, mass = 61.8 ± 9.3 kg; soccer: n = 15, age = 14.8 ± 0.8 years, experience = 8.8 ± 2.5 years, height = 161.8 ± 4.1 cm, mass = 54.6 ± 7.6 kg). Main Outcome Measure(s): Ground reaction forces, stance time, valgus angles, and valgus moments were assessed during (1) a drop vertical jump with an immediate maximal vertical jump and (2) an immediate side-step cut at a 45° angle. Results: Basketball athletes had greater ground reaction forces (P < .001) and decreased stance time (P < .001) during the drop vertical jump, whereas soccer players had greater ground reaction forces (P <.001) and decreased stance time (P < .001) during the cut. Subjects in both sports had greater valgus angles (initial contact and maximum, P = .02 and P = .012, respectively) during cutting than during the drop vertical jump. Greater valgus moments (P = .006) were noted on the dominant side during cutting. Conclusions: Our subjects demonstrated differences in ground reaction forces and stance times during 2 movements associated with noncontact anterior cruciate ligament injuries. Knee valgus moment and angle were significantly influenced by the type of movement performed. Sport-specific neuromuscular training may be warranted, with basketball players focusing on jumping and landing and soccer players focusing on unanticipated cutting maneuvers. PMID:16619097

Effects of random aspects of cutting tool wear on surface roughness and tool life

NASA Astrophysics Data System (ADS)

Nabil, Ben Fredj; Mabrouk, Mohamed

2006-10-01

The effects of random aspects of cutting tool flank wear on surface roughness and on tool lifetime, when turning the AISI 1045 carbon steel, were studied in this investigation. It was found that standard deviations corresponding to tool flank wear and to the surface roughness increase exponentially with cutting time. Under cutting conditions that correspond to finishing operations, no significant differences were found between the calculated values of the capability index C p at the steady-state region of the tool flank wear, using the best-fit method or the Box-Cox transformation, or by making the assumption that the surface roughness data are normally distributed. Hence, a method to establish cutting tool lifetime could be established that simultaneously respects the desired average of surface roughness and the required capability index.

Analyzing the effect of tool edge radius on cutting temperature in micro-milling process

NASA Astrophysics Data System (ADS)

Liang, Y. C.; Yang, K.; Zheng, K. N.; Bai, Q. S.; Chen, W. Q.; Sun, G. Y.

2010-10-01

Cutting heat is one of the important physical subjects in the cutting process. Cutting heat together with cutting temperature produced by the cutting process will directly have effects on the tool wear and the life as well as on the workpiece processing precision and surface quality. The feature size of the workpiece is usually several microns. Thus, the tiny changes of cutting temperature will affect the workpiece on the surface quality and accuracy. Therefore, cutting heat and temperature generated in micro-milling will have significantly different effect than the one in the traditional tools cutting. In this paper, a two-dimensional coupled thermal-mechanical finite element model is adopted to determine thermal fields and cutting temperature during the Micro-milling process, by using software Deform-2D. The effect of tool edge radius on effective stress, effective strain, velocity field and cutting temperature distribution in micro-milling of aluminum alloy Al2024-T6 were investigated and analyzed. Also, the transient cutting temperature distribution was simulated dynamically. The simulation results show that the cutting temperature in Micro-milling is lower than those occurring in conventional milling processes due to the small loads and low cutting velocity. With increase of tool edge radius, the maximum temperature region gradually occurs on the contact region between finished surfaced and flank face of micro-cutter, instead of the rake face or the corner of micro-cutter. And this phenomenon shows an obvious size effect.

Dual-task and anticipation impact lower limb biomechanics during a single-leg cut with body borne load.

PubMed

Seymore, Kayla D; Cameron, Sarah E; Kaplan, Jonathan T; Ramsay, John W; Brown, Tyler N

2017-12-08

This study quantified how a dual cognitive task impacts lower limb biomechanics during anticipated and unanticipated single-leg cuts with body borne load. Twenty-four males performed anticipated and unanticipated cuts with and without a dual cognitive task with three load conditions: no load (∼6 kg), medium load (15% of BW), and heavy load (30% of BW). Lower limb biomechanics were submitted to a repeated measures linear mixed model to test the main and interaction effects of load, anticipation, and dual task. With body borne load, participants increased peak stance (PS) hip flexion (p = .004) and hip internal rotation (p = .001) angle, and PS hip flexion (p = .001) and internal rotation (p = .018), and knee flexion (p = .016) and abduction (p = .001) moments. With the dual task, participants decreased PS knee flexion angle (p < .001) and hip flexion moment (p = .027), and increased PS knee external rotation angle (p = .034). During the unanticipated cut, participants increased PS hip (p = .040) and knee flexion angle (p < .001), and decreased PS hip adduction (p = .001), and knee abduction (p = .005) and external rotation (p = .026) moments. Adding body borne load produces lower limb biomechanical adaptations thought to increase risk of musculoskeletal injury, but neither anticipation nor dual task exaggerated those biomechanical adaptations. With a dual task, participants adopted biomechanics known to increase injury risk; whereas, participants used lower limb biomechanics thought to decrease injury risk during unanticipated cuts. Copyright © 2017 Elsevier Ltd. All rights reserved.

Assessment of wear dependence parameters in complex model of cutting tool wear

NASA Astrophysics Data System (ADS)

Antsev, A. V.; Pasko, N. I.; Antseva, N. V.

2018-03-01

This paper addresses wear dependence of the generic efficient life period of cutting tools taken as an aggregate of the law of tool wear rate distribution and dependence of parameters of this law's on the cutting mode, factoring in the random factor as exemplified by the complex model of wear. The complex model of wear takes into account the variance of cutting properties within one batch of tools, variance in machinability within one batch of workpieces, and the stochastic nature of the wear process itself. A technique of assessment of wear dependence parameters in a complex model of cutting tool wear is provided. The technique is supported by a numerical example.

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

NASA Astrophysics Data System (ADS)

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.

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

PubMed

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.

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

PubMed Central

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

Control of red alder by cutting.

Treesearch

Dean S. DeBell; Thomas C. Turpin

1989-01-01

Effects of tree age, month of cut, and height and angle of cut on sprouting of red alder stumps were evaluated in a study designed to develop an effective method for controlling red alder in Douglas-fir plantations. Ninety-five percent or more of alder stumps cut in June or July died by the end of the next growing season; mortality was 88, 70, and 22 percent for stumps...

Investigation of machinability characteristics on EN47 steel for cutting force and tool wear using optimization technique

NASA Astrophysics Data System (ADS)

M, Vasu; Shivananda Nayaka, H.

2018-06-01

In this experimental work dry turning process carried out on EN47 spring steel with coated tungsten carbide tool insert with 0.8 mm nose radius are optimized by using statistical technique. Experiments were conducted at three different cutting speeds (625, 796 and 1250 rpm) with three different feed rates (0.046, 0.062 and 0.093 mm/rev) and depth of cuts (0.2, 0.3 and 0.4 mm). Experiments are conducted based on full factorial design (FFD) 33 three factors and three levels. Analysis of variance is used to identify significant factor for each output response. The result reveals that feed rate is the most significant factor influencing on cutting force followed by depth of cut and cutting speed having less significance. Optimum machining condition for cutting force obtained from the statistical technique. Tool wear measurements are performed with optimum condition of Vc = 796 rpm, ap = 0.2 mm, f = 0.046 mm/rev. The minimum tool wear observed as 0.086 mm with 5 min machining. Analysis of tool wear was done by confocal microscope it was observed that tool wear increases with increasing cutting time.

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.

PubMed

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.

Effects of Different Cutting Patterns and Experimental Conditions on the Performance of a Conical Drag Tool

NASA Astrophysics Data System (ADS)

Copur, Hanifi; Bilgin, Nuh; Balci, Cemal; Tumac, Deniz; Avunduk, Emre

2017-06-01

This study aims at determining the effects of single-, double-, and triple-spiral cutting patterns; the effects of tool cutting speeds on the experimental scale; and the effects of the method of yield estimation on cutting performance by performing a set of full-scale linear cutting tests with a conical cutting tool. The average and maximum normal, cutting and side forces; specific energy; yield; and coarseness index are measured and compared in each cutting pattern at a 25-mm line spacing, at varying depths of cut per revolution, and using two cutting speeds on five different rock samples. The results indicate that the optimum specific energy decreases by approximately 25% with an increasing number of spirals from the single- to the double-spiral cutting pattern for the hard rocks, whereas generally little effect was observed for the soft- and medium-strength rocks. The double-spiral cutting pattern appeared to be more effective than the single- or triple-spiral cutting pattern and had an advantage of lower side forces. The tool cutting speed had no apparent effect on the cutting performance. The estimation of the specific energy by the yield based on the theoretical swept area was not significantly different from that estimated by the yield based on the muck weighing, especially for the double- and triple-spiral cutting patterns and with the optimum ratio of line spacing to depth of cut per revolution. This study also demonstrated that the cutterhead and mechanical miner designs, semi-theoretical deterministic computer simulations and empirical performance predictions and optimization models should be based on realistic experimental simulations. Studies should be continued to obtain more reliable results by creating a larger database of laboratory tests and field performance records for mechanical miners using drag tools.

Wear and breakage monitoring of cutting tools by an optical method: theory

NASA Astrophysics Data System (ADS)

Li, Jianfeng; Zhang, Yongqing; Chen, Fangrong; Tian, Zhiren; Wang, Yao

1996-10-01

An essential part of a machining system in the unmanned flexible manufacturing system, is the ability to automatically change out tools that are worn or damaged. An optoelectronic method for in situ monitoring of the flank wear and breakage of cutting tools is presented. A flank wear estimation system is implemented in a laboratory environment, and its performance is evaluated through turning experiments. The flank wear model parameters that need to be known a priori are determined through several preliminary experiments, or from data available in the literature. The resulting cutting conditions are typical of those used in finishing cutting operations. Through time and amplitude domain analysis of the cutting tool wear states and breakage states, it is found that the original signal digital specificity (sigma) 2x and the self correlation coefficient (rho) (m) can reflect the change regularity of the cutting tool wear and break are determined, but which is not enough due to the complexity of the wear and break procedure of cutting tools. Time series analysis and frequency spectrum analysis will be carried out, which will be described in the later papers.

Apparatus and process for removing a predetermined portion of reflective material from mirror

DOEpatents

Perry, Stephen J.; Steinmetz, Lloyd L.

1994-01-01

An apparatus and process are disclosed for removal of a stripe of soft reflective material of uniform width from the surface of a mirror by using a blade having a large included angle to inhibit curling of the blade during the cutting operation which could result in damage to the glass substrate of the mirror. The cutting blade is maintained at a low blade angle with respect to the mirror surface to produce minimal chipping along the cut edge and to minimize the force exerted on the coating normal to the glass surface which could deform the flat mirror. The mirror is mounted in a cutting mechanism containing a movable carriage on which the blade is mounted to provide very accurate straightness of the travel of the blade along the mirror.

Pressure-induced critical influences on workpiece-tool thermal interaction in high speed dry machining of titanium

NASA Astrophysics Data System (ADS)

Abdel-Aal, H. A.; Mansori, M. El

2012-12-01

Cutting tools are subject to extreme thermal and mechanical loads during operation. The state of loading is intensified in dry cutting environment especially when cutting the so called hard-to-cut-materials. Although, the effect of mechanical loads on tool failure have been extensively studied, detailed studies on the effect of thermal dissipation on the deterioration of the cutting tool are rather scarce. In this paper we study failure of coated carbide tools due to thermal loading. The study emphasizes the role assumed by the thermo-physical properties of the tool material in enhancing or preventing mass attrition of the cutting elements within the tool. It is shown that within a comprehensive view of the nature of conduction in the tool zone, thermal conduction is not solely affected by temperature. Rather it is a function of the so called thermodynamic forces. These are the stress, the strain, strain rate, rate of temperature rise, and the temperature gradient. Although that within such consideration description of thermal conduction is non-linear, it is beneficial to employ such a form because it facilitates a full mechanistic understanding of thermal activation of tool wear.

Vee-notch tool cuts specimens

NASA Technical Reports Server (NTRS)

Spier, R. A.

1970-01-01

Triangular cutting tool uses carbide tips for notching heat-treated or abrasive materials, and alloys subjected to high structural stresses. The tool is rigidly mounted in a slot of mating contour to prevent deflection during cutting of tensile specimens. No other expensive machine equipment is required.

Influence of Surface Features for Increased Heat Dissipation on Tool Wear

PubMed Central

Beno, Tomas; Hoier, Philipp; Wretland, Anders

2018-01-01

The critical problems faced during the machining process of heat resistant superalloys, (HRSA), is the concentration of heat in the cutting zone and the difficulty in dissipating it. The concentrated heat in the cutting zone has a negative influence on the tool life and surface quality of the machined surface, which in turn, contributes to higher manufacturing costs. This paper investigates improved heat dissipation from the cutting zone on the tool wear through surface features on the cutting tools. Firstly, the objective was to increase the available surface area in high temperature regions of the cutting tool. Secondly, multiple surface features were fabricated for the purpose of acting as channels in the rake face to create better access for the coolant to the proximity of the cutting edge. The purpose was thereby to improve the cooling of the cutting edge itself, which exhibits the highest temperature during machining. These modified inserts were experimentally investigated in face turning of Alloy 718 with high-pressure coolant. Overall results exhibited that surface featured inserts decreased flank wear, abrasion of the flank face, cutting edge deterioration and crater wear probably due to better heat dissipation from the cutting zone. PMID:29693579

Wear-dependent specific coefficients in a mechanistic model for turning of nickel-based superalloy with ceramic tools

NASA Astrophysics Data System (ADS)

López de Lacalle, Luis Norberto; Urbicain Pelayo, Gorka; Fernández-Valdivielso, Asier; Alvarez, Alvaro; González, Haizea

2017-09-01

Difficult to cut materials such as nickel and titanium alloys are used in the aeronautical industry, the former alloys due to its heat-resistant behavior and the latter for the low weight - high strength ratio. Ceramic tools made out alumina with reinforce SiC whiskers are a choice in turning for roughing and semifinishing workpiece stages. Wear rate is high in the machining of these alloys, and consequently cutting forces tends to increase along one operation. This paper establishes the cutting force relation between work-piece and tool in the turning of such difficult-to-cut alloys by means of a mechanistic cutting force model that considers the tool wear effect. The cutting force model demonstrates the force sensitivity to the cutting engagement parameters (ap, f) when using ceramic inserts and wear is considered. Wear is introduced through a cutting time factor, being useful in real conditions taking into account that wear quickly appears in alloys machining. A good accuracy in the cutting force model coefficients is the key issue for an accurate prediction of turning forces, which could be used as criteria for tool replacement or as input for chatter or other models.

The Tool Life of Ball Nose end Mill Depending on the Different Types of Ramping

NASA Astrophysics Data System (ADS)

Vopát, Tomáš; Peterka, Jozef; Kováč, Martin

2014-12-01

The article deals with the cutting tool wear measurement process and tool life of ball nose end mill depending on upward ramping and downward ramping. The aim was to determine and compare the wear (tool life) of ball nose end mill for different types of copy milling operations, as well as to specify particular steps of the measurement process. In addition, we examined and observed cutter contact areas of ball nose end mill with machined material. For tool life test, DMG DMU 85 monoBLOCK 5-axis CNC milling machine was used. In the experiment, cutting speed, feed rate, axial depth of cut and radial depth of cut were not changed. The cutting tool wear was measured on Zoller Genius 3s universal measuring machine. The results show different tool life of ball nose end mills depending on the copy milling strategy.

Mesoplasticity approach to studies of the cutting mechanism in ultra-precision machining

NASA Astrophysics Data System (ADS)

Lee, Rongbin W. B.; Wang, Hao; To, Suet; Cheung, Chi Fai; Chan, Chang Yuen

2014-03-01

There have been various theoretical attempts by researchers worldwide to link up different scales of plasticity studies from the nano-, micro- and macro-scale of observation, based on molecular dynamics, crystal plasticity and continuum mechanics. Very few attempts, however, have been reported in ultra-precision machining studies. A mesoplasticity approach advocated by Lee and Yang is adopted by the authors and is successfully applied to studies of the micro-cutting mechanisms in ultra-precision machining. Traditionally, the shear angle in metal cutting, as well as the cutting force variation, can only be determined from cutting tests. In the pioneering work of the authors, the use of mesoplasticity theory enables prediction of the fluctuation of the shear angle and micro-cutting force, shear band formation, chip morphology in diamond turning and size effect in nano-indentation. These findings are verified by experiments. The mesoplasticity formulation opens up a new direction of studies to enable how the plastic behaviour of materials and their constitutive representations in deformation processing, such as machining can be predicted, assessed and deduced from the basic properties of the materials measurable at the microscale.

An experimental study of flank wear in the end milling of AISI 316 stainless steel with coated carbide inserts

NASA Astrophysics Data System (ADS)

Odedeyi, P. B.; Abou-El-Hossein, K.; Liman, M.

2017-05-01

Stainless steel 316 is a difficult-to-machine iron-based alloys that contain minimum of about 12% of chromium commonly used in marine and aerospace industry. This paper presents an experimental study of the tool wear propagation variations in the end milling of stainless steel 316 with coated carbide inserts. The milling tests were conducted at three different cutting speeds while feed rate and depth of cut were at (0.02, 0.06 and 01) mm/rev and (1, 2 and 3) mm, respectively. The cutting tool used was TiAlN-PVD-multi-layered coated carbides. The effects of cutting speed, cutting tool coating top layer and workpiece material were investigated on the tool life. The results showed that cutting speed significantly affected the machined flank wears values. With increasing cutting speed, the flank wear values decreased. The experimental results showed that significant flank wear was the major and predominant failure mode affecting the tool life.

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

NASA Astrophysics Data System (ADS)

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.

Study on boring hardened materials dryly by ultrasonic vibration cutter

NASA Astrophysics Data System (ADS)

Zhang, Jiangzhong; Zhang, Heng; Zhang, Yue

2011-05-01

It has been one of the difficulties that high-precision hole on hardened materials is machined. The supersonic vibration boring acoustic system in the lathe in which supersonic wave energy is applied on tool is introduced to create pulse power on the cutting process. The separation vibration cutting is achieved by the pulse force. The comparative tests on boring accuracy and surface quality are carried. The quality of surface machined by this method is compared to that by grinding. This cutting is the green cutting. The boring process system is stability. Under the condition that the cutting speed is less than or equal to 1/3 the tool vibration speed, the cutting force is pulse force and the Cutting energy is of high concentration in time, space and direction. The pulse energy effects on the cutting unit in less than one ten-thousandth second. Traditional cutting of irregular movement elastic compression are eliminated. The cutting force is greatly reduced. The cutting temperature is at room temperature. The tool life is greatly increased. Shape precision and surface quality is greatly improved. The regulations of the ultrasonic vibration boring dry cutting of hardened material are also summarized. The test results show that the ultrasonic vibration cutting tool boring is of very superior cutting mechanism and is a high-precision deep-hole machining of hardened materials, efficient cutting methods.

SAW properties in quartz-like α-GeO2 single crystal

NASA Astrophysics Data System (ADS)

Taziev, R. M.

2018-05-01

The paper investigates numerically the properties of surface acoustic waves (SAW) in a new α-GeO2 single crystal of trigonal crystal symmetry (32). It is shown that the SAW has a maximum value of electromechanical coupling coefficient ≈0.14% on Z+120°, X –cut of a crystal with a zero power flow deflection angle. For the case of Z+140°X+25°-cut, the SAW electromechanical coupling coefficient equals 0.17 %, but the power flow deflection angle is not zero. Calculations are made of the frequency dependence of the conductance of SAW interdigital transducers (IDT), which electrode number equals 100 and wavelength is 20 microns on Z+120°,X –cut crystal. The excitations of bulk acoustic waves are absent in this cut case. Leaky acoustic wave, generated by IDT on Z+120°,X –cut of crystal, has a small electromechanical coupling coefficient, which is 4 times less than that for SAW.

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

NASA Astrophysics Data System (ADS)

Samardžiová, Michaela

2016-09-01

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

Core-Cutoff Tool

NASA Technical Reports Server (NTRS)

Gheen, Darrell

2007-01-01

A tool makes a cut perpendicular to the cylindrical axis of a core hole at a predetermined depth to free the core at that depth. The tool does not damage the surrounding material from which the core was cut, and it operates within the core-hole kerf. Coring usually begins with use of a hole saw or a hollow cylindrical abrasive cutting tool to make an annular hole that leaves the core (sometimes called the plug ) in place. In this approach to coring as practiced heretofore, the core is removed forcibly in a manner chosen to shear the core, preferably at or near the greatest depth of the core hole. Unfortunately, such forcible removal often damages both the core and the surrounding material (see Figure 1). In an alternative prior approach, especially applicable to toxic or fragile material, a core is formed and freed by means of milling operations that generate much material waste. In contrast, the present tool eliminates the damage associated with the hole-saw approach and reduces the extent of milling operations (and, hence, reduces the waste) associated with the milling approach. The present tool (see Figure 2) includes an inner sleeve and an outer sleeve and resembles the hollow cylindrical tool used to cut the core hole. The sleeves are thin enough that this tool fits within the kerf of the core hole. The inner sleeve is attached to a shaft that, in turn, can be attached to a drill motor or handle for turning the tool. This tool also includes a cutting wire attached to the distal ends of both sleeves. The cutting wire is long enough that with sufficient relative rotation of the inner and outer sleeves, the wire can cut all the way to the center of the core. The tool is inserted in the kerf until its distal end is seated at the full depth. The inner sleeve is then turned. During turning, frictional drag on the outer core pulls the cutting wire into contact with the core. The cutting force of the wire against the core increases with the tension in the wire and, hence, with the frictional drag acting on the outer sleeve. As the wire cuts toward the center of the core, the inner sleeve rotates farther with respect to the outer sleeve. Once the wire has cut to the center of the core, the tool and the core can be removed from the hole. The proper choice of cutting wire depends on the properties of the core material. For a sufficiently soft core material, a nonmetallic monofilament can be used. For a rubber-like core material, a metal wire can be used. For a harder core material, it is necessary to use an abrasive wire, and the efficiency of the tool can be increased greatly by vacuuming away the particles generated during cutting. For a core material that can readily be melted or otherwise cut by use of heat, it could be preferable to use an electrically heated cutting wire. In such a case, electric current can be supplied to the cutting wire, from an electrically isolated source, via rotating contact rings mounted on the sleeves.

Toolpath strategy for cutter life improvement in plunge milling of AISI H13 tool steel

NASA Astrophysics Data System (ADS)

Adesta, E. Y. T.; Avicenna; hilmy, I.; Daud, M. R. H. C.

2018-01-01

Machinability of AISI H13 tool steel is a prominent issue since the material has the characteristics of high hardenability, excellent wear resistance, and hot toughness. A method of improving cutter life of AISI H13 tool steel plunge milling by alternating the toolpath and cutting conditions is proposed. Taguchi orthogonal array with L9 (3^4) resolution will be employed with one categorical factor of toolpath strategy (TS) and three numeric factors of cutting speed (Vc), radial depth of cut (ae ), and chip load (fz ). It is expected that there are significant differences for each application of toolpath strategy and each cutting condition factor toward the cutting force and tool wear mechanism of the machining process, and medial axis transform toolpath could provide a better tool life improvement by a reduction of cutting force during machining.

Diamond tool machining of materials which react with diamond

DOEpatents

Lundin, Ralph L.; Stewart, Delbert D.; Evans, Christopher J.

1992-01-01

Apparatus for the diamond machining of materials which detrimentally react with diamond cutting tools in which the cutting tool and the workpiece are chilled to very low temperatures. This chilling halts or retards the chemical reaction between the workpiece and the diamond cutting tool so that wear rates of the diamond tool on previously detrimental materials are comparable with the diamond turning of materials which do not react with diamond.

Effects of machining parameters on tool life and its optimization in turning mild steel with brazed carbide cutting tool

NASA Astrophysics Data System (ADS)

Dasgupta, S.; Mukherjee, S.

2016-09-01

One of the most significant factors in metal cutting is tool life. In this research work, the effects of machining parameters on tool under wet machining environment were studied. Tool life characteristics of brazed carbide cutting tool machined against mild steel and optimization of machining parameters based on Taguchi design of experiments were examined. The experiments were conducted using three factors, spindle speed, feed rate and depth of cut each having three levels. Nine experiments were performed on a high speed semi-automatic precision central lathe. ANOVA was used to determine the level of importance of the machining parameters on tool life. The optimum machining parameter combination was obtained by the analysis of S/N ratio. A mathematical model based on multiple regression analysis was developed to predict the tool life. Taguchi's orthogonal array analysis revealed the optimal combination of parameters at lower levels of spindle speed, feed rate and depth of cut which are 550 rpm, 0.2 mm/rev and 0.5mm respectively. The Main Effects plot reiterated the same. The variation of tool life with different process parameters has been plotted. Feed rate has the most significant effect on tool life followed by spindle speed and depth of cut.

Multilayer composition coatings for cutting tools: formation and performance properties

NASA Astrophysics Data System (ADS)

Tabakov, Vladimir P.; Vereschaka, Anatoly S.; Vereschaka, Alexey A.

2018-03-01

The paper considers the concept of a multi-layer architecture of the coating in which each layer has a predetermined functionality. Latest generation of coatings with multi-layered architecture for cutting tools secure a dual nature of the coating, in which coatings should not only improve the mechanical and physical characteristics of the cutting tool material, but also reduce the thermo-mechanical effect on the cutting tool determining wear intensity. Here are presented the results of the development of combined methods of forming multi-layer coatings with improved properties. Combined method of forming coatings using a pulsed laser allowed reducing excessively high levels of compressive residual stress and increasing micro hardness of the multilayered coatings. The results in testing coated HSS tools showed that the use of additional pulse of laser processing increases tool life up to 3 times. Using filtered cathodic vacuum arc deposition for the generation of multilayer coatings based on TiAlN compound has increased the wear-resistance of carbide tools by 2 fold compared with tool life of cutting tool with commercial TiN coatings. The aim of this study was to develop an innovative methodological approach to the deposition of multilayer coatings for cutting tools with functional architectural selection, properties and parameters of the coating based on sound knowledge of coating failure in machining process.

Investigation into the Effects of Textural Properties on Cuttability Performance of a Chisel Tool

NASA Astrophysics Data System (ADS)

Tumac, Deniz; Copur, Hanifi; Balci, Cemal; Er, Selman; Avunduk, Emre

2018-04-01

The main objective of this study is to investigate the effect of textural properties of stones on cutting performance of a standard chisel tool. Therewithal, the relationships between textural properties and cutting performance parameters and physical and mechanical properties were statistically analyzed. For this purpose, physical and mechanical property tests and mineralogical and petrographic analyses were carried out on eighteen natural stone samples, which can be grouped into three fundamentally different geological origins, i.e., metamorphic, igneous, and sedimentary. Then, texture coefficient analyses were performed on the samples. To determine the cuttability of the stones; the samples were cut with a portable linear cutting machine using a standard chisel tool at different depths of cut in unrelieved (non-interactive) cutting mode. The average and maximum forces (normal and cutting) and specific energy were measured, and the obtained values were correlated with texture coefficient, packing weighting, and grain size. With reference to the relation between depth of cut and cutting performance of the chisel tool for three types of natural stone groups, specific energy decreases with increasing depth of cut, and cutting forces increase in proportion to the depth of cut. The same is observed for the relationship between packing weighting and both of specific energy and cutter forces. On the other hand, specific energy and the forces decrease while grain size increases. Based on the findings of the present study, texture coefficient has strong correlation with specific energy. Generally, the lower depth of cut values in cutting tests shows higher and more reliable correlations with texture coefficient than the increased depth of cut. The results of cutting tests show also that, at a lower depth of cut (less than 1.5 mm), even stronger correlations can be observed between texture coefficient and cutting performance. Experimental studies indicate that cutting performance of chisel tools can be predicted based on texture coefficients of the natural stones.

Development of image mappers for hyperspectral biomedical imaging applications

PubMed Central

Kester, Robert T.; Gao, Liang; Tkaczyk, Tomasz S.

2010-01-01

A new design and fabrication method is presented for creating large-format (>100 mirror facets) image mappers for a snapshot hyperspectral biomedical imaging system called an image mapping spectrometer (IMS). To verify this approach a 250 facet image mapper with 25 multiple-tilt angles is designed for a compact IMS that groups the 25 subpupils in a 5 × 5 matrix residing within a single collecting objective's pupil. The image mapper is fabricated by precision diamond raster fly cutting using surface-shaped tools. The individual mirror facets have minimal edge eating, tilt errors of <1 mrad, and an average roughness of 5.4 nm. PMID:20357875

Comparative study of coated and uncoated tool inserts with dry machining of EN47 steel using Taguchi L9 optimization technique

NASA Astrophysics Data System (ADS)

Vasu, M.; Shivananda, Nayaka H.

2018-04-01

EN47 steel samples are machined on a self-centered lathe using Chemical Vapor Deposition of coated TiCN/Al2O3/TiN and uncoated tungsten carbide tool inserts, with nose radius 0.8mm. Results are compared with each other and optimized using statistical tool. Input (cutting) parameters that are considered in this work are feed rate (f), cutting speed (Vc), and depth of cut (ap), the optimization criteria are based on the Taguchi (L9) orthogonal array. ANOVA method is adopted to evaluate the statistical significance and also percentage contribution for each model. Multiple response characteristics namely cutting force (Fz), tool tip temperature (T) and surface roughness (Ra) are evaluated. The results discovered that coated tool insert (TiCN/Al2O3/TiN) exhibits 1.27 and 1.29 times better than the uncoated tool insert for tool tip temperature and surface roughness respectively. A slight increase in cutting force was observed for coated tools.

Cross-Grain Knife Planing Improves Surface Quality and Utilization of Aspen

Treesearch

Harold A. Stewart

1971-01-01

Aspen at 6 percent moisture content was planed parallel to the grain and across the grain on a cabinet planer with a 25? rake angle, 1/16- and 1/32-inch depth of cut, and 20 knife marks per inch. Aspen was also cross-grain knife planed with a 45? rake angle, 1/32-, 1/16-, and 1/8-inch depths of cut, and 20, 10, 5, and 2.5 knife marks per inch. Cross-grain knife...

The influence of machining condition and cutting tool wear on surface roughness of AISI 4340 steel

NASA Astrophysics Data System (ADS)

Natasha, A. R.; Ghani, J. A.; Che Haron, C. H.; Syarif, J.

2018-01-01

Sustainable machining by using cryogenic coolant as the cutting fluid has been proven to enhance some machining outputs. The main objective of the current work was to investigate the influence of machining conditions; dry and cryogenic, as well as the cutting tool wear on the machined surface roughness of AISI 4340 steel. The experimental tests were performed using chemical vapor deposition (CVD) coated carbide inserts. The value of machined surface roughness were measured at 3 cutting intervals; beginning, middle, and end of the cutting based on the readings of the tool flank wear. The results revealed that cryogenic turning had the greatest influence on surface roughness when machined at lower cutting speed and higher feed rate. Meanwhile, the cutting tool wear was also found to influence the surface roughness, either improving it or deteriorating it, based on the severity and the mechanism of the flank wear.

Performance Monitoring Of A Computer Numerically Controlled (CNC) Lathe Using Pattern Recognition Techniques

NASA Astrophysics Data System (ADS)

Daneshmend, L. K.; Pak, H. A.

1984-02-01

On-line monitoring of the cutting process in CNC lathe is desirable to ensure unattended fault-free operation in an automated environment. The state of the cutting tool is one of the most important parameters which characterises the cutting process. Direct monitoring of the cutting tool or workpiece is not feasible during machining. However several variables related to the state of the tool can be measured on-line. A novel monitoring technique is presented which uses cutting torque as the variable for on-line monitoring. A classifier is designed on the basis of the empirical relationship between cutting torque and flank wear. The empirical model required by the on-line classifier is established during an automated training cycle using machine vision for off-line direct inspection of the tool.

Tubing and cable cutting tool

NASA Technical Reports Server (NTRS)

Mcsmith, D. D.; Richardson, J. I. (Inventor)

1984-01-01

A hand held hydraulic cutting tool was developed which is particularly useful in deactivating ejection seats in military aircraft rescue operations. The tool consists primarily of a hydraulic system composed of a fluid reservoir, a pumping piston, and an actuator piston. Mechanical cutting jaws are attached to the actuator piston rod. The hydraulic system is controlled by a pump handle. As the pump handle is operated the actuator piston rod is forced outward and thus the cutting jaws are forced together. The frame of the device is a flexible metal tubing which permits easy positioning of the tool cutting jaws in remote and normally inaccessible locations. Bifurcated cutting edges ensure removal of a section of the tubing or cable to thereby reduce the possibility of accidental reactivation of the tubing or cable being severed.

Cost minimizing of cutting process for CNC thermal and water-jet machines

NASA Astrophysics Data System (ADS)

Tavaeva, Anastasia; Kurennov, Dmitry

2015-11-01

This paper deals with optimization problem of cutting process for CNC thermal and water-jet machines. The accuracy of objective function parameters calculation for optimization problem is investigated. This paper shows that working tool path speed is not constant value. One depends on some parameters that are described in this paper. The relations of working tool path speed depending on the numbers of NC programs frames, length of straight cut, configuration part are presented. Based on received results the correction coefficients for working tool speed are defined. Additionally the optimization problem may be solved by using mathematical model. Model takes into account the additional restrictions of thermal cutting (choice of piercing and output tool point, precedence condition, thermal deformations). At the second part of paper the non-standard cutting techniques are considered. Ones may lead to minimizing of cutting cost and time compared with standard cutting techniques. This paper considers the effectiveness of non-standard cutting techniques application. At the end of the paper the future research works are indicated.

Digital modeling of end-mill cutting tools for FEM applications from the active cutting contour

NASA Astrophysics Data System (ADS)

Salguero, Jorge; Marcos, M.; Batista, M.; Gómez, A.; Mayuet, P.; Bienvenido, R.

2012-04-01

A very current technique in the research field of machining by material removal is the use of simulations using the Finite Element Method (FEM). Nevertheless, and although is widely used in processes that allows approximations to orthogonal cutting, such as shaping, is scarcely used in more complexes processes, such as milling. This fact is due principally to the complex geometry of the cutting tools in these processes, and the need to realize the studi es in an oblique cutting configuration. This paper shows a methodology for the geometrical characterization of commercial endmill cutting tools, by the extraction of the cutting tool contour, making use of optical metrology, and using this geometry to model the active cutting zone with a 3D CAD software. This model is easily exportable to different CAD formats, such as IGES or STEP, and importable from FEM software, where is possible to study the behavior in service of the same ones.

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

PubMed Central

Fox-Rabinovich, German; Wagg, Terry

2017-01-01

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. PMID:29068405

Use of Piezosurgery for removal of retrovertebral body osteophytes in anterior cervical discectomy.

PubMed

Grauvogel, Juergen; Scheiwe, Christian; Kaminsky, Jan

2014-04-01

The relatively new technique of Piezosurgery is based on microvibrations, generated by the piezoelectrical effect, which results in selective bone cutting with preservation of adjacent soft tissue. To study the applicability of Piezosurgery in anterior cervical discectomy with fusion (ACDF) surgery. Prospective clinical study at the neurosurgical department of the University of Freiburg, Germany. Nine patients with cervical disc herniation and retrovertebral osteophytes who underwent ACDF surgery. Piezosurgery was evaluated with respect to practicability, safety, preciseness of bone cutting, and preservation of adjacent neurovascular tissue. Pre- and postoperative clinical and radiological data were assessed. Piezosurgery was supportively used in ACDF in nine patients with either radiculopathy or myelopathy from disc herniation or ventral osteophytes. After discectomy, osteophytes were removed with Piezosurgery to decompress the spinal canal and the foramina. Angled inserts were used, allowing for cutting even retrovertebral osteophytes. In all nine cases, Piezosurgery cut bone selectively with no damage to nerve roots, dura, or posterior longitudinal ligament. None of the patients experienced any new neurological deficit after the operation. The handling of the instrument was safe and the cut precise. Osteophytic spurs, even retrovertebral ones that generally only can be approached via corpectomies, could be safely removed because of the angled inserts through the disc space. Currently, a slightly prolonged operation time was observed for Piezosurgery. Furthermore, the design of the handpiece could be further improved to facilitate the intraoperative handling in ACDF. Piezosurgery proved to be a useful and safe technique for selective bone cutting and removal of osteophytes with preservation of neuronal and soft tissue in ACDF. In particular, the angled inserts were effective in cutting bone spurs behind the adjacent vertebra which cannot be reached with conventional rotating burs. Copyright © 2014 Elsevier Inc. All rights reserved.

Failure in laboratory fault models in triaxial tests

USGS Publications Warehouse

Savage, J.C.; Lockner, D.A.; Byerlee, J.D.

1996-01-01

A model of a fault in the Earth is a sand-filled saw cut in a granite cylinder subjected to a triaxial test. The saw cut is inclined at an angle a to the cylinder axis, and the sand filling is intended to represent gouge. The triaxial test subjects the granite cylinder to a constant confining pressure and increasing axial stress to maintain a constant rate of shortening of the cylinder. The required axial stress increases at a decreasing rate to a maximum, beyond which a roughly constant axial stress is sufficient to maintain the constant rate of shortening: Such triaxial tests were run for saw cuts inclined at angles ?? of 20??, 25??, 30??, 35??, 40??, 45??, and 50?? to the cylinder axis, and the apparent coefficient of friction ??a (ratio of the shear stress to the normal stress, both stresses resolved onto the saw cut) at failure was determined. Subject to the assumption that the observed failure involves slip on Coulomb shears (orientation unspecified), the orientation of the principal compression axis within the gouge can be calculated as a function of ??a for a given value of the coefficient of internal friction ??i. The rotation of the principal stress axes within the gouge in a triaxial test can then be followed as the shear strain across the gouge layer increases. For ??i ??? 0.8, an appropriate value for highly sheared sand, the observed values ??a imply that the principal-axis of compression within the gouge rotates so as to approach being parallel to the cylinder axis for all saw cut angles (20?? < ?? < 50??). In the limiting state (principal compression axis parallel to cylinder axis) the stress state in the gouge layer would be the same as that in the granite cylinder, and the failure criterion would be independent of the saw cut angle.

Influence of Cutting Parameters and Tool Wear on the Surface Integrity of Cobalt-Based Stellite 6 Alloy When Machined Under a Dry Cutting Environment

NASA Astrophysics Data System (ADS)

Yingfei, Ge; de Escalona, Patricia Muñoz; Galloway, Alexander

2017-01-01

The efficiency of a machining process can be measured by evaluating the quality of the machined surface and the tool wear rate. The research reported herein is mainly focused on the effect of cutting parameters and tool wear on the machined surface defects, surface roughness, deformation layer and residual stresses when dry milling Stellite 6, deposited by overlay on a carbon steel surface. The results showed that under the selected cutting conditions, abrasion, diffusion, peeling, chipping and breakage were the main tool wear mechanisms presented. Also the feed rate was the primary factor affecting the tool wear with an influence of 83%. With regard to the influence of cutting parameters on the surface roughness, the primary factors were feed rate and cutting speed with 57 and 38%, respectively. In addition, in general, as tool wear increased, the surface roughness increased and the deformation layer was found to be influenced more by the cutting parameters rather than the tool wear. Compressive residual stresses were observed in the un-machined surface, and when machining longer than 5 min, residual stress changed 100% from compression to tension. Finally, results showed that micro-crack initiation was the main mechanism for chip formation.

3D FEM Simulation of Flank Wear in Turning

NASA Astrophysics Data System (ADS)

Attanasio, Aldo; Ceretti, Elisabetta; Giardini, Claudio

2011-05-01

This work deals with tool wear simulation. Studying the influence of tool wear on tool life, tool substitution policy and influence on final part quality, surface integrity, cutting forces and power consumption it is important to reduce the global process costs. Adhesion, abrasion, erosion, diffusion, corrosion and fracture are some of the phenomena responsible of the tool wear depending on the selected cutting parameters: cutting velocity, feed rate, depth of cut, …. In some cases these wear mechanisms are described by analytical models as a function of process variables (temperature, pressure and sliding velocity along the cutting surface). These analytical models are suitable to be implemented in FEM codes and they can be utilized to simulate the tool wear. In the present paper a commercial 3D FEM software has been customized to simulate the tool wear during turning operations when cutting AISI 1045 carbon steel with uncoated tungsten carbide tip. The FEM software was improved by means of a suitable subroutine able to modify the tool geometry on the basis of the estimated tool wear as the simulation goes on. Since for the considered couple of tool-workpiece material the main phenomena generating wear are the abrasive and the diffusive ones, the tool wear model implemented into the subroutine was obtained as combination between the Usui's and the Takeyama and Murata's models. A comparison between experimental and simulated flank tool wear curves is reported demonstrating that it is possible to simulate the tool wear development.

Ceramic tools insert assesment based on vickers indentation methodology

NASA Astrophysics Data System (ADS)

Husni; Rizal, Muhammad; Aziz M, M.; Wahyu, M.

2018-05-01

In the interrupted cutting process, the risk of tool chipping or fracture is higher than continues cutting. Therefore, the selection of suitable ceramic tools for interrupted cutting application become an important issue to assure that the cutting process is running effectively. At present, the performance of ceramics tools is assessed by conducting some cutting tests, which is required time and cost consuming. In this study, the performance of ceramic tools evaluated using hardness tester machine. The technique, in general, has a certain advantage compare with the more conventional methods; the experimental is straightforward involving minimal specimen preparation and the amount of material needed is small. Three types of ceramic tools AS10, CC650 and K090 have been used, each tool was polished then Vickers indentation test were performed with the load were 0.2, 0.5, 1, 2.5, 5 and 10 kgf. The results revealed that among the load used in the tests, the indentation loads of 5 kgf always produce well cracks as compared with others. Among the cutting tool used in the tests, AS10 has produced the shortest crack length and follow by CC 670, and K090. It is indicated that the shortest crack length of AS10 reflected that the tool has a highest dynamic load resistance among others insert.

Improved tool grinding machine

DOEpatents

Dial, C.E. Sr.

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

Tool grinding machine

DOEpatents

Dial, Sr., Charles E.

1980-01-01

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

Study of the Vibration Effect on the Cutting Forces and Roughness of Slub Milling

NASA Astrophysics Data System (ADS)

Germa, S.; Estrems Amestoy, M.; Sánchez Reinoso, H. T.; Franco Chumillas, P.

2009-11-01

For the planning process of slab milling operations, the vibration of the tool is the main factor to be considered. Under vibration conditions, the effect of the small displacements of the cutting tool and the cutting forces on the chip thickness must be minimized in order to avoid undesirable consequences, such as the fast flank wear, superficial defects and roughness increase. In this work, a mathematical model is developed to take into account the combined effect of the cutting tool and workpiece oscillation, as well as the axial errors of different milling tool tips. As a result, the model estimates the variation of the cutting forces and the ideal surface roughness.

Tool life and cutting speed for the maximum productivity at the drilling of the stainless steel X22CrMoV12-1

NASA Astrophysics Data System (ADS)

Vlase, A.; Blăjină, O.; Iacob, M.; Darie, V.

2015-11-01

Two addressed issues in the research regarding the cutting machinability, establishing of the optimum cutting processing conditions and the optimum cutting regime, do not yet have sufficient data for solving. For this reason, in the paper it is proposed the optimization of the tool life and the cutting speed at the drilling of a certain stainless steel in terms of the maximum productivity. For this purpose, a nonlinear programming mathematical model to maximize the productivity at the drilling of the steel is developed in the paper. The optimum cutting tool life and the associated cutting tool speed are obtained by solving the numerical mathematical model. Using this proposed model allows increasing the accuracy in the prediction of the productivity for the drilling of a certain stainless steel and getting the optimum tool life and the optimum cutting speed for the maximum productivity. The results presented in this paper can be used in the production activity, in order to increase the productivity of the stainless steels machining. Also new research directions for the specialists in this interested field may come off from this paper.

Advances in Cross-Cutting Ideas for Computational Climate Science

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ng, Esmond; Evans, Katherine J.; Caldwell, Peter

This report presents results from the DOE-sponsored workshop titled, ``Advancing X-Cutting Ideas for Computational Climate Science Workshop,'' known as AXICCS, held on September 12--13, 2016 in Rockville, MD. The workshop brought together experts in climate science, computational climate science, computer science, and mathematics to discuss interesting but unsolved science questions regarding climate modeling and simulation, promoted collaboration among the diverse scientists in attendance, and brainstormed about possible tools and capabilities that could be developed to help address them. Emerged from discussions at the workshop were several research opportunities that the group felt could advance climate science significantly. These include (1)more » process-resolving models to provide insight into important processes and features of interest and inform the development of advanced physical parameterizations, (2) a community effort to develop and provide integrated model credibility, (3) including, organizing, and managing increasingly connected model components that increase model fidelity yet complexity, and (4) treating Earth system models as one interconnected organism without numerical or data based boundaries that limit interactions. The group also identified several cross-cutting advances in mathematics, computer science, and computational science that would be needed to enable one or more of these big ideas. It is critical to address the need for organized, verified, and optimized software, which enables the models to grow and continue to provide solutions in which the community can have confidence. Effectively utilizing the newest computer hardware enables simulation efficiency and the ability to handle output from increasingly complex and detailed models. This will be accomplished through hierarchical multiscale algorithms in tandem with new strategies for data handling, analysis, and storage. These big ideas and cross-cutting technologies for enabling breakthrough climate simulation advancements also need the "glue" of outreach and learning across the scientific domains to be successful. The workshop identified several strategies to allow productive, continuous engagement across those who have a broad knowledge of the various angles of the problem. Specific ideas to foster education and tools to make material progress were discussed. Examples include follow-on cross-cutting meetings that enable unstructured discussions of the types this workshop fostered. A concerted effort to recruit undergraduate and graduate students from all relevant domains and provide them experience, training, and networking across their immediate expertise is needed. This will broaden and expand their exposure to the future needs and solutions, and provide a pipeline of scientists with a diversity of knowledge and know-how. Providing real-world experience with subject matter experts from multiple angles may also motivate the students to attack these problems and even come up with the missing solutions.« less

Advances in Cross-Cutting Ideas for Computational Climate Science

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ng, E.; Evans, K.; Caldwell, P.

This report presents results from the DOE-sponsored workshop titled, Advancing X-Cutting Ideas for Computational Climate Science Workshop,'' known as AXICCS, held on September 12--13, 2016 in Rockville, MD. The workshop brought together experts in climate science, computational climate science, computer science, and mathematics to discuss interesting but unsolved science questions regarding climate modeling and simulation, promoted collaboration among the diverse scientists in attendance, and brainstormed about possible tools and capabilities that could be developed to help address them. Emerged from discussions at the workshop were several research opportunities that the group felt could advance climate science significantly. These include (1)more » process-resolving models to provide insight into important processes and features of interest and inform the development of advanced physical parameterizations, (2) a community effort to develop and provide integrated model credibility, (3) including, organizing, and managing increasingly connected model components that increase model fidelity yet complexity, and (4) treating Earth system models as one interconnected organism without numerical or data based boundaries that limit interactions. The group also identified several cross-cutting advances in mathematics, computer science, and computational science that would be needed to enable one or more of these big ideas. It is critical to address the need for organized, verified, and optimized software, which enables the models to grow and continue to provide solutions in which the community can have confidence. Effectively utilizing the newest computer hardware enables simulation efficiency and the ability to handle output from increasingly complex and detailed models. This will be accomplished through hierarchical multiscale algorithms in tandem with new strategies for data handling, analysis, and storage. These big ideas and cross-cutting technologies for enabling breakthrough climate simulation advancements also need the "glue" of outreach and learning across the scientific domains to be successful. The workshop identified several strategies to allow productive, continuous engagement across those who have a broad knowledge of the various angles of the problem. Specific ideas to foster education and tools to make material progress were discussed. Examples include follow-on cross-cutting meetings that enable unstructured discussions of the types this workshop fostered. A concerted effort to recruit undergraduate and graduate students from all relevant domains and provide them experience, training, and networking across their immediate expertise is needed. This will broaden and expand their exposure to the future needs and solutions, and provide a pipeline of scientists with a diversity of knowledge and know-how. Providing real-world experience with subject matter experts from multiple angles may also motivate the students to attack these problems and even come up with the missing solutions.« less

Material Behavior At The Extreme Cutting Edge In Bandsawing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sarwar, Mohammed; Haider, Julfikar; Persson, Martin

2011-01-17

In recent years, bandsawing has been widely accepted as a favourite option for metal cutting off operations where the accuracy of cut, good surface finish, low kerf loss, long tool life and high material removal rate are required. Material removal by multipoint cutting tools such as bandsaw is a complex mechanism owing to the geometry of the bandsaw tooth (e.g., limited gullet size, tooth setting etc.) and the layer of material removed or undeformed chip thickness or depth of cut (5 {mu}m-50 {mu}m) being smaller than or equal to the cutting edge radius (5 {mu}m-15 {mu}m). This situation can leadmore » to inefficient material removal in bandsawing. Most of the research work are concentrated on the mechanics of material removal by single point cutting tool such as lathe tool. However, such efforts are very limited in multipoint cutting tools such as in bandsaw. This paper presents the fundamental understanding of the material behaviour at the extreme cutting edge of bandsaw tooth, which would help in designing and manufacturing of blades with higher cutting performance and life. ''High Speed Photography'' has been carried out to analyse the material removal process at the extreme cutting edge of bandsaw tooth. Geometric model of chip formation mechanisms based on the evidences found during ''High Speed Photography'' and ''Quick Stop'' process is presented. Wear modes and mechanism in bimetal and carbide tipped bandsaw teeth are also presented.« less

A new heat transfer analysis in machining based on two steps of 3D finite element modelling and experimental validation

NASA Astrophysics Data System (ADS)

Haddag, B.; Kagnaya, T.; Nouari, M.; Cutard, T.

2013-01-01

Modelling machining operations allows estimating cutting parameters which are difficult to obtain experimentally and in particular, include quantities characterizing the tool-workpiece interface. Temperature is one of these quantities which has an impact on the tool wear, thus its estimation is important. This study deals with a new modelling strategy, based on two steps of calculation, for analysis of the heat transfer into the cutting tool. Unlike the classical methods, considering only the cutting tool with application of an approximate heat flux at the cutting face, estimated from experimental data (e.g. measured cutting force, cutting power), the proposed approach consists of two successive 3D Finite Element calculations and fully independent on the experimental measurements; only the definition of the behaviour of the tool-workpiece couple is necessary. The first one is a 3D thermomechanical modelling of the chip formation process, which allows estimating cutting forces, chip morphology and its flow direction. The second calculation is a 3D thermal modelling of the heat diffusion into the cutting tool, by using an adequate thermal loading (applied uniform or non-uniform heat flux). This loading is estimated using some quantities obtained from the first step calculation, such as contact pressure, sliding velocity distributions and contact area. Comparisons in one hand between experimental data and the first calculation and at the other hand between measured temperatures with embedded thermocouples and the second calculation show a good agreement in terms of cutting forces, chip morphology and cutting temperature.

Angle performance on optima MDxt

DOE Office of Scientific and Technical Information (OSTI.GOV)

David, Jonathan; Kamenitsa, Dennis

2012-11-06

Angle control on medium current implanters is important due to the high angle-sensitivity of typical medium current implants, such as halo implants. On the Optima MDxt, beam-to-wafer angles are controlled in both the horizontal and vertical directions. In the horizontal direction, the beam angle is measured through six narrow slits, and any angle adjustment is made by electrostatically steering the beam, while cross-wafer beam parallelism is adjusted by changing the focus of the electrostatic parallelizing lens (P-lens). In the vertical direction, the beam angle is measured through a high aspect ratio mask, and any angle adjustment is made by slightlymore » tilting the wafer platen prior to implant. A variety of tests were run to measure the accuracy and repeatability of Optima MDxt's angle control. SIMS profiles of a high energy, channeling sensitive condition show both the cross-wafer angle uniformity, along with the small-angle resolution of the system. Angle repeatability was quantified by running a channeling sensitive implant as a regular monitor over a seven month period and measuring the sheet resistance-to-angle sensitivity. Even though crystal cut error was not controlled for in this case, when attributing all Rs variation to angle changes, the overall angle repeatability was measured as 0.16 Degree-Sign (1{sigma}). A separate angle repeatability test involved running a series of V-curves tests over a four month period using low crystal cut wafers selected from the same boule. The results of this test showed the angle repeatability to be <0.1 Degree-Sign (1{sigma}).« less

Diamond tool machining of materials which react with diamond

DOEpatents

Lundin, R.L.; Stewart, D.D.; Evans, C.J.

1992-04-14

An apparatus is described for the diamond machining of materials which detrimentally react with diamond cutting tools in which the cutting tool and the workpiece are chilled to very low temperatures. This chilling halts or retards the chemical reaction between the workpiece and the diamond cutting tool so that wear rates of the diamond tool on previously detrimental materials are comparable with the diamond turning of materials which do not react with diamond. 1 figs.

Numerical analysis of the flexible roll forming of an automotive component from high strength steel

NASA Astrophysics Data System (ADS)

Abeyrathna, B.; Abvabi, A.; Rolfe, B.; Taube, R.; Weiss, M.

2016-11-01

Conventional roll forming is limited to components with uniform cross-section; the recently developed flexible roll forming (FRF) process can be used to form components which vary in both width and depth. It has been suggested that this process can be used to manufacture automotive components from Ultra High Strength Steel (UHSS) which has limited tensile elongation. In the flexible roll forming process, the pre-cut blank is fed through a set of rolls; some rolls are computer-numerically controlled (CNC) to follow the 3D contours of the part and hence parts with a variable cross-section can be produced. This paper introduces a new flexible roll forming technique which can be used to form a complex shape with the minimum tooling requirements. In this method, the pre-cut blank is held between two dies and the whole system moves back and forth past CNC forming rolls. The forming roll changes its angle and position in each pass to incrementally form the part. In this work, the process is simulated using the commercial software package Copra FEA. The distribution of total strain and final part quality are investigated as well as related shape defects observed in the process. Different tooling concepts are used to improve the strain distribution and hence the part quality.

Experimental evaluation of tool wear throughout a continuous stroke blanking process of quenched 22MnB5 ultra-high-strength steel

NASA Astrophysics Data System (ADS)

Vogt, S.; Neumayer, F. F.; Serkyov, I.; Jesner, G.; Kelsch, R.; Geile, M.; Sommer, A.; Golle, R.; Volk, W.

2017-09-01

Steel is the most common material used in vehicles’ chassis, which makes its research an important topic for the automotive industry. Recently developed ultra-high-strength steels (UHSS) provide extreme tensile strength up to 1,500 MPa and combine great crashworthiness with good weight reduction potential. However, in order to reach the final shape of sheet metal parts additional cutting steps such as trimming and piercing are often required. The final trimming of quenched metal sheets presents a huge challenge to a conventional process, mainly because of the required extreme cutting force. The high cutting impact, due to the materials’ brittleness, causes excessive tool wear or even sudden tool failure. Therefore, a laser is commonly used for the cutting process, which is time and energy consuming. The purpose of this paper is to demonstrate the capability of a conventional blanking tool design in a continuous stroke piercing process using boron steel 22MnB5 sheets. Two different types of tool steel were tested for their suitability as active cutting elements: electro-slag remelted (ESR) cold work tool steel Bohler K340 ISODUR and powder-metallurgic (PM) high speed steel Bohler S390 MICROCLEAN. A FEM study provided information about an optimized punch design, which withstands buckling under high cutting forces. The wear behaviour of the process was assessed by the tool wear of the active cutting elements as well as the quality of cut surfaces.

Experimental investigations on cryogenic cooling by liquid nitrogen in the end milling of hardened steel

NASA Astrophysics Data System (ADS)

Ravi, S.; Pradeep Kumar, M.

2011-09-01

Milling of hardened steel generates excessive heat during the chip formation process, which increases the temperature of cutting tool and accelerates tool wear. Application of conventional cutting fluid in milling process may not effectively control the heat generation also it has inherent health and environmental problems. To minimize health hazard and environmental problems caused by using conventional cutting fluid, a cryogenic cooling set up is developed to cool tool-chip interface using liquid nitrogen (LN 2). This paper presents results on the effect of LN 2 as a coolant on machinability of hardened AISI H13 tool steel for varying cutting speed in the range of 75-125 m/min during end milling with PVD TiAlN coated carbide inserts at a constant feed rate. The results show that machining with LN 2 lowers cutting temperature, tool flank wear, surface roughness and cutting forces as compared with dry and wet machining. With LN 2 cooling, it has been found that the cutting temperature was reduced by 57-60% and 37-42%; the tool flank wear was reduced by 29-34% and 10-12%; the surface roughness was decreased by 33-40% and 25-29% compared to dry and wet machining. The cutting forces also decreased moderately compared to dry and wet machining. This can be attributed to the fact that LN 2 machining provides better cooling and lubrication through substantial reduction in the cutting zone temperature.

Thermal modelling of cooling tool cutting when milling by electrical analogy

NASA Astrophysics Data System (ADS)

Benabid, F.; Arrouf, M.; Assas, M.; Benmoussa, H.

2010-06-01

Measurement temperatures by (some devises) are applied immediately after shut-down and may be corrected for the temperature drop that occurs in the interval between shut-down and measurement. This paper presents a new procedure for thermal modelling of the tool cutting used just after machining; when the tool is out off the chip in order to extrapolate the cutting temperature from the temperature measured when the tool is at stand still. A fin approximation is made in enhancing heat loss (by conduction and convection) to air stream is used. In the modelling we introduce an equivalent thermal network to estimate the cutting temperature as a function of specific energy. In another hand, a local modified element lumped conduction equation is used to predict the temperature gradient with time when the tool is being cooled, with initial and boundary conditions. These predictions provide a detailed view of the global heat transfer coefficient as a function of cutting speed because the heat loss for the tool in air stream is an order of magnitude larger than in normal environment. Finally we deduct the cutting temperature by inverse method.

Investigation of tool wear and surface roughness on machining of titanium alloy with MT-CVD cutting tool

NASA Astrophysics Data System (ADS)

Maity, Kalipada; Pradhan, Swastik

2018-04-01

In this study, machining of titanium alloy (grade 5) is carried out using MT-CVD coated cutting tool. Titanium alloys possess superior strength-to-weight ratio with good corrosion resistance. Most of the industries used titanium alloy for the manufacturing of various types of lightweight components. The parts made from Ti-6Al-4V largely used in aerospace, biomedical, automotive and marine sectors. The conventional machining of this material is very difficult, due to low thermal conductivity and high chemical reactivity properties. To achieve a good surface finish with minimum tool wear of cutting tool, the machining is carried out using MT-CVD coated cutting tool. The experiment is carried out using of Taguchi L27 array layout with three cutting variables and levels. To find out the optimum parametric setting desirability function analysis (DFA) approach is used. The analysis of variance is studied to know the percentage contribution of each cutting variables. The optimum parametric setting results calculated from DFA were validated through the confirmation test.

Operation Reliability Assessment for Cutting Tools by Applying a Proportional Covariate Model to Condition Monitoring Information

PubMed Central

Cai, Gaigai; Chen, Xuefeng; Li, Bing; Chen, Baojia; He, Zhengjia

2012-01-01

The reliability of cutting tools is critical to machining precision and production efficiency. The conventional statistic-based reliability assessment method aims at providing a general and overall estimation of reliability for a large population of identical units under given and fixed conditions. However, it has limited effectiveness in depicting the operational characteristics of a cutting tool. To overcome this limitation, this paper proposes an approach to assess the operation reliability of cutting tools. A proportional covariate model is introduced to construct the relationship between operation reliability and condition monitoring information. The wavelet packet transform and an improved distance evaluation technique are used to extract sensitive features from vibration signals, and a covariate function is constructed based on the proportional covariate model. Ultimately, the failure rate function of the cutting tool being assessed is calculated using the baseline covariate function obtained from a small sample of historical data. Experimental results and a comparative study show that the proposed method is effective for assessing the operation reliability of cutting tools. PMID:23201980

Condition monitoring of turning process using infrared thermography technique - An experimental approach

NASA Astrophysics Data System (ADS)

Prasad, Balla Srinivasa; Prabha, K. Aruna; Kumar, P. V. S. Ganesh

2017-03-01

In metal cutting machining, major factors that affect the cutting tool life are machine tool vibrations, tool tip/chip temperature and surface roughness along with machining parameters like cutting speed, feed rate, depth of cut, tool geometry, etc., so it becomes important for the manufacturing industry to find the suitable levels of process parameters for obtaining maintaining tool life. Heat generation in cutting was always a main topic to be studied in machining. Recent advancement in signal processing and information technology has resulted in the use of multiple sensors for development of the effective monitoring of tool condition monitoring systems with improved accuracy. From a process improvement point of view, it is definitely more advantageous to proactively monitor quality directly in the process instead of the product, so that the consequences of a defective part can be minimized or even eliminated. In the present work, a real time process monitoring method is explored using multiple sensors. It focuses on the development of a test bed for monitoring the tool condition in turning of AISI 316L steel by using both coated and uncoated carbide inserts. Proposed tool condition monitoring (TCM) is evaluated in the high speed turning using multiple sensors such as Laser Doppler vibrometer and infrared thermography technique. The results indicate the feasibility of using the dominant frequency of the vibration signals for the monitoring of high speed turning operations along with temperatures gradient. A possible correlation is identified in both regular and irregular cutting tool wear. While cutting speed and feed rate proved to be influential parameter on the depicted temperatures and depth of cut to be less influential. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation developed.

Comparative Investigation on Tool Wear during End Milling of AISI H13 Steel with Different Tool Path Strategies

NASA Astrophysics Data System (ADS)

Adesta, Erry Yulian T.; Riza, Muhammad; Avicena

2018-03-01

Tool wear prediction plays a significant role in machining industry for proper planning and control machining parameters and optimization of cutting conditions. This paper aims to investigate the effect of tool path strategies that are contour-in and zigzag tool path strategies applied on tool wear during pocket milling process. The experiments were carried out on CNC vertical machining centre by involving PVD coated carbide inserts. Cutting speed, feed rate and depth of cut were set to vary. In an experiment with three factors at three levels, Response Surface Method (RSM) design of experiment with a standard called Central Composite Design (CCD) was employed. Results obtained indicate that tool wear increases significantly at higher range of feed per tooth compared to cutting speed and depth of cut. This result of this experimental work is then proven statistically by developing empirical model. The prediction model for the response variable of tool wear for contour-in strategy developed in this research shows a good agreement with experimental work.

Stability analysis of multipoint tool equipped with metal cutting ceramics

NASA Astrophysics Data System (ADS)

Maksarov, V. V.; Khalimonenko, A. D.; Matrenichev, K. G.

2017-10-01

The article highlights the issues of determining the stability of the cutting process by a multipoint cutting tool equipped with cutting ceramics. There were some recommendations offered on the choice of parameters of replaceable cutting ceramic plates for milling based of the conducted researches. Ceramic plates for milling are proposed to be selected on the basis of value of their electrical volume resistivity.

A micro-scale cutting model for UD CFRP composites with thermo-mechanical coupling

DOE PAGES

Cheng, Hui; Gao, Jiaying; Kafka, Orion Landauer; ...

2017-09-23

Cutting a unidirectional carbon fiber-reinforced polymer (UD CFRP) structure is the basic unit for CFRP machining, which is a complex thermal-mechanically coupled process. To reveal the deformation mechanism and predict cutting force in UD CFRP micro cutting, a micro-scale fracture model for UD CFRP cutting with thermal-mechanical coupling is demonstrated in this paper, which captures the failure modes for fibers, matrix and the interface based on a micro-level RVE using a relatively simple damage based fracture method. The thermal-mechanical coupling model at the micro scale is developed on the basis of the plastic energy dissipation and frictional heating during cutting.more » Failure models for the fiber, matrix and interface region are applied depending on the material properties of each of these three phases. Numerical simulations based on the above model with different fiber orientations were performed to predict the deformation and forces of different components in UD CFRP. Cutting experiments with the same fiber orientations as considered in the simulations were carried out to validate the force and deformation results. The predicted force and deformation patterns match well with evidence from our experiments. In general, the cutting force is larger than the thrust force regardless of fiber orientation. The cutting force reaches a maximum as the fiber orientation approaches 90 , but thrust forces do not vary substantially across cases. When the fiber orientation is acute, the deformation of fibers is much smaller than when the cutting angle is obtuse. Surface roughness follows the same trend with cutting angle as fiber deformation.« less

A micro-scale cutting model for UD CFRP composites with thermo-mechanical coupling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cheng, Hui; Gao, Jiaying; Kafka, Orion Landauer

Cutting a unidirectional carbon fiber-reinforced polymer (UD CFRP) structure is the basic unit for CFRP machining, which is a complex thermal-mechanically coupled process. To reveal the deformation mechanism and predict cutting force in UD CFRP micro cutting, a micro-scale fracture model for UD CFRP cutting with thermal-mechanical coupling is demonstrated in this paper, which captures the failure modes for fibers, matrix and the interface based on a micro-level RVE using a relatively simple damage based fracture method. The thermal-mechanical coupling model at the micro scale is developed on the basis of the plastic energy dissipation and frictional heating during cutting.more » Failure models for the fiber, matrix and interface region are applied depending on the material properties of each of these three phases. Numerical simulations based on the above model with different fiber orientations were performed to predict the deformation and forces of different components in UD CFRP. Cutting experiments with the same fiber orientations as considered in the simulations were carried out to validate the force and deformation results. The predicted force and deformation patterns match well with evidence from our experiments. In general, the cutting force is larger than the thrust force regardless of fiber orientation. The cutting force reaches a maximum as the fiber orientation approaches 90 , but thrust forces do not vary substantially across cases. When the fiber orientation is acute, the deformation of fibers is much smaller than when the cutting angle is obtuse. Surface roughness follows the same trend with cutting angle as fiber deformation.« less

Modeling and Tool Wear in Routing of CFRP

DOE Office of Scientific and Technical Information (OSTI.GOV)

Iliescu, D.; Fernandez, A.; Gutierrez-Orrantia, M. E.

2011-01-17

This paper presents the prediction and evaluation of feed force in routing of carbon composite material. In order to extend tool life and improve quality of the machined surface, a better understanding of uncoated and coated tool behaviors is required. This work describes (1) the optimization of the geometry of multiple teeth tools minimizing the tool wear and the feed force, (2) the optimization of tool coating and (3) the development of a phenomenological model between the feed force, the routing parameters and the tool wear. The experimental results indicate that the feed rate, the cutting speed and the toolmore » wear are the most significant factors affecting the feed force. In the case of multiple teeth tools, a particular geometry with 14 teeth right helix right cut and 11 teeth left helix right cut gives the best results. A thick AlTiN coating or a diamond coating can dramatically improve the tool life while minimizing the axial force, roughness and delamination. A wear model has then been developed based on an abrasive behavior of the tool. The model links the feed rate to the tool geometry parameters (tool diameter), to the process parameters (feed rate, cutting speed and depth of cut) and to the wear. The model presented has been verified by experimental tests.« less

The geometry of the cutting front created by Fibre and CO2 lasers when profiling stainless steel under standard commercial conditions

NASA Astrophysics Data System (ADS)

Pocorni, Jetro; Powell, John; Frostevarg, Jan; Kaplan, Alexander F. H.

2018-07-01

Cutting fronts created by CO2 and fibre lasers in stainless steel at thicknesses between 2 mm and 10 mm have been 'frozen' and their geometry has been measured. Standard commercial cutting parameters were used to generate the cuts for both types of laser. The resulting three-dimensional cutting front shapes have been curve fitted as polynomials and semicircles. Various features of the cutting front geometry are discussed including the lack of correlation of the cut front inclination with either the relevant Brewster angle or the inclination of the striations on the cut edge.

Some aspects of precise laser machining - Part 1: Theory

NASA Astrophysics Data System (ADS)

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.

Finite element simulation of cutting grey iron HT250 by self-prepared Si3N4 ceramic insert

NASA Astrophysics Data System (ADS)

Wang, Bo; Wang, Li; Zhang, Enguang

2017-04-01

The finite element method has been able to simulate and solve practical machining problems, achieve the required accuracy and the highly reliability. In this paper, the simulation models based on the material properties of the self-prepared Si3N4 insert and HT250 were created. Using these models, the results of cutting force, cutting temperature and tool wear rate were obtained, and tool wear mode was predicted after cutting simulation. These approaches may develop as the new method for testing new cutting-tool materials, shortening development cycle and reducing the cost.

Online machining error estimation method of numerical control gear grinding machine tool based on data analysis of internal sensors

NASA Astrophysics Data System (ADS)

Zhao, Fei; Zhang, Chi; Yang, Guilin; Chen, Chinyin

2016-12-01

This paper presents an online estimation method of cutting error by analyzing of internal sensor readings. The internal sensors of numerical control (NC) machine tool are selected to avoid installation problem. The estimation mathematic model of cutting error was proposed to compute the relative position of cutting point and tool center point (TCP) from internal sensor readings based on cutting theory of gear. In order to verify the effectiveness of the proposed model, it was simulated and experimented in gear generating grinding process. The cutting error of gear was estimated and the factors which induce cutting error were analyzed. The simulation and experiments verify that the proposed approach is an efficient way to estimate the cutting error of work-piece during machining process.

Surface roughness model based on force sensors for the prediction of the tool wear.

PubMed

de Agustina, Beatriz; Rubio, Eva María; Sebastián, Miguel Ángel

2014-04-04

In this study, a methodology has been developed with the objective of evaluating the surface roughness obtained during turning processes by measuring the signals detected by a force sensor under the same cutting conditions. In this way, the surface quality achieved along the process is correlated to several parameters of the cutting forces (thrust forces, feed forces and cutting forces), so the effect that the tool wear causes on the surface roughness is evaluated. In a first step, the best cutting conditions (cutting parameters and radius of tool) for a certain quality surface requirement were found for pieces of UNS A97075. Next, with this selection a model of surface roughness based on the cutting forces was developed for different states of wear that simulate the behaviour of the tool throughout its life. The validation of this model reveals that it was effective for approximately 70% of the surface roughness values obtained.

Application of gas-fluid atomization technology in ultrosonic vibration cutting titanium alloy workpiece

NASA Astrophysics Data System (ADS)

Zhou, Zhimin; Zhang, Yuangliang; Li, Xiaoyan; Sun, Baoyuan

2009-11-01

To further improve machined surface quality of diamond cutting titanium workpiece and reduce diamond tool wear, it puts forward a kind of machining technology with mixture of carbon dioxide gas, water and vegetable oil atomized mist as cooling media in the paper. The cooling media is sprayed to cutting area through gas-liquid atomizer device to achieve purpose of cooling, lubricating, and protecting diamond tool. Experiments indicate that carbon dioxide gas can touch cutting surface more adequately through using gas-liquid atomization technology, which makes iron atoms of cutting surface cause a chemical reaction directly with carbon in carbon dioxide gas and reduce graphitizing degree of diamond tool. Thus, this technology of using gas-liquid atomization and ultrasonic vibration together for cutting Titanium Alloy is able to improve machined surface quality of workpiece and slow of diamond tool wear.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Cutting work in thick section cryomicrotomy.

PubMed

Saubermann, A J; Riley, W D; Beeuwkes, R

1977-09-01

The forces during cryosectioning were measured using miniature strain gauges attached to a load cell fitted to the drive arm of the Porter-Blum MT-2 cryomicrotome. Work was calculated and the data normalized to a standard (1 mm X 1 mm X 0.5 micrometer) section. Thermal energy generated was also calculated. Five parameters were studied: cutting angle, thickness, temperature, hardness, and block shape. Force patterns could be divided into three major groups thought to represent cutting (Type I), large fracture planes greater than 10 micrometer in length (Type II), and small fracture planes less than 10 micrometer in length (Type III). Type I and Type II produced satisfactory sections. Work in cutting ranged from an average of 78.4 muJ to 568.8 muJ. Cutting angle and temperature had the greatest effect on sectioning. Heat generated would be sufficient to cause through-section melting for 0.5 micrometer thick sections assuming the worst possible case, namely that all heat went into the section without loss. Presence of a Type II pattern (large fracture pattern) is thought to be presumptive evidence against thawing.

Producing Fe-W-Co-Cr-C Alloy Cutting Tool Material Through Powder Metallurgy Route

NASA Astrophysics Data System (ADS)

Datta Banik, Bibhas; Dutta, Debasish; Ray, Siddhartha

2017-04-01

High speed steel tools can withstand high impact forces as they are tough in nature. But they cannot retain their hardness at elevated temperature i.e. their hot hardness is low. Therefore permissible cutting speed is low and tools wear out easily. Use of lubricants is essential for HSS cutting tools. On the other hand cemented carbide tools can withstand greater compressive force, but due to lower toughness the tool can break easily. Moreover the cost of the tool is comparatively high. To achieve a better machining economy, Fe-W-Co-Cr-C alloys are being used nowadays. Their toughness is as good as HSS tools and hardness is very near to carbide tools. Even, at moderate cutting speeds they can be safely used in old machines having vibration. Moreover it is much cheaper than carbide tools. This paper highlights the Manufacturing Technology of the alloy and studies the comparative tribological properties of the alloy and tungsten mono carbide.

Prediction of Cutting Force in Turning Process-an Experimental Approach

NASA Astrophysics Data System (ADS)

Thangarasu, S. K.; Shankar, S.; Thomas, A. Tony; Sridhar, G.

2018-02-01

This Paper deals with a prediction of Cutting forces in a turning process. The turning process with advanced cutting tool has a several advantages over grinding such as short cycle time, process flexibility, compatible surface roughness, high material removal rate and less environment problems without the use of cutting fluid. In this a full bridge dynamometer has been used to measure the cutting forces over mild steel work piece and cemented carbide insert tool for different combination of cutting speed, feed rate and depth of cut. The experiments are planned based on taguchi design and measured cutting forces were compared with the predicted forces in order to validate the feasibility of the proposed design. The percentage contribution of each process parameter had been analyzed using Analysis of Variance (ANOVA). Both the experimental results taken from the lathe tool dynamometer and the designed full bridge dynamometer were analyzed using Taguchi design of experiment and Analysis of Variance.

Tool wear analysis during duplex stainless steel trochoidal milling

NASA Astrophysics Data System (ADS)

Amaro, Paulo; Ferreira, Pedro; Simões, Fernando

2018-05-01

In this study a tool with interchangeable inserts of sintered carbides coated with AlTiN were used to mill a duplex stainless steel with trochoidal strategies. Cutting speed range from 120 to 300 m/min were used and t he evaluation of tool deterioration and tool life was made according international standard ISO 8688-1. It was observed a progressive development of a flank wear and a cumulative cyclic process of localized adhesion of the chip to the cutting edge, followed by chipping, loss of the coating and substrate exposure. The tool life reached a maximum of 35 min. for cutting speed of 120 m/min. However, it was possible to maintain a tool life of 20-25 minutes when the cutting speed was increased up to 240 m/min.

Force Modelling in Orthogonal Cutting Considering Flank Wear Effect

NASA Astrophysics Data System (ADS)

Rathod, Kanti Bhikhubhai; Lalwani, Devdas I.

2017-05-01

In the present work, an attempt has been made to provide a predictive cutting force model during orthogonal cutting by combining two different force models, that is, a force model for a perfectly sharp tool plus considering the effect of edge radius and a force model for a worn tool. The first force model is for a perfectly sharp tool that is based on Oxley's predictive machining theory for orthogonal cutting as the Oxley's model is for perfectly sharp tool, the effect of cutting edge radius (hone radius) is added and improve model is presented. The second force model is based on worn tool (flank wear) that was proposed by Waldorf. Further, the developed combined force model is also used to predict flank wear width using inverse approach. The performance of the developed combined total force model is compared with the previously published results for AISI 1045 and AISI 4142 materials and found reasonably good agreement.

A Novel Mobile Testing Equipment for Rock Cuttability Assessment: Vertical Rock Cutting Rig (VRCR)

NASA Astrophysics Data System (ADS)

Yasar, Serdar; Yilmaz, Ali Osman

2017-04-01

In this study, a new mobile rock cutting testing apparatus was designed and produced for rock cuttability assessment called vertical rock cutting rig (VRCR) which was designed specially to fit into hydraulic press testing equipment which are available in almost every rock mechanics laboratory. Rock cutting trials were initiated just after the production of VRCR along with calibration of the measuring load cell with an external load cell to validate the recorded force data. Then, controlled rock cutting tests with both relieved and unrelieved cutting modes were implemented on five different volcanic rock samples with a standard simple-shaped wedge tool. Additionally, core cutting test which is an important approach for roadheader performance prediction was simulated with VRCR. Mini disc cutters and point attack tools were used for execution of experimental trials. Results clearly showed that rock cutting tests were successfully realized and measuring system is delicate to rock strength, cutting depth and other variables. Core cutting test was successfully simulated, and it was also shown that rock cutting tests with mini disc cutters and point attack tools are also successful with VRCR.

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

NASA Astrophysics Data System (ADS)

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

2015-07-01

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

BROACHING AND TUBE-INSTALLING APPARATUS

DOEpatents

Frantz, C.E.; Cawley, W.E.

1961-05-16

An apparatus is given for sizing long holes in graphite bodies. The apparatus comprises a shaft having 3 spiral broach cutting elements and a straight broach cutting element rotatably mounted thereon. The broach cutting elements are keyed to each other in end to end relationship with the straight broach cutting element at one end of the shaft. The spiral broach cutting elements when considered toward the straight broach cutting element increase in diameter and the cutting teeth thereon increase in lead angle. The straight broach cutting element, when considered in the same direction, increases in diameter from the minimum to maximum diameters of the spiral broach cutting elements. No longitudinal movement of the broach cutting elements is permitted on the shsft snd means are provided for the removal of chips from the apparatus.

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

NASA Astrophysics Data System (ADS)

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.

In vitro fenestration of aortic stent-grafts: implications of puncture methods for in situ fenestration durability.

PubMed

Riga, Celia V; Bicknell, Colin D; Basra, Melvinder; Hamady, Mohamad; Cheshire, Nicholas J W

2013-08-01

To investigate the quality of stent-graft fenestrations created in vitro using different needle puncture and balloon dilation angles in different commercial endografts. Fenestrations were made in a standardized fashion in 3 different endograft types: Talent monofilament twill woven polyester, Zenith multifilament tubular woven polyester, and Endofit thin-walled expanded polytetrafluoroethylene (PTFE). Punctures were made at 30°, 60°, and 90° angles using a 20-G needle and dilated using 6-mm standard and 7-mm cutting balloons; at least 6 fenestrations were made at each angle with standard balloons and at least 6 with cutting balloons. The 137 fenestrations were examined under light microscopy; quantitative and qualitative digital image analysis was performed to determine size, shape, and fenestration quality. PTFE grafts were easier to puncture/dilate, resulting in larger, elliptical fenestrations with overall better quality than the Dacron grafts; however, the puncture/dilation angle made an impact on the shape and quality of fenestrations. A significant number of fabric tears were observed in PTFE fabric at <90° puncture/dilation angles compared to Dacron grafts. In Dacron grafts, fenestration quality was significantly higher with 90° puncture/dilation angles (higher in Talent grafts). Cutting balloon use resulted in significantly more fabric tears and poor quality fenestrations in all graft types. Different endografts behave significantly differently when fenestrations are fashioned. Optimum puncture/dilation is important when considering in vivo fenestration techniques. Improvements in instrumentation, materials, and techniques are required to make this a reliable and reproducible endovascular option.

A Study on Micro-Machining Technology for the Machining of NiTi: Five-Axis Micro-Milling and Micro Deep-Hole Drilling

NASA Astrophysics Data System (ADS)

Biermann, D.; Kahleyss, F.; Krebs, E.; Upmeier, T.

2011-07-01

Micro-sized applications are gaining more and more relevance for NiTi-based shape memory alloys (SMA). Different types of micro-machining offer unique possibilities for the manufacturing of NiTi components. The advantage of machining is the low thermal influence on the workpiece. This is important, because the phase transformation temperatures of NiTi SMAs can be changed and the components may need extensive post manufacturing. The article offers a simulation-based approach to optimize five-axis micro-milling processes with respect to the special material properties of NiTi SMA. Especially, the influence of the various tool inclination angles is considered for introducing an intelligent tool inclination optimization algorithm. Furthermore, aspects of micro deep-hole drilling of SMAs are discussed. Tools with diameters as small as 0.5 mm are used. The possible length-to-diameter ratio reaches up to 50. This process offers new possibilities in the manufacturing of microstents. The study concentrates on the influence of the cutting speed, the feed and the tool design on the tool wear and the quality of the drilled holes.

Laser cutting plastic materials

NASA Astrophysics Data System (ADS)

Vancleave, R. A.

1980-08-01

A 1000 watt CO2 laser was demonstrated as a reliable production machine tool for cutting of plastics, high strength reinforced composites, and other nonmetals. More than 40 different plastics were laser cut, and the results are tabulated. Applications for laser cutting described include fiberglass reinforced laminates, Kevlar/epoxy composites, fiberglass reinforced phenolics, nylon/epoxy laminates, ceramics, and disposal tooling made from acrylic.

CUTTING AND WEDGING JACKET REMOVER

DOEpatents

Freedman, M.; Raynor, S.

1959-04-01

A tool is presented for stripping cladded jackets from fissionable fuel elements. The tool is a tube which fits closely around the jacket and which has two cutting edges at opposite sides of one end. These cutting edges are adjusted to penetrate only the jacket so that by moving the edges downward the jacket is cut into two pieces.

Tool post modification allows easy turret lathe cutting-tool alignment

NASA Technical Reports Server (NTRS)

Fouts, L.

1966-01-01

Modified tool holder and tool post permit alignment of turret lathe cutting tools on the center of the spindle. The tool is aligned with the spindle by the holder which is kept in position by a hydraulic lock in feature of the tool post. The tool post is used on horizontal and vertical turret lathes and other engine lathes.

Study on Platinum Coating Depth in Focused Ion Beam Diamond Cutting Tool Milling and Methods for Removing Platinum Layer.

PubMed

Choi, Woong Kirl; Baek, Seung Yub

2015-09-22

In recent years, nanomachining has attracted increasing attention in advanced manufacturing science and technologies as a value-added processes to control material structures, components, devices, and nanoscale systems. To make sub-micro patterns on these products, micro/nanoscale single-crystal diamond cutting tools are essential. Popular non-contact methods for the macro/micro processing of diamond composites are pulsed laser ablation (PLA) and electric discharge machining (EDM). However, for manufacturing nanoscale diamond tools, these machining methods are not appropriate. Despite diamond's extreme physical properties, diamond can be micro/nano machined relatively easily using a focused ion beam (FIB) technique. In the FIB milling process, the surface properties of the diamond cutting tool is affected by the amorphous damage layer caused by the FIB gallium ion collision and implantation and these influence the diamond cutting tool edge sharpness and increase the processing procedures. To protect the diamond substrate, a protection layer-platinum (Pt) coating is essential in diamond FIB milling. In this study, the depth of Pt coating layer which could decrease process-induced damage during FIB fabrication is investigated, along with methods for removing the Pt coating layer on diamond tools. The optimum Pt coating depth has been confirmed, which is very important for maintaining cutting tool edge sharpness and decreasing processing procedures. The ultra-precision grinding method and etching with aqua regia method have been investigated for removing the Pt coating layer. Experimental results show that when the diamond cutting tool width is bigger than 500 nm, ultra-precision grinding method is appropriate for removing Pt coating layer on diamond tool. However, the ultra-precision grinding method is not recommended for removing the Pt coating layer when the cutting tool width is smaller than 500 nm, because the possibility that the diamond cutting tool is damaged by the grinding process will be increased. Despite the etching method requiring more procedures to remove the Pt coating layer after FIB milling, it is a feasible method for diamond tools with under 500 nm width.

Apparatus for preparing cornea material for tabbed (sutureless) transplantation

DOEpatents

Collins, Joseph Patrick

1997-01-01

A tool and a method for preparing a donor material used in sutureless corneal transplants uses a first cutting portion to prepare a donor blank having tabbed portions extending outwardly radially. A second cutting portion is used to cut the central portion of the blank. The tool is used as a guide member for the second cutting portion. In one embodiment the tool has slits laterally defined therethrough which allow the tabbed portions of the donor material to be thinned to a desired thickness using a scalpel. In an another embodiment the second cutting portion is a round trephine which is used to simultaneously trim each of the tabbed portions.

Tool Enlarges Hard-to-Reach Holes

NASA Technical Reports Server (NTRS)

Geddes, J. P.

1984-01-01

Tool centers itself and cuts precise depth. Tool consists of crosscut carbide bur; sleeve that serves as depth stop and pilot; length of flexible, strong piano wire; and standard drive socket. Parts brazed together. Piano wire transmits torque and axial force to cutting tool.

Application of Taguchi Method for Analyzing Factors Affecting the Performance of Coated Carbide Tool When Turning FCD700 in Dry Cutting Condition

NASA Astrophysics Data System (ADS)

Ghani, Jaharah A.; Mohd Rodzi, Mohd Nor Azmi; Zaki Nuawi, Mohd; Othman, Kamal; Rahman, Mohd. Nizam Ab.; Haron, Che Hassan Che; Deros, Baba Md

2011-01-01

Machining is one of the most important manufacturing processes in these modern industries especially for finishing an automotive component after the primary manufacturing processes such as casting and forging. In this study the turning parameters of dry cutting environment (without air, normal air and chilled air), various cutting speed, and feed rate are evaluated using a Taguchi optimization methodology. An orthogonal array L27 (313), signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are employed to analyze the effect of these turning parameters on the performance of a coated carbide tool. The results show that the tool life is affected by the cutting speed, feed rate and cutting environment with contribution of 38%, 32% and 27% respectively. Whereas for the surface roughness, the feed rate is significantly controlled the machined surface produced by 77%, followed by the cutting environment of 19%. The cutting speed is found insignificant in controlling the machined surface produced. The study shows that the dry cutting environment factor should be considered in order to produce longer tool life as well as for obtaining a good machined surface.

Electrical contact tool set station

DOEpatents

Byers, M.E.

1988-02-22

An apparatus is provided for the precise setting to zero of electrically conductive cutting tools used in the machining of work pieces. An electrically conductive cylindrical pin, tapered at one end to a small flat, rests in a vee-shaped channel in a base so that its longitudinal axis is parallel to the longitudinal axis of the machine's spindle. Electronic apparatus is connected between the cylindrical pin and the electrically conductive cutting tool to produce a detectable signal when contact between tool and pin is made. The axes of the machine are set to zero by contact between the cutting tool and the sides, end or top of the cylindrical pin. Upon contact, an electrical circuit is completed, and the detectable signal is produced. The tool can then be set to zero for that axis. Should the tool contact the cylindrical pin with too much force, the cylindrical pin would be harmlessly dislodged from the vee-shaped channel, preventing damage either to the cutting tool or the cylindrical pin. 5 figs.

Pilot study of manual sugarcane harvesting using biomechanical analysis.

PubMed

Clementson, C L; Hansen, A C

2008-07-01

In many countries, sugar cane harvesting is a very labor-intensive activity in which workers usually become fatigued after manually cutting the cane for a few hours. They need frequent pauses for rest, and they experience sustained injuries from excessive stress on the joints and muscles of the body. The cutting tool and motion involved directly influence the stresses created. A cutting tool that has not been designed by taking into consideration occupational biomechanics can lead to unnecessary strains in the body's muscle system, resulting in injuries. The purpose of this research was to carry out a pilot study of the impact of two common manual sugarcane cutting tools and the cutting posture they induce on the body with the aid of biomechanics. The machete and the cutlass from South Africa and Guyana, respectively, were examined to determine the cutting forces. Using static strength prediction modeling, the body stress levels at the point of cut in the cutting motion were determined. The cutting postures of three subjects were contrasted, their extreme postures were identified, and suggestions were made to improve the ergonomics of the cutting activity. The results of this pilot study showed that the cutlass required less cutting force than the machete because of the slicing cut provided by the curved blade edge of the cutlass. However, the biomechanical analysis indicated that the bent blade of the machete required less flexion of the back and therefore was likely to cause less back fatigue and injury. An improved design of the sugarcane manual harvesting tool should incorporate the bend of the machete to reduce flexion and a curved cutting edge that provides a slicing cut.

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

NASA Astrophysics Data System (ADS)

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

2007-05-01

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

Knee biomechanics during a jump-cut maneuver: Effects of gender & ACL surgery

PubMed Central

Miranda, Daniel L.; Fadale, Paul D.; Hulstyn, Michael J.; Shalvoy, Robert M.; Machan, Jason T.; Fleming, Braden C.

2012-01-01

Purpose The purpose of this study was to compare kinetic and knee kinematic measurements from male and female ACL-intact (ACLINT) and ACL-reconstructed (ACLREC) subjects during a jump-cut maneuver using biplanar videoradiography. Methods Twenty subjects were recruited; 10 ACLINT (5 males, 5 females) and 10 ACLREC (4 males, 6 females; five years post surgery). Each subject performed a jump-cut maneuver by landing on a single leg and performing a 45° side-step cut. Ground reaction force was measured by a force plate and expressed relative to body weight. Six-degree-of-freedom knee kinematics were determined from a biplanar videoradiography system and an optical motion capture system. Results ACLINT female subjects landed with a larger peak vertical GRF (p<0.001) compared to ACLINT male subjects. ACLINT subjects landed with a larger peak vertical GRF (p≤0.036) compared to ACLREC subjects. Regardless of ACL reconstruction status, female subjects underwent less knee flexion angle excursion (p=0.002) and had an increased average rate of anterior tibial translation (0.05±0.01%/millisecond; p=0.037) after contact compared to male subjects. Furthermore, ACLREC subjects had a lower rate of anterior tibial translation compared to ACLINT subjects (0.05±0.01%/millisecond; p=0.035). Finally, no striking differences were observed in other knee motion parameters. Conclusion Women permit a smaller amount of knee flexion angle excursion during a jump-cut maneuver, resulting in a larger peak vertical GRF and increased rate of anterior tibial translation. Notably, ACLREC subjects also perform the jump cut maneuver with lower GRF than ACLINT subjects five years post surgery. This study proposes a causal sequence whereby increased landing stiffness (larger peak vertical GRF combined with less knee flexion angle excursion) leads to an increased rate of anterior tibial translation while performing a jump-cut maneuver. PMID:23190595

Prediction Of Abrasive And Diffusive Tool Wear Mechanisms In Machining

NASA Astrophysics Data System (ADS)

Rizzuti, S.; Umbrello, D.

2011-01-01

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

Apparatus for preparing cornea material for tabbed (sutureless) transplantation

DOEpatents

Collins, J.P.

1997-07-22

A tool and a method for preparing a donor material used in sutureless corneal transplants uses a first cutting portion to prepare a donor blank having tabbed portions extending outwardly radially. A second cutting portion is used to cut the central portion of the blank. The tool is used as a guide member for the second cutting portion. In one embodiment the tool has slits laterally defined therethrough which allow the tabbed portions of the donor material to be thinned to a desired thickness using a scalpel. In an another embodiment the second cutting portion is a round trephine which is used to simultaneously trim each of the tabbed portions. 26 figs.

Some aspects of precise laser machining - Part 2: Experimental

NASA Astrophysics Data System (ADS)

Grabowski, Marcin; Wyszynski, Dominik; Ostrowski, Robert

2018-05-01

The paper describes the role of laser beam polarization on quality of laser beam machined cutting tool edge. In micromachining the preparation of the cutting tools in play a key role on dimensional accuracy, sharpness and the quality of the cutting edges. In order to assure quality and dimensional accuracy of the cutting tool edge it is necessary to apply laser polarization control. In the research diode pumped Nd:YAG 532nm pulse laser was applied. Laser beam polarization used in the research was linear (horizontal, vertical). The goal of the carried out research was to describe impact of laser beam polarization on efficiency of the cutting process and quality of machined parts (edge, surface) made of polycrystalline diamond (PCD) and cubic boron nitride (cBN). Application of precise cutting tool in micromachining has significant impact on the minimum uncut chip thickness and quality of the parts. The research was carried within the INNOLOT program funded by the National Centre for Research and Development.

Surface Roughness Model Based on Force Sensors for the Prediction of the Tool Wear

PubMed Central

de Agustina, Beatriz; Rubio, Eva María; Sebastián, Miguel Ángel

2014-01-01

In this study, a methodology has been developed with the objective of evaluating the surface roughness obtained during turning processes by measuring the signals detected by a force sensor under the same cutting conditions. In this way, the surface quality achieved along the process is correlated to several parameters of the cutting forces (thrust forces, feed forces and cutting forces), so the effect that the tool wear causes on the surface roughness is evaluated. In a first step, the best cutting conditions (cutting parameters and radius of tool) for a certain quality surface requirement were found for pieces of UNS A97075. Next, with this selection a model of surface roughness based on the cutting forces was developed for different states of wear that simulate the behaviour of the tool throughout its life. The validation of this model reveals that it was effective for approximately 70% of the surface roughness values obtained. PMID:24714391

Senarmont compensation for determining fibril angles of cell wall layers

Treesearch

Floyd G. Manwiller

1966-01-01

A technique originated by Preston, is explained for determining fibril angles of the secondary wall layers of fibers. A polarizing microscope equipped with Senarmont compensator is used to measure birefringence of the wall layers in series of sections cut at various angles to the long axis of the cells. Enough measurements are taken on each section to give a...

“Investigations on the machinability of Waspaloy under dry environment”

NASA Astrophysics Data System (ADS)

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

Lower limb kinematics of male and female soccer players during a self-selected cutting maneuver: Effects of prolonged activity.

PubMed

McGovern, Andrew; Dude, Christopher; Munkley, Daniel; Martin, Thomas; Wallace, David; Feinn, Richard; Dione, Donald; Garbalosa, Juan C

2015-12-01

Despite the recent emphasis on injury prevention, anterior cruciate ligament (ACL) injury rates remain high. This study aimed to ascertain the effects of prolonged activity on lower limb kinematics during a self-selected cutting maneuver. Angular kinematics were recorded during an agility test performed until the completion time was greater than the mean plus one SD of baseline trials. Cut type was identified and the hip and knee angles at 33 ms post heel strike were determined. A linear mixed effects model assessed the effects of cut type, gender, and activity status on the hip and knee angles. Males performed sidestep cuts more frequently than females. Females increased the incidence of sidestep cuts after prolonged activity. At the hip, a gender-cut type interaction existed for the transverse (p=0.001) and sagittal (p=0.11) planes. Females showed more internal rotation during sidestep and more external rotation and less flexion during crossover cuts. For the frontal plane, a gender-activity status interaction (p = 0.032) was due to no change within females but greater hip adduction during prolonged activity within males. With prolonged activity, both genders displayed less hip (p=0.29) and knee (p=0.009) flexion and more knee (p=0.001) adduction. Females displayed less hip and knee flexion than men (p=0.001). Sidestep may be more risky than crossover cuts. Both genders place themselves in at-risk postures with prolonged activity due to less hip and knee flexion. Copyright © 2015 Elsevier B.V. All rights reserved.

Finite Element Simulations of Micro Turning of Ti-6Al-4V using PCD and Coated Carbide tools

NASA Astrophysics Data System (ADS)

Jagadesh, Thangavel; Samuel, G. L.

2017-02-01

The demand for manufacturing axi-symmetric Ti-6Al-4V implants is increasing in biomedical applications and it involves micro turning process. To understand the micro turning process, in this work, a 3D finite element model has been developed for predicting the tool chip interface temperature, cutting, thrust and axial forces. Strain gradient effect has been included in the Johnson-Cook material model to represent the flow stress of the work material. To verify the simulation results, experiments have been conducted at four different feed rates and at three different cutting speeds. Since titanium alloy has low Young's modulus, spring back effect is predominant for higher edge radius coated carbide tool which leads to the increase in the forces. Whereas, polycrystalline diamond (PCD) tool has smaller edge radius that leads to lesser forces and decrease in tool chip interface temperature due to high thermal conductivity. Tool chip interface temperature increases by increasing the cutting speed, however the increase is less for PCD tool as compared to the coated carbide tool. When uncut chip thickness decreases, there is an increase in specific cutting energy due to material strengthening effects. Surface roughness is higher for coated carbide tool due to ploughing effect when compared with PCD tool. The average prediction error of finite element model for cutting and thrust forces are 11.45 and 14.87 % respectively.

Cut marks on bone surfaces: influences on variation in the form of traces of ancient behaviour

PubMed Central

Braun, David R.; Pante, Michael; Archer, William

2016-01-01

Although we know that our lineage has been producing sharp-edged tools for over 2.6 Myr, our knowledge of what they were doing with these tools is far less complete. Studies of these sharp-edged stone tools show that they were most probably used as cutting implements. However, the only substantial evidence of this is the presence of cut marks on the bones of animals found in association with stone tools in ancient deposits. Numerous studies have aimed to quantify the frequency and placement of these marks. At present there is little consensus on the meaning of these marks and how the frequency relates to specific behaviours in the past. Here we investigate the possibility that mechanical properties associated with edges of stone tools as well as the properties of bones themselves may contribute to the overall morphology of these marks and ultimately their placement in the archaeological record. Standardized tests of rock mechanics (Young's modulus and Vickers hardness) indicate that the hardness of tool edges significantly affects cut-mark morphology. In addition, we show that indentation hardness of bones also impacts the overall morphology of cut marks. Our results show that rock type and bone portions influence the shape and prevalence of cut marks on animal bones. PMID:27274806

Determination of the Basic Friction Angle of Rock Surfaces by Tilt Tests

NASA Astrophysics Data System (ADS)

Jang, Hyun-Sic; Zhang, Qing-Zhao; Kang, Seong-Seung; Jang, Bo-An

2018-04-01

Samples of Hwangdeung granite from Korea and Berea sandstone from USA, both containing sliding planes, were prepared by saw-cutting or polishing using either #100 or #600 grinding powders. Their basic friction angles were measured by direct shear testing, triaxial compression testing, and tilt testing. The direct shear tests and triaxial compression tests on the saw-cut, #100, and #600 surfaces indicated that the most reliable results were obtained from the #100 surface: basic friction angle of 29.4° for granite and 34.1° for sandstone. To examine the effect of surface conditions on the friction angle in tilt tests, the sliding angles were measured 50 times with two surface conditions (surfaces cleaned and not cleaned after each measurement). The initial sliding angles were high regardless of rock type and surface conditions and decreased exponentially as measurements continued. The characteristics of the sliding angles, differences between tilt tests, and dispersion between measurements in each test indicated that #100 surface produced the most reliable basic friction angle measurement. Without cleaning the surfaces, the average angles for granite (32 measurements) and sandstone (23 measurements) were similar to the basic friction angle. When 20-50 measurements without cleaning were averaged, the basic friction angle was within ± 2° for granite and ± 3° for sandstone. Sliding angles using five different tilting speeds were measured but the average was similar, indicating that tilting speed (between 0.2° and 1.6°/s) has little effect on the sliding angle. Sliding angles using four different sample sizes were measured with the best results obtained for samples larger than 8 × 8 cm.

Measurement of Knee Rotation Angles Using a Smartphone Application: An Experimental Study of Porcine Knees.

PubMed

Kim, Hee-June; Lee, Hyun-Joo; Shin, Ji-Yeon; Choi, Young-Seo; Kyung, Hee-Soo

2017-12-01

This study evaluated the efficacy of a smartphone application in the measurement of rotation angles in porcine knees. Two K-wires were fixated to the femoral condyle and anterior tibial crest of 10 porcine legs. The angle created between the K-wires with an external rotation force applied was measured on a photograph and defined as the true angle. The same force was applied to the legs placed on a splint with a smartphone attached to the plantar side. The angle presented on a smartphone application was determined as the measured angle. The differences between the true and measured angles in 30° and 90° knee flexion and differences in measured angles depending on the status of the popliteus tendon were compared. In the intact knees, the mean true angles in 30° and 90° flexion were 20.5°±1.4° and 19.1°±1.3°, respectively, and the mean measured angles in 30° and 90° flexion were 21.1°±0.9° and 18.6°±1.6°, respectively. When the popliteus tendon was cut, the mean true angles in 30° and 90° flexion were 31.4°±1.1° and 38.5°±2.5°, respectively, and the mean measured angles in 30° and 90° flexion were 31.8°±1.2° and 39.2°±2.8°, respectively. The differences between the true and measured angles were not significant. The measured angle increased by more than 10° after cutting of the popliteus tendon in both 30° and 90° flexion. Using a smartphone application could be a good method of measuring knee rotation.

Patient's Height and Hip Medial Offset Are the Main Determinants of the Valgus Cut Angle During Total Knee Arthroplasty.

PubMed

Drexler, Michael; Abolghasemian, Mansour; Barbuto, Richard; Naini, Mohsen S; Voshmeh, Neda; Rutenberg, Tal F; Schwarzkopf, Ran; Backstein, David J

2017-05-01

Valgus cut angle (VCA), defined as the angle between the anatomical and the mechanical axes of femur, is an important parameter upon which a critical step of knee arthroplasty is based. Some variables have been proposed to affect the magnitude of this cut. However, little information is available regarding whether a generic value can be used, or if a patient-specific value from a long leg X-ray, or factors that can be determined preoperatively, is necessary to accurately set the VCA. Standard standing 3-joint views were used to measure a number of anatomical measurements in 358 limbs, 202 patients (116 women, 86 men). Neck-shaft angle, medial offset, femoral length (FL), distal femoral articular angle, and VCA were measured. Demographic data including gender and height were extracted from hospital charts. The correlation of VCA with each of the other factors was evaluated using linear regression and t-test and finally multivariate analysis. The average VCA was 5.76° (range 4-8). Gender and distal femoral articular angle were not related to VCA (P = .343 and .995). FL was found to be a function of height with similar effects on multivariate analysis. Only the height (or FL) and femoral offset were identified as independent factors, with a negative correlation for the former (P < .001) and a positive correlation for the latter (P < .001). Femoral offset and height are the 2 independent factors determining VCA. Other parameters are indirectly related to these 2 factors. Tall patients with a small femoral offset have smaller VCA and short patients with a large offset have larger VCA. The wide variety of VCA values does not support using a generic value for all patients during knee arthroplasty. Copyright © 2016 Elsevier Inc. All rights reserved.

High-efficiency spectral purity filter for EUV lithography

DOEpatents

Chapman, Henry N [Livermore, CA

2006-05-23

An asymmetric-cut multilayer diffracts EUV light. A multilayer cut at an angle has the same properties as a blazed grating, and has been demonstrated to have near-perfect performance. Instead of having to nano-fabricate a grating structure with imperfections no greater than several tens of nanometers, a thick multilayer is grown on a substrate and then cut at an inclined angle using coarse and inexpensive methods. Effective grating periods can be produced this way that are 10 to 100 times smaller than those produced today, and the diffraction efficiency of these asymmetric multilayers is higher than conventional gratings. Besides their ease of manufacture, the use of an asymmetric multilayer as a spectral purity filter does not require that the design of an EUV optical system be modified in any way, unlike the proposed use of blazed gratings for such systems.

CO2 laser cutting of ultra thin (75 μm) glass based rigid optical solar reflector (OSR) for spacecraft application

NASA Astrophysics Data System (ADS)

Mishra, Shubham; Sridhara, N.; Mitra, Avijit; Yougandar, B.; Dash, Sarat Kumar; Agarwal, Sanjay; Dey, Arjun

2017-03-01

Present study reports for the first time laser cutting of multilayered coatings on both side of ultra thin (i.e., 75 μm) glass substrate based rigid optical solar reflector (OSR) for spacecraft thermal control application. The optimization of cutting parameters was carried out as a function of laser power, cutting speed and number of cutting passes and their effect on cutting edge quality. Systematic and in-detail microstructural characterizations were carried out by optical and scanning electron microscopy techniques to study the laser affected zone and cutting edge quality. Sheet resistance and water contact angle experiments were also conducted locally both prior and after laser cut to investigate the changes of electrical and surface properties, if any.

Tool wear of (Ti, Al) N-coated polycrystalline cubic boron nitride compact in cutting of hardened steel

NASA Astrophysics Data System (ADS)

Wada, Tadahiro; Hanyu, Hiroyuki

2017-11-01

Polycrystalline cubic boron nitride compact (cBN) is effective tool material for cutting hardened steel. In addition to coated high speed steel and coated cemented carbide that has long been used for cutting materials, more recently, coated cBN has also been used. In this study, to verify the effectiveness of the (Ti,Al)N-coated cBN, which is formed on the substrate of cBN by the physical vapor deposition method, the hardened steel was turned with the (Ti,Al)N-coated cBN tool at a cutting speed of 3.33, 5.00 m/s, a feed rate of 0.3 mm/rev and a depth of cut of 0.1 mm. Furthermore, the uncoated cBN, which was the substrate of the (Ti,Al)N-coated, was also used. The tool wear of the cBN tools was experimentally investigated. The following results were obtained: (1) The contact area between the rake face and the chip of the (Ti,.Al)N-coated cBN tool was smaller than that of the uncoated cBN tool. (2) The tool wear of the (Ti,Al)N-coated cBN was smaller than that of uncoated cBN. (3) The wear progress of the (Ti,Al)N-coated cBN with the main element phase of the TiCN-Al, was slower than that of the (Ti,Al)N-coated cBN with the main element phase of the TiN-Al. (4) In the case of the high cutting speed of 5.00 m/s, the tool wear of the (Ti,Al)N-coated cBN was also smaller than that of uncoated cBN. The above results clarify that the (Ti,Al)N-coated cBN can be used as a tool material in high feed cutting of hardened steel.

Estimation of the influence of tool wear on force signals: A finite element approach in AISI 1045 orthogonal cutting

NASA Astrophysics Data System (ADS)

Equeter, Lucas; Ducobu, François; Rivière-Lorphèvre, Edouard; Abouridouane, Mustapha; Klocke, Fritz; Dehombreux, Pierre

2018-05-01

Industrial concerns arise regarding the significant cost of cutting tools in machining process. In particular, their improper replacement policy can lead either to scraps, or to early tool replacements, which would waste fine tools. ISO 3685 provides the flank wear end-of-life criterion. Flank wear is also the nominal type of wear for longest tool lifetimes in optimal cutting conditions. Its consequences include bad surface roughness and dimensional discrepancies. In order to aid the replacement decision process, several tool condition monitoring techniques are suggested. Force signals were shown in the literature to be strongly linked with tools flank wear. It can therefore be assumed that force signals are highly relevant for monitoring the condition of cutting tools and providing decision-aid information in the framework of their maintenance and replacement. The objective of this work is to correlate tools flank wear with numerically computed force signals. The present work uses a Finite Element Model with a Coupled Eulerian-Lagrangian approach. The geometry of the tool is changed for different runs of the model, in order to obtain results that are specific to a certain level of wear. The model is assessed by comparison with experimental data gathered earlier on fresh tools. Using the model at constant cutting parameters, force signals under different tool wear states are computed and provide force signals for each studied tool geometry. These signals are qualitatively compared with relevant data from the literature. At this point, no quantitative comparison could be performed on worn tools because the reviewed literature failed to provide similar studies in this material, either numerical or experimental. Therefore, further development of this work should include experimental campaigns aiming at collecting cutting forces signals and assessing the numerical results that were achieved through this work.

Toolpath Strategy and Optimum Combination of Machining Parameter during Pocket Mill Process of Plastic Mold Steels Material

NASA Astrophysics Data System (ADS)

Wibowo, Y. T.; Baskoro, S. Y.; Manurung, V. A. T.

2018-02-01

Plastic based products spread all over the world in many aspects of life. The ability to substitute other materials is getting stronger and wider. The use of plastic materials increases and become unavoidable. Plastic based mass production requires injection process as well Mold. The milling process of plastic mold steel material was done using HSS End Mill cutting tool that is widely used in a small and medium enterprise for the reason of its ability to be re sharpened and relatively inexpensive. Study on the effect of the geometry tool states that it has an important effect on the quality improvement. Cutting speed, feed rate, depth of cut and radii are input parameters beside to the tool path strategy. This paper aims to investigate input parameter and cutting tools behaviors within some different tool path strategy. For the reason of experiments efficiency Taguchi method and ANOVA were used. Response studied is surface roughness and cutting behaviors. By achieving the expected quality, no more additional process is required. Finally, the optimal combination of machining parameters will deliver the expected roughness and of course totally reduced cutting time. However actually, SMEs do not optimally use this data for cost reduction.

Cutting Zone Temperature Identification During Machining of Nickel Alloy Inconel 718

NASA Astrophysics Data System (ADS)

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.

Process improvement of knives production in a small scale industry

NASA Astrophysics Data System (ADS)

Ananto, Gamawan; Muktasim, Irfan

2017-06-01

Small scale industry that produces several kinds of knive should increase its capacity due to the demand from the market. Qualitatively, this case study consisted of formulating the problems, collecting and analyzing the necessary data, and determining the possible recommendations for the improvement. While the current capacity is only 9 (nine), it is expected that 20 units of knife will produced per month. The processes sequence are: profiling (a), truing (b), beveling (c), heat treatment (d), polishing (e), assembly (f), sharpening (g) and finishing (h). The first process (a) is held by out-house vendor company while other steps from (b) to (g) are executed by in-house vendor. However, there is a high dependency upon the high skilled operator who executes the in -house processes that are mostly held manually with several unbalance successive tasks, where the processing time of one or two tasks require longer duration than others since the operation is merely relied on the operator's skill. The idea is the improvement or change of the profiling and beveling process. Due to the poor surface quality and suboptimal hardness resulted from the laser cut machine for profiling, it is considered to subst itute this kind of process with wire cut that is capable to obtain good surface quality with certain range levels of roughness. Through simple cutting experiments on the samples, it is expected that the generated surface quality is adequate to omit the truing process (b). In addition, the cutting experiments on one, two, and four test samples resulted the shortest time that was obtained through four pieces in one cut. The technical parameters were set according to the recommendation of machine standard as referred to samples condition such as thickness and path length that affect ed the rate of wear. Meanwhile, in order to guarantee the uniformity of knife angles that are formed through beveling process (c), a grinding fixture was created. This kind of tool diminishes the dependency upon the operator's skill as well. The main conclusions are: the substitution of laser cut with wire cut machine for the first task (a) could reduce the operation time from 60 to 39.26 minutes with good result of surface quality and the truing process (b) could be omitted; the additional grinding fixture in beveling process (c) is required and two workstations have to be assigned instead of one as in previous condition. They lead to improvements including the guarantee of the uniformity of knifes' angle, the reduction on the operators' skills dependency, the shortening of cycle time from 855 to 420 minutes, and the higher number of productivity from 9 units/month into 20units/month.

Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs

PubMed Central

Feito, Norberto; Díaz-Álvarez, José; Díaz-Álvarez, Antonio; Cantero, José Luis; Miguélez, María Henar

2014-01-01

This paper focuses on the effect of the drill geometry on the drilling of woven Carbon Fiber Reinforced Polymer composite (CFRPs). Although different geometrical effects can be considered in drilling CFRPs, the present work focuses on the influence of point angle and wear because they are the important factors influencing hole quality and machining forces. Surface quality was evaluated in terms of delamination and superficial defects. Three different point angles were tested representative of the geometries commonly used in the industry. Two wear modes were considered, being representative of the wear patterns commonly observed when drilling CFRPs: flank wear and honed cutting edge. It was found that the crossed influence of the point angle and wear were significant to the thrust force. Delamination at the hole entry and exit showed opposite trends with the change of geometry. Also, cutting parameters were checked showing the feed’s dominant influence on surface damage. PMID:28788675

Generalized interactions using virtual tools within the spring framework: cutting

NASA Technical Reports Server (NTRS)

Montgomery, Kevin; Bruyns, Cynthia D.

2002-01-01

We present schemes for real-time generalized mesh cutting. Starting with the a basic example, we describe the details of implementing cutting on single and multiple surface objects as well as hybrid and volumetric meshes using virtual tools with single and multiple cutting surfaces. These methods have been implemented in a robust surgical simulation environment allowing us to model procedures ranging from animal dissection to cleft lip correction.

Highly Productive Tools For Turning And Milling

NASA Astrophysics Data System (ADS)

Vasilko, Karol

2015-12-01

Beside cutting speed, shift is another important parameter of machining. Its considerable influence is shown mainly in the workpiece machined surface microgeometry. In practice, mainly its combination with the radius of cutting tool tip rounding is used. Options to further increase machining productivity and machined surface quality are hidden in this approach. The paper presents variations of the design of productive cutting tools for lathe work and milling on the base of the use of the laws of the relationship among the highest reached uneveness of machined surface, tool tip radius and shift.

Monitoring of Surface Roughness in Aluminium Turning Process

NASA Astrophysics Data System (ADS)

Chaijareenont, Atitaya; Tangjitsitcharoen, Somkiat

2018-01-01

As the turning process is one of the most necessary process. The surface roughness has been considered for the quality of workpiece. There are many factors which affect the surface roughness. Hence, the objective of this research is to monitor the relation between the surface roughness and the cutting forces in aluminium turning process with a wide range of cutting conditions. The coated carbide tool and aluminium alloy (Al 6063) are used for this experiment. The cutting parameters are investigated to analyze the effects of them on the surface roughness which are the cutting speed, the feed rate, the tool nose radius and the depth of cut. In the case of this research, the dynamometer is installed in the turret of CNC turning machine to generate a signal while turning. The relation between dynamic cutting forces and the surface roughness profile is examined by applying the Fast Fourier Transform (FFT). The experimentally obtained results showed that the cutting force depends on the cutting condition. The surface roughness can be improved when increasing the cutting speed and the tool nose radius in contrast to the feed rate and the depth of cut. The relation between the cutting parameters and the surface roughness can be explained by the in-process cutting forces. It is understood that the in-process cutting forces are able to predict the surface roughness in the further research.

Computational Fluid Dynamic Simulation of Flow in Abrasive Water Jet Machining

NASA Astrophysics Data System (ADS)

Venugopal, S.; Sathish, S.; Jothi Prakash, V. M.; Gopalakrishnan, T.

2017-03-01

Abrasive water jet cutting is one of the most recently developed non-traditional manufacturing technologies. In this machining, the abrasives are mixed with suspended liquid to form semi liquid mixture. The general nature of flow through the machining, results in fleeting wear of the nozzle which decrease the cutting performance. The inlet pressure of the abrasive water suspension has main effect on the major destruction characteristics of the inner surface of the nozzle. The aim of the project is to analyze the effect of inlet pressure on wall shear and exit kinetic energy. The analysis could be carried out by changing the taper angle of the nozzle, so as to obtain optimized process parameters for minimum nozzle wear. The two phase flow analysis would be carried by using computational fluid dynamics tool CFX. It is also used to analyze the flow characteristics of abrasive water jet machining on the inner surface of the nozzle. The availability of optimized process parameters of abrasive water jet machining (AWJM) is limited to water and experimental test can be cost prohibitive. In this case, Computational fluid dynamics analysis would provide better results.

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

NASA Astrophysics Data System (ADS)

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.

Effect of magneto rheological damper on tool vibration during hard turning

NASA Astrophysics Data System (ADS)

Paul, P. Sam; Varadarajan, A. S.

2012-12-01

Recently, the concept of hard turning has gained considerable attention in metal cutting as it can apparently replace the traditional process cycle of turning, heat treating, and finish grinding for assembly of hard wear resistant steel parts. The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing tool vibration and promoting better cutting performance during hard turning. The magneto rheological Fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by the composition of the magneto rheological fluid, the shape of the plunger and the electric parameters of the magnetizing field. Cutting experiments were conducted to arrive at a set of electrical, compositional and shape parameters that can suppress tool vibration and promote better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. It was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance effectively. Also commercialization of this idea holds promise to the metal cutting industry.

Micromachined cutting blade formed from {211}-oriented silicon

DOEpatents

Fleming, James G.; Sniegowski, Jeffry J.; Montague, Stephen

2003-09-09

A cutting blade is disclosed fabricated of micromachined silicon. The cutting blade utilizes a monocrystalline silicon substrate having a {211} crystalline orientation to form one or more cutting edges that are defined by the intersection of {211} crystalline planes of silicon with {111} crystalline planes of silicon. This results in a cutting blade which has a shallow cutting-edge angle .theta. of 19.5.degree.. The micromachined cutting blade can be formed using an anisotropic wet etching process which substantially terminates etching upon reaching the {111} crystalline planes of silicon. This allows multiple blades to be batch fabricated on a common substrate and separated for packaging and use. The micromachined cutting blade, which can be mounted to a handle in tension and optionally coated for increased wear resistance and biocompatibility, has multiple applications including eye surgery (LASIK procedure).

Micromachined cutting blade formed from {211}-oriented silicon

DOEpatents

Fleming, James G [Albuquerque, NM; Fleming, legal representative, Carol; Sniegowski, Jeffry J [Tijeras, NM; Montague, Stephen [Albuquerque, NM

2011-08-09

A cutting blade is disclosed fabricated of micromachined silicon. The cutting blade utilizes a monocrystalline silicon substrate having a {211} crystalline orientation to form one or more cutting edges that are defined by the intersection of {211} crystalline planes of silicon with {111} crystalline planes of silicon. This results in a cutting blade which has a shallow cutting-edge angle .theta. of 19.5.degree.. The micromachined cutting blade can be formed using an anisotropic wet etching process which substantially terminates etching upon reaching the {111} crystalline planes of silicon. This allows multiple blades to be batch fabricated on a common substrate and separated for packaging and use. The micromachined cutting blade, which can be mounted to a handle in tension and optionally coated for increased wear resistance and biocompatibility, has multiple applications including eye surgery (LASIK procedure).

Anticipatory Effects on Lower Extremity Neuromechanics During a Cutting Task.

PubMed

Meinerz, Carolyn M; Malloy, Philip; Geiser, Christopher F; Kipp, Kristof

2015-09-01

Continued research into the mechanism of noncontact anterior cruciate ligament injury helps to improve clinical interventions and injury-prevention strategies. A better understanding of the effects of anticipation on landing neuromechanics may benefit training interventions. To determine the effects of anticipation on lower extremity neuromechanics during a single-legged land-and-cut task. Controlled laboratory study. University biomechanics laboratory. Eighteen female National Collegiate Athletic Association Division I collegiate soccer players (age = 19.7 ± 0.8 years, height = 167.3 ± 6.0 cm, mass = 66.1 ± 2.1 kg). Participants performed a single-legged land-and-cut task under anticipated and unanticipated conditions. Three-dimensional initial contact angles, peak joint angles, and peak internal joint moments and peak vertical ground reaction forces and sagittal-plane energy absorption of the 3 lower extremity joints; muscle activation of selected hip- and knee-joint muscles. Unanticipated cuts resulted in less knee flexion at initial contact and greater ankle toe-in displacement. Unanticipated cuts were also characterized by greater internal hip-abductor and external-rotator moments and smaller internal knee-extensor and external-rotator moments. Muscle-activation profiles during unanticipated cuts were associated with greater activation of the gluteus maximus during the precontact and landing phases. Performing a cutting task under unanticipated conditions changed lower extremity neuromechanics compared with anticipated conditions. Most of the observed changes in lower extremity neuromechanics indicated the adoption of a hip-focused strategy during the unanticipated condition.

Variations in the short wavelength cut-off of the solar UV spectra.

PubMed

Parisi, A V; Turner, J

2006-03-01

Cloud and solar zenith angle (SZA) are two major factors that influence the magnitude of the biologically damaging UV (UVBD) irradiances for humans. However, the effect on the short wavelength cut-off due to SZA and due to clouds has not been investigated for biologically damaging UV for cataracts. This research aims to investigate the influence of cloud and SZA on the short wavelength cut-off of the spectral UVBD for cataracts. The spectral biologically damaging UV for cataracts on a horizontal plane was calculated by weighting the spectral UV measured with a spectroradiometer with the action spectrum for the induction of cataracts in a porcine lens. The UV spectra were obtained on an unshaded plane at a latitude of 29.5 degrees S. The cut-off wavelength (lambdac) was defined as the wavelength at which the biologically damaging spectral irradiance was 0.1% of the maximum biologically damaging irradiance for that scan. For the all sky conditions, the short wavelength cut-off ranged by 12 nm for the SZA range of 5 to 80 degrees and the maximum in the spectral UVBD ranged by 15 nm. Similarly, for the cloud free cases, the short wavelength cut-off ranged by 9 nm for the same SZA range. Although, cloud has a large influence on the magnitude of the biologically damaging UV for cataracts, the influence of cloud on the short wavelength cut-off for the biologically damaging UV for cataracts is less than the influence of the solar zenith angle.

Hybrid ABC Optimized MARS-Based Modeling of the Milling Tool Wear from Milling Run Experimental Data

PubMed Central

García Nieto, Paulino José; García-Gonzalo, Esperanza; Ordóñez Galán, Celestino; Bernardo Sánchez, Antonio

2016-01-01

Milling cutters are important cutting tools used in milling machines to perform milling operations, which are prone to wear and subsequent failure. In this paper, a practical new hybrid model to predict the milling tool wear in a regular cut, as well as entry cut and exit cut, of a milling tool is proposed. The model was based on the optimization tool termed artificial bee colony (ABC) in combination with multivariate adaptive regression splines (MARS) technique. This optimization mechanism involved the parameter setting in the MARS training procedure, which significantly influences the regression accuracy. Therefore, an ABC–MARS-based model was successfully used here to predict the milling tool flank wear (output variable) as a function of the following input variables: the time duration of experiment, depth of cut, feed, type of material, etc. Regression with optimal hyperparameters was performed and a determination coefficient of 0.94 was obtained. The ABC–MARS-based model's goodness of fit to experimental data confirmed the good performance of this model. This new model also allowed us to ascertain the most influential parameters on the milling tool flank wear with a view to proposing milling machine's improvements. Finally, conclusions of this study are exposed. PMID:28787882

Hybrid ABC Optimized MARS-Based Modeling of the Milling Tool Wear from Milling Run Experimental Data.

PubMed

García Nieto, Paulino José; García-Gonzalo, Esperanza; Ordóñez Galán, Celestino; Bernardo Sánchez, Antonio

2016-01-28

Milling cutters are important cutting tools used in milling machines to perform milling operations, which are prone to wear and subsequent failure. In this paper, a practical new hybrid model to predict the milling tool wear in a regular cut, as well as entry cut and exit cut, of a milling tool is proposed. The model was based on the optimization tool termed artificial bee colony (ABC) in combination with multivariate adaptive regression splines (MARS) technique. This optimization mechanism involved the parameter setting in the MARS training procedure, which significantly influences the regression accuracy. Therefore, an ABC-MARS-based model was successfully used here to predict the milling tool flank wear (output variable) as a function of the following input variables: the time duration of experiment, depth of cut, feed, type of material, etc . Regression with optimal hyperparameters was performed and a determination coefficient of 0.94 was obtained. The ABC-MARS-based model's goodness of fit to experimental data confirmed the good performance of this model. This new model also allowed us to ascertain the most influential parameters on the milling tool flank wear with a view to proposing milling machine's improvements. Finally, conclusions of this study are exposed.

Comparison of tool life and surface roughness with MQL, flood cooling, and dry cutting conditions with P20 and D2 steel

NASA Astrophysics Data System (ADS)

Senevirathne, S. W. M. A. I.; Punchihewa, H. K. G.

2017-09-01

Minimum quantity lubrication (MQL) is a cutting fluid (CF) application method that has given promising results in improving machining performances. It has shown that, the performance of cutting systems, depends on the work and tool materials used. AISI P20, and D2 are popular in tool making industry. However, the applicability of MQL in machining these two steels has not been studied previously. This experimental study is focused on evaluating performances of MQL compared to dry cutting, and conventional flood cooling method. Trials were carried out with P20, and D2 steels, using coated carbides as tool material, emulsion cutting oil as the CF. Tool nose wear, and arithmetic average surface roughness (Ra) were taken as response variables. Results were statistically analysed for differences in response variables. Although many past literature has suggested that MQL causes improvements in tool wear, and surface finish, this study has found contradicting results. MQL has caused nearly 200% increase in tool nose wear, and nearly 11-13% increase in surface roughness compared flood cooling method with both P20 and D2. Therefore, this study concludes that MQL affects adversely in machining P20, and D2 steels.

Is fracture a bigger problem for smaller animals? Force and fracture scaling for a simple model of cutting, puncture and crushing

PubMed Central

Choi, Seunghee; Coon, Joshua J.; Goggans, Matthew Scott; Kreisman, Thomas F.; Silver, Daniel M.; Nesson, Michael H.

2016-01-01

Many of the materials that are challenging for large animals to cut or puncture are also cut and punctured by much smaller organisms that are limited to much smaller forces. Small organisms can overcome their force limitations by using sharper tools, but one drawback may be an increased susceptibility to fracture. We use simple contact mechanics models to estimate how much smaller the diameter of the tips or edges of tools such as teeth, claws and cutting blades must be in smaller organisms in order for them to puncture or cut the same materials as larger organisms. In order to produce the same maximum stress when maximum force scales as the square of body length, the diameter of the tool region that is in contact with the target material must scale isometrically for punch-like tools (e.g. scorpion stings) on thick targets, and for crushing tools (e.g. molars). For punch-like tools on thin targets, and for cutting blades on thick targets, the tip or edge diameters must be even smaller than expected from isometry in smaller animals. The diameters of a small sample of unworn punch-like tools from a large range of animal sizes are consistent with the model, scaling isometrically or more steeply (positively allometric). In addition, we find that the force required to puncture a thin target using real biological tools scales linearly with tip diameter, as predicted by the model. We argue that, for smaller tools, the minimum energy to fracture the tool will be a greater fraction of the minimum energy required to puncture the target, making fracture more likely. Finally, energy stored in tool bending, relative to the energy to fracture the tool, increases rapidly with the aspect ratio (length/width), and we expect that smaller organisms often have to employ higher aspect ratio tools in order to puncture or cut to the required depth with available force. The extra stored energy in higher aspect ratio tools is likely to increase the probability of fracture. We discuss some of the implications of the suggested scaling rules and possible adaptations to compensate for fracture sensitivity in smaller organisms. PMID:27274804

Multisurface fixture permits easy grinding of tool bit angles

NASA Technical Reports Server (NTRS)

Jones, C. R.

1966-01-01

Multisurface fixture with a tool holder permits accurate grinding and finishing of right and left hand single point threading tools. All angles are ground by changing the fixture position to rest at various references angles without removing the tool from the holder.

The Methodology of Calculation of Cutting Forces When Machining Composite Materials

NASA Astrophysics Data System (ADS)

Rychkov, D. A.; Yanyushkin, A. S.

2016-08-01

Cutting of composite materials has specific features and is different from the processing of metals. When this characteristic intense wear of the cutting tool. An important criterion in the selection process parameters composite processing is the value of the cutting forces, which depends on many factors and is determined experimentally, it is not always appropriate. The study developed a method of determining the cutting forces when machining composite materials and the comparative evaluation of the calculated and actual values of cutting forces. The methodology for calculating cutting forces into account specific features of the cutting tool and the extent of wear, the strength properties of the processed material and cutting conditions. Experimental studies conducted with fiberglass milling cutter equipped with elements of hard metal VK3M. The discrepancy between the estimated and the actual values of the cutting force is not more than 10%.

Gradient cuts and extremal edges in relative depth and figure-ground perception.

PubMed

Ghose, Tandra; Palmer, Stephen E

2016-02-01

Extremal edges (EEs) are borders consisting of luminance gradients along the projected edge of a partly self-occluding curved surface (e.g., a cylinder), with equiluminant contours (ELCs) that run approximately parallel to that edge. Gradient cuts (GCs) are similar luminance gradients with ELCs that intersect (are "cut" by) an edge that could be due to occlusion. EEs are strongly biased toward being seen as closer/figural surfaces (Palmer & Ghose, Psychological Science, 19(1), 77-83, 2008). Do GCs produce a complementary bias toward being seen as ground? Experiment 1 shows that, with EEs on the opposite side, GCs produce a ground bias that increases with increasing ELC angles between ELCs and the shared edge. Experiment 2 shows that, with flat surfaces on the opposite side, GCs do not produce a ground bias, suggesting that more than one factor may be operating. We suggest that two partially dissociable factors may operate for curved surfaces-ELC angle and 3-D surface convexity-that reinforce each other in the figural cues of EEs but compete with each other in GCs. Moreover, this figural bias is modulated by the presence of EEs and GCs, as specified by the ELC angle between ELCs and the shared contour.

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

NASA Astrophysics Data System (ADS)

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.

Cutting force measurement of electrical jigsaw by strain gauges

NASA Astrophysics Data System (ADS)

Kazup, L.; Varadine Szarka, A.

2016-11-01

This paper describes a measuring method based on strain gauges for accurate specification of electric jigsaw's cutting force. The goal of the measurement is to provide an overall perspective about generated forces in a jigsaw's gearbox during a cutting period. The lifetime of the tool is affected by these forces primarily. This analysis is part of the research and development project aiming to develop a special linear magnetic brake for realizing automatic lifetime tests of electric jigsaws or similar handheld tools. The accurate specification of cutting force facilitates to define realistic test cycles during the automatic lifetime test. The accuracy and precision resulted by the well described cutting force characteristic and the possibility of automation provide new dimension for lifetime testing of the handheld tools with alternating movement.

Open ended tubing cutters

NASA Technical Reports Server (NTRS)

Girala, A. S. (Inventor)

1981-01-01

A self clamping cutting tool which includes a handle attached to a C-shaped housing is described. Rotatably mounted within the housing is a C-shaped tool body carrying a set of clamping rolls, two support rolls, and an edged cutting roll (64). The support rolls are disposed to one side of the axis of a pipe and the cutting roll is disposed to the other side of a pipe axis so that these rolls contact a pipe at three circumferential points. Cutter advancing apparatus advance the cutting roll toward the support rollers. The support rolls and cutting roll are rotatable independently of the C-shaped housing. A one way ratchet mechanism disposed between the C-shaped housing and the C-shaped tool body permits operation by movement in one rotational direction about the pipe axis.

Study on electroplating technology of diamond tools for machining hard and brittle materials

NASA Astrophysics Data System (ADS)

Cui, Ying; Chen, Jian Hua; Sun, Li Peng; Wang, Yue

2016-10-01

With the development of the high speed cutting, the ultra-precision machining and ultrasonic vibration technique in processing hard and brittle material , the requirement of cutting tools is becoming higher and higher. As electroplated diamond tools have distinct advantages, such as high adaptability, high durability, long service life and good dimensional stability, the cutting tools are effective and extensive used in grinding hard and brittle materials. In this paper, the coating structure of electroplating diamond tool is described. The electroplating process flow is presented, and the influence of pretreatment on the machining quality is analyzed. Through the experimental research and summary, the reasonable formula of the electrolyte, the electroplating technologic parameters and the suitable sanding method were determined. Meanwhile, the drilling experiment on glass-ceramic shows that the electroplating process can effectively improve the cutting performance of diamond tools. It has laid a good foundation for further improving the quality and efficiency of the machining of hard and brittle materials.

Generating Fiducial Cuts for CLAS E5

NASA Astrophysics Data System (ADS)

Greenholt, Kristen

2005-04-01

The Thomas Jefferson National Accelerator Facility, located in Newport News, Virginia, is home to CLAS (CEBAF Large Acceptance Spectrometer) which observes the scattering effects of high-energy collisions of an electron beam and a proton or deuteron target. When data are collected with CLAS, one of the properties measured is the cross-section, which is proportional to the number of events and the efficiency and inversely proportional to the solid angle. The efficiency, or acceptance of the detector, is the ratio between the data one expects to observe in an ideal detector and the data that we actually measure with the real CLAS detector. In outlying azimuthal regions, the efficiency is less clearly understood, which leads to measurements which are reliant on the conditions of the detector itself. In order to analyze data which fall in regions of stable and well-understood efficiency, we generated fiducial cuts on CLAS. Our fiducial cuts fit a function to the edges of regions of stable efficiency. These cuts enable us to focus on the data with good acceptance/efficiency. When examining at the fiducial cuts, we required stable efficiency, or flat regions, a good visual fit, a minimized chi squared, and a reasonable behavior in each in azimuthal versus polar angle plane for each electron-momentum bin. Generating these fiducial cuts enables us to focus on data from CLAS where the efficiency of the detector is well understood.

Clinical Study of 3D Imaging and 3D Printing Technique for Patient-Specific Instrumentation in Total Knee Arthroplasty.

PubMed

Qiu, Bing; Liu, Fei; Tang, Bensen; Deng, Biyong; Liu, Fang; Zhu, Weimin; Zhen, Dong; Xue, Mingyuan; Zhang, Mingjiao

2017-10-01

Patient-specific instrumentation (PSI) was designed to improve the accuracy of preoperative planning and postoperative prosthesis positioning in total knee arthroplasty (TKA). However, better understanding needs to be achieved due to the subtle nature of the PSI systems. In this study, 3D printing technique based on the image data of computed tomography (CT) has been utilized for optimal controlling of the surgical parameters. Two groups of TKA cases have been randomly selected as PSI group and control group with no significant difference of age and sex ( p  > 0.05). The PSI group is treated with 3D printed cutting guides whereas the control group is treated with conventional instrumentation (CI). By evaluating the proximal osteotomy amount, distal osteotomy amount, valgus angle, external rotation angle, and tibial posterior slope angle of patients, it can be found that the preoperative quantitative assessment and intraoperative changes can be controlled with PSI whereas CI is relied on experience. In terms of postoperative parameters, such as hip-knee-ankle (HKA), frontal femoral component (FFC), frontal tibial component (FTC), and lateral tibial component (LTC) angles, there is a significant improvement in achieving the desired implant position ( p  < 0.05). Assigned from the morphology of patients' knees, the PSI represents the convergence of congruent designs with current personalized treatment tools. The PSI can achieve less extremity alignment and greater accuracy of prosthesis implantation compared against control method, which indicates potential for optimal HKA, FFC, and FTC angles. Thieme Medical Publishers 333 Seventh Avenue, New York, NY 10001, USA.

Modeling of tool path for the CNC sheet cutting machines

NASA Astrophysics Data System (ADS)

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.

Detection of Cutting Tool Wear using Statistical Analysis and Regression Model

NASA Astrophysics Data System (ADS)

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.

High speed turning of compacted graphite iron using controlled modulation

NASA Astrophysics Data System (ADS)

Stalbaum, Tyler Paul

Compacted graphite iron (CGI) is a material which emerged as a candidate material to replace cast iron (CI) in the automotive industry for engine block castings. Its thermal and mechanical properties allow the CGI-based engines to operate at higher cylinder pressures and temperatures than CI-based engines, allowing for lower fuel emissions and increased fuel economy. However, these same properties together with the thermomechanical wear mode in the CGI-CBN system result in poor machinability and inhibit CGI from seeing wide spread use in the automotive industry. In industry, machining of CGI is done only at low speeds, less than V = 200 m/min, to avoid encountering rapid wear of the cutting tools during cutting. Studies have suggested intermittent cutting operations such as milling suffer less severe tool wear than continuous cutting. Furthermore, evidence that a hard sulfide layer which forms over the cutting edge in machining CI at high speeds is absent during machining CGI is a major factor in the difference in machinability of these material systems. The present study addresses both of these issues by modification to the conventional machining process to allow intermittent continuous cutting. The application of controlled modulation superimposed onto the cutting process -- modulation-assisted machining (MAM) -- is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining CGI at high machining speeds (> 500 m/min). The tool life is at least 20 times greater than found in conventional machining of CGI. This significant reduction in wear is a consequence of reduction in the severity of the tool-work contact conditions with MAM. The propensity for thermochemical wear of CBN is thus reduced. It is found that higher cutting speed (> 700 m/min) leads to lower tool wear with MAM. The MAM configuration employing feed-direction modulation appears feasible for implementation at high speeds and offers a solution to this challenging class of industrial machining applications. This study's approach is by series of high speed turning tests of CGI with CBN tools, comparing conventional machining to MAM for similar parameters otherwise, by tool wear measurements and machinability observations.

Efficient extraction of high power THz radiation generated by an ultra-relativistic electron beam in a dielectric loaded waveguide

DOE PAGES

Antipov, S.; Baryshev, S. V.; Kostin, R.; ...

2016-10-03

Here, we have measured an intense THz radiation produced by a sub-picosecond, relativistic electron bunch in a dielectric loaded waveguide. For efficient THz pulse extraction, the dielectric loaded waveguide end was cut at an angle. For an appropriate choice of angle cut, such antenna converts the TM 01 mode excited in the waveguide into a free-space fundamental Gauss-Hermite mode propagating at an angle with respect to the electron beam trajectory. Simulations show that more than 95% of energy can be extracted using such a simple approach. More than 40 oscillations of about 170 ps long 0.48 THz signal were explicitlymore » measured with an interferometer and 10 μJ of energy per pulse, as determined with a calorimetric energy meter, were delivered outside the electron beamline to an area suitable for THz experiments.« less

Laser beam machining of polycrystalline diamond for cutting tool manufacturing

NASA Astrophysics Data System (ADS)

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.

Documenting Differences between Early Stone Age Flake Production Systems: An Experimental Model and Archaeological Verification.

PubMed

Presnyakova, Darya; Archer, Will; Braun, David R; Flear, Wesley

2015-01-01

This study investigates morphological differences between flakes produced via "core and flake" technologies and those resulting from bifacial shaping strategies. We investigate systematic variation between two technological groups of flakes using experimentally produced assemblages, and then apply the experimental model to the Cutting 10 Mid -Pleistocene archaeological collection from Elandsfontein, South Africa. We argue that a specific set of independent variables--and their interactions--including external platform angle, platform depth, measures of thickness variance and flake curvature should distinguish between these two technological groups. The role of these variables in technological group separation was further investigated using the Generalized Linear Model as well as Linear Discriminant Analysis. The Discriminant model was used to classify archaeological flakes from the Cutting 10 locality in terms of their probability of association, within either experimentally developed technological group. The results indicate that the selected independent variables play a central role in separating core and flake from bifacial technologies. Thickness evenness and curvature had the greatest effect sizes in both the Generalized Linear and Discriminant models. Interestingly the interaction between thickness evenness and platform depth was significant and played an important role in influencing technological group membership. The identified interaction emphasizes the complexity in attempting to distinguish flake production strategies based on flake morphological attributes. The results of the discriminant function analysis demonstrate that the majority of flakes at the Cutting 10 locality were not associated with the production of the numerous Large Cutting Tools found at the site, which corresponds with previous suggestions regarding technological behaviors reflected in this assemblage.

Documenting Differences between Early Stone Age Flake Production Systems: An Experimental Model and Archaeological Verification

PubMed Central

Presnyakova, Darya; Archer, Will; Braun, David R.; Flear, Wesley

2015-01-01

This study investigates morphological differences between flakes produced via “core and flake” technologies and those resulting from bifacial shaping strategies. We investigate systematic variation between two technological groups of flakes using experimentally produced assemblages, and then apply the experimental model to the Cutting 10 Mid -Pleistocene archaeological collection from Elandsfontein, South Africa. We argue that a specific set of independent variables—and their interactions—including external platform angle, platform depth, measures of thickness variance and flake curvature should distinguish between these two technological groups. The role of these variables in technological group separation was further investigated using the Generalized Linear Model as well as Linear Discriminant Analysis. The Discriminant model was used to classify archaeological flakes from the Cutting 10 locality in terms of their probability of association, within either experimentally developed technological group. The results indicate that the selected independent variables play a central role in separating core and flake from bifacial technologies. Thickness evenness and curvature had the greatest effect sizes in both the Generalized Linear and Discriminant models. Interestingly the interaction between thickness evenness and platform depth was significant and played an important role in influencing technological group membership. The identified interaction emphasizes the complexity in attempting to distinguish flake production strategies based on flake morphological attributes. The results of the discriminant function analysis demonstrate that the majority of flakes at the Cutting 10 locality were not associated with the production of the numerous Large Cutting Tools found at the site, which corresponds with previous suggestions regarding technological behaviors reflected in this assemblage. PMID:26111251

Modeling and analysis of the chip formation and transient cutting force during elliptical vibration cutting process

NASA Astrophysics Data System (ADS)

Lin, Jieqiong; Guan, Liang; Lu, Mingming; Han, Jinguo; Kan, Yudi

2017-12-01

In traditional diamond cutting, the cutting force is usually large and it will affect tool life and machining quality. Elliptical vibration cutting (EVC) as one of the ultra-precision machining technologies has a lot of advantages, such as reduces cutting force, extend tool life and so on. It's difficult to predict the transient cutting force of EVC due to its unique elliptical motion trajectory. Study on chip formation will helpfully to predict cutting force. The geometric feature of chip has important effects on cutting force, however, few scholars have studied the chip formation. In order to investigate the time-varying cutting force of EVC, the geometric feature model of chip is established based on analysis of chip formation, and the effects of cutting parameters on the geometric feature of chip are analyzed. To predict transient force quickly and effectively, the geometric feature of chip is introduced into the cutting force model. The calculated results show that the error between the predicted cutting force in this paper and that in the literature is less than 2%, which proves its feasibility.

Energy Scaling of Nanosecond Gain-Switched Cr2+:ZnSe Lasers

DTIC Science & Technology

2011-01-01

outcoupler or absorption from the lightly-doped active ions. Additionally, the edges of the crystals are cut at the Brewster angle , which raises...experiments we used Brewster cut Cr:ZnSe gain elements with a chromium concentration of 8x1018 cm-3. Under Cr:Tm:Ho:YAG pumping, the first Cr:ZnSe laser...the energy scaling of nanosecond gain-switched Cr:ZnSe lasers is optimization of the gain medium. In this study we used Brewster cut Cr:ZnSe gain

Influence of the Regime of Electropulsing-Assisted Machining on the Plastic Deformation of the Layer Being Cut.

PubMed

Hameed, Saqib; González Rojas, Hernán A; Perat Benavides, José I; Nápoles Alberro, Amelia; Sánchez Egea, Antonio J

2018-05-25

In this article, the influence of electropulsing on the machinability of steel S235 and aluminium 6060 has been studied during conventional and electropulsing-assisted turning processes. The machinability indices such as chip compression ratio ξ , shear plane angle ϕ and specific cutting energy (SCE) are investigated by using different cutting parameters such as cutting speed, cutting feed and depth of cut during electrically-assisted turning process. The results and analysis of this work indicated that the electrically-assisted turning process improves the machinability of steel S235, whereas the machinability of aluminium 6060 gets worse. Finally, due to electropluses (EPs), the chip compression ratio ξ increases with the increase in cutting speed during turning of aluminium 6060 and the SCE decreases during turning of steel S235.

Investigation of the shape transferability of nanoscale multi-tip diamond tools in the diamond turning of nanostructures

NASA Astrophysics Data System (ADS)

Luo, Xichun; Tong, Zhen; Liang, Yingchun

2014-12-01

In this article, the shape transferability of using nanoscale multi-tip diamond tools in the diamond turning for scale-up manufacturing of nanostructures has been demonstrated. Atomistic multi-tip diamond tool models were built with different tool geometries in terms of the difference in the tip cross-sectional shape, tip angle, and the feature of tool tip configuration, to determine their effect on the applied forces and the machined nano-groove geometries. The quality of machined nanostructures was characterized by the thickness of the deformed layers and the dimensional accuracy achieved. Simulation results show that diamond turning using nanoscale multi-tip tools offers tremendous shape transferability in machining nanostructures. Both periodic and non-periodic nano-grooves with different cross-sectional shapes can be successfully fabricated using the multi-tip tools. A hypothesis of minimum designed ratio of tool tip distance to tip base width (L/Wf) of the nanoscale multi-tip diamond tool for the high precision machining of nanostructures was proposed based on the analytical study of the quality of the nanostructures fabricated using different types of the multi-tip tools. Nanometric cutting trials using nanoscale multi-tip diamond tools (different in L/Wf) fabricated by focused ion beam (FIB) were then conducted to verify the hypothesis. The investigations done in this work imply the potential of using the nanoscale multi-tip diamond tool for the deterministic fabrication of period and non-periodic nanostructures, which opens up the feasibility of using the process as a versatile manufacturing technique in nanotechnology.

Experimental investigation on hard turning of AISI 4340 steel using cemented coated carbide insert

NASA Astrophysics Data System (ADS)

Pradeep Kumar, J.; Kishore, K. P.; Ranjith Kumar, M.; Saran Karthick, K. R.; Vishnu Gowtham, S.

2018-02-01

Hard turning is a developing technology that offers many potential advantages compared to grinding, which remains the standard finishing process for critical hardened surfaces. In this work, an attempt has been made to experimentally investigate hard turning of AISI 4340 steel under wet and dry condition using cemented coated carbide insert. Hardness of the workpiece material is tested using Brinell and Rockwell hardness testers. CNC LATHE and cemented coated carbide inserts of designation CNMG 120408 are used for conducting experimental trials. Significant cutting parameters like cutting speed, feed rate and depth of cut are considered as controllable input parameters and surface roughness (Ra), tool wear are considered as output response parameters. Design of experiments is carried out with the help of Taguchi’s L9 orthogonal array. Results of response parameters like surface roughness and tool wear under wet and dry condition are analysed. It is found that surface roughness and tool wear are higher under dry machining condition when compared to wet machining condition. Feed rate significantly influences the surface roughness followed by cutting speed. Depth of cut significantly influences the tool wear followed by cutting speed.

Impact of high-pressure coolant supply on chip formation in milling

NASA Astrophysics Data System (ADS)

Klocke, F.; Döbbeler, B.; Lakner, T.

2017-10-01

Machining of titanium alloys is considered as difficult, because of their high temperature strength, low thermal conductivity and low E-modulus, which contributes to high mechanical loads and high temperatures in the contact zone between tool and workpiece. The generated heat in the cutting zone can be dissipated only in a low extent. When cutting steel materials, up to 75% of the process heat is transported away by the chips, contrary to only 25% when machining titanium alloys. As a result, the cutting tool heats up, which leads to high tool wear. Therefore, machining of titanium alloys is only possible with relatively low cutting speeds. This leads to low levels of productivity for milling processes with titanium alloys. One way to increase productivity is to use more cutting edges in tools with the same diameter. However, the limiting factor of adding more cutting edges to a milling tool is the minimum size of the chip spaces, which are sufficient for a stable chip evacuation. This paper presents experimental results on the chip formation and chip size influenced by high-pressure coolant supply, which can lead to smaller chips and to smaller sizes of the chip spaces, respectively. Both influences, the pressure of the supplied coolant and the volumetric flow rate were individually examined. Alpha-beta annealed titanium TiAl6V4 was examined in relation to the reference material quenched and tempered steel 42CrMo4+QT (AISI 4140+QT). The work shows that with proper chip control due to high-pressure coolant supply in milling, the number of cutting edges on the same diameter tool can be increased, which leads to improved productivity.

Photon Doppler velocimetry measurements of transverse surface velocities

NASA Astrophysics Data System (ADS)

Johnson, C. R.; LaJeunesse, J. W.; Sable, P. A.; Dawson, A.; Hatzenbihler, A.; Borg, J. P.

2018-06-01

The goal of this work was to develop a technique for making transverse surface velocity measures utilizing Photon Doppler Velocimetry (PDV). Such a task is achieved by transmitting light and collecting Doppler-shifted light at an angle relative to the normal axis, where measured velocities are representative of a component of the transverse velocity. Because surface characteristics have an intrinsic effect on light scatter, different surface preparations were explored to direct reflectivity, including diffusion by means of sandpapering, or increasing retroreflectivity by coating with microspheres, milling v-cuts, and electrochemically etching grooves. Testing of these surface preparations was performed using an experiment featuring a 30 mm diameter aluminum disk rotating at 6000 or 6600 RPM. A single PDV collimator was positioned along the rotational axis of the disk at various angles, resolving the apparent transverse velocity. To characterize surface preparations, light return and velocities were recorded as a function of probe angle ranging from 0° to 51° from the surface normal for each preparation. Polished and electrochemically etched surfaces did not provide enough reflected light to resolve a beat frequency; however, sandpapered surfaces, retroreflective microspheres, and milled v-cuts provided adequate reflected light for incidence angles up to 51°. Applications of the surface preparations were then studied in gas gun experiments. Retroreflective microspheres were studied in a planar impact experiment, and milled v-cuts were studied in an oblique impact experiment. A normal and transverse profile of particle velocity was resolved in the oblique impact experiment.

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

NASA Astrophysics Data System (ADS)

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.

Tube cutter tool and method of use for coupon removal

DOEpatents

Nachbar, H.D.; Etten, M.P. Jr.; Kurowski, P.A.

1997-05-06

A tube cutter tool is insertable into a tube for cutting a coupon from a damaged site on the exterior of the tube. Prior to using the tool, the damaged site is first located from the interior of the tube using a multi-coil pancake eddy current test probe. The damaged site is then marked. A fiber optic probe is used to monitor the subsequent cutting procedure which is performed using a hole saw mounted on the tube cutter tool. Prior to completion of the cutting procedure, a drill in the center of the hole saw is drilled into the coupon to hold it in place. 4 figs.

Tube cutter tool and method of use for coupon removal

DOEpatents

Nachbar, Henry D.; Etten, Jr., Marvin P.; Kurowski, Paul A.

1997-01-01

A tube cutter tool is insertable into a tube for cutting a coupon from a damaged site on the exterior of the tube. Prior to using the tool, the damaged site is first located from the interior of the tube using a multi-coil pancake eddy current test probe. The damaged site is then marked. A fiber optic probe is used to monitor the subsequent cutting procedure which is performed using a hole saw mounted on the tube cutter tool. Prior to completion of the cutting procedure, a drill in the center of the hole saw is drilled into the coupon to hold it in place.

Orthogonal cutting of laser beam melted parts

NASA Astrophysics Data System (ADS)

Götze, Elisa; Zanger, Frederik; Schulze, Volker

2018-05-01

The finishing process of parts manufactured by laser beam melting is of high concern due to the lack of surface accuracy. Therefore, the focus of this work lies on the influence of the build-up direction of the parts and their effect on the finishing process. The orthogonal cutting reveals findings in the fields of chip formation, involved forces and temperatures appearing during machining. In the investigations, the cutting depth was varied between 0.05 and 0.15 mm representing a finishing process and the cutting velocity ranges from 30 to 200 m/min depending on the material. The experiments contain the materials stainless steel (AISI 316L), titanium (Ti6Al4V) and nickel-base alloy (IN718). The two materials named latter are of high interest in the aerospace sector and at the same time titanium is used in the medical field due to its biocompatibility. For the materials IN718 and Ti6Al4V a negative rake angle of -7.5° and for stainless steel a rake angle of 12.5° are chosen for the cutting experiments. The results provide the base for processing strategies. Therefore, the specimens were solely laser beam melted without post-processing like heat treatment. The evaluation of the experiments shows that an increase in cutting speed has different effects depending on the material. For stainless steel the measured forces regarding the machining direction to the layers approach the same values. In contrast, the influence of the layers regarding the forces appearing during orthogonal cutting of the materials IN718 and Ti6Al4V differ for lower cutting speeds.

Green Turning of FCD 700 Ductile Cast Iron Using Coated Carbide Tool

NASA Astrophysics Data System (ADS)

Rodzi, Mohd Nor Azmi Mohd; Ghani, Jaharah A.; Eghawail, A. M.; Othman, Kamal; Rahman, Mohd. Nizam Ab.; Haron, Che Hassan Che

2010-10-01

This paper presents the performance of carbide coated cutting insert in turning FCD700 ductile cast iron in various dry machining conditions (without air, using air and chilled air). The turning parameters studied were, cutting speed of 120 m/min., feed rate of 0.15 mm/rev-0.4 mm/rev, and depth of cut of 0.6 mm-1.0 mm. The results show that the tool life was significantly controlled by the type of air coolant used, whereas the cutting force and surface roughness were not influenced by these coolants. Chilled air was found to be significantly improved the tool life by about 30% and 40% respectively when compared with normal air and without air conditions. The wear mechanism was predominantly controlled by the flank and crater wears on the flank and rake faces respectively. Due to the low cutting speed used in the experiment, both flank and crater wears were uniformly formed along the cutting edge and no catastrophic failure was observed under the scanning electron microscope (SEM).

Smart tool holder

DOEpatents

Day, Robert Dean; Foreman, Larry R.; Hatch, Douglas J.; Meadows, Mark S.

1998-01-01

There is provided an apparatus for machining surfaces to accuracies within the nanometer range by use of electrical current flow through the contact of the cutting tool with the workpiece as a feedback signal to control depth of cut.

Orbital Injection of the SEDSAT Satellite: Tethered Systems Dynamics and Flight Data Analysis

NASA Technical Reports Server (NTRS)

Lorenzini, Enrico C.; Gullahorn, Gordon E.; Cosmo, Mario L.; Ruiz, Manuel; Pelaez, Jesus

1996-01-01

This report deals with the following topics which are all related to the orbital injection of the SEDSAT satellite: Dynamics and Stability of Tether Oscillations after the First Cut. The dynamics of the tether after the first cut (i.e., without the Shuttle attached to it) is investigated. The tether oscillations with the free end are analyzed in order to assess the stability of the rectilinear configuration in between the two tether cuts; analysis of Unstable Modes. The unstable modes that appear for high libration angles are further investigated in order to determine their occurrences and the possible transition from bound librations to rotations; Orbital Release Strategies for SEDSAT. A parametric analysis of the orbital decay rate of the SEDSAT satellite after the two tether cuts has been carried out as a function of the following free parameters: libration amplitude at the end of deployment, deviation angle from LV at the first cut, and orbital anomaly at the second cut. The values of these parameters that provide a minimum orbital decay rate of the satellite (after the two cuts) have been computed; and Dynamics and Control of SEDSAT. The deployment control law has been modified to cope with the new ejection velocity of the satellite from the Shuttle cargo bay. New reference profiles have been derived as well as new control parameters. Timing errors at the satellite release as a function of the variations of the initial conditions and the tension model parameters have been estimated for the modified control law.

Sidestep and crossover lower limb kinematics during a prolonged sport-like agility test.

PubMed

Potter, Danielle; Reidinger, Kellie; Szymialowicz, Rebecca; Martin, Thomas; Dione, Donald; Feinn, Richard; Wallace, David; Garbalosa, Juan C

2014-10-01

Non-contact anterior cruciate ligament (ACL) injuries in athletes occur more often towards the end of athletic competitions. However, the exact mechanisms of how prolonged activity increases the risk for ACL injuries are not clear. To determine the effect of prolonged activity on the hip and knee kinematics observed during self-selected cutting maneuvers performed in a timed agility test. Nineteen female Division I collegiate soccer players completed a self-selected cutting agility test until they were unable to meet a set performance time (one standard deviation of the average baseline trial). Using the 3D dimensional coordinate data the cut type was identified by the principle investigators. The 3D hip and knee angles at 32ms post heel strike were analyzed using a two-factor, linear mixed model to assess the effect of prolonged activity and cut type on the recorded mean hip and knee angles. Athletes performed either sidestep or crossover cuts. An effect of cut type and prolonged activity was seen at the hip and knee. During the prolonged activity trials, the knee was relatively more adducted and both the hip and knee were less flexed than during the baseline trials regardless of cut type. Regardless of activity status, during sidestep cuts, the hip was more internally rotated and abducted, and less flexed than during crossover cuts while the knee was more abducted and less flexed during the sidestep than crossover cuts. During a sport-like agility test, prolonged activity appears to predispose the athlete to position their knee in a more extended and abducted posture and their hip in a more extended posture. This position has been suggested to place stress on the ACL and potentially increase the risk for injury. Clinicians may want to consider the effects of prolonged activity on biomechanical risk factors for sustaining ACL injuries in the design of intervention strategies to prevent ACL injuries. Level 4.

On-line Monitoring for Cutting Tool Wear Condition Based on the Parameters

NASA Astrophysics Data System (ADS)

Han, Fenghua; Xie, Feng

2017-07-01

In the process of cutting tools, it is very important to monitor the working state of the tools. On the basis of acceleration signal acquisition under the constant speed, time domain and frequency domain analysis of relevant indicators monitor the online of tool wear condition. The analysis results show that the method can effectively judge the tool wear condition in the process of machining. It has certain application value.

Effect of cutting edge radius on surface roughness in diamond tool turning of transparent MgAl2O4 spinel ceramic

NASA Astrophysics Data System (ADS)

Yue, Xiaobin; Xu, Min; Du, Wenhao; Chu, Chong

2017-09-01

Transparent magnesium aluminate spinel (MgAl2O4) ceramic is one of an important optical materials. However, due to its pronounced hardness and brittleness, the optical machining of this material is very difficult. Diamond turning has advantages over the grinding process in flexibility and material removal rate. However, there is a lack of research that could support the use of diamond turning technology in the machining of MgAl2O4 spinel ceramic. Using brittle-ductile transition theory of brittle material machining, this work provides critical information that may help to realize ductile-regime turning of MgAl2O4 spinel ceramic. A characterization method of determination the cutting edge radius is introduced here. Suitable diamond tools were measured for sharpness and then chosen from a large number of candidate tools. The influence of rounded cutting edges on surface roughness of the MgAl2O4 spinel ceramic is also investigated. These results indicate that surface quality of MgAl2O4 spinel is relate to the radius of diamond tool's cutting edge, cutting speed, and feed rate. Sharp diamond tools (small radius of cutting edge) facilitated ductile-regime turning of MgAl2O4 spinel and shows great potential to reduce surface roughness and produce smoother final surface.

Tailoring polarization of electromagnetically induced transparency based on non-centrosymmetric metasurfaces

NASA Astrophysics Data System (ADS)

Li, Hai-ming; Xue, Feng

2017-09-01

In this manuscript, tailoring polarization of analogy of electromagnetically induced transparency (EIT-like) based on non-centrosymmetric metasurfaces has been numerically and experimentally demonstrated. The EIT-like metamaterial is composed of a rectangle ring and two cut wires. The rectangle ring and the cut wire are chosen as the bright mode and the quasi-dark mode, respectively. Under the incident electromagnetic wave excitation, a polarization insensitive EIT-like transmission window can be observed at specific polarization angles. Within the transmission window, the phase steeply changes, which leads to the large group index. Tailoring polarization of EIT-like metamaterial with large group index at specific polarization angles may have potential application in slow light devices.

Experimental study of directionally solidified ferromagnetic shape memory alloy under multi-field coupling

NASA Astrophysics Data System (ADS)

Zhu, Yuping; Chen, Tao; Teng, Yao; Liu, Bingfei; Xue, Lijun

2016-11-01

Directionally solidified, polycrystalline Ni-Mn-Ga is studied in this paper. The polycrystalline Ni-Mn-Ga samples were cut at different angles to solidification direction. The magnetic field induced strain under constant stress and the temperature-induced strain under constant magnetic field during the loading-unloading cycle were measured. The experimental results show that the mechanical behavior during the loading-unloading cycle of the material is nonlinear and anisotropic. Based on the experimental results, the effects of multi-field coupling factors, such as stress, magnetic field, temperature and cutting angle on the mechanical behaviors were analyzed. Some useful conclusions were obtained, which will provide guidance for practical applications.

On-line Tool Wear Detection on DCMT070204 Carbide Tool Tip Based on Noise Cutting Audio Signal using Artificial Neural Network

NASA Astrophysics Data System (ADS)

Prasetyo, T.; Amar, S.; Arendra, A.; Zam Zami, M. K.

2018-01-01

This study develops an on-line detection system to predict the wear of DCMT070204 tool tip during the cutting process of the workpiece. The machine used in this research is CNC ProTurn 9000 to cut ST42 steel cylinder. The audio signal has been captured using the microphone placed in the tool post and recorded in Matlab. The signal is recorded at the sampling rate of 44.1 kHz, and the sampling size of 1024. The recorded signal is 110 data derived from the audio signal while cutting using a normal chisel and a worn chisel. And then perform signal feature extraction in the frequency domain using Fast Fourier Transform. Feature selection is done based on correlation analysis. And tool wear classification was performed using artificial neural networks with 33 input features selected. This artificial neural network is trained with back propagation method. Classification performance testing yields an accuracy of 74%.

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

PubMed

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.

Cutting Symmetrical Recesses In Soft Ceramic Tiles

NASA Technical Reports Server (NTRS)

Nesotas, Tony C.; Tyler, Brent

1989-01-01

Simple tool cuts hemispherical recesses in soft ceramic tiles. Designed to expose wires of thermocouples embedded in tiles without damaging leads. Creates neat, precise holes around wires. End mill includes axial hole to accommodate thermocouple wires embedded in material to be cut. Wires pass into hole without being bent or broken. Dimensions in inches. Used in place of such tools as dental picks, tweezers, spatulas, and putty knives.

A Performance Comparison Study of Uncoated and TiAlN Coated Carbide End Mill on Machining of the Al-35Zn Alloy

NASA Astrophysics Data System (ADS)

Bayraktar, S.; Hekimoglu, A. P.; Turgut, Y.; Haciosmanoglu, M.

2018-01-01

In this study, Al-35Zn alloy was produced by permanent mold casting. To investigate the cutting performance of uncoated and TiAlN coated carbide end mills on this alloy, a series of tests were carried out in the CNC vertical machining center at a constant cutting speed, feed rate and depth of cut. The results obtained from the tests showed that uncoated carbide end mill have lower cutting force and surface roughness than TiAlN coated carbide end mill. These observations are discussed in terms of the alloys properties, cutting tool surfaces, and friction and wear behavior between the cutting tool and the material.

Smart tool holder

DOEpatents

Day, R.D.; Foreman, L.R.; Hatch, D.J.; Meadows, M.S.

1998-09-08

There is provided an apparatus for machining surfaces to accuracies within the nanometer range by use of electrical current flow through the contact of the cutting tool with the workpiece as a feedback signal to control depth of cut. 3 figs.

Study of heat generation and cutting force according to minimization of grain size (500 nm to 180 nm) of WC ball endmill using FEM

NASA Astrophysics Data System (ADS)

Byeon, J. H.; Ahmed, F.; Ko, T. J.; lee, D. K.; Kim, J. S.

2018-03-01

As the industry develops, miniaturization and refinement of products are important issues. Precise machining is required for cutting, which is a typical method of machining a product. The factor determining the workability of the cutting process is the material of the tool. Tool materials include carbon tool steel, alloy tool steel, high-speed steel, cemented carbide, and ceramics. In the case of a carbide material, the smaller the particle size, the better the mechanical properties with higher hardness, strength and toughness. The specific heat, density, and thermal diffusivity are also changed through finer particle size of the material. In this study, finite element analysis was performed to investigate the change of heat generation and cutting power depending on the physical properties (specific heat, density, thermal diffusivity) of tool material. The thermal conductivity coefficient was obtained by measuring the thermal diffusivity, specific heat, and density of the material (180 nm) in which the particle size was finer and the particle material (0.05 μm) in the conventional size. The coefficient of thermal conductivity was calculated as 61.33 for 180nm class material and 46.13 for 0.05μm class material. As a result of finite element analysis using this value, the average temperature of exothermic heat of micronized particle material (180nm) was 532.75 °C and the temperature of existing material (0.05μm) was 572.75 °C. Cutting power was also compared but not significant. Therefore, if the thermal conductivity is increased through particle refinement, the surface power can be improved and the tool life can be prolonged by lowering the temperature generated in the tool during machining without giving a great influence to the cutting power.

Application of carbide cutting tools with nano-structured multilayer composite coatings for turning austenitic steels, type 16Cr-10NI

NASA Astrophysics Data System (ADS)

Vereschaka, Alexey; Migranov, Mars; Oganyan, Gaik; Sotova, Catherine S.; Batako, Andre

2018-03-01

This paper addresses the challenges of increasing the efficiency of the machining of austenitic stainless steels AISI 321 and S31600 by application of cutting tools with multilayer composite nano-structured coatings. The main mechanical properties and internal structures of the coatings under study (hardness, adhesion strength in the "coating-substrate" system) were investigated, and their chemical compositions were analyzed. The conducted research of tool life and nature of wear of carbide tools with the investigated coatings during turning of the above mentioned steels showed that the application of those coatings increases the tool life by up to 2.5 times. In addition, the use of a cutting tool with coatings allows machining at higher cutting speeds. It was also found that the use of a tool with multilayer composite nano-structured coating (Zr,Nb)N-(Zr,Al,Nb)N ensures better results compared with not only monolithic coating TiN, but also with nano-structured coatings Ti-TiN-(Ti,Al)N and (Zr,Nb)N-(Cr,Zr,Nb,Al)N. The mechanism of failure of the coatings under study was also investigated.

Experimental Investigation of Minimum Quantity Lubrication in Meso-scale Milling with Varying Tool Diameter

NASA Astrophysics Data System (ADS)

Yusof, M. Q. M.; Harun, H. N. S. B.; Bahar, R.

2018-01-01

Minimum quantity lubrication (MQL) is a method that uses a very small amount of liquid to reduce friction between cutting tool and work piece during machining. The implementation of MQL machining has become a viable alternative to flood cooling machining and dry machining. The overall performance has been evaluated during meso-scale milling of mild steel using different diameter milling cutters. Experiments have been conducted under two different lubrication condition: dry and MQL with variable cutting parameters. The tool wear and its surface roughness, machined surfaces microstructure and surface roughness were observed for both conditions. It was found from the results that MQL produced better results compared to dry machining. The 0.5 mm tool has been selected as the most optimum tool diameter to be used with the lowest surface roughness as well as the least flank wear generation. For the workpiece, it was observed that the cutting temperature possesses crucial effect on the microstructure and the surface roughness of the machined surface and bigger diameter tool actually resulted in higher surface roughness. The poor conductivity of the cutting tool may be one of reasons behind.

Rotary fast tool servo system and methods

DOEpatents

Montesanti, Richard C.; Trumper, David L.

2007-10-02

A high bandwidth rotary fast tool servo provides tool motion in a direction nominally parallel to the surface-normal of a workpiece at the point of contact between the cutting tool and workpiece. Three or more flexure blades having all ends fixed are used to form an axis of rotation for a swing arm that carries a cutting tool at a set radius from the axis of rotation. An actuator rotates a swing arm assembly such that a cutting tool is moved in and away from the lathe-mounted, rotating workpiece in a rapid and controlled manner in order to machine the workpiece. A pair of position sensors provides rotation and position information for a swing arm to a control system. A control system commands and coordinates motion of the fast tool servo with the motion of a spindle, rotating table, cross-feed slide, and in-feed slide of a precision lathe.

Rotary fast tool servo system and methods

DOEpatents

Montesanti, Richard C [Cambridge, MA; Trumper, David L [Plaistow, NH; Kirtley, Jr., James L.

2009-08-18

A high bandwidth rotary fast tool servo provides tool motion in a direction nominally parallel to the surface-normal of a workpiece at the point of contact between the cutting tool and workpiece. Three or more flexure blades having all ends fixed are used to form an axis of rotation for a swing arm that carries a cutting tool at a set radius from the axis of rotation. An actuator rotates a swing arm assembly such that a cutting tool is moved in and away from the lathe-mounted, rotating workpiece in a rapid and controlled manner in order to machine the workpiece. One or more position sensors provides rotation and position information for a swing arm to a control system. A control system commands and coordinates motion of the fast tool servo with the motion of a spindle, rotating table, cross-feed slide, and in-feed slide of a precision lathe.

An experimental study of cutting performances in machining of nimonic super alloy GH2312

NASA Astrophysics Data System (ADS)

Du, Jinfu; Wang, Xi; Xu, Min; Mao, Jin; Zhao, Xinglong

2018-05-01

Nimonic super alloy are extensively used in the aerospace industry because of its unique properties. As they are quite costly and difficult to machine, the machining tool is easy to get worn. To solve the problem, an experiment was carried out on a numerical control slitting automatic lathe to analysis the tool wearing conditions and parts' surface quality of nimonic super alloy GH2132 under different cutters. The selection of suitable cutter, reasonable cutting data and cutting speed is obtained and some conclusions are made. The excellent coating tool, compared with other hard alloy cutters, along with suitable cutting data will greatly improve the production efficiency and product quality, it can completely meet the process of nimonic super alloy GH2312.

An Experimental Study of Cutting Performances of Worn Picks

NASA Astrophysics Data System (ADS)

Dogruoz, Cihan; Bolukbasi, Naci; Rostami, Jamal; Acar, Cemil

2016-01-01

The best means to assess rock cuttability and efficiency of cutting process for using mechanical excavation is specific energy (SE), measured in full-scale rock cutting test. This is especially true for the application of roadheaders, often fitted with drag-type cutting tools. Radial picks or drag bits are changed during the operation as they reach a certain amount of wear and become blunt. In this study, full-scale cutting tests in different sedimentary rock types with bits having various degree of wear were used to evaluate the influence of bit wear on cutting forces and specific energy. The relationship between the amount of wear as represented by the size of the wear flats at the tip of the bit, and cutting forces as well as specific energy was examined. The influence of various rock properties such as mineral content, uniaxial compressive strength, tensile strength, indentation index, shore hardness, Schmidt hammer hardness, and density with required SE of cutting using different levels of tool wear was also studied. The preliminary analysis of the data shows that the mean cutting forces increase 2-3 times and SE by 4-5 times when cutting with 4 mm wear flat as compared to cutting with new or sharp wedge shape bits. The grain size distribution of the muck for cutting different rock types and different level of bit wear was analyzed and discussed. The best fit prediction models for SE based on statistical analysis of laboratory test results are introduced. The model can be used for estimating the performance of mechanical excavators using radial tools, especially roadheaders, continuous miners and longwall drum shearers.

Finite Element Simulation of Machining of Ti6Al4V Alloy

NASA Astrophysics Data System (ADS)

Rizzuti, S.; Umbrello, D.

2011-05-01

Titanium and its alloys are an important class of materials, especially for aerospace applications, due to their excellent combination of strength and fracture toughness as well as low density. However, these materials are generally regarded as difficult to machine because of their low thermal conductivity and high chemical reactivity with cutting tool materials. Moreover, the low thermal conductivity of Titanium inhibits dissipation of heat within the workpiece causing an higher temperature at the cutting edge and generating for higher cutting speed a rapid chipping at the cutting edge which leads to catastrophic failure. In addition, chip morphology significantly influences the thermo-mechanical behaviour at the workpiece/tool interface, which also affects the tool life. In this paper a finite element analysis of machining of TiAl6V4 is presented. In particular, cutting force, chip morphology and segmentation are taken into account due to their predominant roles to determine machinability and tool wear during the machining of these alloys. Results in terms of residual stresses are also presented. Moreover, the numerical results are compared with experimental ones.

Far-field noise and internal modes from a ducted propeller at simulated aircraft takeoff conditions

NASA Astrophysics Data System (ADS)

Woodward, Richard P.; Bock, Lawrence A.; Heidelberg, Laurence J.; Hall, David G.

1992-01-01

The ducted propeller offers structural and acoustic benefits typical of conventional turbofan engines while retaining much of the aeroacoustic benefits of the unducted propeller. A model Advanced Ducted Propeller (ADP) was tested in the NASA Lewis Low-Speed Anechoic Wind Tunnel at a simulated takeoff velocity of Mach 0.2. The ADP model was designed and manufactured by the Pratt and Whitney Division of United Technologies. The 16-blade rotor ADP was tested with 22- and 40-vane stators to achieve cut-on and cut-off criterion with respect to propagation of the fundamental rotor-stator interaction tone. Additional test parameters included three inlet lengths, three nozzle sizes, two spinner configurations, and two rotor rub strip configurations. The model was tested over a range of rotor blade setting angles and propeller axis angles-of-attack. Acoustic data were taken with a sideline translating microphone probe and with a unique inlet microphone probe which identified inlet rotating acoustic modes. The beneficial acoustic effects of cut-off were clearly demonstrated. A 5 dB fundamental tone reduction was associated with the long inlet and 40-vane sector, which may relate to inlet propeller axis angle-of-attack at rotor speeds of at least 96 percent design.

Far-field noise and internal modes from a ducted propeller at simulated aircraft takeoff conditions

NASA Astrophysics Data System (ADS)

Woodward, Richard P.; Bock, Lawrence A.; Heidelberg, Laurence J.; Hall, David G.

The ducted propeller offers structural and acoustic benefits typical of conventional turbofan engines while retaining much of the aeroacoustic benefits of the unducted propeller. A model Advanced Ducted Propeller (ADP) was tested in the NASA Lewis Low-Speed Anechoic Wind Tunnel at a simulated takeoff velocity of Mach 0.2. The ADP model was designed and manufactured by the Pratt and Whitney Division of United Technologies. The 16-blade rotor ADP was tested with 22- and 40-vane stators to achieve cut-on and cut-off criterion with respect to propagation of the fundamental rotor-stator interaction tone. Additional test parameters included three inlet lengths, three nozzle sizes, two spinner configurations, and two rotor rub strip configurations. The model was tested over a range of rotor blade setting angles and propeller axis angles-of-attack. Acoustic data were taken with a sideline translating microphone probe and with a unique inlet microphone probe which identified inlet rotating acoustic modes. The beneficial acoustic effects of cut-off were clearly demonstrated. A 5 dB fundamental tone reduction was associated with the long inlet and 40-vane sector, which may relate to inlet duct geometry. The fundamental tone level was essentially unaffected by propeller axis angle-of-attack at rotor speeds of at least 96 percent design.

Far-field noise and internal modes from a ducted propeller at simulated aircraft takeoff conditions

NASA Technical Reports Server (NTRS)

Woodward, Richard P.; Bock, Lawrence A.; Heidelberg, Laurence J.; Hall, David G.

1992-01-01

The ducted propeller offers structural and acoustic benefits typical of conventional turbofan engines while retaining much of the aeroacoustic benefits of the unducted propeller. A model Advanced Ducted Propeller (ADP) was tested in the NASA Lewis Low-Speed Anechoic Wind Tunnel at a simulated takeoff velocity of Mach 0.2. The ADP model was designed and manufactured by the Pratt and Whitney Division of United Technologies. The 16-blade rotor ADP was tested with 22- and 40-vane stators to achieve cut-on and cut-off criterion with respect to propagation of the fundamental rotor-stator interaction tone. Additional test parameters included three inlet lengths, three nozzle sizes, two spinner configurations, and two rotor rub strip configurations. The model was tested over a range of rotor blade setting angles and propeller axis angles-of-attack. Acoustic data were taken with a sideline translating microphone probe and with a unique inlet microphone probe which identified inlet rotating acoustic modes. The beneficial acoustic effects of cut-off were clearly demonstrated. A 5 dB fundamental tone reduction was associated with the long inlet and 40-vane sector, which may relate to inlet duct geometry. The fundamental tone level was essentially unaffected by propeller axis angle-of-attack at rotor speeds of at least 96 percent design.

Aeroballistics of Corkscrew Projectiles

DTIC Science & Technology

1978-06-01

obtained by cutting a solid cylinder with a series of six skewed planes to obtain the con- figuration shown in Figure 1. Three skewed planes form the...respect to the cylinder centerline can be varied; however, the angles of the three. nose planes must be the same as well as the angles of the three...b) At low angles of attack, the Magnus forces and moments are small at all spin rates near the configuration twist. This is due to the zero spin

Diagnosis of edge condition based on force measurement during milling of composites

NASA Astrophysics Data System (ADS)

Felusiak, Agata; Twardowski, Paweł

2018-04-01

The present paper presents comparative results of the forecasting of a cutting tool wear with the application of different methods of diagnostic deduction based on the measurement of cutting force components. The research was carried out during the milling of the Duralcan F3S.10S aluminum-ceramic composite. Prediction of the toolwear was based on one variable, two variables regression Multilayer Perceptron(MLP)and Radial Basis Function(RBF)neural networks. Forecasting the condition of the cutting tool on the basis of cutting forces has yielded very satisfactory results.

Tool path strategy and cutting process monitoring in intelligent machining

NASA Astrophysics Data System (ADS)

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.

INTERNAL CUTTING DEVICE

DOEpatents

Russell, W.H. Jr.

1959-06-30

A device is described for removing material from the interior of a hollow workpiece so as to form a true spherical internal surface in a workpiece, or to cut radial slots of an adjustable constant depth in an already established spherical internal surface. This is accomplished by a spring loaded cutting tool adapted to move axially wherein the entire force urging the tool against the workpiece is derived from the spring. Further features of importance involve the provision of a seal between the workpiece and the cutting device and a suction device for carrying away particles of removed material.

Geometrical analysis of circular-cut spiral bevel gears

NASA Technical Reports Server (NTRS)

Huston, R. L.

1983-01-01

Geometrical studies of circular cut spiral bevel gears are reported. Tooth profile changes heel to toe are studied in the transverse plane. Pressure angle changes are determined. The radiuses of curvature of the tooth surfaces generated by various cutter profiles are also determined. The consequences of cutter profile changes are explored. Crown gears are emphasized and the implications for conical gears are discussed.

Fibre laser cutting of polycaprolactone sheet for stents manufacturing: A feasibility study

NASA Astrophysics Data System (ADS)

Guerra, Antonio J.; Farjas, Jordi; Ciurana, Joaquim

2017-10-01

The role of the stent is temporary and it is limited to the intervention and shortly thereafter. Bioresorbable polymer stents were introduced to overcome this problem, making the stent manufacturing process rather difficult considering the complexity of the material. The stent forecast sale makes constant technology development necessary on this field. The adaptation of the laser manufacturing industry to these new materials is costly, thus further studies employing different sorts of lasers are necessary. This paper aims to explore the feasibility of 1.08 μm wavelength fibre laser to cut polycaprolactone sheet, which is especially interesting for long-term implantable devices, such as stents. The laser cut samples were analysed by Differential Scanning Calorimetry (DSC), Tensile Stress Test, and Optical Microscopy in order to study the effects of the laser process over the workpiece. The parameters measured were: taper angle, dimensional precision, material structure changes and mechanical properties changes. Results showed a dimensional precision above 95.75% with a taper angle lower than 0.033°. The laser ablation process has exhibited a minor influence upon material properties. Results exhibit the feasibility of fibre laser to cut polycaprolactone, making the fibre laser an alternative to manufacture stents.

75 FR 34179 - Tivoly, Inc., Derby Line, VT; Notice of Negative Determination on Reconsideration

Federal Register 2010, 2011, 2012, 2013, 2014

2010-06-16

... firm regarding their purchases of cutting tools, taps, and reamers during 2007, 2008, and during the... five months in 2008. Those surveys showed customer imports of cutting tools, taps, and reamers to be...

Developing Lathing Parameters for PBX 9501

DOE Office of Scientific and Technical Information (OSTI.GOV)

Woodrum, Randall Brock

This thesis presents the work performed on lathing PBX 9501 to gather and analyze cutting force and temperature data during the machining process. This data will be used to decrease federal-regulation-constrained machining time of the high explosive PBX 9501. The effects of machining parameters depth of cut, surface feet per minute, and inches per revolution on cutting force and cutting interface were evaluated. Cutting tools of tip radius 0.005 -inches and 0.05 -inches were tested to determine what effect the tool shape had on the machining process as well. A consistently repeatable relationship of temperature to changing depth of cutmore » and surface feet per minute is found, while only a weak dependence was found to changing inches per revolution. Results also show the relation of cutting force to depth of cut and inches per revolution, while weak dependence on SFM is found. Conclusions suggest rapid, shallow cuts optimize machining time for a billet of PBX 9501, while minimizing temperature increase and cutting force.« less

Theoretical and experimental research on machine tool servo system for ultra-precision position compensation on CNC lathe

NASA Astrophysics Data System (ADS)

Ma, Zhichao; Hu, Leilei; Zhao, Hongwei; Wu, Boda; Peng, Zhenxing; Zhou, Xiaoqin; Zhang, Hongguo; Zhu, Shuai; Xing, Lifeng; Hu, Huang

2010-08-01

The theories and techniques for improving machining accuracy via position control of diamond tool's tip and raising resolution of cutting depth on precise CNC lathes have been extremely focused on. A new piezo-driven ultra-precision machine tool servo system is designed and tested to improve manufacturing accuracy of workpiece. The mathematical model of machine tool servo system is established and the finite element analysis is carried out on parallel plate flexure hinges. The output position of diamond tool's tip driven by the machine tool servo system is tested via a contact capacitive displacement sensor. Proportional, integral, derivative (PID) feedback is also implemented to accommodate and compensate dynamical change owing cutting forces as well as the inherent non-linearity factors of the piezoelectric stack during cutting process. By closed loop feedback controlling strategy, the tracking error is limited to 0.8 μm. Experimental results have shown the proposed machine tool servo system could provide a tool positioning resolution of 12 nm, which is much accurate than the inherent CNC resolution magnitude. The stepped shaft of aluminum specimen with a step increment of cutting depth of 1 μm is tested, and the obtained contour illustrates the displacement command output from controller is accurately and real-time reflected on the machined part.

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

NASA Astrophysics Data System (ADS)

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

2009-11-01

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

The use of power tools in the insertion of cortical bone screws.

PubMed

Elliott, D

1992-01-01

Cortical bone screws are commonly used in fracture surgery, most patterns are non-self-tapping and require a thread to be pre-cut. This is traditionally performed using hand tools rather than their powered counterparts. Reasons given usually imply that power tools are more dangerous and cut a less precise thread, but there is no evidence to support this supposition. A series of experiments has been performed which show that the thread pattern cut with either method is identical and that over-penetration with the powered tap is easy to control. The conclusion reached is that both methods produce consistently reliable results but use of power tools is much faster.

The Dance of the Foci

ERIC Educational Resources Information Center

Seppala-Holtzman, David

2010-01-01

It's well known that slicing a cone with a plane and then allowing the plane to rotate through all possible angles of inclination yields the conic sections. What paths then do the foci of these conics trace out as this cutting plane passes through the different angles? In this article, we derive formulae for these trajectories and generate the…

The Generation Rate of Respirable Dust from Cutting Fiber Cement Siding Using Different Tools

PubMed Central

Qi, Chaolong; Echt, Alan; Gressel, Michael G

2017-01-01

This article describes the evaluation of the generation rate of respirable dust (GAPS, defined as the mass of respirable dust generated per unit linear length cut) from cutting fiber cement siding using different tools in a laboratory testing system. We used an aerodynamic particle sizer spectrometer (APS) to continuously monitor the real-time size distributions of the dust throughout cutting tests when using a variety of tools, and calculated the generation rate of respirable dust for each testing condition using the size distribution data. The test result verifies that power shears provided an almost dust-free operation with a GAPS of 0.006 gram meter−1 (g m−1) at the testing condition. For the same power saws, the cuts using saw blades with more teeth generated more respirable dusts. Using the same blade for all four miter saws tested in this study, a positive linear correlation was found between the saws’ blade rotating speed and its dust generation rate. In addition, a circular saw running at the highest blade rotating speed of 9068 RPM generated the greatest amount of dust. All the miter saws generated less dust in the ‘chopping mode’ than in the ‘chopping and sliding’ mode. For the tested saws, GAPS consistently decreased with the increases of the saw cutting feed rate and the number of board in the stack. All the test results point out that fewer cutting interactions between the saw blade’s teeth and the siding board for a unit linear length of cut tend to result in a lower generation rate of respirable dust. These results may help guide optimal operation in practice and future tool development aimed at minimizing dust generation while producing a satisfactory cut. PMID:28395343

The Generation Rate of Respirable Dust from Cutting Fiber Cement Siding Using Different Tools.

PubMed

Qi, Chaolong; Echt, Alan; Gressel, Michael G

2017-03-01

This article describes the evaluation of the generation rate of respirable dust (GAPS, defined as the mass of respirable dust generated per unit linear length cut) from cutting fiber cement siding using different tools in a laboratory testing system. We used an aerodynamic particle sizer spectrometer (APS) to continuously monitor the real-time size distributions of the dust throughout cutting tests when using a variety of tools, and calculated the generation rate of respirable dust for each testing condition using the size distribution data. The test result verifies that power shears provided an almost dust-free operation with a GAPS of 0.006 g m-1 at the testing condition. For the same power saws, the cuts using saw blades with more teeth generated more respirable dusts. Using the same blade for all four miter saws tested in this study, a positive linear correlation was found between the saws' blade rotating speed and its dust generation rate. In addition, a circular saw running at the highest blade rotating speed of 9068 rpm generated the greatest amount of dust. All the miter saws generated less dust in the 'chopping mode' than in the 'chopping and sliding' mode. For the tested saws, GAPS consistently decreased with the increases of the saw cutting feed rate and the number of board in the stack. All the test results point out that fewer cutting interactions between the saw blade's teeth and the siding board for a unit linear length of cut tend to result in a lower generation rate of respirable dust. These results may help guide optimal operation in practice and future tool development aimed at minimizing dust generation while producing a satisfactory cut. Published by Oxford University Press on behalf of The British Occupational Hygiene Society 2017.

Properties and Cutting Performance of TiAlSiN Coating Prepared by Cathode Arc Ion Plating

NASA Astrophysics Data System (ADS)

Zhang, Er-Geng; Chen, Qiang; Wang, Qin-Xue; Huang, Biao

2016-06-01

TiAlSiN coating was deposited on high-speed steel (HSS) samples and cemented carbide tool inserts, respectively, by a new coating preparation procedure, and its properties and cutting performance were characterized. The coating thickness, chemical composition, microstructure morphology and mechanical properties were investigated by X-ray fluorescence measurement system, energy dispersive spectrometer (EDS), scanning electron microscope (SEM), nanoindentation, Rockwell hardness tester and ball-on-disc tribometer. A 3D orthogonal cutting experiment model was established by DEFORM-3D to study the influences of different coating thicknesses on cutting force and temperature, and the field cutting experiment was carried out. The results show that the thickness of TiAlSiN coating is 3.14μm prepared by the 3μm preparation procedure, microhardness is 36.727GPa with the Si content of about 5.22at.% as well as good fracture toughness and adhesion strength. The TC4 and AISI 1045 cutting tool inserts with 4μm coating thickness have the minimum cutting forces of about 734.7N and 450.7N, respectively. Besides, tool inserts with a thickness of 3μm have the minimum cutting temperatures of about 510.2∘C and 230.6∘C, respectively.

Anterior Chamber Angle Measurements Using Schwalbe's Line with High Resolution Fourier-Domain Optical Coherence Tomography

PubMed Central

Qin, Bing; Francis, Brian A.; Li, Yan; Tang, Maolong; Zhang, Xinbo; Jiang, Chunhui; Cleary, Catherine; Huang, David

2012-01-01

Purpose To use Fourier-domain optical coherence tomography (OCT) to measure the angle opening distance at Schwalbe's line (AOD-SL) and determine its value in anterior chamber angle assessment. Methods Horizontal scans of the nasal and temporal anterior chamber angles in glaucoma subjects were performed by 830 nm wavelength Fourier-domain OCT. Images were graded by two ophthalmologists who assessed the visibility of Schwalbe’s line (SL), anterior limbus (AL), scleral spur (SS), and angle recess (AR). AOD-SL was measured with computer calipers. SL was manually identified by the termination of the corneal endothelium. Gonioscopy was used to classify anterior chamber angles according to a modified Shaffer system. Spearman's rho analysis was performed to assess correlation between AOD-SL and modified Shaffer grade. A cut-off value of AOD-SL for diagnosing occludable angles (modified Shaffer grade ≤1) was determined by receiver operating characteristic (ROC) analyses. Results Thirty-five glaucoma subjects (65 eyes) were enrolled. SL, AL, AR, and SS were visible by OCT in 97.7%, 99.2%, 87.3%, and 80.8% of eyes, respectively. Nasal and temporal AOD-SLs were 322.6 ± 200.2 µm and 341.4 ± 197.4 µm, respectively. Correlation coefficients between AOD-SL and modified Shaffer grade were 0.80 (nasal) and 0.81 (temporal). The diagnostic cut-off value of AOD-SL for occludable angles was 290 µm. The areas under the ROC curve, sensitivity, specificity values were 0.90, 0.80, 0.87 (nasal) and 0.90, 0.85, 0.77 (temporal). Conclusions The measurement of AOD-SL by Fourier-domain OCT is highly correlated with gonioscopy and may be a useful noncontact method of assessing angle closure risk. PMID:22827999

Endoscopic-assisted resection of peripheral osteoma using piezosurgery.

PubMed

Ochiai, Shigeki; Kuroyanagi, Norio; Sakuma, Hidenori; Sakuma, Hidenobu; Miyachi, Hitoshi; Shimozato, Kazuo

2013-01-01

Endoscopic-assisted surgery has gained widespread popularity as a minimally invasive procedure, particularly in the field of maxillofacial surgery. Because the surgical field around the mandibular angle is extremely narrow, the surrounding tissues may get caught in sharp rotary cutting instruments. In piezosurgery, bone tissues are selectively cut. This technique has various applications because minimal damage is caused by the rotary cutting instruments when they briefly come in contact with soft tissues. We report the case of a 33-year-old man who underwent resection of an osteoma in the region of the mandibular angle region via an intraoral approach. During surgery, the complete surgical field was within the view of the endoscope, thereby enabling the surgeon to easily resection the osteoma with the piezosurgery device. Considering that piezosurgery limits the extent of surgical invasion, this is an excellent low-risk technique that can be used in the field of maxillofacial surgery. Copyright © 2013 Elsevier Inc. All rights reserved.

Influence of the axial rotation angle on tool mark striations.

PubMed

Garcia, Derrel Louis; Pieterman, René; Baiker, Martin

2017-10-01

A tool's axial rotation influences the geometric properties of a tool mark. The larger the axial rotation angle, the larger the compression of structural details like striations. This complicates comparing tool marks at different axial rotations. Using chisels, tool marks were made from 0° to 75° axial rotation and compared using an automated approach Baiker et al. [10]. In addition, a 3D topographic surface of a chisel was obtained to generate virtual tool marks and to test whether the axial rotation angle of a mark could be predicted. After examination of the tool mark and chisel data-sets it was observed that marks lose information with increasing rotation due to the change in relative distance between geometrical details on the tool and the disappearance of smaller details. The similarity and repeatability were high for comparisons between marks with no difference in axial rotation, but decreasing with increased rotation angle from 0° to 75°. With an increasing difference in the rotation angles, the tool marks had to be corrected to account for the different compression factors between them. For compression up to 7.5%, this was obtained automatically by the tool mark alignment method. For larger compression, manually re-sizing the marks to the uncompressed widths at 0° rotation before the alignment was found suitable for successfully comparing even large differences in axial rotation. The similarity and repeatability were decreasing however, with increasing degree of re-sizing. The quality was assessed by determining the similarity at different detail levels within a tool mark. With an axial rotation up to 75°, tool marks were found to reliably represent structural details down to 100μm. The similarity of structural details below 100μm was dependent on the angle, with the highest similarity at small rotation angles and the lowest similarity at large rotation angles. Filtering to remove the details below 100μm lead to consistently higher similarity between tool marks at all angles and allowed for a comparison of marks up to 75° axial rotation. Finally, generated virtual tool mark profiles with an axial rotation were compared to experimental tool marks. The similarity between virtual and experimental tool marks remained high up to 60° rotation after which it decreased due to the loss in quality in both marks. Predicting the rotation angle is possible under certain conditions up to 45° rotation with an accuracy of 2.667±0.577° rotation. Copyright © 2017 Elsevier B.V. All rights reserved.

An experimental investigation on orthogonal cutting of hybrid CFRP/Ti stacks

NASA Astrophysics Data System (ADS)

Xu, Jinyang; El Mansori, Mohamed

2016-10-01

Hybrid CFRP/Ti stack has been widely used in the modern aerospace industry owing to its superior mechanical/physical properties and excellent structural functions. Several applications require mechanical machining of these hybrid composite stacks in order to achieve dimensional accuracy and assembly performance. However, machining of such composite-to-metal alliance is usually an extremely challenging task in the manufacturing sectors due to the disparate natures of each stacked constituent and their respective poor machinability. Special issues may arise from the high force/heat generation, severe subsurface damage and rapid tool wear. To study the fundamental mechanisms controlling the bi-material machining, this paper presented an experimental study on orthogonal cutting of hybrid CFRP/Ti stack by using superior polycrystalline diamond (PCD) tipped tools. The utilized cutting parameters for hybrid CFRP/Ti machining were rigorously adopted through a compromise selection due to the disparate machinability behaviors of the CFRP laminate and Ti alloy. The key cutting responses in terms of cutting force generation, machined surface quality and tool wear mechanism were precisely addressed. The experimental results highlighted the involved five stages of CFRP/Ti cutting and the predominant crater wear and edge fracture failure governing the PCD cutting process.

Cut-laceration injuries and related career groups in New Jersey career, vocational, and technical education courses and programs.

PubMed

Shendell, Derek G; Mizan, Samina S; Marshall, Elizabeth G; Kelly, Sarah W; Therkorn, Jennifer H; Campbell, Jennifer K; Miller, Ashley E

2012-09-01

Investigations of young workers, including limited surveys in supervised school settings, suggested their elevated injury risk. This study identified factors contributing to cuts-lacerations among adolescents in New Jersey secondary school career, technical, and vocational education programs. Of 1,772 injuries reported between December 1, 1998, and September 1, 2010, 777 (44%) were cuts-lacerations; analyses focused on 224 reports (n = 182 post-exclusions) submitted after fall 2005 in three career groups-Food, Hospitality & Tourism (FH&T) (n = 71), Manufacturing & Construction (M&C) (n = 84), and Automotive & Transportation (A&T) (n = 27). Most students were "struck by" tools or hard surfaces (n = 93, 51%); 63 cuts were from knives in FH&T. In M&C, most cuts-lacerations were caused by hand-held tools (n = 18) and being "struck against/by" or "caught between hard surfaces" (n = 19). Males reported more cuts-lacerations (n = 145), most commonly among 11th graders (n = 54) and ages 16 to 17 years (n = 79). Fingers (n = 117) were most often injured, usually by cutting tools (n = 83). Training, supervision, and appropriate equipment, and further assessments of "struck by" and "pinch point" hazards, are needed. Copyright 2012, SLACK Incorporated.

Development of Minimally Invasive Medical Tools Using Laser Processing on Cylindrical Substrates

NASA Astrophysics Data System (ADS)

Haga, Yoichi; Muyari, Yuta; Goto, Shoji; Matsunaga, Tadao; Esashi, Masayoshi

This paper reports micro-fabrication techniques using laser processing on cylindrical substrates for the realization of high-performance multifunctional minimally invasive medical tools with small sizes. A spring-shaped shape memory alloy (SMA) micro-coil with a square cross section has been fabricated by spiral cutting of a Ti-Ni SMA tube with a femtosecond laser. Small diameter active bending catheter which is actuated by hydraulic suction mechanism for intravascular minimally invasive diagnostics and therapy has also been developed. The catheter is made of a Ti-Ni super elastic alloy (SEA) tube which is processed by laser micromachining and a silicone rubber tube which covers the outside of the SEA tube. The active catheter is effective for insertion in branch of blood vessel which diverse in acute angle which is difficult to proceed. Multilayer metallization and patterning have been performed on glass tubes with 2 and 3 mm external diameters using maskless lithography techniques using a laser exposure system. Using laser soldering technique, a integrated circuit parts have been mounted on a multilayer circuit patterned on a glass tube. These fabrication techniques will effective for realization of high-performance multifunctional catheters, endoscopic tools, and implanted small capsules.

Surface Finish and Residual Stresses Induced by Orthogonal Dry Machining of AA7075-T651

PubMed Central

Jomaa, Walid; Songmene, Victor; Bocher, Philippe

2014-01-01

The surface finish was extensively studied in usual machining processes (turning, milling, and drilling). For these processes, the surface finish is strongly influenced by the cutting feed and the tool nose radius. However, a basic understanding of tool/surface finish interaction and residual stress generation has been lacking. This paper aims to investigate the surface finish and residual stresses under the orthogonal cutting since it can provide this information by avoiding the effect of the tool nose radius. The orthogonal machining of AA7075-T651 alloy through a series of cutting experiments was performed under dry conditions. Surface finish was studied using height and amplitude distribution roughness parameters. SEM and EDS were used to analyze surface damage and built-up edge (BUE) formation. An analysis of the surface topography showed that the surface roughness was sensitive to changes in cutting parameters. It was found that the formation of BUE and the interaction between the tool edge and the iron-rich intermetallic particles play a determinant role in controlling the surface finish during dry orthogonal machining of the AA7075-T651 alloy. Hoop stress was predominantly compressive on the surface and tended to be tensile with increased cutting speed. The reverse occurred for the surface axial stress. The smaller the cutting feed, the greater is the effect of cutting speed on both axial and hoop stresses. By controlling the cutting speed and feed, it is possible to generate a benchmark residual stress state and good surface finish using dry machining. PMID:28788534

The distance from the extramedullary cutting guide rod to the skin surface as a reference guide for the tibial slope in total knee arthroplasty.

PubMed

Tsukeoka, Tadashi; Tsuneizumi, Yoshikazu

2016-03-01

Although sagittal tibial alignment in total knee arthroplasty (TKA) is important, no landmarks exist to achieve a reproducible slope. The purpose of this study was to evaluate the clinical usefulness of the distance from the guide rod to the skin surface for the tibial slope in TKA. Computer simulation studies were performed on 100 consecutive knees scheduled for TKA. The angle between the line connecting the most anterior point of the predicted tibial cut surface and the skin surface 20 cm distal to the predicted cut surface (Line S) and the mechanical axis (MA) of the tibia in the sagittal plane was measured. The mean (±SD) absolute angle difference between the Line S and the MA was 0.9°±0.7°. The Line S was almost parallel to the MA in the sagittal plane (95% and 99% within two degrees and three degrees of deviation from MA, respectively). The guide rod orientation is a surrogate for the tibial cut slope because the targeted posterior slope is usually built into the cutting block and ensuring the rod is parallel to the MA in the sagittal plane is recommended. Therefore the distance between the skin surface and the rod can be a useful guide for the tibial slope. II. Copyright © 2015 Elsevier B.V. All rights reserved.

Analysis Of The Surface Roughness Obtained During The Dry Turning Of UNS A97050-T7 Aluminium Alloys

NASA Astrophysics Data System (ADS)

de Agustina, B.; Rubio, E. M.; Villeta, M.; Sebastián, M. A.

2009-11-01

Currently, in the aeronautical, aerospace and automotive industries there is high demand of materials such as the aluminium alloys that have high resistance even at high temperatures as well as a low density. For this reason, these alloys are widely used for the production of different elements that compose aircraft and aerospace vehicles. Nevertheless, in spite of the important role these materials have from the competitive point of view, they can commonly show problems of machinability associated with the tool wear. That has made that traditionally cutting fluids had been used in machining processes. However, they can contain environmentally harmful constituents and increase considerably the total cost of the process. Therefore, researches have been focused on the development of cleaner production technologies applications as dry machining. This leads to the search for combinations of cutting parameters and type of tools (types of coatings and different geometries) that could improve the machining under such conditions. The aim of this study is to analyse the relationship between the surface roughness obtained during the dry turning of aluminium UNS A97050-T7 bars and the cutting parameters (cutting speed and feed) using three different tools. As a first conclusion it could be affirmed that the feed was the cutting parameter more influential on the surface roughness and to a lesser extend the cutting speed, the type of tool and the interaction between the type of tool and the feed.

Augmented Endoscopic Images Overlaying Shape Changes in Bone Cutting Procedures.

PubMed

Nakao, Megumi; Endo, Shota; Nakao, Shinichi; Yoshida, Munehito; Matsuda, Tetsuya

2016-01-01

In microendoscopic discectomy for spinal disorders, bone cutting procedures are performed in tight spaces while observing a small portion of the target structures. Although optical tracking systems are able to measure the tip of the surgical tool during surgery, the poor shape information available during surgery makes accurate cutting difficult, even if preoperative computed tomography and magnetic resonance images are used for reference. Shape estimation and visualization of the target structures are essential for accurate cutting. However, time-varying shape changes during cutting procedures are still challenging issues for intraoperative navigation. This paper introduces a concept of endoscopic image augmentation that overlays shape changes to support bone cutting procedures. This framework handles the history of the location of the measured drill tip as a volume label and visualizes the remains to be cut overlaid on the endoscopic image in real time. A cutting experiment was performed with volunteers, and the feasibility of this concept was examined using a clinical navigation system. The efficacy of the cutting aid was evaluated with respect to the shape similarity, total moved distance of a cutting tool, and required cutting time. The results of the experiments showed that cutting performance was significantly improved by the proposed framework.

Zigzag laser with reduced optical distortion

DOEpatents

Albrecht, G.F.; Comaskey, B.; Sutton, S.B.

1994-04-19

The architecture of the present invention has been driven by the need to solve the beam quality problems inherent in Brewster's angle tipped slab lasers. The entrance and exit faces of a solid state slab laser are cut perpendicular with respect to the pump face, thus intrinsically eliminating distortion caused by the unpumped Brewster's angled faces. For a given zigzag angle, the residual distortions inherent in the remaining unpumped or lightly pumped ends may be reduced further by tailoring the pump intensity at these ends. 11 figures.

Zigzag laser with reduced optical distortion

DOEpatents

Albrecht, Georg F.; Comaskey, Brian; Sutton, Steven B.

1994-01-01

The architecture of the present invention has been driven by the need to solve the beam quality problems inherent in Brewster's angle tipped slab lasers. The entrance and exit faces of a solid state slab laser are cut perpendicular with respect to the pump face, thus intrinsically eliminating distortion caused by the unpumped Brewster's angled faces. For a given zigzag angle, the residual distortions inherent in the remaining unpumped or lightly pumped ends may be reduced further by tailoring the pump intensity at these ends.

USSR Report, Machine Tools and Metalworking Equipment, No. 6

DTIC Science & Technology

1983-05-18

production output per machine tool at a tool plant average 2-3 times the figures for tool shops. This is explained by the well-known advantages of...specialized production. Specifically, the advantages of standardization and unification of machine- attachment design can be fully exploited in...lemiiiiä IS MVCti\\e UtiUzation °f appropriate special equipmeT ters)! million thread-cutting dies, and 2.3 million milling cut- The advantages of

Tool Wear Monitoring Using Time Series Analysis

NASA Astrophysics Data System (ADS)

Song, Dong Yeul; Ohara, Yasuhiro; Tamaki, Haruo; Suga, Masanobu

A tool wear monitoring approach considering the nonlinear behavior of cutting mechanism caused by tool wear and/or localized chipping is proposed, and its effectiveness is verified through the cutting experiment and actual turning machining. Moreover, the variation in the surface roughness of the machined workpiece is also discussed using this approach. In this approach, the residual error between the actually measured vibration signal and the estimated signal obtained from the time series model corresponding to dynamic model of cutting is introduced as the feature of diagnosis. Consequently, it is found that the early tool wear state (i.e. flank wear under 40µm) can be monitored, and also the optimal tool exchange time and the tool wear state for actual turning machining can be judged by this change in the residual error. Moreover, the variation of surface roughness Pz in the range of 3 to 8µm can be estimated by the monitoring of the residual error.

Estimation of tool wear during CNC milling using neural network-based sensor fusion

NASA Astrophysics Data System (ADS)

Ghosh, N.; Ravi, Y. B.; Patra, A.; Mukhopadhyay, S.; Paul, S.; Mohanty, A. R.; Chattopadhyay, A. B.

2007-01-01

Cutting tool wear degrades the product quality in manufacturing processes. Monitoring tool wear value online is therefore needed to prevent degradation in machining quality. Unfortunately there is no direct way of measuring the tool wear online. Therefore one has to adopt an indirect method wherein the tool wear is estimated from several sensors measuring related process variables. In this work, a neural network-based sensor fusion model has been developed for tool condition monitoring (TCM). Features extracted from a number of machining zone signals, namely cutting forces, spindle vibration, spindle current, and sound pressure level have been fused to estimate the average flank wear of the main cutting edge. Novel strategies such as, signal level segmentation for temporal registration, feature space filtering, outlier removal, and estimation space filtering have been proposed. The proposed approach has been validated by both laboratory and industrial implementations.

Fracture patterns after bilateral sagittal split osteotomy of the mandibular ramus according to the Obwegeser/Dal Pont and Hunsuck/Epker modifications.

PubMed

Möhlhenrich, Stephan Christian; Kniha, Kristian; Peters, Florian; Ayoub, Nassim; Goloborodko, Evgeny; Hölzle, Frank; Fritz, Ulrike; Modabber, Ali

2017-05-01

The aim of this study was to compare the fracture patterns after sagittal split osteotomy according to Obwegeser/Dal Pont (ODP) and Hunsuck/Epker (HE), as well as to investigate the relationship between lateral bone cut ending or angle and the incidence of unfavorable/bad splits. Postoperative cone-beam computed tomograms of 124 splits according to ODP and 60 according to HE were analyzed. ODP led to 75.8% and HE led to 60% lingual fractures with mandibular foramen contact. Horizontal fractures were found in 9.7% and 6.7%, respectively, and unfavorable/bad splits were found in 11.3% and 10%, respectively. The lateral osteotomy angle was 106.22° (SD 12.03)° for bad splits and 106.6° (SD 13.12)° for favorable splits. Correlations were found between favorable fracture patterns and split modifications and between buccal ending of the lateral bone cut and bad splits (p < 0.001). No relationship was observed between split modifications (p = 0.792) or the osteotomy angle (p = 0.937) and the incidence of unfavorable/bad splits. Split modifications had no influence on the incidence of unfavorable/bad splits, but the buccal ending of the lateral bone cut did have an influence. More lingual fractures with mandibular foramen contact are expected with the ODP modification. The osteotomy angle did not differ between favorable and bad splits. Copyright © 2017 European Association for Cranio-Maxillo-Facial Surgery. Published by Elsevier Ltd. All rights reserved.

Zero degree contour cutting below 100 μm feature size with femtosecond laser

NASA Astrophysics Data System (ADS)

Stolberg, Klaus; Friedel, Susanna

2016-03-01

By the use of a 16 W femtosecond laser we demonstrate steep wall angles and small feature spacings for non-thermal melt-free laser drilling and contour cutting of 100 to 500 μm thick metals like Cu-alloy, stainless steel, titanium and tantalum as well as for ceramics and polymer (polycarbonate). Especially processing of thin materials is a challenge, because heat accumulation in thermal processing usually causes mechanical distortion or edge melting as well as material. The combination of beam deflection in trepanning optics and sample motion allowed us to work in a special "laser milling mode" with rotating beam. Zero degree taper angle as well as positive or negative tapers can be achieved at micrometer scale.

Multitemporal Observations of Sugarcane by TerraSAR-X Images

PubMed Central

Baghdadi, Nicolas; Cresson, Rémi; Todoroff, Pierre; Moinet, Soizic

2010-01-01

The objective of this study is to investigate the potential of TerraSAR-X (X-band) in monitoring sugarcane growth on Reunion Island (located in the Indian Ocean). Multi-temporal TerraSAR data acquired at various incidence angles (17°, 31°, 37°, 47°, 58°) and polarizations (HH, HV, VV) were analyzed in order to study the behaviour of SAR (synthetic aperture radar) signal as a function of sugarcane height and NDVI (Normalized Difference Vegetation Index). The potential of TerraSAR for mapping the sugarcane harvest was also studied. Radar signal increased quickly with crop height until a threshold height, which depended on polarization and incidence angle. Beyond this threshold, the signal increased only slightly, remained constant, or even decreased. The threshold height is slightly higher with cross polarization and higher incidence angles (47° in comparison with 17° and 31°). Results also showed that the co-polarizations channels (HH and VV) were well correlated. High correlation between SAR signal and NDVI calculated from SPOT-4/5 images was observed. TerraSAR data showed that after strong rains the soil contribution to the backscattering of sugarcane fields can be important for canes with heights of terminal visible dewlap (htvd) less than 50 cm (total cane heights around 155 cm). This increase in radar signal after strong rains could involve an ambiguity between young and mature canes. Indeed, the radar signal on TerraSAR images acquired in wet soil conditions could be of the same order for fields recently harvested and mature sugarcane fields, making difficult the detection of cuts. Finally, TerraSAR data at high spatial resolution were shown to be useful for monitoring sugarcane harvest when the fields are of small size or when the cut is spread out in time. The comparison between incidence angles of 17°, 37° and 58° shows that 37° is more suitable to monitor the sugarcane harvest. The cut is easily detectable on TerraSAR images for data acquired less than two or three months after the cut. The radar signal decreases about 5dB for images acquired some days after the cut and 3 dB for data acquired two month after the cut (VV-37°). The difference in radar signal becomes negligible (<1 dB) between harvested fields and mature canes for sugarcane harvested since three months or more. PMID:22163387

Investigations on Surface Milling of Hardened AISI 4140 Steel with Pulse Jet MQL Applicator

NASA Astrophysics Data System (ADS)

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

2018-06-01

In this article, an experimental investigation was performed in milling hardened AISI 4140 steel of hardness 40 HRC. The machining was performed in both dry and minimal quantity lubricant (MQL) conditions, as part of neat machining, to make a strong comparison of the undertaken machining environments. The MQL was impinged int the form of pulse jet, by using the specially developed pulse-jet-attachment, to ensure that the cutting fluid can be applied in different timed pulses and quantities at critical zones. The tool wear, cutting force and surface roughness were taken as the quality responses while cutting speed, table feed rate and flow rate of the pulse were considered as influential factors. The depth of cut was kept constant at 1.50 mm because of its less significant effects and the straight oil was adopted as cutting fluid in pulse-jet-MQL. The effects of different factors, on the quality responses, are analyzed using ANOVA. It is observed that MQL applicator system exhibits overall better performance when compared to dry milling by reducing surface roughness, cutting force and prolonging tool life but a flow rate of 150 ml/h has tremendous effects on the responses. This investigation and afterward results are expected to aid the industrial practitioner and researcher to adopt the pulse-MQL in high speed milling to prolong tool life, reduce tool wear, diminish cutting force generation and promote better surface finish.

Investigations on Surface Milling of Hardened AISI 4140 Steel with Pulse Jet MQL Applicator

NASA Astrophysics Data System (ADS)

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

2016-06-01

In this article, an experimental investigation was performed in milling hardened AISI 4140 steel of hardness 40 HRC. The machining was performed in both dry and minimal quantity lubricant (MQL) conditions, as part of neat machining, to make a strong comparison of the undertaken machining environments. The MQL was impinged int the form of pulse jet, by using the specially developed pulse-jet-attachment, to ensure that the cutting fluid can be applied in different timed pulses and quantities at critical zones. The tool wear, cutting force and surface roughness were taken as the quality responses while cutting speed, table feed rate and flow rate of the pulse were considered as influential factors. The depth of cut was kept constant at 1.50 mm because of its less significant effects and the straight oil was adopted as cutting fluid in pulse-jet-MQL. The effects of different factors, on the quality responses, are analyzed using ANOVA. It is observed that MQL applicator system exhibits overall better performance when compared to dry milling by reducing surface roughness, cutting force and prolonging tool life but a flow rate of 150 ml/h has tremendous effects on the responses. This investigation and afterward results are expected to aid the industrial practitioner and researcher to adopt the pulse-MQL in high speed milling to prolong tool life, reduce tool wear, diminish cutting force generation and promote better surface finish.

Discrete and continuum modelling of soil cutting

NASA Astrophysics Data System (ADS)

Coetzee, C. J.

2014-12-01

Both continuum and discrete methods are used to investigate the soil cutting process. The Discrete Element Method ( dem) is used for the discrete modelling and the Material-Point Method ( mpm) is used for continuum modelling. M pmis a so-called particle method or meshless finite element method. Standard finite element methods have difficulty in modelling the entire cutting process due to large displacements and deformation of the mesh. The use of meshless methods overcomes this problem. M pm can model large deformations, frictional contact at the soil-tool interface, and dynamic effects (inertia forces). In granular materials the discreteness of the system is often important and rotational degrees of freedom are active, which might require enhanced theoretical approaches like polar continua. In polar continuum theories, the material points are considered to possess orientations. A material point has three degrees-of-freedom for rigid rotations, in addition to the three classic translational degrees-of-freedom. The Cosserat continuum is the most transparent and straightforward extension of the nonpolar (classic) continuum. Two-dimensional dem and mpm (polar and nonpolar) simulations of the cutting problem are compared to experiments. The drag force and flow patterns are compared using cohesionless corn grains as material. The corn macro (continuum) and micro ( dem) properties were obtained from shear and oedometer tests. Results show that the dilatancy angle plays a significant role in the flow of material but has less of an influence on the draft force. Nonpolar mpm is the most accurate in predicting blade forces, blade-soil interface stresses and the position and orientation of shear bands. Polar mpm fails in predicting the orientation of the shear band, but is less sensitive to mesh size and mesh orientation compared to nonpolar mpm. dem simulations show less material dilation than observed during experiments.

Trajectory Calculator for Finite-Radius Cutter on a Lathe

NASA Technical Reports Server (NTRS)

Savchenkov, Anatoliy; Strekalov, Dmitry; Yu, Nan

2009-01-01

A computer program calculates the two-dimensional trajectory (radial vs. axial position) of a finite-radius-of-curvature cutting tool on a lathe so as to cut a workpiece to a piecewise-continuous, analytically defined surface of revolution. (In the original intended application, the tool is a diamond cutter, and the workpiece is made of a crystalline material and is to be formed into an optical resonator disk.) The program also calculates an optimum cutting speed as F/L, where F is a material-dependent empirical factor and L is the effective instantaneous length of the cutting edge.

Mechanical strength assessment of a drilled hole in the contralateral cortex at the end of the open wedge for high tibial osteotomy.

PubMed

Diffo Kaze, Arnaud; Maas, Stefan; Hoffmann, Alexander; Pape, Dietrich

2017-12-01

This study aimed to investigate, by means of finite element analysis, the effect of a drill hole at the end of a horizontal osteotomy to reduce the risk of lateral cortex fracture while performing an opening wedge high tibial osteotomy (OWHTO). The question was whether drilling a hole relieves stress and increases the maximum correction angle without fracture of the lateral cortex depending on the ductility of the cortical bone. Two different types of osteotomy cuts were considered; one with a drill hole (diameter 5 mm) and the other without the hole. The drill holes were located about 20 mm distally to the tibial plateau and 6 mm medially to the lateral cortex, such that the minimal thickness of the contralateral cortical bone was 5 mm. Based on finite element calculations, two approaches were used to compare the two types of osteotomy cuts considered: (1) Assessing the static strength using local stresses following the idea of the FKM-guideline, subsequently referred to as the "FKM approach" and (2) limiting the total strain during the opening of the osteotomy wedge, subsequently referred to as "strain approach". A critical opening angle leading to crack initiation in the opposite lateral cortex was determined for each approach and was defined as comparative parameter. The relation to bone aging was investigated by considering the material parameters of cortical bones from young and old subjects. The maximum equivalent (von-Mises) stress was smaller for the cases with a drill hole at the end of the osteotomy cut. The critical angle was approximately 1.5 times higher for the specimens with a drill hole compared to those without. This corresponds to an average increase of 50%. The calculated critical angle for all approaches is below 5°. The critical angle depends on the used approach, on patient's age and assumed ductility of the cortical bone. Drilling a hole at the end of the osteotomy reduces the stresses in the lateral cortex and increases the critical opening angle prior to cracking of the opposite cortex in specimen with small correction angles. But the difference from having a drill hole or not is not so significant, especially for older patients. The ductility of the cortical bone is the decisive parameter for the critical opening angle.

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

NASA Astrophysics Data System (ADS)

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

Apparatus and method for variable angle slant hole collimator

DOEpatents

Lee, Seung Joon; Kross, Brian J.; McKisson, John E.

2017-07-18

A variable angle slant hole (VASH) collimator for providing collimation of high energy photons such as gamma rays during radiological imaging of humans. The VASH collimator includes a stack of multiple collimator leaves and a means of quickly aligning each leaf to provide various projection angles. Rather than rotate the detector around the subject, the VASH collimator enables the detector to remain stationary while the projection angle of the collimator is varied for tomographic acquisition. High collimator efficiency is achieved by maintaining the leaves in accurate alignment through the various projection angles. Individual leaves include unique angled cuts to maintain a precise target collimation angle. Matching wedge blocks driven by two actuators with twin-lead screws accurately position each leaf in the stack resulting in the precise target collimation angle. A computer interface with the actuators enables precise control of the projection angle of the collimator.

Physical Modeling of Contact Processes on the Cutting Tools Surfaces of STM When Turning

NASA Astrophysics Data System (ADS)

Belozerov, V. A.; Uteshev, M. H.

2016-08-01

This article describes how to create an optimization model of the process of fine turning of superalloys and steel tools from STM on CNC machines, flexible manufacturing units (GPM), machining centers. Creation of the optimization model allows you to link (unite) contact processes simultaneously on the front and back surfaces of the tool from STM to manage contact processes and the dynamic strength of the cutting tool at the top of the STM. Established optimization model of management of the dynamic strength of the incisors of the STM in the process of fine turning is based on a previously developed thermomechanical (physical, heat) model, which allows the system thermomechanical approach to choosing brands STM (domestic and foreign) for cutting tools from STM designed for fine turning of heat resistant alloys and steels.

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

NASA Astrophysics Data System (ADS)

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.

Method and apparatus for optimizing the efficiency and quality of laser material processing

DOEpatents

Susemihl, Ingo

1990-01-01

The efficiency of laser welding and other laser material processing is optimized according to this invention by rotating the plane of polarization of a linearly polarized laser beam in relation to a work piece of the material being processed simultaneously and in synchronization with steering the laser beam over the work piece so as to keep the plane of polarization parallel to either the plane of incidence or the direction of travel of the beam in relation to the work piece. Also, depending to some extent on the particular processing being accomplished, such as welding or fusing, the angle of incidence of the laser beam on the work piece is kept at or near the polarizing or Brewster's angle. The combination of maintaining the plane of polarization parallel to plane of incidence while also maintaining the angle of incidence at or near the polarizing or Brewster's angle results in only minimal, if any, reflection losses during laser welding. Also, coordinating rotation of the plane of polarization with the translation or steering of a work piece under a laser cutting beam maximizes efficiency and kerf geometry, regardless of the direction of cut.

Method and apparatus for optimizing the efficiency and quality of laser material processing

DOEpatents

Susemihl, I.

1990-03-13

The efficiency of laser welding and other laser material processing is optimized according to this invention by rotating the plane of polarization of a linearly polarized laser beam in relation to a work piece of the material being processed simultaneously and in synchronization with steering the laser beam over the work piece so as to keep the plane of polarization parallel to either the plane of incidence or the direction of travel of the beam in relation to the work piece. Also, depending to some extent on the particular processing being accomplished, such as welding or fusing, the angle of incidence of the laser beam on the work piece is kept at or near the polarizing or Brewster's angle. The combination of maintaining the plane of polarization parallel to plane of incidence while also maintaining the angle of incidence at or near the polarizing or Brewster's angle results in only minimal, if any, reflection losses during laser welding. Also, coordinating rotation of the plane of polarization with the translation or steering of a work piece under a laser cutting beam maximizes efficiency and kerf geometry, regardless of the direction of cut. 7 figs.

Low-angle faulting in strike-slip dominated settings: Seismic evidence from the Maritimes Basin, Canada

NASA Astrophysics Data System (ADS)

Pinet, Nicolas; Dietrich, Jim; Duchesne, Mathieu J.; Hinds, Steve J.; Brake, Virginia

2018-07-01

The Maritimes Basin is an upper Paleozoic sedimentary basin centered in the Gulf of St. Lawrence (Canada). Early phases of basin formation included the development of partly connected sub-basins bounded by high-angle faults, in an overall strike-slip setting. Interpretation of reprocessed seismic reflection data indicates that a low-angle detachment contributed to the formation of a highly asymmetric sub-basin. This detachment was rotated toward a lower angle and succeeded by high-angle faults that sole into the detachment or cut it. This model bears similarities to other highly extended terranes and appears to be applicable to strike-slip and/or transtensional settings.

View of a stone age adze cutting tool floating freely in the flight deck.

NASA Technical Reports Server (NTRS)

1992-01-01

View of a stone age adze cutting tool floating freely in the forward flight deck and framed by the forward and side windows. On the Earth below, the big island of Hawaii can be seen through the window.

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

NASA Astrophysics Data System (ADS)

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.

Generation Mechanism of Work Hardened Surface Layer in Metal Cutting

NASA Astrophysics Data System (ADS)

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.

Investigation of Cutting Quality of Remote DOE Laser Cutting in 0.5 mm Stainless Steel

NASA Astrophysics Data System (ADS)

Villumsen, Sigurd Lazic; Kristiansen, Morten

It has previously been shown that the stability of the remote fusion cutting (RFC) process can be increased by modifying the intensity profile of the laser by means of a diffractive optical element (DOE). This paper investigates the quality of remote DOE cutting (RDC) conducted with a 3 kW single mode fiber laser in 0.5 mm stainless steel. An automatic measurement system is used to investigate how the travel speed, focus offset and angle of incidence effect the kerf width and kerf variance. The study shows that the RDC process has a very low kerf width variance, and that the kerf width decreases with cutting speed. Furthermore, selected etched samples show a significant increase in the perpendicularity of the cuts when compared to RFC. Also, on average, the depth of the layer of molten material for RFC is 83% deeper than for RDC.

Laser assisted machining: a state of art review

NASA Astrophysics Data System (ADS)

Punugupati, Gurabvaiah; Kandi, Kishore Kumar; Bose, P. S. C.; Rao, C. S. P.

2016-09-01

Difficult-to-cut materials have increasing demand in aerospace and automobile industries due to their high yield stress, high strength to weight ratio, high toughness, high wear resistance, high creep, high corrosion resistivity, ability to retain high strength at high temperature, etc. The machinability of these advanced materials, using conventional methods of machining is typical due to the high temperature and pressure at the cutting zone and tool and properties such as low thermal conductivity, high cutting forces and cutting temperatures makes the materials difficult to machine. Laser assisted machining (LAM) is a new and innovative technique for machining the difficult-to-cut materials. This paper deals with a review on the advances in lasers, tools and the mechanism of machining using LAM and their effects.

Irena : tool suite for modeling and analysis of small-angle scattering.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ilavsky, J.; Jemian, P.

2009-04-01

Irena, a tool suite for analysis of both X-ray and neutron small-angle scattering (SAS) data within the commercial Igor Pro application, brings together a comprehensive suite of tools useful for investigations in materials science, physics, chemistry, polymer science and other fields. In addition to Guinier and Porod fits, the suite combines a variety of advanced SAS data evaluation tools for the modeling of size distribution in the dilute limit using maximum entropy and other methods, dilute limit small-angle scattering from multiple non-interacting populations of scatterers, the pair-distance distribution function, a unified fit, the Debye-Bueche model, the reflectivity (X-ray and neutron)more » using Parratt's formalism, and small-angle diffraction. There are also a number of support tools, such as a data import/export tool supporting a broad sampling of common data formats, a data modification tool, a presentation-quality graphics tool optimized for small-angle scattering data, and a neutron and X-ray scattering contrast calculator. These tools are brought together into one suite with consistent interfaces and functionality. The suite allows robust automated note recording and saving of parameters during export.« less

Recording multiple spatially-heterodyned direct to digital holograms in one digital image

DOEpatents

Hanson, Gregory R [Clinton, TN; Bingham, Philip R [Knoxville, TN

2008-03-25

Systems and methods are described for recording multiple spatially-heterodyned direct to digital holograms in one digital image. A method includes digitally recording, at a first reference beam-object beam angle, a first spatially-heterodyned hologram including spatial heterodyne fringes for Fourier analysis; Fourier analyzing the recorded first spatially-heterodyned hologram by shifting a first original origin of the recorded first spatially-heterodyned hologram to sit on top of a first spatial-heterodyne carrier frequency defined by the first reference beam-object beam angle; digitally recording, at a second reference beam-object beam angle, a second spatially-heterodyned hologram including spatial heterodyne fringes for Fourier analysis; Fourier analyzing the recorded second spatially-heterodyned hologram by shifting a second original origin of the recorded second spatially-heterodyned hologram to sit on top of a second spatial-heterodyne carrier frequency defined by the second reference beam-object beam angle; applying a first digital filter to cut off signals around the first original origin and define a first result; performing a first inverse Fourier transform on the first result; applying a second digital filter to cut off signals around the second original origin and define a second result; and performing a second inverse Fourier transform on the second result, wherein the first reference beam-object beam angle is not equal to the second reference beam-object beam angle and a single digital image includes both the first spatially-heterodyned hologram and the second spatially-heterodyned hologram.

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

PubMed

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.

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

PubMed Central

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

2013-01-01

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. PMID:28809266

Chatter reduction in boring process by using piezoelectric shunt damping with experimental verification

NASA Astrophysics Data System (ADS)

Yigit, Ufuk; Cigeroglu, Ender; Budak, Erhan

2017-09-01

Chatter is a self-excited type of vibration that develops during machining due to process-structure dynamic interactions resulting in modulated chip thickness. Chatter is an important problem as it results in poor surface quality, reduced productivity and tool life. The stability of a cutting process is strongly influenced by the frequency response function (FRF) at the cutting point. In this study, the effect of piezoelectric shunt damping on chatter vibrations in a boring process is studied. In piezoelectric shunt damping method, an electrical impedance is connected to a piezoelectric transducer which is bonded on cutting tool. Electrical impedance of the circuit consisting of piezoceramic transducer and passive shunt is tuned to the desired natural frequency of the cutting tool in order to maximize damping. The optimum damping is achieved in analytical and finite element models (FEM) by using a genetic algorithm focusing on the real part of the tool point FRF rather than the amplitude. Later, a practical boring bar is considered where the optimum circuit parameters are obtained by the FEM. Afterwards, the effect of the optimized piezoelectric shunt damping on the dynamic rigidity and absolute stability limit of the cutting process are investigated experimentally by modal analysis and cutting tests. It is both theoretically and experimentally shown that application of piezoelectric shunt damping results in a significant increase in the absolute stability limit in boring operations.

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

NASA Astrophysics Data System (ADS)

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.

Method and device for determining the position of a cutting tool relative to the rotational axis of a spindle-mounted workpiece

DOEpatents

Williams, R.R.

1980-09-03

The present invention is directed to a method and device for determining the location of a cutting tool with respect to the rotational axis of a spindle-mounted workpiece. A vacuum cup supporting a machinable sacrificial pin is secured to the workpiece at a location where the pin will project along and encompass the rotational axis of the workpiece. The pin is then machined into a cylinder. The position of the surface of the cutting tool contacting the machine cylinder is spaced from the rotational axis of the workpiece a distance equal to the radius of the cylinder.

Method and device for determining the position of a cutting tool relative to the rotational axis of a spindle-mounted workpiece

DOEpatents

Williams, Richard R.

1982-01-01

The present invention is directed to a method and device for determining the location of a cutting tool with respect to the rotational axis of a spindle-mounted workpiece. A vacuum cup supporting a machinable sacrifical pin is secured to the workpiece at a location where the pin will project along and encompass the rotational axis of the workpiece. The pin is then machined into a cylinder. The position of the surface of the cutting tool contacting the machine cylinder is spaced from the rotational aixs of the workpiece a distance equal to the radius of the cylinder.

The effect of cutting parameters on the performance of ZTA-MgO cutting tool

NASA Astrophysics Data System (ADS)

Ali, A. M.; Hamidon, N. E.; Zaki, N. K. M.; Mokhtar, S.; Azhar, A. Z. A.; Bahar, R.; Ahmad, Z. A.

2018-01-01

The effect of cutting parameters on the performances of ZTA-MgO ceramic cutting tool investigated. The aim of this project is to discover the effect of cutting speed and feedrate on the performance of the ZTA-MgO cutting tool via wear and surface roughness measurement. CNC turning machining performed using the cutting speed, Vc range from 354 to 471 m/min and the feed rate, f 0.1, 0.3 and 0.5 mm/rev while the depth of cut, d is kept constant at 0.2 mm. The flank wear, crater wear, and chipping were measured accordingly using optical microscope, Matlab programming and SEM. Surface roughness of machined stainless steel 316L surface were measured using the surface roughness tester (Mitutoyo MTR097-8. The result showing the increment trend of flank wear with increment of cutting speed and feed rate with the lowest value of flank wear, 0.061 mm achieved at Vc = 354 m/min and f = 0.1 mm/rev while the highest flank wear is 0.480 mm at Vc = 471 m/min and f = 0.5 mm/rev. The increasing pattern also observed in the crater wear results. The lowest area of crater wear is 2.2736 mm2 at Vc = 354 m/min and f = 0.1 mm/rev while the highest value is 4.8524 mm2 at Vc = 471 m/min and f = 0.5 mm/rev. As for the surface roughness, the higher the cutting speed, the lower the average roughness (Ra) value. Cutting speed, Vc = 471 m/min with f = 0.1 mm/rev has the lowest value of Ra which is 0.72µm.

High performance cutting using micro-textured tools and low pressure jet coolant

NASA Astrophysics Data System (ADS)

Obikawa, Toshiyuki; Nakatsukasa, Ryuta; Hayashi, Mamoru; Ohno, Tatsumi

2018-05-01

Tool inserts with different kinds of microtexture on the flank face were fabricated by laser irradiation for promoting the heat transfer from the tool face to the coolant. In addition to the micro-textured tools, jet coolant was applied to the tool tip from the side of the flank face, but under low-pressure conditions, to make Reynolds number of coolant as high as possible in the wedge shape zone between the tool flank and machined surface. First, the effect of jet coolant on the flank wear evolution was investigated using a tool without microtexture. The jet coolant showed an excellent improvement of the tool life in machining stainless steel SUS304 at higher cutting speeds. It was found that both the flow rate and velocity of jet coolant were indispensable to high performance cutting. Next, the effect of microtexture on the flank wear evolution was investigated using jet coolant. Three types of micro grooves extended tool life largely compared to the tool without microtexture. It was found that the depth of groove was one of important parameters affecting the tool life extension. As a result, the tool life was extended by more than l00 % using the microtextured tools and jet coolant compared to machining using flood coolant and a tool without microtexture.

The effects of wind on the flame characteristics of individual leaves

Treesearch

W. J. Cole; McKaye H. Dennis; Thomas H. Fletcher; David R. Weise

2011-01-01

Individual cuttings from five shrub species were burned over a flat-flame burner under wind conditions of 0.75–2.80 m s–1. Both live and dead cuttings were used. These included single leaves from broadleaf species as well as 3 to 5 cm-long branches from coniferous and small broadleaf species. Flame angles and flame lengths were determined by semi...

Influence of coolant on ductile mode processing of binderless nanocrystalline tungsten carbide through ultraprecision diamond turning

NASA Astrophysics Data System (ADS)

Doetz, Marius; Dambon, Olaf; Klocke, Fritz; Fähnle, Oliver

2015-08-01

Molds made of tungsten carbide are typically used for the replicative mass production of glass lenses by precision glass molding. Consequently an ultra-precision grinding process with a subsequent fresh-feed polishing operation is conventionally applied. These processes are time consuming and have a relatively low reproducibility. An alternative manufacturing technology, with a high predictability and efficiency, which additionally allows a higher geometrical flexibility, is the single point diamond turning technique (SPDT). However, the extreme hardness and the chemical properties of tungsten carbide lead to significant tool wear and therefore the impossibility of machining the work pieces in an economical way. One approach to enlarge the tool life is to affect the contact zone between tool and work piece by the use of special cutting fluids. This publication emphasizes on the most recent investigations and results in direct machining of nano-grained tungsten carbide with mono crystal diamonds under the influence of various kinds of cutting fluids. Therefore basic ruling experiments on binderless nano grained tungsten carbide were performed, where the tool performed a linear movement with a steadily increasing depth of cut. As the ductile cutting mechanism is a prerequisite for the optical manufacturing of tungsten carbide these experiments serve the purpose for establish the influence of different cutting fluid characteristics on the cutting performance of mono crystal diamonds. Eventually it is shown that by adjusting the coolant fluid it is possible to significantly shift the transition point from ductile to brittle removal to larger depths of cut eventually enabling a SPDT of binderless tungsten carbide molds.

Testing Of Choiced Ceramics Cutting Tools At Irregular Interrupted Cut

NASA Astrophysics Data System (ADS)

Kyncl, Ladislav; Malotová, Šárka; Nováček, Pavel; Nicielnik, Henryk; Šoková, Dagmar; Hemžský, Pavel; Pitela, David; Holubjak, Jozef

2015-12-01

This article discusses the test of removable ceramic cutting inserts during machining irregular interrupted cut. Tests were performed on a lathe, with the preparation which simulated us the interrupted cut. By changing the number of plates mounted in a preparation it simulate us a regular or irregular interrupted cut. When with four plates it was regular interrupted cut, the remaining three variants were already irregular cut. It was examined whether it will have the irregular interrupted cutting effect on the insert and possibly how it will change life of inserts during irregular interrupted cut (variable delay between shocks).

A modeling of elementary passes taking into account the firing angle in abrasive water jet machining of titanium alloy

NASA Astrophysics Data System (ADS)

Bui, Van-Hung; Gilles, Patrick; Cohen, Guillaume; Rubio, Walter

2018-05-01

The use of titanium alloys in the aeronautical and high technology domains is widespread. The high strength and the low mass are two outstanding characteristics of titanium alloys which permit to produce parts for these domains. As other hard materials, it is challenging to generate 3D surfaces (e.g. pockets) when using conventional cutting methods. The development of Abrasive Water Jet Machining (AWJM) technology shows the capability to cut any kind of materials and it seems to be a good solution for such titanium materials with low specific force, low deformation of parts and low thermal shocks. Applying this technology for generating 3D surfaces requires to adopt a modelling approach. However, a general methodology results in complex models due to a lot of parameters of the machining process and based on numerous experiments. This study introduces an extended geometry model of an elementary pass when changing the firing angle during machining Ti-6AL-4V titanium alloy with a given machine configuration. Several experiments are conducted to observe the influence of major kinematic operating parameters, i.e. jet inclination angle (α) (perpendicular to the feed direction) and traverse speed (Vf). The material exposure time and the erosion capability of abrasives particles are affected directly by a variation of the traverse speed (Vf) and firing angle (α). These variations lead to different erosion rates along the kerf profile characterized by the depth and width of cut. A comparison demonstrated an efficiency of the proposed model for depth and width of elementary passes. Based on knowledge of the influence of both firing angle and traverse speed on the elementary pass shape, the proposed model allows to develop the simulation of AWJM process and paves a way for milling flat bottom pockets and 3D complex shapes.

The Orthogonal In-Situ Machining of Single and Polycrystalline Aluminum and Copper, Volume 1. Ph.D. Thesis Final Report

NASA Technical Reports Server (NTRS)

Cohen, P. H.

1982-01-01

Metal cutting is a unique deformation process characterized by large strains, exceptionally high strain rates and few constraints to the deformation. These factors, along with the difficulty of directly measuring the shear angle, make chip formation difficult to model and understand. One technique for skirting the difficulty of post mortem chip measurement is to perform a cutting experiment dynamically in a scanning electron microscope. The performance of the in-situ experiment with full instrumentation allows for component force measurement, orientation measurement (on a round single crystal disk) and a timing device, all superimposed below the deformation on the TV monitor and recorded for future viewing. This allows the sher angle to be directly measured for the screen along with the other needed information.

Comparison of custom-moulded ankle orthosis with hinged joints and off-the-shelf ankle braces in preventing ankle sprain in lateral cutting movements.

PubMed

Lee, Winson C C; Kobayashi, Toshiki; Choy, Barton T S; Leung, Aaron K L

2012-06-01

A custom moulded ankle orthosis with hinged joints potentially offers a better control over the subtalar joint and the ankle joint during lateral cutting movements, due to total contact design and increase in material strength. To test the above hypothesis by comparing it to three other available orthoses. Repeated measures. Eight subjects with a history of ankle sprains (Grade 2), and 11 subjects without such history performed lateral cutting movements in four test conditions: 1) non-orthotic, 2) custom-moulded ankle orthosis with hinges, 3) Sport-Stirrup, and 4) elastic ankle sleeve with plastic support. A VICON motion analysis system was used to study the motions at the ankle and subtalar joints. The custom-moulded ankle orthosis significantly lowered the inversion angle at initial contact (p = 0.006) and the peak inversion angle (p = 0.000) during lateral cutting movements in comparison to non-orthotic condition, while the other two orthoses did not. The three orthoses did not affect the plantarflexion motions, which had been suggested by previous studies to be important in shock wave attenuation. The custom-moulded ankle orthosis with hinges could better control inversion and thus expected to better prevent ankle sprain in lateral cutting movements. Custom-moulded ankle orthoses are not commonly used in preventing ankle sprains. This study raises the awareness of the use of custom-moulded ankle orthoses which are expected to better prevent ankle sprains.

Two Problems with Table Saws

ERIC Educational Resources Information Center

Vautaw, William R.

2008-01-01

We solve two problems that arise when constructing picture frames using only a table saw. First, to cut a cove running the length of a board (given the width of the cove and the angle the cove makes with the face of the board) we calculate the height of the blade and the angle the board should be turned as it is passed over the blade. Second, to…

Rapid analysis of the microfibril angle of loblolly pine from two test sites using near-infrared analysis

Treesearch

ChiLeung So; Jennifer Myszewski; Thomas Elder; Les Groom

2013-01-01

Abstract There have been several recent studies employing near infrared (NIR) spectroscopy for the rapid determination of microfibril angle (MFA). However, only a few have utilized samples cut from individual rings of increment cores, and none have been as large as this present study, sampling over 600 trees from two test sites producing over 3000 individual ring...

Membrane technology for treating of waste nanofluids coolant: A review

NASA Astrophysics Data System (ADS)

Mohruni, Amrifan Saladin; Yuliwati, Erna; Sharif, Safian; Ismail, Ahmad Fauzi

2017-09-01

The treatment of cutting fluids wastes concerns a big number of industries, especially from the machining operations to foster environmental sustainability. Discharging cutting fluids, waste through separation technique could protect the environment and also human health in general. Several methods for the separation emulsified oils or oily wastewater have been proposed as three common methods, namely chemical, physicochemical and mechanical and membrane technology application. Membranes are used into separate and concentrate the pollutants in oily wastewater through its perm-selectivity. Meanwhile, the desire to compensate for the shortcomings of the cutting fluid media in a metal cutting operation led to introduce the using of nanofluids (NFs) in the minimum quantity lubricant (MQL) technique. NFs are prepared based on nanofluids technology by dispersing nanoparticles (NPs) in liquids. These fluids have potentially played to enhance the performance of traditional heat transfer fluids. Few researchers have studied investigation of the physical-chemical, thermo-physical and heat transfer characteristics of NFs for heat transfer applications. The use of minimum quantity lubrication (MQL) technique by NFs application is developed in many metal cutting operations. MQL did not only serve as a better alternative to flood cooling during machining operation and also increases better-finished surface, reduces impact loads on the environment and fosters environmental sustainability. Waste coolant filtration from cutting tools using membrane was treated by the pretreated process, coagulation technique and membrane filtration. Nanomaterials are also applied to modify the membrane structure and morphology. Polyvinylidene fluoride (PVDF) is the better choice in coolant wastewater treatment due to its hydrophobicity. Using of polyamide nanofiltration membranes BM-20D and UF-PS-100-100, 000, it resulted in the increase of permeability of waste coolant filtration. Titanium dioxide is nanomaterials additive to modify the Nanopores of the surface membrane. Contact angle and average pore size were used in the investigation of the surface morphology of membranes. An adequate choice in modifying the membrane surface in waste coolant filtration may bring a promised alternative as a solution in waste coolant remediation.

Validation of tool mark analysis of cut costal cartilage.

PubMed

Love, Jennifer C; Derrick, Sharon M; Wiersema, Jason M; Peters, Charles

2012-03-01

This study was designed to establish the potential error rate associated with the generally accepted method of tool mark analysis of cut marks in costal cartilage. Three knives with different blade types were used to make experimental cut marks in costal cartilage of pigs. Each cut surface was cast, and each cast was examined by three analysts working independently. The presence of striations, regularity of striations, and presence of a primary and secondary striation pattern were recorded for each cast. The distance between each striation was measured. The results showed that striations were not consistently impressed on the cut surface by the blade's cutting edge. Also, blade type classification by the presence or absence of striations led to a 65% misclassification rate. Use of the classification tree and cross-validation methods and inclusion of the mean interstriation distance decreased the error rate to c. 50%. © 2011 American Academy of Forensic Sciences.

Electromagnetic variable degrees of freedom actuator systems and methods

DOEpatents

Montesanti, Richard C [Pleasanton, CA; Trumper, David L [Plaistow, NH; Kirtley, Jr., James L.

2009-02-17

The present invention provides a variable reluctance actuator system and method that can be adapted for simultaneous rotation and translation of a moving element by applying a normal-direction magnetic flux on the moving element. In a beneficial example arrangement, the moving element includes a swing arm that carries a cutting tool at a set radius from an axis of rotation so as to produce a rotary fast tool servo that provides a tool motion in a direction substantially parallel to the surface-normal of a workpiece at the point of contact between the cutting tool and workpiece. An actuator rotates a swing arm such that a cutting tool moves toward and away from a mounted rotating workpiece in a controlled manner in order to machine the workpiece. Position sensors provide rotation and displacement information for a swing arm to a control system. A control system commands and coordinates motion of the fast tool servo with the motion of a spindle, rotating table, cross-feed slide, and in feed slide of a precision lathe.

Angle Performance on Optima XE

DOE Office of Scientific and Technical Information (OSTI.GOV)

David, Jonathan; Satoh, Shu

2011-01-07

Angle control on high energy implanters is important due to shrinking device dimensions, and sensitivity to channeling at high beam energies. On Optima XE, beam-to-wafer angles are controlled in both the horizontal and vertical directions. In the horizontal direction, the beam angle is measured through a series of narrow slits, and any angle adjustment is made by steering the beam with the corrector magnet. In the vertical direction, the beam angle is measured through a high aspect ratio mask, and any angle adjustment is made by slightly tilting the wafer platen during implant.Using a sensitive channeling condition, we were ablemore » to quantify the angle repeatability of Optima XE. By quantifying the sheet resistance sensitivity to both horizontal and vertical angle variation, the total angle variation was calculated as 0.04 deg. (1{sigma}). Implants were run over a five week period, with all of the wafers selected from a single boule, in order to control for any crystal cut variation.« less

Asymmetrically cut crystal pair as x-ray magnifier for imaging at high intensity laser facilitiesa)

NASA Astrophysics Data System (ADS)

Szabo, C. I.; Feldman, U.; Seely, J. F.; Curry, J. J.; Hudson, L. T.; Henins, A.

2010-10-01

The potential of an x-ray magnifier prepared from a pair of asymmetrically cut crystals is studied to explore high energy x-ray imaging capabilities at high intensity laser facilities. OMEGA-EP and NIF when irradiating mid and high Z targets can be a source of high-energy x-rays whose production mechanisms and use as backlighters are a subject of active research. This paper studies the properties and potential of existing asymmetric cut crystal pairs from the National Institute of Standards and Technology (NIST) built in a new enclosure for imaging x-ray sources. The technique of the x-ray magnifier has been described previously. This new approach is aimed to find a design that could be used at laser facilities by magnifying the x-ray source into a screen far away from the target chamber center, with fixed magnification defined by the crystals' lattice spacing and the asymmetry angles. The magnified image is monochromatic and the imaging wavelength is set by crystal asymmetry and incidence angles. First laboratory results are presented and discussed.

Effect of cutting temperature on hardness of SiC and diamond in the nano-cutting process of monocrystalline silicon

NASA Astrophysics Data System (ADS)

Wang, Jiachun; Li, Yuntao; Liu, Xiaoxuan; Lv, Maoqiang

2016-10-01

In the process of cutting silicon by natural diamond tools, groove wear happens on the flank face of cutting tool frequently.Scholars believe that one of the wear reasons is mechanical scratching effect by hard particles like SiC. To reveal the mechanical scratching mechanism, it is essential to study changes in the mechanical properties of hard particles and diamond, especially the effect of cutting temperature on hardness of diamond and hard particles. Molecular dynamics (MD) model that contact-zone temperature between tool and workpiece was calculated by dividing zone while nano-cutting monocrystalline silicon was established, cutting temperature values in different regions were computed as the simulation was carried out.On this basis, the models of molecular dynamics simulation of SiC and diamond were established separately with setting the initial temperature to room temperature. The laws of length change of C-C bond and Si-C bond varing with increase of simulation temperature were studied. And drawing on predecessors' research on theoretical calculation of hardness of covalent crystals and the relationship between crystal valence electron density and bond length, the curves that the hardness of diamond and SiC varing with bond length were obtained. The effect of temperature on the hardness was calculated. Results show that, local cutting temperature can reach 1300K.The rise in cutting temperature leaded to a decrease in the diamond local atomic clusters hardness,SiC local atomic clusters hardness increased. As the cutting temperature was more than 1100K,diamond began to soften, the local clusters hardness was less than that of SiC.

Oriented microtexturing on the surface of high-speed steel cutting tool

NASA Astrophysics Data System (ADS)

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

2016-11-01

Microtexturing the metal cutting tool surfaces is a novel technique intended for enhancing the workability of these tools. The microtexturing is used in machining the titanium alloys for air-space applications for reducing the adhesion wear of metal cutting blades. This paper is focused on forming the microtextured dotted, banded and overlapped areas on the surfaces of high-speed steel samples. The treated areas have been examined using laser scanning microscopy for the microtexture pattern and roughness. It has been shown that the microtextured surfaces obtained on the high-speed steel samples were free of cracks. Surface pattern and roughness of all three microtextured areas have been examined and analyzed.

Simulation of router action on a lathe to test the cutting tool performance in edge-trimming of graphite/epoxy composite

NASA Astrophysics Data System (ADS)

Ramulu, M.; Rogers, E.

1994-04-01

The predominant machining application with graphite/epoxy composite materials in aerospace industry is peripheral trimming. The computer numerically controlled (CNC) high speed routers required to do edge trimming work are generally scheduled for production work in industry and are not available for extensive cutter testing. Therefore, an experimental method of simulating the conditions of periphery trim using a lathe is developed in this paper. The validity of the test technique will be demonstrated by conducting carbide tool wear tests under dry cutting conditions. The experimental results will be analyzed to characterize the wear behavior of carbide cutting tools in machining the composite materials.

Optimization of Milling Parameters Employing Desirability Functions

NASA Astrophysics Data System (ADS)

Ribeiro, J. L. S.; Rubio, J. C. Campos; Abrão, A. M.

2011-01-01

The principal aim of this paper is to investigate the influence of tool material (one cermet and two coated carbide grades), cutting speed and feed rate on the machinability of hardened AISI H13 hot work steel, in order to identify the cutting conditions which lead to optimal performance. A multiple response optimization procedure based on tool life, surface roughness, milling forces and the machining time (required to produce a sample cavity) was employed. The results indicated that the TiCN-TiN coated carbide and cermet presented similar results concerning the global optimum values for cutting speed and feed rate per tooth, outperforming the TiN-TiCN-Al2O3 coated carbide tool.

Diamond Smoothing Tools

NASA Technical Reports Server (NTRS)

Voronov, Oleg

2007-01-01

Diamond smoothing tools have been proposed for use in conjunction with diamond cutting tools that are used in many finish-machining operations. Diamond machining (including finishing) is often used, for example, in fabrication of precise metal mirrors. A diamond smoothing tool according to the proposal would have a smooth spherical surface. For a given finish machining operation, the smoothing tool would be mounted next to the cutting tool. The smoothing tool would slide on the machined surface left behind by the cutting tool, plastically deforming the surface material and thereby reducing the roughness of the surface, closing microcracks and otherwise generally reducing or eliminating microscopic surface and subsurface defects, and increasing the microhardness of the surface layer. It has been estimated that if smoothing tools of this type were used in conjunction with cutting tools on sufficiently precise lathes, it would be possible to reduce the roughness of machined surfaces to as little as 3 nm. A tool according to the proposal would consist of a smoothing insert in a metal holder. The smoothing insert would be made from a diamond/metal functionally graded composite rod preform, which, in turn, would be made by sintering together a bulk single-crystal or polycrystalline diamond, a diamond powder, and a metallic alloy at high pressure. To form the spherical smoothing tip, the diamond end of the preform would be subjected to flat grinding, conical grinding, spherical grinding using diamond wheels, and finally spherical polishing and/or buffing using diamond powders. If the diamond were a single crystal, then it would be crystallographically oriented, relative to the machining motion, to minimize its wear and maximize its hardness. Spherically polished diamonds could also be useful for purposes other than smoothing in finish machining: They would likely also be suitable for use as heat-resistant, wear-resistant, unlubricated sliding-fit bearing inserts.

Critically Loaded Hole Technology Pilot Collaborative Test Programme.

DTIC Science & Technology

1980-11-01

270 rpm Spindle Speed - 1450 rpm Feed Rate - Manual Feed Rate - Manual Cutting Fluid - Dry Cutting Fluid - Dry Tool Type - Cordia S-18 Tool Type... Cordia S-18 TABLE XI MANUFACTURING DETAILS FOR HIGH AND LOW QUALITY HOLES SELECTED BY THE UNITED KINGDOM HIGH QUALITY LOW QUALITY Pilot Hole: - 1/8 inch

Key improvements in machining of Ti6al4v alloy: A review

NASA Astrophysics Data System (ADS)

Katta, Sivakoteswararao; Chaitanya, G.

2017-07-01

Now a days the use of ti-6al-4v alloy is high in demand in many industries like aero space, bio medical automobile, space, military etc. the production rates in the industries are not sufficient because the machiniability of ti-6al-4v is the main problem, there are several cutting tools available for metal cutting operations still there is a gap in finding the proper cutting tool material for machining of ti-6al-4v. because the properties of titanium like high heat resistant, low thermal conductivity, low weight ratio, less corrosiveness, and more many properties attracting the industrialists to use titanium as their material for their products, many researchers done the research on machininbility of ti-6al-4v by using different tool materials. but as for my literature survey there is still lot of scope is available, to find better cutting tool with techniques for machining ti-6al-4v. in this paper iam discussing the work done by various researchers on ti-6al-4v alloy with different techniques.

One of possible variants of the organization for recycling lubricate cooling of technological means for small businesses

NASA Astrophysics Data System (ADS)

Rusica, I.; Toca, A.; Stingaci, I.; Scaticailov, S.; Scaticailov, I.; Marinescu, O.; Kosenko, P.

2016-11-01

In the paper we analyze the application lubricate cooling technological environment in the processing of various materials in the past century greatly have increased cutting speed and respectively, has increased productivity [1]. Today, none of production in which anyway is used metal cutting machines of all types (milling, turning, grinding, drilling, etc.) is not without lubricant cooling technological liquid which in turn are designed to reduce cutting force and the load on metal cutting machine tools and machined parts in order to increase durability machine tools and reduce errors of processing details and also in resource energy saving. When using lubricate cooling technological environment reduces the temperature in the cutting zone resulting in higher tool life and the preservation of the surface structure being treated reducing wear of metal parts of the machine. Typically, lubricant cooling process fluids is used without replacing as long as possible not yet beginning to negatively affect the quality of process. However life expectancy lubricate cooling technological environment is limited. According to existing normative acts every kind of lubricate cooling technological environment through certain time must be deleted by from the system and subjected to a recycling. Lubricate cooling technological environment must be disposed of for the following reasons: occurs the microbial and the mechanical pollution cutting fluid, free oil impairs operational characteristics cutting fluid and increases consumption.

Wear Mechanism of Chemical Vapor Deposition (CVD) Carbide Insert in Orthogonal Cutting Ti-6Al-4V ELI at High Cutting Speed

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gusri, A. I.; Che Hassan, C. H.; Jaharah, A. G.

2011-01-17

The performance of Chemical Vapor Deposition (CVD) carbide insert with ISO designation of CCMT 12 04 04 LF, when turning titanium alloys was investigated. There were four layers of coating materials for this insert i.e.TiN-Al2O3-TiCN-TiN. The insert performance was evaluated based on the insert's edge resistant towards the machining parameters used at high cutting speed range of machining Ti-6Al-4V ELI. Detailed study on the wear mechanism at the cutting edge of CVD carbide tools was carried out at cutting speed of 55-95 m/min, feed rate of 0.15-0.35 mm/rev and depth of cut of 0.10-0.20 mm. Wear mechanisms such as abrasivemore » and adhesive were observed on the flank face. Crater wear due to diffusion was also observed on the rake race. The abrasive wear occurred more at nose radius and the fracture on tool were found at the feed rate of 0.35 mm/rev and the depth of cut of 0.20 mm. The adhesion wear takes place after the removal of the coating or coating delaminating. Therefore, adhesion or welding of titanium alloy onto the flank and rake faces demonstrates a strong bond at the workpiece-tool interface.« less

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Wear Mechanism of Chemical Vapor Deposition (CVD) Carbide Insert in Orthogonal Cutting Ti-6Al-4V ELI at High Cutting Speed

NASA Astrophysics Data System (ADS)

Gusri, A. I.; Che Hassan, C. H.; Jaharah, A. G.

2011-01-01

The performance of Chemical Vapor Deposition (CVD) carbide insert with ISO designation of CCMT 12 04 04 LF, when turning titanium alloys was investigated. There were four layers of coating materials for this insert i.e.TiN-Al2O3-TiCN-TiN. The insert performance was evaluated based on the insert's edge resistant towards the machining parameters used at high cutting speed range of machining Ti-6Al-4V ELI. Detailed study on the wear mechanism at the cutting edge of CVD carbide tools was carried out at cutting speed of 55-95 m/min, feed rate of 0.15-0.35 mm/rev and depth of cut of 0.10-0.20 mm. Wear mechanisms such as abrasive and adhesive were observed on the flank face. Crater wear due to diffusion was also observed on the rake race. The abrasive wear occurred more at nose radius and the fracture on tool were found at the feed rate of 0.35 mm/rev and the depth of cut of 0.20 mm. The adhesion wear takes place after the removal of the coating or coating delaminating. Therefore, adhesion or welding of titanium alloy onto the flank and rake faces demonstrates a strong bond at the workpiece-tool interface.

Engineering specification and system design for CAD/CAM of custom shoes. Phase 5: UMC involvement (January 1, 1989 - June 30, 1989)

NASA Technical Reports Server (NTRS)

Bao, Han P.

1989-01-01

The CAD/CAM of custom shoes is discussed. The solid object for machining is represented by a wireframe model with its nodes or vertices specified systematically in a grid pattern covering its entire length (point-to-point configuration). Two sets of data from CENCIT and CYBERWARE were used for machining purposes. It was found that the indexing technique (turning the stock by a small angle then moving the tool on a longitudinal path along the foot) yields the best result in terms of ease of programming, savings in wear and tear of the machine and cutting tools, and resolution of fine surface details. The work done using the LASTMOD last design system results in a shoe last specified by a number of congruent surface patches of different sizes. This data format was converted into a form amenable to the machine tool. It involves a series of sorting algorithms and interpolation algorithms to provide the grid pattern that the machine tool needs as was the case in the point to point configuration discussed above. This report also contains an in-depth treatment of the design and production technique of an integrated sole to complement the task of design and manufacture of the shoe last. Clinical data and essential production parameters are discussed. Examples of soles made through this process are given.

A Flexure-Based Tool Holder for Sub-(micro)m Positioning of a Single Point Cutting Tool on a Four-axis Lathe

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bono, M J; Hibbard, R L

2005-12-05

A tool holder was designed to facilitate the machining of precision meso-scale components with complex three-dimensional shapes with sub-{micro}m accuracy on a four-axis lathe. A four-axis lathe incorporates a rotary table that allows the cutting tool to swivel with respect to the workpiece to enable the machining of complex workpiece forms, and accurately machining complex meso-scale parts often requires that the cutting tool be aligned precisely along the axis of rotation of the rotary table. The tool holder designed in this study has greatly simplified the process of setting the tool in the correct location with sub-{micro}m precision. The toolmore » holder adjusts the tool position using flexures that were designed using finite element analyses. Two flexures adjust the lateral position of the tool to align the center of the nose of the tool with the axis of rotation of the B-axis, and another flexure adjusts the height of the tool. The flexures are driven by manual micrometer adjusters, each of which provides a minimum increment of motion of 20 nm. This tool holder has simplified the process of setting a tool with sub-{micro}m accuracy, and it has significantly reduced the time required to set a tool.« less

Evaluation of Process Performance for Sustainable Hard Machining

NASA Astrophysics Data System (ADS)

Rotella, Giovanna; Umbrello, Domenico; , Oscar W. Dillon, Jr.; Jawahir, I. S.

This paper aims to evaluate the sustainability performance of machining operation of through-hardening steel, AISI 52100, taking into account the impact of the material removal process in its various aspects. Experiments were performed for dry and cryogenic cutting conditions using chamfered cubic boron nitride (CBN) tool inserts at varying cutting conditions (cutting speed and feed rate). Cutting forces, mechanical power, tool wear, white layer thickness, surface roughness and residual stresses were investigated in order to evaluate the effects of extreme in-process cooling on the machined surface. The results indicate that cryogenic cooling has the potential to be used for surface integrity enhancement for improved product life and more sustainable functional performance.

Anisotropy in thermal conductivity of graphite flakes–SiC{sub p}/matrix composites: Implications in heat sinking design for thermal management applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Molina, J.M., E-mail: jmmj@ua.es; Departamento de Física Aplicada, Universidad de Alicante, Ap. 99, E-03080 Alicante; Departamento de Química Inorgánica, Universidad de Alicante, Ap. 99, | E-03080 Alicante

2015-11-15

Within the frame of heat dissipation for electronics, a very interesting family of anisotropic composite materials, fabricated by liquid infiltration of a matrix into preforms of oriented graphite flakes and SiC particles, has been recently proposed. Aiming to investigate the implications of the inherent anisotropy of these composites on their thermal conductivity, and hence on their potential applications, materials with matrices of Al–12 wt.% Si alloy and epoxy polymer have been fabricated. Samples have been cut at a variable angle with respect to the flakes plane and thermal conductivity has been measured by means of two standard techniques, namely, steadymore » state technique and laser flash method. Experimental results are presented and discussed in terms of current models, from which important technological implications for heat sinking design can be derived. - Highlights: • Anisotropy in thermal conductivity of graphite flakes-based composites is evaluated. • Samples are cut in a direction forming a variable angle with the oriented flakes. • For angles 0° and 90°, thermal conductivity does not depend on sample geometry. • For intermediate angles, thermal conductivity strongly depends on sample geometry. • “Thin” samples must be thicker than 600 μm, “thick” samples must be encapsulated.« less

Zero-stress states of human pulmonary arteries and veins.

PubMed

Huang, W; Yen, R T

1998-09-01

The zero-stress states of the pulmonary arteries and veins from order 3 to order 9 were determined in six normal human lungs within 15 h postmortem. The zero-stress state of each vessel was obtained by cutting the vessel transversely into a series of short rings, then cutting each ring radially, which caused the ring to spring open into a sector. Each sector was characterized by its opening angle. The mean opening angle varied between 92 and 163 degrees in the arterial tree and between 89 and 128 degrees in the venous tree. There was a tendency for opening angles to increase as the sizes of the arteries and veins increased. We computed the residual strains based on the experimental measurements and estimated the residual stresses according to Hooke's law. We found that the inner wall of a vessel at the state in which the internal pressure, external pressure, and longitudinal stress are all zero was under compression and the outer wall was in tension, and that the magnitude of compressive stress was greater than the magnitude of tensile stress.

Laser Cutting of Thin Nickel Bellows

NASA Technical Reports Server (NTRS)

Butler, C. L.

1986-01-01

Laser cutting technique produces narrow, precise, fast, and repeatable cuts in thin nickel-allow bellows material. Laser cutting operation uses intense focused beam to melt material and assisting gas to force melted material through part thickness, creating void. When part rotated or moved longitudinally, melting and material removal continuous and creates narrow, fast, precise, and repeatable cut. Technique used to produce cuts of specified depths less than material thickness. Avoids distortion, dents, and nicks produced in delicate materials during lathe trimming operations, which require high cutting-tool pressure and holding-fixture forces.

Water Powered Tools

NASA Technical Reports Server (NTRS)

1976-01-01

Space Spin-Offs, Inc. under a contract with Lewis Research Center and Marshall Space Flight Center produced a new water-powered saw that cuts through concrete and steel plate reducing danger of explosion or electric shock in rescue and other operations. In prototype unit efficient water-powered turbine drives an 8 inch diameter grinding disk at 6,600 rpm. Exhaust water cools disk and workpiece quenching any sparks produced by cutting head. At maximum power, tool easily cuts through quarter inch steel plate. Adapter heads for chain saws, impact wrenches, heavy duty drills, and power hack saws can be fitted.

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

NASA Astrophysics Data System (ADS)

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

2015-11-01

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

The material performance of HSS (high speed steel) tools and its relation with chemical composition and carbide distribution

NASA Astrophysics Data System (ADS)

Darmawan, B.; Kusman, M.; Hamdani, R. A.

2016-04-01

The study aims to compare the performance of two types of material HSS (High Speed Steel) are widely used. It also will be the chemical composition and distribution of carbide particles therein. Two types of HSS are available in the market: HSS from Germany (Bohler) and HSS from China. This research employed the pure experimental design. It consists of two stages. The first, aims to test/operate lathe machines to determine the lifetime and performance of tools based on specified wear criteria. The second, characterization of microstructure using SEM-EDS was conducted. Firstly, grinding of toolss was done so that the toolss could be used for cutting metal in the turning process. Grinding processes of the two types of toolss were done at the same geometry, that is side rake angle (12°-18°), angle of keenness (60°-68°), and side relief angle (10°-12°). Likewise, machining parameters were set in the same machining conditions. Based on the results of the tests, it is found that to reach 0.2 mm wear point, toolss made of HSS from Germany needed 24 minutes, while toolss made of HSS from China needed 8 minutes. Next, microstructure tests using SEM/EDS were done. The results of the SEM tests indicate that the carbide particles of HSS from Germany were more evenly distributed than the carbide particles of HSS from China. Carbide compounds identified in HSS from China were Cr23C6 and Fe4Mo2C. Oxide impurity of Al2O3 was also found in the material. On the other hand, in HSS from Germany, no impurity and other carbide compounds were identified, except Cr23C6 and Fe4Mo2C, also Fe4W2C, and VC or V4C3.

Predicting tool life in turning operations using neural networks and image processing

NASA Astrophysics Data System (ADS)

Mikołajczyk, T.; Nowicki, K.; Bustillo, A.; Yu Pimenov, D.

2018-05-01

A two-step method is presented for the automatic prediction of tool life in turning operations. First, experimental data are collected for three cutting edges under the same constant processing conditions. In these experiments, the parameter of tool wear, VB, is measured with conventional methods and the same parameter is estimated using Neural Wear, a customized software package that combines flank wear image recognition and Artificial Neural Networks (ANNs). Second, an ANN model of tool life is trained with the data collected from the first two cutting edges and the subsequent model is evaluated on two different subsets for the third cutting edge: the first subset is obtained from the direct measurement of tool wear and the second is obtained from the Neural Wear software that estimates tool wear using edge images. Although the complete-automated solution, Neural Wear software for tool wear recognition plus the ANN model of tool life prediction, presented a slightly higher error than the direct measurements, it was within the same range and can meet all industrial requirements. These results confirm that the combination of image recognition software and ANN modelling could potentially be developed into a useful industrial tool for low-cost estimation of tool life in turning operations.

Cutting performance orthogonal test of single plane puncture biopsy needle based on puncture force

NASA Astrophysics Data System (ADS)

Xu, Yingqiang; Zhang, Qinhe; Liu, Guowei

2017-04-01

Needle biopsy is a method to extract the cells from the patient's body with a needle for tissue pathological examination. Many factors affect the cutting process of soft tissue, including the geometry of the biopsy needle, the mechanical properties of the soft tissue, the parameters of the puncture process and the interaction between them. This paper conducted orthogonal experiment of main cutting parameters based on single plane puncture biopsy needle, and obtained the cutting force curve of single plane puncture biopsy needle by studying the influence of the inclination angle, diameter and velocity of the single plane puncture biopsy needle on the puncture force of the biopsy needle. Stage analysis of the cutting process of biopsy needle puncture was made to determine the main influencing factors of puncture force during the cutting process, which provides a certain theoretical support for the design of new type of puncture biopsy needle and the operation of puncture biopsy.

Obsidianus lapis rugosity and hardness determination: fibre laser craftsmanship

NASA Astrophysics Data System (ADS)

Aguilar-Morales, A. I.; Velazquez-Gonzalez, J. S.; Marrujo-García, S.; Reyes-Sanchez, J. I.; Alvarez-Chávez, J. A.

2014-05-01

Obsidianus lapis is a volcanic rock that has been worked into tools for cutting or weaponry by Teotihuacan people for hundreds of years. Currently it is used in jewelry or for house decorative items such as elaborated sculptures. From the physico-chemical properties point of view, obsidianus lapis is considered a glass as its composition is 80% silicon dioxide. In México there are different kinds of obsidianus lapis according to its colour: rainbow, black, brown, red, silver, golden and snowflake. The traditional grinding process for working with obsidianus lapis includes fixed grinders and sandpaper for the polishing process, where the craftsman grinds the rock manually obtaining a variety of shapes. Laser processing of natural stones is a relatively new topic. We propose the use of an Yb3+-doped fibre laser for cutting and ablating obsidianus lapis into spherical, rectangular and oval shapes. By means of a theoretical analysis of roughness and hardness, which affect the different surfaces and final shapes, and considering the changes in material temperature during laser interaction, this work will focus on parameter determination such as: laser fluence, incidence angle, laser average power and peak pulse energy, from the proposed Q-switched fibre laser design. Full optical, hardness and rugosity, initial and final, characterization will be included in the presentation.

Computation of noise radiation from turbofans: A parametric study

NASA Technical Reports Server (NTRS)

Nallasamy, M.

1995-01-01

This report presents the results of a parametric study of the turbofan far-field noise radiation using a finite element technique. Several turbofan noise radiation characteristics of both the inlet and the aft ducts have been examined through the finite element solutions. The predicted far-field principal lobe angle variations with duct Mach number and cut-off ratio compare very well with the available analytical results. The solutions also show that the far-field lobe angle is only a function of cut-off ratio, and nearly independent of the mode number. These results indicate that the finite element codes are well suited for the prediction of noise radiation characteristics of a turbofan. The effects of variations in the aft duct geometry are examined. The ability of the codes to handle ducts with acoustic treatments is also demonstrated.

A molecular dynamics investigation into the mechanisms of subsurface damage and material removal of monocrystalline copper subjected to nanoscale high speed grinding

NASA Astrophysics Data System (ADS)

Li, Jia; Fang, Qihong; Liu, Youwen; Zhang, Liangchi

2014-06-01

This paper investigates the mechanisms of subsurface damage and material removal of monocrystalline copper when it is under a nanoscale high speed grinding of a diamond tip. The analysis was carried out with the aid of three-dimensional molecular dynamics simulations. The key factors that would influence the deformation of the material were carefully explored by analyzing the chip, dislocation movement, and workpiece deformation, which include grinding speed, depth of cut, grid tip radius, crystal orientation and machining angle of copper. An analytical model was also established to predict the emission of partial dislocations during the nanoscale high speed grinding. The investigation showed that a higher grinding velocity, a larger tip radius or a larger depth of cut would result in a larger chipping volume and a greater temperature rise in the copper workpiece. A lower grinding velocity would produce more intrinsic stacking faults. It was also found that the transition of deformation mechanisms depends on the competition between the dislocations and deformation twinning. There is a critical machining angle, at which a higher velocity, a smaller tip radius, or a smaller depth of cut will reduce the subsurface damage and improve the smoothness of a ground surface. The established analytical model showed that the Shockley dislocation emission is most likely to occur with the crystal orientations of (0 0 1)[1 0 0] at 45° angle.

SAW parameters on Y-cut langasite structured materials.

PubMed

Puccio, Derek; Malocha, Donald C; Saldanha, Nancy; da Cunha, Mauricio Pereira

2007-09-01

This paper presents results and investigations of several new, man-made piezoelectric single crystal, Czochralski-grown substrate materials for surface acoustic waves (SAW) applications. These materials, langanite (LGN), langatate (LGT), Sr3TaGa3Si2O14 (STGS), Sr3NbGa3Si2O14 (SNGS), Ca3TaGa3Si2O14 (CTGS), and Ca3NbGa3Si2O14 (CNGS), have the same structure as langasite (LGS) and are of the same crystal class as quartz. These compounds are denser than quartz, resulting in lower phase velocities. They also have higher coupling. Unlike quartz and lithium niobate, there is no degradation of material properties below the material melting points resulting in the possibility of extreme high-temperature operation (> 1000 degrees C). This paper gives a summary of extracted SAW material parameters for various propagation angles on Y-cut substrates of the six materials. Parameters included are electromechanical coupling, phase velocity, transducer capacitance, metal strip reflectivity, and temperature coefficient of frequency. Using previously published fundamental material constants, extracted parameters are compared with predictions for LGT and LGN. In addition, power flow angle and fractional frequency curvature data are reported for propagation angles on CTGS and CNGS Y-cut substrates that exhibit temperature compensation near room temperature. Detailed descriptions of the SAW parameter extraction techniques are given. A discussion of the results is provided, including a comparison of extracted parameters and an overview of possible SAW applications.

Technical Manual for the Conceptual Learning and Development Assessment Series II: Cutting Tool. Technical Report No. 435. Reprinted December 1977.

ERIC Educational Resources Information Center

DiLuzio, Geneva J.; And Others

This document accompanies Conceptual Learning and Development Assessment Series II: Cutting Tool, a test constructed to chart the conceptual development of individuals. As a technical manual, it contains information on the rationale, development, standardization, and reliability of the test, as well as essential information and statistical data…

Identification of Tool Wear when Machining of Austenitic Steels and Titatium by Miniature Machining

NASA Astrophysics Data System (ADS)

Pilc, Jozef; Kameník, Roman; Varga, Daniel; Martinček, Juraj; Sadilek, Marek

2016-12-01

Application of miniature machining is currently rapidly increasing mainly in biomedical industry and machining of hard-to-machine materials. Machinability of materials with increased level of toughness depends on factors that are important in the final state of surface integrity. Because of this, it is necessary to achieve high precision (varying in microns) in miniature machining. If we want to guarantee machining high precision, it is necessary to analyse tool wear intensity in direct interaction with given machined materials. During long-term cutting process, different cutting wedge deformations occur, leading in most cases to a rapid wear and destruction of the cutting wedge. This article deal with experimental monitoring of tool wear intensity during miniature machining.

Tool for cutting insulation from electrical cables

DOEpatents

Harless, Charles E.; Taylor, Ward G.

1978-01-01

This invention is an efficient hand tool for precisely slitting the sheath of insulation on an electrical cable--e.g., a cable two inches in diameter--in a manner facilitating subsequent peeling or stripping of the insulation. The tool includes a rigid frame which is slidably fitted on an end section of the cable. The frame carries a rigidly affixed handle and an opposed, elongated blade-and-handle assembly. The blade-and-handle assembly is pivotally supported by a bracket which is slidably mounted on the frame for movement toward and away from the cable, thus providing an adjustment for the depth of cut. The blade-and-handle assembly is mountable to the bracket in two pivotable positions. With the assembly mounted in the first position, the tool is turned about the cable to slit the insulation circumferentially. With the assembly mounted in the second position, the tool is drawn along the cable to slit the insulation axially. When cut both circumferentially and axially, the insulation can easily be peeled from the cable.

The development of Zirconia and Copper toughened Alumina ceramic insert

NASA Astrophysics Data System (ADS)

Amalina Sabuan, Nur; Zolkafli, Nurfatini; Mebrahitom, A.; Azhari, Azmir; Mamat, Othman

2018-04-01

Ceramic cutting tools have been utilized in industry for over a century for its productivity and efficiency in machine tools and cutting tool material. However, due to the brittleness property the application has been limited. In order to manufacture high strength ceramic cutting tools, there is a need for suitable reinforcement to improve its toughness. In this case, copper (Cu) and zirconia (ZrO2) powders were added to investigate the hardness and physical properties of the developed composite insert. A uniaxial pre-forming process of the mix powder was done prior to densification by sintering at 1000 and 1300°C. The effect of the composition of the reinforcement on the hardness, density, shrinkage and microstructure of the inserts was investigated. It was found that an optimum density of 3.26 % and hardness 1385HV was obtained for composite of 10wt % zirconia and 10wt% copper at temperature 1000 °C.

The Cut-Score Operating Function: A New Tool to Aid in Standard Setting

ERIC Educational Resources Information Center

Grabovsky, Irina; Wainer, Howard

2017-01-01

In this essay, we describe the construction and use of the Cut-Score Operating Function in aiding standard setting decisions. The Cut-Score Operating Function shows the relation between the cut-score chosen and the consequent error rate. It allows error rates to be defined by multiple loss functions and will show the behavior of each loss…

Tool Forces and Chip Formation In Orthogonal Cutting Of Loblolly Pine

Treesearch

George E. Woodson; Peter Koch

1970-01-01

Specimens of earlywood and latewood of Pinus taeda L. were excised so that length along the grain was 3 inches and thickness was 0.1 inch. These specimens were cut orthogonally-as with a carpenter's plane-in the three major directions. Cutting velocity was 2 inches per minute. When cutting was in the planing (90-O) direction, thin chips,...

Studies on nanosecond 532nm and 355nm and ultrafast 515nm and 532nm laser cutting super-hard materials

NASA Astrophysics Data System (ADS)

Zhang, Jie; Tao, Sha; Wang, Brian; Zhao, Jay

2017-02-01

In this paper, micro-processing of three kinds of super-hard materials of poly-crystal diamond (PCD)/tungsten-carbide (WC), CVD-diamond and cubic boron nitride (CNB) has been systematically studied using nanosecond laser (532nm and 355nm), and ultrafast laser (532nm and 515nm). Our purpose is to investigate a full laser micro-cutting solution to achieve a ready-to-use cutting tool insert (CTI). The results show a clean cut with little burns and recasting at edge. The cutting speed of 2-10mm/min depending on thickness was obtained. The laser ablation process was also studied by varying laser parameters (wavelength, pulse width, pulse energy, repetition rate) and tool path to improve cutting speed. Also, studies on material removal efficiency (MRE) of PCD/WC with 355nm-ns and 515nm-fs laser as a function of laser fluence show that 355nm-ns laser is able to achieve higher MRE for PCD and WC. Thus, ultrafast laser is not necessarily used for superhard material cutting. Instead, post-polishing with ultrafast laser can be used to clean cutting surface and improve smoothness.

Machinability of titanium metal matrix composites (Ti-MMCs)

NASA Astrophysics Data System (ADS)

Aramesh, Maryam

Titanium metal matrix composites (Ti-MMCs), as a new generation of materials, have various potential applications in aerospace and automotive industries. The presence of ceramic particles enhances the physical and mechanical properties of the alloy matrix. However, the hard and abrasive nature of these particles causes various issues in the field of their machinability. Severe tool wear and short tool life are the most important drawbacks of machining this class of materials. There is very limited work in the literature regarding the machinability of this class of materials especially in the area of tool life estimation and tool wear. By far, polycrystalline diamond (PCD) tools appear to be the best choice for machining MMCs from researchers' point of view. However, due to their high cost, economical alternatives are sought. Cubic boron nitride (CBN) inserts, as the second hardest available tools, show superior characteristics such as great wear resistance, high hardness at elevated temperatures, a low coefficient of friction and a high melting point. Yet, so far CBN tools have not been studied during machining of Ti-MMCs. In this study, a comprehensive study has been performed to explore the tool wear mechanisms of CBN inserts during turning of Ti-MMCs. The unique morphology of the worn faces of the tools was investigated for the first time, which led to new insights in the identification of chemical wear mechanisms during machining of Ti-MMCs. Utilizing the full tool life capacity of cutting tools is also very crucial, due to the considerable costs associated with suboptimal replacement of tools. This strongly motivates development of a reliable model for tool life estimation under any cutting conditions. In this study, a novel model based on the survival analysis methodology is developed to estimate the progressive states of tool wear under any cutting conditions during machining of Ti-MMCs. This statistical model takes into account the machining time in addition to the effect of cutting parameters. Thus, promising results were obtained which showed a very good agreement with the experimental results. Moreover, a more advanced model was constructed, by adding the tool wear as another variable to the previous model. Therefore, a new model was proposed for estimating the remaining life of worn inserts under different cutting conditions, using the current tool wear data as an input. The results of this model were validated with the experimental results. The estimated results were well consistent with the results obtained from the experiments.

Space Science

NASA Image and Video Library

2001-05-01

This photograph shows Wes Brown, Marshall Space Flight Center's (MSFC's) lead diamond tuner, an expert in the science of using diamond-tipped tools to cut metal, inspecting the mold's physical characteristics to ensure the uniformity of its more than 6,000 grooves. This king-size copper disk, manufactured at the Space Optics Manufacturing and Technology Center (SOMTC) at MSFC, is a special mold for making high resolution monitor screens. This master mold will be used to make several other molds, each capable of forming hundreds of screens that have a type of lens called a fresnel lens. Weighing much less than conventional optics, fresnel lenses have multiple concentric grooves, each formed to a precise angle, that together create the curvature needed to focus and project images. The MSFC leads NASA's space optics manufacturing technology development as a technology leader for diamond turning. The machine used to manufacture this mold is among many one-of-a-kind pieces of equipment of MSFC's SOMTC.

Evaluation of the performance during hard turning of OHNS steel with minimal cutting fluid application and its comparison with minimum quantity lubrication

NASA Astrophysics Data System (ADS)

Raj, Anil; Wins, K. Leo Dev; Varadarajan, A. S.

2016-09-01

Cutting fluid application plays a significant role in the manufacturing industries that acts as a coolant as well as a lubricant. The conventional flood cooling application of cutting fluids not only increases the production cost on account of the expenses involved in procurement, storage and disposal but also creates serious environmental and health hazards. In order to overcome these negative effects, techniques like Minimum quantity lubrication (MQL) and Minimal Cutting fluid application (MCFA) have increasingly found their way into the area of metal cutting and have already been established as an alternative to conventional wet machining. This paper investigates the effect of minimal Cutting fluid application (MCFA) which involves application of high velocity pulsing jet of proprietary cutting fluids at the contact zones using a special fluid application system. During hard turning of oil hardened non shrinkable steel (OHNS) on cutting temperature and tool wear and to compare the performance with Minimum quantity lubrication (MQL) assisted hard turning in which cutting fluid is carried in a high velocity stream of air. An attempt was also made to compare the performance during Turning with MCFA and MQL application with conventional wet and dry turning by analysing the tool wear pattern using SEM images.

Perceived orientation, spatial layout and the geometry of pictures

NASA Technical Reports Server (NTRS)

Goldstein, E. Bruce

1989-01-01

The purpose is to discuss the role of geometry in determining the perception of spatial layout and perceived orientation in pictures viewed at an angle. This discussion derives from Cutting's (1988) suggestion, based on his analysis of some of the author's data (Goldstein, 1987), that the changes in perceived orientation that occur when pictures are viewed at an angle can be explained in terms of geometrically produced changes in the picture's virtual space.

Study of the time and effort signal in cutting operations

NASA Astrophysics Data System (ADS)

Grosset, E.; Maillard, A.; Bouhelier, C.; Gasnier, J.

1990-02-01

Perception and treatment of an effort signal by computer methods is discussed. An automatic control system used to measure the wear of machine tools and carry out quality control throughout the cutting process is described. The testing system is used to evaluate the performance of tools which have been vacuum plated. The system is used as part of the BRITE study, the goal of which is to develop an expert system for measuring the wear of tools used during drilling and perforation operations.

Performance of Metal Cutting on Endmills Manufactured by Cooling-Air and Minimum Quantity Lubrication Grinding

NASA Astrophysics Data System (ADS)

Inoue, Shigeru; Aoyama, Tojiro

Grinding fluids have been commonly used during the grinding of tools for their cooling and lubricating effect since the hard, robust materials used for cutting tools are difficult to grind. Grinding fluids help prevent a drop in hardness due to burning of the cutting edge and keep chipping to an absolute minimum. However, there is a heightened awareness of the need to improve the work environment and protect the global environment. Thus, the present study is aimed at applying dry grinding, cooling-air grinding, cooling-air grinding with minimum quantity lubrication (MQL), and oil-based fluid grinding to manufacturing actual endmills (HSS-Co). Cutting tests were performed by a vertical machining center. The results indicated that the lowest surface inclination values and longest tool life were obtained by cooling-air grinding with MQL. Thus, cooling-air grinding with MQL has been demonstrated to be at least as effective as oil-based fluid grinding.

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075.

PubMed

Ghasemi, Amir Hossein; Khorasani, Amir Mahyar; Gibson, Ian

2018-01-16

Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5-8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy.

Structural state scale-dependent physical characteristics and endurance of cermet composite for cutting metal

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ovcharenko, V. E., E-mail: ovcharenko.ove45@mail.ru; Ivanov, Yu. F., E-mail: ivanov.yufi55@mail.ru; Mohovikov, A. A., E-mail: mohovikov.maa28@rambler.ru

A structural-phase state developed on the surface of a TiC/Ni–Cr–Al cermet alloy under superfast heating and cooling produced by pulse electron beam melting has been presented. The effect of the surface’s structural state multimodality on the temperature dependencies of the friction and endurance of the cermet tool in cutting metal has been investigated. The high-energy flux treatment of subsurface layers by electron beam pulses in argon-containing gas discharge plasma serves to improve the endurance of metal cutting tools manifold (by a factor of 6), to reduce the friction via precipitation of secondary 200 nm carbides in binder interlayers. It ismore » possible to improve the cermet tool endurance for cutting metal by a factor of 10–12 by irradiating the cermet in a reactive nitrogen-containing atmosphere with the ensuing precipitation of nanosize 50 nm AlN particles in the binder interlayers.« less

Fractal characteristic in the wearing of cutting tool

NASA Astrophysics Data System (ADS)

Mei, Anhua; Wang, Jinghui

1995-11-01

This paper studies the cutting tool wear with fractal geometry. The wearing image of the flank has been collected by machine vision which consists of CCD camera and personal computer. After being processed by means of preserving smoothing, binary making and edge extracting, the clear boundary enclosing the worn area has been obtained. The fractal dimension of the worn surface is calculated by the methods called `Slit Island' and `Profile'. The experiments and calciating give the conclusion that the worn surface is enclosed by a irregular boundary curve with some fractal dimension and characteristics of self-similarity. Furthermore, the relation between the cutting velocity and the fractal dimension of the worn region has been submitted. This paper presents a series of methods for processing and analyzing the fractal information in the blank wear, which can be applied to research the projective relation between the fractal structure and the wear state, and establish the fractal model of the cutting tool wear.

Experimental Parametric Model for Indirect Adhesion Wear Measurement in the Dry Turning of UNS A97075 (Al-Zn) Alloy

PubMed Central

Trujillo, Francisco Javier; Sevilla, Lorenzo; Marcos, Mariano

2017-01-01

In this work, the study of the influence of cutting parameters (cutting speed, feed, and depth of cut) on the tool wear used in in the dry turning of cylindrical bars of the UNS A97075 (Al-Zn) alloy, has been analyzed. In addition, a study of the physicochemical mechanisms of the secondary adhesion wear has been carried out. The behavior of this alloy, from the point of view of tool wear, has been compared to similar aeronautical aluminum alloys, such as the UNS A92024 (Al-Cu) alloy and UNS A97050 (Al-Zn) alloy. Furthermore, a first approach to the measurement of the 2D surface of the adhered material on the rake face of the tool has been conducted. Finally, a parametric model has been developed from the experimental results. This model allows predicting the intensity of the secondary adhesion wear as a function of the cutting parameters applied. PMID:28772510

Drilling of CFRP and GFRP composite laminates using one shot solid carbide step drill K44

NASA Astrophysics Data System (ADS)

Nagaraja, R.; Rangaswamy, T.

2018-04-01

Drilling is a very common machining operation to install fasteners for assembly of laminates Drilling of Carbon Fiber Reinforced Plastic (CFRP) and Glass Fiber Reinforced Plastic (GFRP) composite laminate materials are different from that of convention materials that causes excessive tool wear and edge delamination. This paper reports on the tool geometry, cutting speed and feed rate. In this work two composite materials CFRP-G926 and Glass-7781 composite materials of varying thickness are drilled to investigate the effect of feed rate, and cutting speed. The study mainly focused on drilling laminates specimen of varying thickness 9 mm, 9.6 mm and 12 mm by using a single shot solid carbide step drill K44. The drilling is performed from lower to higher feed rate and cutting speed to investigate the hole quality, bottom top edge delamination, fiber breakages and local cracks. The work performed shows that a proper combination of tool geometry, cutting speed and feed rate can help to reduce the occurrence of delamination.

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

PubMed Central

Ghasemi, Amir Hossein; Khorasani, Amir Mahyar

2018-01-01

Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5–8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy. PMID:29337858

Microwave interferometer controls cutting depth of plastics

NASA Technical Reports Server (NTRS)

Heisman, R. M.; Iceland, W. F.

1969-01-01

Microwave interferometer system controls the cutting of plastic materials to a prescribed depth. The interferometer is mounted on a carriage with a spindle and cutting tool. A cross slide, mounted on the carriage, allows the interferometer and cutter to move toward or away from the plastic workpiece.

AN EXPERIMENTAL STUDY OF CUTTING FLUID EFFECTS IN DRILLING. (R825370C057)

EPA Science Inventory

Experiments were designed and conducted on aluminum alloys and gray cast iron to determine the function of cutting fluid in drilling. The variables examined included speed, feed, hole depth, tool and workpiece material, cutting fluid condition, workpiece temperatures and drill...

Scissors: More than a Cut Above

ERIC Educational Resources Information Center

Suzanne, Teri

2005-01-01

Scissors are a unique interactive tool when successfully used, allowing teachers and students to recognize and explore each other's creative ability while nurturing mutual communication. Freehand cutting gives children freedom to create as they cut. Scissors have the power to improve fine motor skills, stimulate creative imagination, reinforce…

Machine Tool Software

NASA Technical Reports Server (NTRS)

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.

Thermographic measurements of high-speed metal cutting

NASA Astrophysics Data System (ADS)

Mueller, Bernhard; Renz, Ulrich

2002-03-01

Thermographic measurements of a high-speed cutting process have been performed with an infrared camera. To realize images without motion blur the integration times were reduced to a few microseconds. Since the high tool wear influences the measured temperatures a set-up has been realized which enables small cutting lengths. Only single images have been recorded because the process is too fast to acquire a sequence of images even with the frame rate of the very fast infrared camera which has been used. To expose the camera when the rotating tool is in the middle of the camera image an experimental set-up with a light barrier and a digital delay generator with a time resolution of 1 ns has been realized. This enables a very exact triggering of the camera at the desired position of the tool in the image. Since the cutting depth is between 0.1 and 0.2 mm a high spatial resolution was also necessary which was obtained by a special close-up lens allowing a resolution of app. 45 microns. The experimental set-up will be described and infrared images and evaluated temperatures of a titanium alloy and a carbon steel will be presented for cutting speeds up to 42 m/s.

Evaluation of Hard Coating Performance in Drilling Compacted Graphite Iron (CGI)

NASA Astrophysics Data System (ADS)

de Paiva, José M. F.; Amorim, Fred L.; Soares, P.; Torres, Ricardo D.

2013-10-01

The aim of this investigation was to compare the performance of the following commercial coatings system, TiAlN/TiN, AlCrN, and TiSiN/AlCrN, deposited in cemented carbide tools in drilling compact graphite iron (CGI). The drilling tests were conducted adopting two cutting speeds: 80 or 150 m/min. For each test condition, the tool flank wear, the machining feed force, and the circularity and the roughness of the resulting drilled hole were determined. At the cutting speed of 80 m/min, the results revealed that the tool life, in terms of flank wear, was improved for the Cr-based coatings, while the multilayered coatings presented a better performance at the cutting speed of 150 m/min. It was also found that feed force is substantially increased when drilling at a cutting speed of 150 m/min. The holes drilled with the TiSiN/AlCrN at a cutting speed of 150 m/min showed the best circularity. The drill roughness is directly influenced by the coating system wear and iron adhesion. Consequently, it was found that the lowest holes' roughness was obtained with TiSiN/AlCrN at 80 m/min.

Two-dimensional planning can result in internal rotation of the femoral component in total knee arthroplasty.

PubMed

Okamoto, Shigetoshi; Mizu-uchi, Hideki; Okazaki, Ken; Hamai, Satoshi; Tashiro, Yasutaka; Nakahara, Hiroyuki; Iwamoto, Yukihide

2016-01-01

The first purpose of this study was to compare the reproducibility of two-dimensional (2D) and three-dimensional (3D) measurements for preoperative planning of the femoral side in total knee arthroplasty (TKA). The second purpose was to evaluate the factors affecting the differences between the 2D and 3D measurements. Two-dimensional and 3D measurements for preoperative planning of the femoral side in TKA were evaluated in 75 varus knees with osteoarthritis. The femoral valgus angle, defined as the angle between the mechanical and anatomical axes of the femur, and the clinical rotation angle and surgical rotation angle, defined by the angles between the posterior condylar line and the clinical or surgical transepicondylar axes, respectively, were analysed using 2D (radiographs and axial CT slices) and 3D (3D bone models reconstructed from CT images) measurements. For all variables, 3D measurements were more reliable and reproducible than 2D measurements. The medians and ranges of the clinical rotation angle and surgical rotation angle were 6.6° (-1.7° to 12.1°) and 2.3° (-2.5° to 8.6°) in 2D, and 7.1° (2.7° to 11.4°) and 3.0° (-2.0° to 7.5°) in 3D. Varus/valgus alteration of the CT scanning direction relative to the mechanical axis affected the difference in clinical rotation angles between 2D and 3D measurements. Significantly, smaller values of the clinical rotation angle and surgical rotation angle were obtained by 2D compared to 3D measurements, which could result in internal rotation of the femoral component even if the surgeon performs the bone cutting precisely. Regarding clinical relevance, first, this study confirmed the reliability of 3D measurements. Second, it underscored the risk of internal rotation of the femoral component when using 2D measurement, even with precise bone cutting technique. These results will help surgeons avoid malpositioning of the femoral component if 2D measurements are used for preoperative planning in TKA. Prospective comparative study, Level Ш.

Application of dynamic milling in stainless steel processing

NASA Astrophysics Data System (ADS)

Shan, Wenju

2017-09-01

This paper mainly introduces the method of parameter setting for NC programming of stainless steel parts by dynamic milling. Stainless steel is of high plasticity and toughness, serious hard working, large cutting force, high temperature in cutting area and easy wear of tool. It is difficult to process material. Dynamic motion technology is the newest NC programming technology of Mastercam software. It is an advanced machining idea. The tool path generated by the dynamic motion technology is more smooth, more efficient and more stable in the machining process. Dynamic motion technology is very suitable for cutting hard machining materials.

Tool wear modeling using abductive networks

NASA Astrophysics Data System (ADS)

Masory, Oren

1992-09-01

A tool wear model based on Abductive Networks, which consists of a network of `polynomial' nodes, is described. The model relates the cutting parameters, components of the cutting force, and machining time to flank wear. Thus real time measurements of the cutting force can be used to monitor the machining process. The model is obtained by a training process in which the connectivity between the network's nodes and the polynomial coefficients of each node are determined by optimizing a performance criteria. Actual wear measurements of coated and uncoated carbide inserts were used for training and evaluating the established model.

Surface coating metrology of carbides of cutting tools

NASA Astrophysics Data System (ADS)

Parfenov, V. D.; Basova, G. D.

2017-10-01

The coatings were studied by their main sign of the micrometric thickness by means of coating destruction and electron microscopical study of cleavage surfaces. Shock stress ruptures of heated carbides of cutting tools were performed. The discovery of the coating technology and creation of the coating structure for nonuniform and nonequilibrium conditions of the cutting process were dealt with. Multifracture microdestruction of nitride coatings, caused by complex external influences, was analysed to reveal the mechanism of interaction of elementary failures. Positive results were obtained in the form of improving the strength and wear resistance of the product, crack resistance increasing.

Metal Flow in Friction Stir Welding

NASA Technical Reports Server (NTRS)

Nunes, Arthur C., Jr.

2006-01-01

The plastic deformation field in Friction Stir Welding (FSW) is compared to that in metal cutting. A shear surface around the FSW tool analogous to the metal cutting shear plane is identified and comprises the basis of the "rotating plug" flow field model and the "wiping" model of tool interaction with weld metal. Within the context of these models: The FSW shear rate is estimated to be comparable to metal cutting shear rates. The effect of tool geometry on the FSW shear surface is discussed and related to published torque measurements. Various FS W structural features are explained, including a difference in structure of bimetallic welds when alloys on the advancing and retreating sides of the weld seam are exchanged. The joining mechanism and critical parameters of the FSW process are made clear.

Thinning Guidelines For Southern Bottomland Hardwood Forests

Treesearch

James S. Meadows

1996-01-01

Thinnings, improvement cuttings, and other partial cuttings in southern bottomland hardwood forests are generally designed to enhance the growth and development of those species favored for management objectives. Hardwood tree classes and stocking guides can be used as tools to aid in planning and conducting partial cuttings in hardwood forests. Two disadvantages...

Spinal sagittal contour affecting falls: cut-off value of the lumbar spine for falls.

PubMed

Ishikawa, Yoshinori; Miyakoshi, Naohisa; Kasukawa, Yuji; Hongo, Michio; Shimada, Yoichi

2013-06-01

Spinal deformities reportedly affect postural instability or falls. To prevent falls in clinical settings, the determination of a cut-off angle of spinal sagittal contour associated with increase risk for falls would be useful for screening for high-risk fallers. The purpose of this study was to calculate the spinal sagittal contour angle associated with increased risk for falls during medical checkups in community dwelling elders. The subjects comprised 213 patients (57 men, 156 women) with a mean age of 70.1 years (range, 55-85 years). The upright and flexion/extension thoracic kyphosis and lumbar lordosis angles, and the spinal inclination were evaluated with SpinalMouse(®). Postural instability was evaluated by stabilometry, using the total track length (LNG), enveloped areas (ENV), and track lengths in the lateral and anteroposterior directions (X LNG and Y LNG, respectively). The back extensor strength (BES) was measured using a strain-gauge dynamometer. The relationships among the parameters were analyzed statistically. Age, lumbar lordosis, spinal inclination, LNG, X LNG, Y LNG, and BES were significantly associated with falls (P<0.05). Multivariate logistic regression analyses revealed that lumbar lordosis was the most significant factor (P<0.01). Univariate logistic regression analyses for falls about lumbar lordosis angles revealed that angles of 3° and less were significant for falls. The present findings suggest that increased age, spinal inclination, LNG, X LNG, Y LNG, and decreased BES and lumbar lordosis, are associated with falls. An angle of lumbar lordosis of 3° or less was associated with falls in these community-dwelling elders. Copyright © 2012 Elsevier B.V. All rights reserved.

Barb geometry of asymmetrical feathers reveals a transitional morphology in the evolution of avian flight

PubMed Central

Feo, Teresa J.; Field, Daniel J.; Prum, Richard O.

2015-01-01

The geometry of feather barbs (barb length and barb angle) determines feather vane asymmetry and vane rigidity, which are both critical to a feather's aerodynamic performance. Here, we describe the relationship between barb geometry and aerodynamic function across the evolutionary history of asymmetrical flight feathers, from Mesozoic taxa outside of modern avian diversity (Microraptor, Archaeopteryx, Sapeornis, Confuciusornis and the enantiornithine Eopengornis) to an extensive sample of modern birds. Contrary to previous assumptions, we find that barb angle is not related to vane-width asymmetry; instead barb angle varies with vane function, whereas barb length variation determines vane asymmetry. We demonstrate that barb geometry significantly differs among functionally distinct portions of flight feather vanes, and that cutting-edge leading vanes occupy a distinct region of morphospace characterized by small barb angles. This cutting-edge vane morphology is ubiquitous across a phylogenetically and functionally diverse sample of modern birds and Mesozoic stem birds, revealing a fundamental aerodynamic adaptation that has persisted from the Late Jurassic. However, in Mesozoic taxa stemward of Ornithurae and Enantiornithes, trailing vane barb geometry is distinctly different from that of modern birds. In both modern birds and enantiornithines, trailing vanes have larger barb angles than in comparatively stemward taxa like Archaeopteryx, which exhibit small trailing vane barb angles. This discovery reveals a previously unrecognized evolutionary transition in flight feather morphology, which has important implications for the flight capacity of early feathered theropods such as Archaeopteryx and Microraptor. Our findings suggest that the fully modern avian flight feather, and possibly a modern capacity for powered flight, evolved crownward of Confuciusornis, long after the origin of asymmetrical flight feathers, and much later than previously recognized. PMID:25673687

Analysis and control on changeable wheel tool system of hybrid grinding and polishing machine tool for blade finishing

NASA Astrophysics Data System (ADS)

He, Qiuwei; Lv, Xingming; Wang, Xin; Qu, Xingtian; Zhao, Ji

2017-01-01

Blade is the key component in the energy power equipment of turbine, aircraft engines and so on. Researches on the process and equipment for blade finishing become one of important and difficult point. To control precisely tool system of developed hybrid grinding and polishing machine tool for blade finishing, the tool system with changeable wheel for belt polishing is analyzed in this paper. Firstly, the belt length and wrap angle of each wheel in different position of tension wheel swing angle in the process of changing wheel is analyzed. The reasonable belt length is calculated by using MATLAB, and relationships between wrap angle of each wheel and cylinder expansion amount of contact wheel are obtained. Then, the control system for changeable wheel tool structure is developed. Lastly, the surface roughness of blade finishing is verified by experiments. Theoretical analysis and experimental results show that reasonable belt length and wheel wrap angle can be obtained by proposed analysis method, the changeable wheel tool system can be controlled precisely, and the surface roughness of blade after grinding meets the design requirements.

Nonlinear Properties in Langasite Isomorphs for Advanced Frequency Control Devices and Clocks

DTIC Science & Technology

2006-11-01

or LGN), and langatate (La3Ga5.5Ta0.5O14 or LGT), have emerged as new materials to replace quartz in advanced frequency control devices and clocks...application and of angle Ψ. Fig. 1. Langatate boule (photo courtesy of the Univ. Central Florida) and typical resonators for testing. Table 1...langanite and y-cut langatate ,” IEEE Tr. Ultrason. Ferroelec. Freq. Contr., pp. 1678-1682, 2003. Kim, Y., “Amplitude-frequency effect of Y-cut langanite

Modelling and simulation of effect of ultrasonic vibrations on machining of Ti6Al4V.

PubMed

Patil, Sandip; Joshi, Shashikant; Tewari, Asim; Joshi, Suhas S

2014-02-01

The titanium alloys cause high machining heat generation and consequent rapid wear of cutting tool edges during machining. The ultrasonic assisted turning (UAT) has been found to be very effective in machining of various materials; especially in the machining of "difficult-to-cut" material like Ti6Al4V. The present work is a comprehensive study involving 2D FE transient simulation of UAT in DEFORM framework and their experimental characterization. The simulation shows that UAT reduces the stress level on cutting tool during machining as compared to that of in continuous turning (CT) barring the penetration stage, wherein both tools are subjected to identical stress levels. There is a 40-45% reduction in cutting forces and about 48% reduction in cutting temperature in UAT over that of in CT. However, the reduction magnitude reduces with an increase in the cutting speed. The experimental analysis of UAT process shows that the surface roughness in UAT is lower than in CT, and the UATed surfaces have matte finish as against the glossy finish on the CTed surfaces. Microstructural observations of the chips and machined surfaces in both processes reveal that the intensity of thermal softening and shear band formation is reduced in UAT over that of in CT. Copyright © 2013 Elsevier B.V. All rights reserved.

A novel diamond micro-/nano-machining process for the generation of hierarchical micro-/nano-structures

NASA Astrophysics Data System (ADS)

Zhu, Zhiwei; To, Suet; Ehmann, Kornel F.; Xiao, Gaobo; Zhu, Wule

2016-03-01

A new mechanical micro-/nano-machining process that combines rotary spatial vibrations (RSV) of a diamond tool and the servo motions of the workpiece is proposed and applied for the generation of multi-tier hierarchical micro-/nano-structures. In the proposed micro-/nano-machining system, the servo motion, as the primary cutting motion generated by a slow-tool-servo, is adopted for the fine generation of the primary surfaces with complex shapes. The RSV, as the tertiary cutting operation, is superimposed on the secondary fundamental rotary cutting motion to construct secondary nano-structures on the primary surface. Since the RSV system generally works at much higher frequencies and motion resolution than the primary and secondary motions, it leads to an inherent hierarchical cutting architecture. To investigate the machining performance, complex micro-/nano-structures were generated and explored by both numerical simulations and actual cutting tests. Rotary vibrations of the diamond tool at a constant rotational distance offer an inherent constant cutting velocity, leading to the ability for the generation of homogeneous micro-/nano-structures with fixed amplitudes and frequencies of the vibrations, even over large-scale surfaces. Furthermore, by deliberately combining the non-resonant three-axial vibrations and the servo motion, the generation of a variety of micro-/nano-structures with complex shapes and with flexibly tunable feature sizes can be achieved.

Posterior Tibial Slope Angle Correlates With Peak Sagittal and Frontal Plane Knee Joint Loading During Robotic Simulations of Athletic Tasks.

PubMed

Bates, Nathaniel A; Nesbitt, Rebecca J; Shearn, Jason T; Myer, Gregory D; Hewett, Timothy E

2016-07-01

Tibial slope angle is a nonmodifiable risk factor for anterior cruciate ligament (ACL) injury. However, the mechanical role of varying tibial slopes during athletic tasks has yet to be clinically quantified. To examine the influence of posterior tibial slope on knee joint loading during controlled, in vitro simulation of the knee joint articulations during athletic tasks. Descriptive laboratory study. A 6 degree of freedom robotic manipulator positionally maneuvered cadaveric knee joints from 12 unique specimens with varying tibial slopes (range, -7.7° to 7.7°) through drop vertical jump and sidestep cutting tasks that were derived from 3-dimensional in vivo motion recordings. Internal knee joint torques and forces were recorded throughout simulation and were linearly correlated with tibial slope. The mean (±SD) posterior tibial slope angle was 2.2° ± 4.3° in the lateral compartment and 2.3° ± 3.3° in the medial compartment. For simulated drop vertical jumps, lateral compartment tibial slope angle expressed moderate, direct correlations with peak internally generated knee adduction (r = 0.60-0.65), flexion (r = 0.64-0.66), lateral (r = 0.57-0.69), and external rotation torques (r = 0.47-0.72) as well as inverse correlations with peak abduction (r = -0.42 to -0.61) and internal rotation torques (r = -0.39 to -0.79). Only frontal plane torques were correlated during sidestep cutting simulations. For simulated drop vertical jumps, medial compartment tibial slope angle expressed moderate, direct correlations with peak internally generated knee flexion torque (r = 0.64-0.69) and lateral knee force (r = 0.55-0.74) as well as inverse correlations with peak external torque (r = -0.34 to -0.67) and medial knee force (r = -0.58 to -0.59). These moderate correlations were also present during simulated sidestep cutting. The investigation supported the theory that increased posterior tibial slope would lead to greater magnitude knee joint moments, specifically, internally generated knee adduction and flexion torques. The knee torques that positively correlated with increased tibial slope angle in this investigation are associated with heightened risk of ACL injury. Therefore, the present data indicated that a higher posterior tibial slope is correlated to increased knee loads that are associated with heightened risk of ACL injury. © 2016 The Author(s).

Demodulation method for tilted fiber Bragg grating refractometer with high sensitivity

NASA Astrophysics Data System (ADS)

Pham, Xuantung; Si, Jinhai; Chen, Tao; Wang, Ruize; Yan, Lihe; Cao, Houjun; Hou, Xun

2018-05-01

In this paper, we propose a demodulation method for refractive index (RI) sensing with tilted fiber Bragg gratings (TFBGs). It operates by monitoring the TFBG cladding mode resonance "cut-off wavelengths." The idea of a "cut-off wavelength" and its determination method are introduced. The RI sensitivities of TFBGs are significantly enhanced in certain RI ranges by using our demodulation method. The temperature-induced cross sensitivity is eliminated. We also demonstrate a parallel-double-angle TFBG (PDTFBG), in which two individual TFBGs are inscribed in the fiber core in parallel using a femtosecond laser and a phase mask. The RI sensing range of the PDTFBG is significantly broader than that of a conventional single-angle TFBG. In addition, its RI sensitivity can reach 1023.1 nm/refractive index unit in the 1.4401-1.4570 RI range when our proposed demodulation method is used.

Effective suppression of stray light in rotational coherent anti-stokes Raman spectroscopy using an angle-tuned short-wave-pass filter.

PubMed

Bohlin, Alexis; Bengtsson, Per-Erik

2010-08-01

Stray light interference is a common problem in spontaneous rotational Raman spectroscopy and rotational coherent anti-Stokes Raman spectropscopy (CARS). The reason is that the detected spectrum appears in the spectral vicinity of the probe beam wavelength, and stray light at this wavelength from optics and surfaces is hard to suppress. In this Note, efficient suppression of stray light is demonstrated for rotational CARS measurements using a commercially available short-wave-pass filter. By angle-tuning this filter with a specified cut-off wavelength at 561 nm, the cut-off wavelength could be tuned to a desired spectral position so that more than 80% transmission is achieved as close as 15 cm(-1) (approximately 0.4 nm) from the probe beam wavelength of 532.0 nm, while the intensity at this wavelength is suppressed by two orders of magnitude.

Quaternary low-angle slip on detachment faults in Death Valley, California

USGS Publications Warehouse

Hayman, N.W.; Knott, J.R.; Cowan, D.S.; Nemser, E.; Sarna-Wojcicki, A. M.

2003-01-01

Detachment faults on the west flank of the Black Mountains (Nevada and California) dip 29??-36?? and cut subhorizontal layers of the 0.77 Ma Bishop ash. Steeply dipping normal faults confined to the hanging walls of the detachments offset layers of the 0.64 Ma Lava Creek B tephra and the base of 0.12-0.18 Ma Lake Manly gravel. These faults sole into and do not cut the low-angle detachments. Therefore the detachments accrued any measurable slip across the kinematically linked hanging-wall faults. An analysis of the orientations of hundreds of the hanging-wall faults shows that extension occurred at modest slip rates (<1 mm/yr) under a steep to vertically oriented maximum principal stress. The Black Mountain detachments are appropriately described as the basal detachments of near-critical Coulomb wedges. We infer that the formation of late Pleistocene and Holocene range-front fault scarps accompanied seismogenic slip on the detachments.

Absorptivity modulation on wavy molten steel surfaces: The influence of laser wavelength and angle of incidence

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kaplan, A. F. H.

The modulation of the angle-dependent Fresnel absorptivity across wavy molten steel surfaces during laser materials processing, like drilling, cutting, or welding, has been calculated. The absorptivity is strongly altered by the grazing angle of incidence of the laser beam on the processing front. Owing to its specific Brewster-peak characteristics, the 10.64 {mu}m wavelength CO{sub 2}-laser shows an opposite trend with respect to roughness and angle-of-incidence compared to lasers in the wavelength range of 532-1070 nm. Plateaus or rings of Brewster-peak absorptivity can lead to hot spots on a wavy surface, often in close proximity to cold spots caused by shadowmore » domains.« less

A mechanical analysis of conduit arteries accounting for longitudinal residual strains.

PubMed

Wang, Ruoya; Gleason, Rudolph L

2010-04-01

Identification of an appropriate stress-free reference configuration is critically important in providing a reasonable prediction of the intramural stress distribution when performing biomechanical analyses on arteries. The stress-free state is commonly approximated as a radially cut ring that typically opens into a nearly circular sector, relieving much of the circumferential residual strains that exist in the traction-free configuration. An opening angle is often used to characterize this sector. In this study, we first present experimental results showing significant residual deformations in the longitudinal direction of two commonly studied arteries in the pig: the common carotid artery and the left anterior descending coronary artery. We concluded that a radially cut ring cannot completely describe the stress-free state of the arteries. Instead, we propose the use of a longitudinal opening angle, in conjunction with the traditional circumferential opening angle, to experimentally quantify the stress-free state of an artery. Secondly, we propose a new kinematic model to account for the addition of longitudinal residual strains through employing the longitudinal opening angle and performed a stress analysis. We found that with the inclusion of longitudinal residual strains in the stress analysis, the predicted circumferential stress gradient was decreased by 3-fold and the predicted longitudinal stress gradient was increased by 5.7-fold. Thus, inclusion of longitudinal residual strains has a significant effect on the predicted stress distribution in arteries.

Second Cross-Sectional Study of Attainment of the Concepts "Equilateral Triangle,""Cutting Tool,""Noun," and "Tree" by Children Age 6 to 16 of City B. Technical Report No. 347.

ERIC Educational Resources Information Center

Klausmeier, Herbert J.; And Others

For this study, the second in the cross sectional series, based on the Conceptual Learning and Development (CLD) model, assessment batteries were developed to determine each child's level of attainment and related use of the concepts "equilateral triangle,""cutting tool,""noun," and "tree." Batteries were…

Manufacturing Process Applications Team (MATeam)

NASA Technical Reports Server (NTRS)

1978-01-01

The activities of the Manufacturing Process Applications Team concerning the promotion of joint Industry/Federal Agency/NASA funded research and technology operating plan (RTOP) programs are reported. Direct transfers occurred in cutting tools, laser wire stripping, soldering, and portable X-ray unit technology. TROP program funding approval was obtained for the further development of the cutting tool Sialon and development of an automated nondestructive fracture toughness testing system.

High power laser downhole cutting tools and systems

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zediker, Mark S; Rinzler, Charles C; Faircloth, Brian O

Downhole cutting systems, devices and methods for utilizing 10 kW or more laser energy transmitted deep into the earth with the suppression of associated nonlinear phenomena. Systems and devices for the laser cutting operations within a borehole in the earth. These systems and devices can deliver high power laser energy down a deep borehole, while maintaining the high power to perform cutting operations in such boreholes deep within the earth.

Optimized path planning for soft tissue resection via laser vaporization

NASA Astrophysics Data System (ADS)

Ross, Weston; Cornwell, Neil; Tucker, Matthew; Mann, Brian; Codd, Patrick

2018-02-01

Robotic and robotic-assisted surgeries are becoming more prevalent with the promise of improving surgical outcomes through increased precision, reduced operating times, and minimally invasive procedures. The handheld laser scalpel in neurosurgery has been shown to provide a more gentle approach to tissue manipulation on or near critical structures over classical tooling, though difficulties of control have prevented large scale adoption of the tool. This paper presents a novel approach to generating a cutting path for the volumetric resection of tissue using a computer-guided laser scalpel. A soft tissue ablation simulator is developed and used in conjunction with an optimization routine to select parameters which maximize the total resection of target tissue while minimizing the damage to surrounding tissue. The simulator predicts the ablative properties of tissue from an interrogation cut for tuning and simulates the removal of a tumorous tissue embedded on the surface of healthy tissue using a laser scalpel. We demonstrate the ability to control depth and smoothness of cut using genetic algorithms to optimize the ablation parameters and cutting path. The laser power level, cutting rate and spacing between cuts are optimized over multiple surface cuts to achieve the desired resection volumes.

The effects of fatigue and anticipation on the mechanics of the knee during cutting in female athletes.

PubMed

Collins, Joseph D; Almonroeder, Thomas G; Ebersole, Kyle T; O'Connor, Kristian M

2016-06-01

Unanticipated cutting tasks which do not allow for pre-planning of a movement have been reported to promote knee mechanics which may increase the risk of anterior cruciate ligament injury. Fatigue has also been reported to have similar effects. Athletes must often perform unanticipated tasks when they are fatigued. Previous studies have reported that the effects of anticipation become more prominent as an athlete progresses through a fatigue protocol. However, the protocols previously utilized may not mimic the demands of sports participation. Three-dimensional knee joint kinematics and kinetics were collected from 13 female athletes while they performed a run-and-cut task, before and after completion of an intermittent shuttle run. Trials were further divided (pre-planned, unanticipated) to assess the effects of anticipation. There were no significant interactions between the effects of fatigue and anticipation for the peak knee angles or moments of the knee joint in any plane. Subjects did demonstrate a 68% increase in their peak knee abduction angles following completion of the intermittent shuttle run. Anticipation also had a significant effect on the mechanics of the knee in all planes. Most notably, there was a 23% increase in peak knee abduction angles and a 33% increase in the peak internal knee adduction moments. Both fatigue and anticipation promoted knee mechanics which are associated with an increased risk of knee injury. However, it does not appear that their effects combine when athletes are at a level of fatigue which is thought to reflect sports participation. Copyright © 2016 Elsevier Ltd. All rights reserved.

Numerical Investigation of Delamination in Drilling of Carbon Fiber Reinforced Polymer Composites

NASA Astrophysics Data System (ADS)

Tang, Wenliang; Chen, Yan; Yang, Haojun; Wang, Hua; Yao, Qiwei

2018-03-01

Drilling of carbon fiber reinforced polymer (CFRP) is a challenging task in modern manufacturing sector and machining induced delamination is one of the major problems affecting assembly precision. In this work, a new three-dimensional (3D) finite element model is developed to study the chip formation and entrance delamination in drilling of CFRP composites on the microscopic level. Fiber phase, matrix phase and equivalent homogeneous phase in the multi-phase model have different constitutive behaviors, respectively. A comparative drilling test, in which the cement carbide drill and unidirectional CFRP laminate are employed, is conducted to validate the proposedmodel in terms of the delamination and the similar changing trend is obtained. Microscopic mechanism of entrance delamination together with the chip formation process at four special fiber cutting angles (0°, 45°, 90° and 135°) is investigated. Moreover, the peeling force is also predicted. The results show that the delamination occurrence and the chip formation are both strongly dependent on the fiber cutting angle. The length of entrance delamination rises with increasing fiber cutting angles. Negligible delamination at 0° is attributed to the compression by the minor flank face. For 45° and 90°, the delamination resulted from the mode III fracture. At 135°, serious delamination which is driven by the mode I and III fractures is more inclined to occur and the peeling force reaches its maximum. Such numerical models can help understand the mechanism of hole entrance delamination further and provide guidance for the damage-free drilling of CFRP.

Freon, T-B1 cutting fluid

NASA Technical Reports Server (NTRS)

Peters, R. L.

1969-01-01

Improved cutting fluid completely controls the heat generated from machining operations, thus providing longer tool life. Fluid is especially useful in the working of plastics and replaces less efficient contaminating oils.

Performance evaluation of NEEM oil and HONGE Oil as cutting fluid in drilling operation of mild steel

NASA Astrophysics Data System (ADS)

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

2017-04-01

Cutting fluids are used in machining industries for improving tool life, reducing work piece and thermal deformation, improving surface finish and flushing away chips from the cutting zone. Although the application of cutting fluids increases the tool life and Machining efficiency, but it has many major problems related to environmental impacts and health hazards along with recycling & disposal. These problems gave provision for the introduction of mineral, vegetable and animal oils. These oils play an important role in improving various machining properties, including corrosion protection, lubricity, antibacterial protection, even emulsibility and chemical stability. Compared to mineral oils, vegetable oils in general possess high viscosity index, high flash point, high lubricity and low evaporative losses. Vegetable oils can be edible or non-edible oils and Various researchers have proved that edible vegetable oils viz., palm oil, coconut oil, canola oil, soya bean oil can be effectively used as eco-friendly cutting fluid in machining operations. But in present situations harnessing edible oils for lubricants formation restricts the use due to increased demands of growing population worldwide and availability. In the present work, Non-edible vegetable oil like Neem and Honge are been used as cutting fluid for drilling of Mild steel and its effect on cutting temperature, hardness and surface roughness are been investigated. Results obtained are compared with SAE 20W40 (petroleum based cutting fluid)and dry cutting condition.

A Review on High-Speed Machining of Titanium Alloys

NASA Astrophysics Data System (ADS)

Rahman, Mustafizur; Wang, Zhi-Gang; Wong, Yoke-San

Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine them due to their poor machinability. When machining titanium alloys with conventional tools, the tool wear rate progresses rapidly, and it is generally difficult to achieve a cutting speed of over 60m/min. Other types of tool materials, including ceramic, diamond, and cubic boron nitride (CBN), are highly reactive with titanium alloys at higher temperature. However, binder-less CBN (BCBN) tools, which do not have any binder, sintering agent or catalyst, have a remarkably longer tool life than conventional CBN inserts even at high cutting speeds. In order to get deeper understanding of high speed machining (HSM) of titanium alloys, the generation of mathematical models is essential. The models are also needed to predict the machining parameters for HSM. This paper aims to give an overview of recent developments in machining and HSM of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of titanium alloys.

Novel Gyroscopic Mounting for Crystal Oscillators to Increase Short and Medium Term Stability under Highly Dynamic Conditions.

PubMed

Abedi, Maryam; Jin, Tian; Sun, Kewen

2015-06-17

In this paper, a gyroscopic mounting method for crystal oscillators to reduce the impact of dynamic loads on their output stability has been proposed. In order to prove the efficiency of this mounting approach, each dynamic load-induced instability has been analyzed in detail. A statistical study has been performed on the elevation angle of the g-sensitivity vector of Stress Compensated-cut (SC-cut) crystals. The analysis results show that the proposed gyroscopic mounting method gives good performance for host vehicle attitude changes. A phase noise improvement of 27 dB maximum and 5.7 dB on average can be achieved in the case of steady state loads, while under sinusoidal vibration conditions, the maximum and average phase noise improvement are as high as 24 dB and 7.5 dB respectively. With this gyroscopic mounting method, random vibration-induced phase noise instability is reduced 30 dB maximum and 8.7 dB on average. Good effects are apparent for crystal g-sensitivity vectors with low elevation angle φ and azimuthal angle β. under highly dynamic conditions, indicating the probability that crystal oscillator instability will be significantly reduced by using the proposed mounting approach.

Erosion of a grooved surface caused by impact of particle-laden flow

NASA Astrophysics Data System (ADS)

Jung, Sohyun; Yang, Eunjin; Kim, Ho-Young

2016-11-01

Solid erosion can be a life-limiting process for mechanical elements in erosive environments, thus it is of practical importance in many industries such as construction, mining, and coal conversion. Erosion caused by particle-laden flow occurs through diverse mechanisms, such as cutting, plastic deformation, brittle fracture, fatigue and melting, depending on particle velocity, total particle mass and impingement angle. Among a variety of attempts to lessen erosion, here we investigate the effectiveness of millimeter-sized grooves on the surface. By experimentally measuring the erosion rates of smooth and triangular-grooved surfaces under various impingement angles, we find that erosion can be significantly reduced within a finite range of impingement angles. We show that such erosion resistance is attributed to the swirls of air within grooves and the differences in erosive strength of normal and slanted impact. In particular, erosion is mitigated when we increase the effective area under normal impact causing plastic deformation and fracture while decreasing the area under slanted impact that cuts the surface to a large degree. Our quantitative model for the erosion rate of grooved surfaces considering the foregoing effects agrees with the measurement results.

Three-Dimensional Profiles Using a Spherical Cutting Bit: Problem Solving in Practice

ERIC Educational Resources Information Center

Ollerton, Richard L.; Iskov, Grant H.; Shannon, Anthony G.

2002-01-01

An engineering problem concerned with relating the coordinates of the centre of a spherical cutting tool to the actual cutting surface leads to a potentially rich example of problem-solving techniques. Basic calculus, Lagrange multipliers and vector calculus techniques are employed to produce solutions that may be compared to better understand…

Dentine chips produced by nickel-titanium rotary instruments.

PubMed

Guppy, D R; Curtis, R V; Ford, T R

2000-12-01

This study aimed to compare the cross-sectional shape of two nickel-titanium rotary instruments, namely ProFile and Quantec files, both ISO 25, 0.06 taper, and sought to relate this to the chips produced by cutting dentine. A limited comparison was made with stainless steel engine reamers. First, five files of each type were sectioned transversely at 12 mm, 8 mm and 4 mm from the tip and examined by scanning electron microscopy. The cutting angles were assessed by a direct measurement technique which allowed for the inclination of a cutting edge to the root canal. Second, eight samples of cutting debris were collected from instrumentation by each type of nickel-titanium file and four samples from the engine reamers. The major and minor axis, area and roundness of the dentine chips in each sample were measured using computerized particle analysis. The results demonstrated that all files had a negative cutting angle which varied at the different levels (ProFiles range 69.4 degrees to 58.4 degrees and Quantec range 74.8 degrees to 56.8 degrees). The consistency within files of the same type was good as demonstrated by low standard deviations, except for Quantec files at the 4 mm level where higher standard deviations of 4.1 degrees and 5.5 degrees for the two blades were found. The chip analysis showed significant differences between chips produced by ProFile and Quantec files (P < 0.05). The latter were larger and rounder. The chips from the ProFile and the engine reamer chips were similar in dimension (P > 0.05). No simple relationship existed between file geometry and the dentine chips produced during instrumentation.

Hard particle effect on surface generation in nano-cutting

NASA Astrophysics Data System (ADS)

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-12-01

The influence of the hard particle on the surface generation, plastic deformation and processing forces in nano-cutting of aluminum is investigated by means of molecular dynamics simulations. In this investigation, a hard particle which is simplified as a diamond ball is embedded under the free surface of workpiece with different depths. The influence of the position of the hard ball on the surface generation and other material removal mechanism, such as the movement of the ball under the action of cutting tool edge, is revealed. The results show that when the hard particle is removed, only a small shallow pit is left on the machined surface. Otherwise, it is pressed down to the subsurface of the workpiece left larger and deeper pit on the generated surface. Besides that, the hard particle in the workpiece would increase the processing force when the cutting tool edge or the plastic carriers interact with the hard particle. It is helpful to optimize the cutting parameters and material properties for obtaining better surface quality in nano-cutting of composites or other materials with micro/nanoscale hard particles in it.

A probabilistic-based approach to monitoring tool wear state and assessing its effect on workpiece quality in nickel-based alloys

NASA Astrophysics Data System (ADS)

Akhavan Niaki, Farbod

The objective of this research is first to investigate the applicability and advantage of statistical state estimation methods for predicting tool wear in machining nickel-based superalloys over deterministic methods, and second to study the effects of cutting tool wear on the quality of the part. Nickel-based superalloys are among those classes of materials that are known as hard-to-machine alloys. These materials exhibit a unique combination of maintaining their strength at high temperature and have high resistance to corrosion and creep. These unique characteristics make them an ideal candidate for harsh environments like combustion chambers of gas turbines. However, the same characteristics that make nickel-based alloys suitable for aggressive conditions introduce difficulties when machining them. High strength and low thermal conductivity accelerate the cutting tool wear and increase the possibility of the in-process tool breakage. A blunt tool nominally deteriorates the surface integrity and damages quality of the machined part by inducing high tensile residual stresses, generating micro-cracks, altering the microstructure or leaving a poor roughness profile behind. As a consequence in this case, the expensive superalloy would have to be scrapped. The current dominant solution for industry is to sacrifice the productivity rate by replacing the tool in the early stages of its life or to choose conservative cutting conditions in order to lower the wear rate and preserve workpiece quality. Thus, monitoring the state of the cutting tool and estimating its effects on part quality is a critical task for increasing productivity and profitability in machining superalloys. This work aims to first introduce a probabilistic-based framework for estimating tool wear in milling and turning of superalloys and second to study the detrimental effects of functional state of the cutting tool in terms of wear and wear rate on part quality. In the milling operation, the mechanisms of tool failure were first identified and, based on the rapid catastrophic failure of the tool, a Bayesian inference method (i.e., Markov Chain Monte Carlo, MCMC) was used for parameter calibration of tool wear using a power mechanistic model. The calibrated model was then used in the state space probabilistic framework of a Kalman filter to estimate the tool flank wear. Furthermore, an on-machine laser measuring system was utilized and fused into the Kalman filter to improve the estimation accuracy. In the turning operation the behavior of progressive wear was investigated as well. Due to the nonlinear nature of wear in turning, an extended Kalman filter was designed for tracking progressive wear, and the results of the probabilistic-based method were compared with a deterministic technique, where significant improvement (more than 60% increase in estimation accuracy) was achieved. To fulfill the second objective of this research in understanding the underlying effects of wear on part quality in cutting nickel-based superalloys, a comprehensive study on surface roughness, dimensional integrity and residual stress was conducted. The estimated results derived from a probabilistic filter were used for finding the proper correlations between wear, surface roughness and dimensional integrity, along with a finite element simulation for predicting the residual stress profile for sharp and worn cutting tool conditions. The output of this research provides the essential information on condition monitoring of the tool and its effects on product quality. The low-cost Hall effect sensor used in this work to capture spindle power in the context of the stochastic filter can effectively estimate tool wear in both milling and turning operations, while the estimated wear can be used to generate knowledge of the state of workpiece surface integrity. Therefore the true functionality and efficiency of the tool in superalloy machining can be evaluated without additional high-cost sensing.

Machines employing a hot gas jet to cut metals and nonmetallic materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Polyaev, V.M.; Aleksandrenkov, V.P.

1995-07-01

The flame-cutting of metals is a basic materials-processing operation performed in the course of machine-building and, in some sectors (shipbuilding, aircraft construction, petrochemicals) it is the most important operation. In addition, this method of cutting remains the main operation performed in the processing of scrap metal. The importance of it has occasioned the development of a wide range of cutting tools within just the last decade. Not surprisingly, VNIIavtogen-mash (the All-Union Scientific Research Institute of Machinery for the Gas Welding and Cutting of Metals) is the leading designer of metal-cutting tools in this country. The problem of efficiently cutting metalsmore » is gaining in importance and will continue to do so in coming years in connection with the conversion of military hardware to other uses, the decommissioning of old and obsolete equipment, and utilization of the enormous reserves of scrap in this country. There will thus be a significant increase in the amounts of existing high-alloy steels, nonferrous metals and their alloys, and composites that require cutting. A wide range of cutters is available for the gas-flame cutting of metals, Liquid fuels based on petroleum products are promising from the viewpoint of energy efficiency and performance. The operation of a new generation of cutters, referred to as thermo-gas jet cutters, is based on the principle of the destructive action of a hot, fast-moving, chemically active jet on the material to be cut.« less

Test and study on mirror quality of ultra-precision diamond turning

NASA Astrophysics Data System (ADS)

Chang, Yanyan; Sun, Tao; Li, Zengqiang; Wu, Baosen

2014-09-01

Using the diamond turning lathe and mono crystalline diamond tool, the aluminum alloy of 2A12 was cut under different cutting parameters including cutting speed, feed rate and depth of cut and the mirror surfaces were made. The surface roughness, micro hardness and residual stress of the mirror surface were tested by the surface profiler, the universal hardness tester and X-stress Robot. The influences of the cutting parameters on the mirror quality were studied. The research results have theoretical and practical significance to the selection of the optimal cutting parameters in ultraprecision diamond turning.

Development of a lemon cutting machine.

PubMed

Hrishikesh Tavanandi, A; Deepak, S; Venkateshmurthy, K; Raghavarao, K S M S

2014-12-01

Cutting of lemon and other similar fruits is conventionally done manually by sharp knife, which is labor intensive and often un-hygienic. In the present work, a device has been designed and developed for cutting of lemon hygienically into four pieces of similar shape based on stationery cutters and rotating centralizing/locating slit plate concept. Machine has a unique knife assembly consisting of two bird wing shaped knives, joined by welding perpendicularly to a vertical knife, so that the lemon can be cut into four pieces in a single sweep. Six numbers of rotating centralizing/locating slit plates are welded on to the side plates and the plates carry a groove on its inner face, to enable the wing shaped knife to complete the horizontal cut. The rotating slit plates, having centralizing angle of 90°, are rotated by an electric geared motor. The prototype machine has capacity of over 5,000 lemons/h with a power consumption of 0.11 kW.

Influence of Cut-outs in Elevator on the Static Longitudinal Stability and on the Static Elevator Effect

NASA Technical Reports Server (NTRS)

Biechteler, Curt

1934-01-01

The rudder effect of a sport airplane at high angles of attack was to be improved. This made it necessary to make a cut-out in the center of the continuous elevator so as to enlarge the rudder downward. This cut-out which reduced the rudder area by 12.5 percent changed the static stability of the airplane as well as the elevator effect. Flight measurements showed the stability zone with locked elevator to be 1.8 percent less at full throttle and at idling to be 1.3 percent less than the mean wing chord. The effect of the cut-out on the control forces could not be determined owing to insufficient instrumental accuracy at the extremely low existing forces. The measurement of the static controllability resulting from the cut-out manifested an 18 percent drop in elevator effect at full throttle and a 10 to 20 percent drop at idling, depending on lift.

Ankle mechanics during sidestep cutting implicates need for 2-degrees of freedom powered ankle-foot prostheses.

PubMed

Ficanha, Evandro M; Rastgaar, Mohammad; Kaufman, Kenton R

2015-01-01

The ankle joint of currently available powered prostheses is capable of controlling one degree of freedom (DOF), focusing on improved mobility in the sagittal plane. To increase agility, the requirements of turning in prosthesis design need to be considered. Ankle kinematics and kinetics were studied during sidestep cutting and straight walking. There were no significant differences between the ankle sagittal plane mechanics when comparing sidestep cutting and straight walking; however, significant differences were observed in ankle frontal plane mechanics. During straight walking, the inversion-eversion (IE) angles were smaller than with sidestep cutting. The ankle that initiated the sidestep cutting showed progressively increasing inversion from 2 to 13 degrees while the following contralateral step showed progressively decreasing inversion from 8 to -4 degrees during normal walking speed. The changes in IE kinematics were the most significant during sidestep cutting compared with straight walking. The IE moments of the step that initiated the sidestep cutting were always in eversion, acting as a braking moment opposing the inverting motion. This suggests that an ankle-foot prosthesis with active DOFs in the sagittal and frontal planes will increase the agility of gait for patients with limb loss.

Investigation on Effect of Material Hardness in High Speed CNC End Milling Process.

PubMed

Dhandapani, N V; Thangarasu, V S; Sureshkannan, G

2015-01-01

This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the operator on floor is based on suggested values of the tool manufacturer or by trial and error method. This paper describes effect of various parameters on the surface roughness characteristics of the precision machining part. The prediction method suggested is based on various experimental analysis of parameters in different compositions of input conditions which would benefit the industry on standardization of high speed CNC end milling processes. The results show a basis for selection of parameters to get better results of surface roughness values as predicted by the case study results.

Investigation on Effect of Material Hardness in High Speed CNC End Milling Process

PubMed Central

Dhandapani, N. V.; Thangarasu, V. S.; Sureshkannan, G.

2015-01-01

This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the operator on floor is based on suggested values of the tool manufacturer or by trial and error method. This paper describes effect of various parameters on the surface roughness characteristics of the precision machining part. The prediction method suggested is based on various experimental analysis of parameters in different compositions of input conditions which would benefit the industry on standardization of high speed CNC end milling processes. The results show a basis for selection of parameters to get better results of surface roughness values as predicted by the case study results. PMID:26881267

Liquid Phase Sintering

NASA Technical Reports Server (NTRS)

2004-01-01

Industry spends billions of dollars each year on machine tools to manufacture products out of metal. This includes tools for cutting every kind of metal part from engine blocks to Shuttle main engine components. Cutting tool tips often break because of weak spots or defects in their composition. Based on a new concept called defect trapping, space offers a novel environment to study defect formation in molten metal materials as they solidify. After the return of these materials from space, researchers can evaluate the source of the defect and seek ways to eliminate them in products prepared on Earth. A widely used process for cutting tip manufacturing is liquid phase sintering. Compared to Earth-sintered samples which slump due to buoyancy induced by gravity, space samples are uniformly shaped and defects remain where they are formed. By studying metals sintered in space the US tool industry can potentially enhance its worldwide competitiveness. The Consortium for Materials Development in Space along with Wyle Labs, Teledyne Advanced Materials, and McDornell Douglas have conducted experiments in space.

Microgravity

NASA Image and Video Library

2004-04-15

Industry spends billions of dollars each year on machine tools to manufacture products out of metal. This includes tools for cutting every kind of metal part from engine blocks to Shuttle main engine components. Cutting tool tips often break because of weak spots or defects in their composition. Based on a new concept called defect trapping, space offers a novel environment to study defect formation in molten metal materials as they solidify. After the return of these materials from space, researchers can evaluate the source of the defect and seek ways to eliminate them in products prepared on Earth. A widely used process for cutting tip manufacturing is liquid phase sintering. Compared to Earth-sintered samples which slump due to buoyancy induced by gravity, space samples are uniformly shaped and defects remain where they are formed. By studying metals sintered in space the US tool industry can potentially enhance its worldwide competitiveness. The Consortium for Materials Development in Space along with Wyle Labs, Teledyne Advanced Materials, and McDornell Douglas have conducted experiments in space.

Chatter active control in a lathe machine using magnetostrictive actuator

NASA Astrophysics Data System (ADS)

Nosouhi, R.; Behbahani, S.

2011-01-01

This paper analyzes the chatter phenomena in lathe machines. Chatter is one of the main causes of inaccuracy, reduction of life cycle of the machine and tool wear in machine tools. This phenomenon limits the depth of cut as a function of the cutting speed, which consequently reduces the material removal rate and machining efficiency. Chatter control is therefore important since it increases the stability region in machining and increases the critical depth of cut in machining case. To control the chatter in lathe machines, a magnetostrictive actuator is used. The materials with magnetostriction properties are kind of smart materials of which their length changes as a result of applying an exterior magnetic field, which make them suitable for control applications. It is assumed that the actuator applies the proper force exactly at the point where the machining force is applied on the tool. In this paper the chatter stability lobes is excelled as a result of applying a PID controller on the magnetostrictive actuator equipped-tool in turning.

Evaluation of Partial Cut-out of Sacroiliac Screws From the Sacral Ala Slope via Pelvic Inlet and Outlet View.

PubMed

Zhang, Jingwei; Hamilton, Ryan; Li, Ming; Ebraheim, Nabil A; He, Xianfeng; Liu, Jiayong; Zhu, Limei

2015-12-01

An anatomic and radiographic study of placement of sacroiliac screws. The aim of this study was to quantitatively assess the risk of partial cut-out of sacroiliac screws from the sacral ala slope via inlet and outlet view. The partial cut-out of sacroiliac screws from the superior surface of sacral ala can jeopardize the L5 nerve root, which is difficult to identify on the pelvic inlet and outlet views. Computed tomography images of 60 patients without pelvic ring deformity or injury were used to measure the width (on inlet view) and height (on outlet view) of the sacral ala. The angle of the sacral ala slope was measured on lateral view. According to the measured parameters, the theoretical safe trajectories of screw placement were calculated using inverse trigonometric functions. Under fluoroscopic guidance, a sacroiliac screw was placed close to the midline on both inlet and outlet views, including posterosuperior, posteroinferior, anterosuperior, and anteroinferior regions to the midline. The incidence of screw partial cut-out from the superior surface of sacral ala was identified. The measured widths and heights of the sacral alas were 28.1 ± 2.8 and 29.8 ± 3.1 mm, respectively. The average angle between the superior aspect of the S1 vertebral body and the superior aspect of the sacral ala was 37.2 ± 2.5 degrees. The rate of partial cut-out of the screws from the superior surface of sacral ala slope was 12.5% (5/40) in posterosuperior, 0% (0/40) in posteroinferior, 70% (28/40) in anterosuperior, and 20% (8/40) in anteroinferior. To avoid the risk of partial cut-out from sacroiliac screw placement, more precise description should be added to the conventional description: the sacroiliac screws should be placed at the inferior half portion on outlet view and at the posterior half portion on inlet view. 4.

Large-scale fabrication of micro-lens array by novel end-fly-cutting-servo diamond machining.

PubMed

Zhu, Zhiwei; To, Suet; Zhang, Shaojian

2015-08-10

Fast/slow tool servo (FTS/STS) diamond turning is a very promising technique for the generation of micro-lens array (MLA). However, it is still a challenge to process MLA in large scale due to certain inherent limitations of this technique. In the present study, a novel ultra-precision diamond cutting method, as the end-fly-cutting-servo (EFCS) system, is adopted and investigated for large-scale generation of MLA. After a detailed discussion of the characteristic advantages for processing MLA, the optimal toolpath generation strategy for the EFCS is developed with consideration of the geometry and installation pose of the diamond tool. A typical aspheric MLA over a large area is experimentally fabricated, and the resulting form accuracy, surface micro-topography and machining efficiency are critically investigated. The result indicates that the MLA with homogeneous quality over the whole area is obtained. Besides, high machining efficiency, extremely small volume of control points for the toolpath, and optimal usage of system dynamics of the machine tool during the whole cutting can be simultaneously achieved.

Atomistic aspects of ductile responses of cubic silicon carbide during nanometric cutting

PubMed Central

2011-01-01

Cubic silicon carbide (SiC) is an extremely hard and brittle material having unique blend of material properties which makes it suitable candidate for microelectromechanical systems and nanoelectromechanical systems applications. Although, SiC can be machined in ductile regime at nanoscale through single-point diamond turning process, the root cause of the ductile response of SiC has not been understood yet which impedes significant exploitation of this ceramic material. In this paper, molecular dynamics simulation has been carried out to investigate the atomistic aspects of ductile response of SiC during nanometric cutting process. Simulation results show that cubic SiC undergoes sp3-sp2 order-disorder transition resulting in the formation of SiC-graphene-like substance with a growth rate dependent on the cutting conditions. The disorder transition of SiC causes the ductile response during its nanometric cutting operations. It was further found out that the continuous abrasive action between the diamond tool and SiC causes simultaneous sp3-sp2 order-disorder transition of diamond tool which results in graphitization of diamond and consequent tool wear. PMID:22078069

Atomistic aspects of ductile responses of cubic silicon carbide during nanometric cutting.

PubMed

Goel, Saurav; Luo, Xichun; Reuben, Robert L; Rashid, Waleed Bin

2011-11-11

Cubic silicon carbide (SiC) is an extremely hard and brittle material having unique blend of material properties which makes it suitable candidate for microelectromechanical systems and nanoelectromechanical systems applications. Although, SiC can be machined in ductile regime at nanoscale through single-point diamond turning process, the root cause of the ductile response of SiC has not been understood yet which impedes significant exploitation of this ceramic material. In this paper, molecular dynamics simulation has been carried out to investigate the atomistic aspects of ductile response of SiC during nanometric cutting process. Simulation results show that cubic SiC undergoes sp3-sp2 order-disorder transition resulting in the formation of SiC-graphene-like substance with a growth rate dependent on the cutting conditions. The disorder transition of SiC causes the ductile response during its nanometric cutting operations. It was further found out that the continuous abrasive action between the diamond tool and SiC causes simultaneous sp3-sp2 order-disorder transition of diamond tool which results in graphitization of diamond and consequent tool wear.

Microstructure, Mechanical and Wear Behaviors of Hot-Pressed Copper-Nickel-Based Materials for Diamond Cutting Tools

NASA Astrophysics Data System (ADS)

Miranda, G.; Ferreira, P.; Buciumeanu, M.; Cabral, A.; Fredel, M.; Silva, F. S.; Henriques, B.

2017-08-01

The current trend to replace cobalt in diamond cutting tools (DCT) for stone cutting has motivated the study of alternative materials for this end. The present study characterizes several copper-nickel-based materials (Cu-Ni; Cu-Ni-10Sn, Cu-Ni-15Sn, Cu-Ni-Sn-2WC and Cu-Ni-Sn-10WC) for using as matrix material for diamond cutting tools for stone. Copper-nickel-based materials were produced by hot pressing, at a temperature of 850 °C during 15 min and under an applied pressure of 50 MPa. The mechanical properties were evaluated though the shear strength and hardness values. The microstructures and fracture surfaces were analyzed by SEM. The wear behavior of all specimens was assessed using a reciprocating ball-on-plate tribometer. The hot pressing produced compacts with good densification. Sn and WC promoted enhanced mechanical properties and wear performance to Cu-Ni alloys. Cu-Ni-10Sn and Cu-Ni-10Sn-2WC displayed the best compromise between mechanical and wear performance.

Tool for reading psychrometric charts

NASA Technical Reports Server (NTRS)

De Angelo, F. T.

1969-01-01

Three-legged, clear plastic tool is designed so that the angles of each leg correspond with the angles of psychometric chart construction for each of the three required scales. The appropriate edges are tapered to the chart surface.

The DSM-5 Self-Rated Level 1 Cross-Cutting Symptom Measure as a Screening Tool.

PubMed

Bastiaens, Leo; Galus, James

2018-03-01

The DSM-5 Self-Rated Level 1 Cross-Cutting Symptom Measure was developed to aid clinicians with a dimensional assessment of psychopathology; however, this measure resembles a screening tool for several symptomatic domains. The objective of the current study was to examine the basic parameters of sensitivity, specificity, positive and negative predictive power of the measure as a screening tool. One hundred and fifty patients in a correctional community center filled out the measure prior to a psychiatric evaluation, including the Mini International Neuropsychiatric Interview screen. The above parameters were calculated for the domains of depression, mania, anxiety, and psychosis. The results showed that the sensitivity and positive predictive power of the studied domains was poor because of a high rate of false positive answers on the measure. However, when the lowest threshold on the Cross-Cutting Symptom Measure was used, the sensitivity of the anxiety and psychosis domains and the negative predictive values for mania, anxiety and psychosis were good. In conclusion, while it is foreseeable that some clinicians may use the DSM-5 Self-Rated Level 1 Cross-Cutting Symptom Measure as a screening tool, it should not be relied on to identify positive findings. It functioned well in the negative prediction of mania, anxiety and psychosis symptoms.

Modeling the forces of cutting with scissors.

PubMed

Mahvash, Mohsen; Voo, Liming M; Kim, Diana; Jeung, Kristin; Wainer, Joshua; Okamura, Allison M

2008-03-01

Modeling forces applied to scissors during cutting of biological materials is useful for surgical simulation. Previous approaches to haptic display of scissor cutting are based on recording and replaying measured data. This paper presents an analytical model based on the concepts of contact mechanics and fracture mechanics to calculate forces applied to scissors during cutting of a slab of material. The model considers the process of cutting as a sequence of deformation and fracture phases. During deformation phases, forces applied to the scissors are calculated from a torque-angle response model synthesized from measurement data multiplied by a ratio that depends on the position of the cutting crack edge and the curve of the blades. Using the principle of conservation of energy, the forces of fracture are related to the fracture toughness of the material and the geometry of the blades of the scissors. The forces applied to scissors generally include high-frequency fluctuations. We show that the analytical model accurately predicts the average applied force. The cutting model is computationally efficient, so it can be used for real-time computations such as haptic rendering. Experimental results from cutting samples of paper, plastic, cloth, and chicken skin confirm the model, and the model is rendered in a haptic virtual environment.

Femtosecond Lasers with Diode Pumping for Using in Precision Metrology and Optical Fiber Communication

DTIC Science & Technology

2008-11-24

folding angle of 32° to compensate astigmatism of the Brewster -cut Cr:F crystal. The gain crystal was 17 mm long and introduced positive group-delay...accomplished. For complete stabilization of the femtosecond comb one needs to control its absolute frequency. To realize this we use either angle - tilted...Kerr- lens mode-locking. To the best of our knowledge there is no published works on KLM ytterbium femtosecond lasers with multimode pumping. Stable

Modelling of tunnelling processes and rock cutting tool wear with the particle finite element method

NASA Astrophysics Data System (ADS)

Carbonell, Josep Maria; Oñate, Eugenio; Suárez, Benjamín

2013-09-01

Underground construction involves all sort of challenges in analysis, design, project and execution phases. The dimension of tunnels and their structural requirements are growing, and so safety and security demands do. New engineering tools are needed to perform a safer planning and design. This work presents the advances in the particle finite element method (PFEM) for the modelling and the analysis of tunneling processes including the wear of the cutting tools. The PFEM has its foundation on the Lagrangian description of the motion of a continuum built from a set of particles with known physical properties. The method uses a remeshing process combined with the alpha-shape technique to detect the contacting surfaces and a finite element method for the mechanical computations. A contact procedure has been developed for the PFEM which is combined with a constitutive model for predicting the excavation front and the wear of cutting tools. The material parameters govern the coupling of frictional contact and wear between the interacting domains at the excavation front. The PFEM allows predicting several parameters which are relevant for estimating the performance of a tunnelling boring machine such as wear in the cutting tools, the pressure distribution on the face of the boring machine and the vibrations produced in the machinery and the adjacent soil/rock. The final aim is to help in the design of the excavating tools and in the planning of the tunnelling operations. The applications presented show that the PFEM is a promising technique for the analysis of tunnelling problems.

Relationship between directions of wave and energy propagation for cold plasma waves

NASA Technical Reports Server (NTRS)

Musielak, Zdzislaw E.

1986-01-01

The dispersion relation for plasma waves is considered in the 'cold' plasma approximation. General formulas for the dependence of the phase and group velocities on the direction of wave propagation with respect to the local magnetic field are obtained for a cold magnetized plasma. The principal cold plasma resonances and cut-off frequencies are defined for an arbitrary angle and are used to establish basic regimes of frequency where the cold plasma waves can propagate or can be evanescent. The relationship between direction of wave and energy propagation, for cold plasma waves in hydrogen atmosphere, is presented in the form of angle diagrams (angle between group velocity and magnetic field versus angle between phase velocity and magnetic field) and polar diagrams (also referred to as 'Friedrich's diagrams') for different directions of wave propagation. Morphological features of the diagrams as well as some critical angles of propagation are discussed.

High energy resolution, high angular acceptance crystal monochromator

DOEpatents

Alp, E.E.; Mooney, T.M.; Toellner, T.

1996-06-04

A 4-bounce dispersive crystal monochromator reduces the bandpass of synchrotron radiation to a 10-50 meV range without sacrificing angular acceptance. The monochromator includes the combination of an asymmetrical channel-cut single crystal of lower order reflection and a symmetrical channel-cut single crystal of higher order reflection in a nested geometric configuration. In the disclosed embodiment, a highly asymmetrically cut ({alpha}=20) outer silicon crystal (4 2 2) with low order reflection is combined with a symmetrically cut inner silicon crystal (10 6 4) with high order reflection to condition a hard x-ray component (5--30 keV) of synchrotron radiation down to the {micro}eV-neV level. Each of the crystals is coupled to the combination of a positioning inchworm and angle encoder via a respective rotation stage for accurate relative positioning of the crystals and precise energy tuning of the monochromator. 7 figs.

High energy resolution, high angular acceptance crystal monochromator

DOEpatents

Alp, Ercan E.; Mooney, Timothy M.; Toellner, Thomas

1996-06-04

A 4-bounce dispersive crystal monochromator reduces the bandpass of synchrotron radiation to a 10-50 meV range without sacrificing angular acceptance. The monochromator includes the combination of an asymmetrical channel-cut single crystal of lower order reflection and a symmetrical channel-cut single crystal of higher order reflection in a nested geometric configuration. In the disclosed embodiment, a highly asymmetrically cut (.alpha.=20) outer silicon crystal (4 2 2) with low order reflection is combined with a symmetrically cut inner silicon crystal (10 6 4) with high order reflection to condition a hard x-ray component (5-30 keV) of synchrotron radiation down to the .mu.eV-neV level. Each of the crystals is coupled to the combination of a positioning inchworm and angle encoder via a respective rotation stage for accurate relative positioning of the crystals and precise energy tuning of the monochromator.

FINAL REPORT: DOE CONTRACT NUMBER FG0205ER64026 Biological Neutron Scattering: A Collaboration with the Oak Ridge Center for Structural Molecular Biology

DOE Office of Scientific and Technical Information (OSTI.GOV)

Trewhella, Jill

2011-01-12

The overarching goal of this project was to promote applications of small-angle scattering in structural molecular biology by providing model examples of cutting edge applications that demonstrate the unique capabilities and potential of the DOE national user facilities at Oak Ridge, especially the newly commissioned BioSANS. The approach taken was three-fold: (1) to engage in high impact collaborative research projects that would benefit from small-angle neutron scattering to both demonstrate the power of the technique while expanding the potential user community; (2) to provide access to scattering facilities established at the University of Utah to as broad a set ofmore » researchers as possible to increase the expertise in small-angle scattering generally; and (3) to develop new methods and tools for small-angle scattering. To these ends, three major research collaborations were pursued that resulted in a significant body of published work where neutron scattering and contrast variation played a major role. These major collaborations involved studies of protein complexes involved in (1) bacterial transcription regulation and adaptive response (a DOE/BER priority area); (2) regulation of cardiac muscle; and (3) neuronal disorders. In addition, to broaden the impact of the project, smaller collaborative efforts were supported that used either small-angle X-ray or neutron scattering. Finally, the DOE supported facilities at the University of Utah were made available to researchers on a service basis and a number of independent groups took advantage of this opportunity. In all of this work, there was an emphasis on the training of students and post docs in scattering techniques, and a set of publications (a book chapter, a review, and an encyclopedia article) were produced to guide the non-specialist potential user of scattering techniques in successful applications of the techniques. We also developed a suite of user friendly web-based computational tools currently being accessed world-wide by researchers as an aid in neutron scattering data interpretation. In all, these collaborative projects and resulted in 29 original refereed journal articles published between 2005 and 2010 and engaged groups from at least 14 Universities (10 US, 4 international) and 3 National Laboratories (2 US, 1 international). An important final initiative from this project was to begin a process for international community agreement on a set of standards for the publication of biomolecular small-angle scattering data. This initiative is being championed with the International Union of Crystallography and has engaged a number of Journal Editors and is a very important step in the maturing of this now burgeoning field.« less