Foam-machining tool with eddy-current transducer

NASA Technical Reports Server (NTRS)

Copper, W. P.

1975-01-01

Three-cutter machining system for foam-covered tanks incorporates eddy-current sensor. Sensor feeds signal to numerical controller which programs rotational and vertical axes of sensor travel, enabling cutterhead to profile around tank protrusions.

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

PubMed

Caggiano, Alessandra

2018-03-09

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

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

PubMed Central

2018-01-01

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

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.

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.

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.

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.

Heat-Assisted Machining for Material Removal Improvement

NASA Astrophysics Data System (ADS)

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

2015-09-01

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

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.

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.

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

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 High-speed Milling tool path strategies on the surface roughness of Stavax ESR mold insert machining

NASA Astrophysics Data System (ADS)

Mebrahitom, A.; Rizuan, D.; Azmir, M.; Nassif, M.

2016-02-01

High speed milling is one of the recent technologies used to produce mould inserts due to the need for high surface finish. It is a faster machining process where it uses a small side step and a small down step combined with very high spindle speed and feed rate. In order to effectively use the HSM capabilities, optimizing the tool path strategies and machining parameters is an important issue. In this paper, six different tool path strategies have been investigated on the surface finish and machining time of a rectangular cavities of ESR Stavax material. CAD/CAM application of CATIA V5 machining module for pocket milling of the cavities was used for process planning.

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.

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.

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.

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

Drilling Precise Orifices and Slots

NASA Technical Reports Server (NTRS)

Richards, C. W.; Seidler, J. E.

1983-01-01

Reaction control thrustor injector requires precisely machined orifices and slots. Tooling setup consists of rotary table, numerical control system and torque sensitive drill press. Components used to drill oxidizer orifices. Electric discharge machine drills fuel-feed orifices. Device automates production of identical parts so several are completed in less time than previously.

Experiments and simulation of thermal behaviors of the dual-drive servo feed system

NASA Astrophysics Data System (ADS)

Yang, Jun; Mei, Xuesong; Feng, Bin; Zhao, Liang; Ma, Chi; Shi, Hu

2015-01-01

The machine tool equipped with the dual-drive servo feed system could realize high feed speed as well as sharp precision. Currently, there is no report about the thermal behaviors of the dual-drive machine, and the current research of the thermal characteristics of machines mainly focuses on steady simulation. To explore the influence of thermal characterizations on the precision of a jib boring machine assembled dual-drive feed system, the thermal equilibrium tests and the research on thermal-mechanical transient behaviors are carried out. A laser interferometer, infrared thermography and a temperature-displacement acquisition system are applied to measure the temperature distribution and thermal deformation at different feed speeds. Subsequently, the finite element method (FEM) is used to analyze the transient thermal behaviors of the boring machine. The complex boundary conditions, such as heat sources and convective heat transfer coefficient, are calculated. Finally, transient variances in temperatures and deformations are compared with the measured values, and the errors between the measurement and the simulation of the temperature and the thermal error are 2 °C and 2.5 μm, respectively. The researching results demonstrate that the FEM model can predict the thermal error and temperature distribution very well under specified operating condition. Moreover, the uneven temperature gradient is due to the asynchronous dual-drive structure that results in thermal deformation. Additionally, the positioning accuracy decreases as the measured point became further away from the motor, and the thermal error and equilibrium period both increase with feed speeds. The research proposes a systematical method to measure and simulate the boring machine transient thermal behaviors.

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.

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

Bunshah, R.F.; Shabaik, A.H.

The process of Activated Reactive Evaporation is used to synthesize superhard materials like carbides, oxides, nitrides, ultrafine grain cermets. The deposits are characterized by hardness, microstructure and lattice parameter measurements. The synthesis and characterization of TiC-Ni cermets, Al/sub 2/O/sub 3/ and VC-TiC alloy carbides is given. Tools of different coating characteristics are tested for machining performance at different speeds and feeds. The machining evaluation and the selection of coatings is based on the rate of deterioration of the costing, tool temperature, and cutting forces. Tool life tests show coated high speed steel tools show a 300% improvement in tool life.more » (Author) (GRA)« less

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.

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

Bunshah, R.F.; Shabaik, A.H.

The process of Activated Reactive Evaporation is used to synthesize superhard materials like carbides, oxides, nitrides and ultrafine grain cermets. The deposits are characterized by hardness, microstructure, microprobe analysis for chemistry and lattice parameter measurements. The synthesis and characterization of TiC-Ni cermets and Al/sub 2/O/sub 3/ are given. High speed steel tool coated with TiC, TiC-Ni and TaC are tested for machining performance at different speeds and feeds. The machining evaluation and the selection of coatings is based on the rate of deterioration of the coating tool temperature, and cutting forces. Tool life tests show coated high speed steel toolsmore » having 150 to 300% improvement in tool life compared to uncoated tools. Variability in the quality of the ground edge on high speed steel inserts produce a great scatter in the machining evaluation data.« less

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.

Side Flow Effect on Surface Generation in Nano Cutting

NASA Astrophysics Data System (ADS)

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-05-01

The side flow of material in nano cutting is one of the most important factors that deteriorate the machined surface quality. The effects of the crystallographic orientation, feed, and the cutting tool geometry, including tool edge radius, rake angle and inclination angle, on the side flow are investigated employing molecular dynamics simulation. The results show that the stagnation region is formed in front of tool edge and it is characterized by the stagnation radius R s and stagnation height h s . The side flow is formed because the material at or under the stagnation region is extruded by the tool edge to flow to the side of the tool edge. Higher stagnation height would increase the size of the side flow. The anisotropic nature of the material which partly determines the stagnation region also influences the side flow due to the different deformation mechanism under the action of the tool edge. At different cutting directions, the size of the side flow has a great difference which would finally affect the machined surface quality. The cutting directions of {100} < 011>, {110} < 001>, and {110} < 1-10 > are beneficial to obtain a better surface quality with small side flow. Besides that, the side flow could be suppressed by reducing the feed and optimizing the cutting tool geometry. Cutting tool with small edge radius, large positive rake angle, and inclination angle would decrease the side flow and consequently improve the machined surface quality.

Side Flow Effect on Surface Generation in Nano Cutting.

PubMed

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-12-01

The side flow of material in nano cutting is one of the most important factors that deteriorate the machined surface quality. The effects of the crystallographic orientation, feed, and the cutting tool geometry, including tool edge radius, rake angle and inclination angle, on the side flow are investigated employing molecular dynamics simulation. The results show that the stagnation region is formed in front of tool edge and it is characterized by the stagnation radius R s and stagnation height h s . The side flow is formed because the material at or under the stagnation region is extruded by the tool edge to flow to the side of the tool edge. Higher stagnation height would increase the size of the side flow. The anisotropic nature of the material which partly determines the stagnation region also influences the side flow due to the different deformation mechanism under the action of the tool edge. At different cutting directions, the size of the side flow has a great difference which would finally affect the machined surface quality. The cutting directions of {100} < 011>, {110} < 001>, and {110} < 1-10 > are beneficial to obtain a better surface quality with small side flow. Besides that, the side flow could be suppressed by reducing the feed and optimizing the cutting tool geometry. Cutting tool with small edge radius, large positive rake angle, and inclination angle would decrease the side flow and consequently improve the machined surface quality.

Nondimensional parameter for conformal grinding: combining machine and process parameters

NASA Astrophysics Data System (ADS)

Funkenbusch, Paul D.; Takahashi, Toshio; Gracewski, Sheryl M.; Ruckman, Jeffrey L.

1999-11-01

Conformal grinding of optical materials with CNC (Computer Numerical Control) machining equipment can be used to achieve precise control over complex part configurations. However complications can arise due to the need to fabricate complex geometrical shapes at reasonable production rates. For example high machine stiffness is essential, but the need to grind 'inside' small or highly concave surfaces may require use of tooling with less than ideal stiffness characteristics. If grinding generates loads sufficient for significant tool deflection, the programmed removal depth will not be achieved. Moreover since grinding load is a function of the volumetric removal rate the amount of load deflection can vary with location on the part, potentially producing complex figure errors. In addition to machine/tool stiffness and removal rate, load generation is a function of the process parameters. For example by reducing the feed rate of the tool into the part, both the load and resultant deflection/removal error can be decreased. However this must be balanced against the need for part through put. In this paper a simple model which permits combination of machine stiffness and process parameters into a single non-dimensional parameter is adapted for a conformal grinding geometry. Errors in removal can be minimized by maintaining this parameter above a critical value. Moreover, since the value of this parameter depends on the local part geometry, it can be used to optimize process settings during grinding. For example it may be used to guide adjustment of the feed rate as a function of location on the part to eliminate figure errors while minimizing the total grinding time required.

“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

Applications of Support Vector Machines In Chemo And Bioinformatics

NASA Astrophysics Data System (ADS)

Jayaraman, V. K.; Sundararajan, V.

2010-10-01

Conventional linear & nonlinear tools for classification, regression & data driven modeling are being replaced on a rapid scale by newer techniques & tools based on artificial intelligence and machine learning. While the linear techniques are not applicable for inherently nonlinear problems, newer methods serve as attractive alternatives for solving real life problems. Support Vector Machine (SVM) classifiers are a set of universal feed-forward network based classification algorithms that have been formulated from statistical learning theory and structural risk minimization principle. SVM regression closely follows the classification methodology. In this work recent applications of SVM in Chemo & Bioinformatics will be described with suitable illustrative examples.

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.

Aspects of ultra-high-precision diamond machining of RSA 443 optical aluminium

NASA Astrophysics Data System (ADS)

Mkoko, Z.; Abou-El-Hossein, K.

2015-08-01

Optical aluminium alloys such as 6061-T6 are traditionally used in ultra-high precision manufacturing for making optical mirrors for aerospace and other applications. However, the optics industry has recently witnessed the development of more advanced optical aluminium grades that are capable of addressing some of the issues encountered when turning with single-point natural monocrystalline diamond cutters. The advent of rapidly solidified aluminium (RSA) grades has generally opened up new possibilities for ultra-high precision manufacturing of optical components. In this study, experiments were conducted with single-point diamond cutters on rapidly solidified aluminium RSA 443 material. The objective of this study is to observe the effects of depth of cut and feed rate at a fixed rotational speed on the tool wear rate and resulting surface roughness of diamond turned specimens. This is done to gain further understanding of the rate of wear on the diamond cutters versus the surface texture generated on the RSA 443 material. The diamond machining experiments yielded machined surfaces which are less reflective but with consistent surface roughness values. Cutting tools were observed for wear through scanning microscopy; relatively low wear pattern was evident on the diamond tool edge. The highest tool wear were obtained at higher depth of cut and increased feed rate.

Feed rate affecting surface roughness and tool wear in dry hard turning of AISI 4140 steel automotive parts using TiN+AlCrN coated inserts

NASA Astrophysics Data System (ADS)

Paengchit, Phacharadit; Saikaew, Charnnarong

2018-02-01

This work aims to investigate the effects of feed rate on surface roughness (Ra) and tool wear (VB) and to obtain the optimal operating condition of the feed rate in dry hard turning of AISI 4140 chromium molybdenum steel for automotive industry applications using TiN+AlCrN coated inserts. AISI 4140 steel bars were employed in order to carry out the dry hard turning experiments by varying the feed rates of 0.06, 0.08 and 0.1 mm/rev based on experimental design technique that can be analyzed by analysis of variance (ANOVA). In addition, the cutting tool inserts were examined after machining experiments by SEM to evaluate the effect of turning operations on tool wear. The results showed that averages Ra and VB were significantly affected by the feed rate at the level of significance of 0.05. Averages Ra and VB values at the feed rate of 0.06 mm/rev were lowest compared to average values at the feed rates of 0.08 and 0.1 mm/rev, based on the main effect plot.

Application of Artificial Neural Network and Support Vector Machines in Predicting Metabolizable Energy in Compound Feeds for Pigs.

PubMed

Ahmadi, Hamed; Rodehutscord, Markus

2017-01-01

In the nutrition literature, there are several reports on the use of artificial neural network (ANN) and multiple linear regression (MLR) approaches for predicting feed composition and nutritive value, while the use of support vector machines (SVM) method as a new alternative approach to MLR and ANN models is still not fully investigated. The MLR, ANN, and SVM models were developed to predict metabolizable energy (ME) content of compound feeds for pigs based on the German energy evaluation system from analyzed contents of crude protein (CP), ether extract (EE), crude fiber (CF), and starch. A total of 290 datasets from standardized digestibility studies with compound feeds was provided from several institutions and published papers, and ME was calculated thereon. Accuracy and precision of developed models were evaluated, given their produced prediction values. The results revealed that the developed ANN [ R 2  = 0.95; root mean square error (RMSE) = 0.19 MJ/kg of dry matter] and SVM ( R 2  = 0.95; RMSE = 0.21 MJ/kg of dry matter) models produced better prediction values in estimating ME in compound feed than those produced by conventional MLR ( R 2  = 0.89; RMSE = 0.27 MJ/kg of dry matter). The developed ANN and SVM models produced better prediction values in estimating ME in compound feed than those produced by conventional MLR; however, there were not obvious differences between performance of ANN and SVM models. Thus, SVM model may also be considered as a promising tool for modeling the relationship between chemical composition and ME of compound feeds for pigs. To provide the readers and nutritionist with the easy and rapid tool, an Excel ® calculator, namely, SVM_ME_pig, was created to predict the metabolizable energy values in compound feeds for pigs using developed support vector machine model.

AE Monitoring of Diamond Turned Rapidly Soldified Aluminium 443

NASA Astrophysics Data System (ADS)

Onwuka, G.; Abou-El-Hossein, K.; Mkoko, Z.

2017-05-01

The fast replacement of conventional aluminium with rapidly solidified aluminium alloys has become a noticeable trend in the current manufacturing industries involved in the production of optics and optical molding inserts. This is as a result of the improved performance and durability of rapidly solidified aluminium alloys when compared to conventional aluminium. Melt spinning process is vital for manufacturing rapidly solidified aluminium alloys like RSA 905, RSA 6061 and RSA 443 which are common in the industries today. RSA 443 is a newly developed alloy with few research findings and huge research potential. There is no available literature focused on monitoring the machining of RSA 443 alloys. In this research, Acoustic Emission sensing technique was applied to monitor the single point diamond turning of RSA 443 on an ultrahigh precision lathe machine. The machining process was carried out after careful selection of feed, speed and depths of cut. The monitoring process was achieved with a high sampling data acquisition system using different tools while concurrent measurement of the surface roughness and tool wear were initiated after covering a total feed distance of 13km. An increasing trend of raw AE spikes and peak to peak signal were observed with an increase in the surface roughness and tool wear values. Hence, acoustic emission sensing technique proves to be an effective monitoring method for the machining of RSA 443 alloy.

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.

Chip morphology as a performance predictor during high speed end milling of soda lime glass

NASA Astrophysics Data System (ADS)

Bagum, M. N.; Konneh, M.; Abdullah, K. A.; Ali, M. Y.

2018-01-01

Soda lime glass has application in DNA arrays and lab on chip manufacturing. Although investigation revealed that machining of such brittle material is possible using ductile mode under controlled cutting parameters and tool geometry, it remains a challenging task. Furthermore, ability of ductile machining is usually assed through machined surface texture examination. Soda lime glass is a strain rate and temperature sensitive material. Hence, influence on attainment of ductile surface due to adiabatic heat generated during high speed end milling using uncoated tungsten carbide tool is investigated in this research. Experimental runs were designed using central composite design (CCD), taking spindle speed, feed rate and depth of cut as input variable and tool-chip contact point temperature (Ttc) and the surface roughness (Rt) as responses. Along with machined surface texture, Rt and chip morphology was examined to assess machinability of soda lime glass. The relation between Ttc and chip morphology was examined. Investigation showed that around glass transition temperature (Tg) ductile chip produced and subsequently clean and ductile final machined surface produced.

Analysis on the multi-dimensional spectrum of the thrust force for the linear motor feed drive system in machine tools

NASA Astrophysics Data System (ADS)

Yang, Xiaojun; Lu, Dun; Ma, Chengfang; Zhang, Jun; Zhao, Wanhua

2017-01-01

The motor thrust force has lots of harmonic components due to the nonlinearity of drive circuit and motor itself in the linear motor feed drive system. What is more, in the motion process, these thrust force harmonics may vary with the position, velocity, acceleration and load, which affects the displacement fluctuation of the feed drive system. Therefore, in this paper, on the basis of the thrust force spectrum obtained by the Maxwell equation and the electromagnetic energy method, the multi-dimensional variation of each thrust harmonic is analyzed under different motion parameters. Then the model of the servo system is established oriented to the dynamic precision. The influence of the variation of the thrust force spectrum on the displacement fluctuation is discussed. At last the experiments are carried out to verify the theoretical analysis above. It can be found that the thrust harmonics show multi-dimensional spectrum characteristics under different motion parameters and loads, which should be considered to choose the motion parameters and optimize the servo control parameters in the high-speed and high-precision machine tools equipped with the linear motor feed drive system.

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.

Surface topography and roughness of high-speed milled AlMn1Cu

NASA Astrophysics Data System (ADS)

Wang, Zhenhua; Yuan, Juntang; Yin, Zengbin; Hu, Xiaoqiu

2016-10-01

The aluminum alloy AlMn1Cu has been broadly applied for functional parts production because of its good properties. But few researches about the machining mechanism and the surface roughness were reported. The high-speed milling experiments are carried out in order to improve the machining quality and reveal the machining mechanism. The typical topography features of machined surface are observed by scan electron microscope(SEM). The results show that the milled surface topography is mainly characterized by the plastic shearing deformation surface and material piling zone. The material flows plastically along the end cutting edge of the flat-end milling tool and meanwhile is extruded by the end cutting edge, resulting in that materials partly adhere to the machined surface and form the material piling zone. As the depth of cut and the feed per tooth increase, the plastic flow of materials is strengthened and the machined surface becomes rougher. However, as the cutting speed increases, the plastic flow of materials is weakened and the milled surface becomes smoother. The cutting parameters (e.g. cutting speed, feed per tooth and depth of cut) influencing the surface roughness are analyzed. It can be concluded that the roughness of the machined surface formed by the end cutting edge is less than that by the cylindrical cutting edge when a cylindrical flat-end mill tool is used for milling. The proposed research provides the typical topography features of machined surface of the anti-rust aluminum alloy AlMn1Cu in high speed milling.

Engineering of Impulse Mechanism for Mechanical Hander Power Tools

NASA Astrophysics Data System (ADS)

Nikolaevich Drozdov, Anatoliy

2018-03-01

The solution to the problem of human security in cities should be considered on the basis of an integrated and multidisciplinary approach, including issues of security and ecology in the application of technical means used to ensure the viability and development of technocracy. In this regard, an important task is the creation of a safe technique with improved environmental properties with high technological characteristics. This primarily relates to mechanised tool — the division of technological machines with built in engines is that their weight is fully or partially perceived by the operator’s hands, making the flow and control of the car. For this subclass of machines is characterized by certain features: a built-in motor, perception of at least part of their weight by the operator during the work, the implementation of feeding and management at the expense of the muscular power of the operator. Therefore, among the commonly accepted technical and economic characteristics, machines in this case, important ergonomic (ergonomics), regulation of levels which ensures the safety of the operator. To ergonomics include vibration, noise characteristics, mass, and force feeding machine operator. Vibration is a consequence of the dynamism of the system operator machine - processed object (environment) in which the engine energy is redistributed among all the structures, causing their instability. In the machine vibration caused by technological and constructive (transformative mechanisms) unbalance of individual parts of the drive, the presence of technological and design (impact mechanisms) clearances and other reasons. This article describes a new design of impulse mechanism for hander power tools (wrenches, screwdrivers) with enhanced torque. The article substantiates a simulation model of dynamic compression process in an operating chamber during impact, provides simulation results and outlines further lines of research.

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.

Electro-chemical grinding

NASA Technical Reports Server (NTRS)

Feagans, P. L.

1972-01-01

Electro-chemical grinding technique has rotation speed control, constant feed rates, and contour control. Hypersonic engine parts of nickel alloys can be almost 100% machined, keeping tool pressure at virtual zero. Technique eliminates galling and permits constant surface finish and burr-free interrupted cutting.

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.

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.

Drilling High Precision Holes in Ti6Al4V Using Rotary Ultrasonic Machining and Uncertainties Underlying Cutting Force, Tool Wear, and Production Inaccuracies.

PubMed

Chowdhury, M A K; Sharif Ullah, A M M; Anwar, Saqib

2017-09-12

Ti6Al4V alloys are difficult-to-cut materials that have extensive applications in the automotive and aerospace industry. A great deal of effort has been made to develop and improve the machining operations of Ti6Al4V alloys. This paper presents an experimental study that systematically analyzes the effects of the machining conditions (ultrasonic power, feed rate, spindle speed, and tool diameter) on the performance parameters (cutting force, tool wear, overcut error, and cylindricity error), while drilling high precision holes on the workpiece made of Ti6Al4V alloys using rotary ultrasonic machining (RUM). Numerical results were obtained by conducting experiments following the design of an experiment procedure. The effects of the machining conditions on each performance parameter have been determined by constructing a set of possibility distributions (i.e., trapezoidal fuzzy numbers) from the experimental data. A possibility distribution is a probability-distribution-neural representation of uncertainty, and is effective in quantifying the uncertainty underlying physical quantities when there is a limited number of data points which is the case here. Lastly, the optimal machining conditions have been identified using these possibility distributions.

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.

Optimization of process parameters in drilling of fibre hybrid composite using Taguchi and grey relational analysis

NASA Astrophysics Data System (ADS)

Vijaya Ramnath, B.; Sharavanan, S.; Jeykrishnan, J.

2017-03-01

Nowadays quality plays a vital role in all the products. Hence, the development in manufacturing process focuses on the fabrication of composite with high dimensional accuracy and also incurring low manufacturing cost. In this work, an investigation on machining parameters has been performed on jute-flax hybrid composite. Here, the two important responses characteristics like surface roughness and material removal rate are optimized by employing 3 machining input parameters. The input variables considered are drill bit diameter, spindle speed and feed rate. Machining is done on CNC vertical drilling machine at different levels of drilling parameters. Taguchi’s L16 orthogonal array is used for optimizing individual tool parameters. Analysis Of Variance is used to find the significance of individual parameters. The simultaneous optimization of the process parameters is done by grey relational analysis. The results of this investigation shows that, spindle speed and drill bit diameter have most effect on material removal rate and surface roughness followed by feed rate.

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

PubMed

Venkatesan, K

2017-07-01

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

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.

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.

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.

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

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

Modeling of Passive Forces of Machine Tool Covers

NASA Astrophysics Data System (ADS)

Kolar, Petr; Hudec, Jan; Sulitka, Matej

The passive forces acting against the drive force are phenomena that influence dynamical properties and precision of linear axes equipped with feed drives. Covers are one of important sources of passive forces in machine tools. The paper describes virtual evaluation of cover passive forces using the cover complex model. The model is able to compute interaction between flexible cover segments and sealing wiper. The result is deformation of cover segments and wipers which is used together with measured friction coefficient for computation of cover total passive force. This resulting passive force is dependent on cover position. Comparison of computational results and measurement on the real cover is presented in the paper.

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.

Comparison of machinability of manganese alloyed austempered ductile iron produced using conventional and two step austempering processes

NASA Astrophysics Data System (ADS)

Hegde, Ananda; Sharma, Sathyashankara

2018-05-01

Austempered Ductile Iron (ADI) is a revolutionary material with high strength and hardness combined with optimum ductility and toughness. The discovery of two step austempering process has lead to the superior combination of all the mechanical properties. However, because of the high strength and hardness of ADI, there is a concern regarding its machinability. In the present study, machinability of ADI produced using conventional and two step heat treatment processes is assessed using tool life and the surface roughness. Speed, feed and depth of cut are considered as the machining parameters in the dry turning operation. The machinability results along with the mechanical properties are compared for ADI produced using both conventional and two step austempering processes. The results have shown that two step austempering process has produced better toughness with good hardness and strength without sacrificing ductility. Addition of 0.64 wt% manganese did not cause any detrimental effect on the machinability of ADI, both in conventional and two step processes. Marginal improvement in tool life and surface roughness were observed in two step process compared to that with conventional process.

Effect of cutting parameters on surface finish and machinability of graphite reinforced Al-8011 matrix composite

NASA Astrophysics Data System (ADS)

Anil, K. C.; Vikas, M. G.; Shanmukha Teja, B.; Sreenivas Rao, K. V.

2017-04-01

Many materials such as alloys, composites find their applications on the basis of machinability, cost and availability. In the present work, graphite (Grp) reinforced Aluminium 8011 is synthesized by convention stir casting process and Surface finish & machinability of prepared composite is examined by using lathe tool dynamometer attached with BANKA Lathe by varying the machining parameters like spindle speed, Depth of cut and Feed rate in 3 levels. Also, Roughness Average (Ra) of machined surfaces is measured by using Surface Roughness Tester (Mitutoyo SJ201). From the studies it is cleared that mechanical properties of a composites increases with addition of Grp and The cutting force were decreased with the reinforcement percentage and thus increases the machinability of composites and also results in increased surface finish.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

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.

An experimental investigation of pulsed laser-assisted machining of AISI 52100 steel

NASA Astrophysics Data System (ADS)

Panjehpour, Afshin; Soleymani Yazdi, Mohammad R.; Shoja-Razavi, Reza

2014-11-01

Grinding and hard turning are widely used for machining of hardened bearing steel parts. Laser-assisted machining (LAM) has emerged as an efficient alternative to grinding and hard turning for hardened steel parts. In most cases, continuous-wave lasers were used as a heat source to cause localized heating prior to material removal by a cutting tool. In this study, an experimental investigation of pulsed laser-assisted machining of AISI 52100 bearing steel was conducted. The effects of process parameters (i.e., laser mean power, pulse frequency, pulse energy, cutting speed and feed rate) on state variables (i.e., material removal temperature, specific cutting energy, surface roughness, microstructure, tool wear and chip formation) were investigated. At laser mean power of 425 W with frequency of 120 Hz and cutting speed of 70 m/min, the benefit of LAM was shown by 25% decrease in specific cutting energy and 18% improvement in surface roughness, as compared to those of the conventional machining. It was shown that at constant laser power, the increase of laser pulse energy causes the rapid increase in tool wear rate. Pulsed laser allowed efficient control of surface temperature and heat penetration in material removal region. Examination of the machined subsurface microstructure and microhardness profiles showed no change under LAM and conventional machining. Continuous chips with more uniform plastic deformation were produced in LAM.

Osteoporosis risk prediction for bone mineral density assessment of postmenopausal women using machine learning.

PubMed

Yoo, Tae Keun; Kim, Sung Kean; Kim, Deok Won; Choi, Joon Yul; Lee, Wan Hyung; Oh, Ein; Park, Eun-Cheol

2013-11-01

A number of clinical decision tools for osteoporosis risk assessment have been developed to select postmenopausal women for the measurement of bone mineral density. We developed and validated machine learning models with the aim of more accurately identifying the risk of osteoporosis in postmenopausal women compared to the ability of conventional clinical decision tools. We collected medical records from Korean postmenopausal women based on the Korea National Health and Nutrition Examination Surveys. The training data set was used to construct models based on popular machine learning algorithms such as support vector machines (SVM), random forests, artificial neural networks (ANN), and logistic regression (LR) based on simple surveys. The machine learning models were compared to four conventional clinical decision tools: osteoporosis self-assessment tool (OST), osteoporosis risk assessment instrument (ORAI), simple calculated osteoporosis risk estimation (SCORE), and osteoporosis index of risk (OSIRIS). SVM had significantly better area under the curve (AUC) of the receiver operating characteristic than ANN, LR, OST, ORAI, SCORE, and OSIRIS for the training set. SVM predicted osteoporosis risk with an AUC of 0.827, accuracy of 76.7%, sensitivity of 77.8%, and specificity of 76.0% at total hip, femoral neck, or lumbar spine for the testing set. The significant factors selected by SVM were age, height, weight, body mass index, duration of menopause, duration of breast feeding, estrogen therapy, hyperlipidemia, hypertension, osteoarthritis, and diabetes mellitus. Considering various predictors associated with low bone density, the machine learning methods may be effective tools for identifying postmenopausal women at high risk for osteoporosis.

Computer numerically controlled (CNC) aspheric shaping with toroidal Wheels (Abstract Only)

NASA Astrophysics Data System (ADS)

Ketelsen, D.; Kittrell, W. C.; Kuhn, W. M.; Parks, R. E.; Lamb, George L.; Baker, Lynn

1987-01-01

Contouring with computer numerically controlled (CNC) machines can be accomplished with several different tool geometries and coordinated machine axes. To minimize the number of coordinated axes for nonsymmetric work to three, it is common practice to use a spherically shaped tool such as a ball-end mill. However, to minimize grooving due to the feed and ball radius, it is desirable to use a long ball radius, but there is clearly a practical limit to ball diameter with the spherical tool. We have found that the use of commercially available toroidal wheels permits long effective cutting radii, which in turn improve finish and minimize grooving for a set feed. In addition, toroidal wheels are easier than spherical wheels to center accurately. Cutting parameters are also easier to control because the feed rate past the tool does not change as the slope of the work changes. The drawback to the toroidal wheel is the more complex calculation of the tool path. Of course, once the algorithm is worked out, the tool path is as easily calculated as for a spherical tool. We have performed two experiments with the Large Optical Generator (LOG) that were ideally suited to three-axis contouring--surfaces that have no axis of rotational symmetry. By oscillating the cutting head horizontally or vertically (in addition to the motions required to generate the power of the surface) , and carefully coordinating those motions with table rotation, the mostly astigmatic departure for these surfaces is produced. The first experiment was a pair of reflector molds that together correct the spherical aberration of the Arecibo radio telescope. The larger of these was 5 m in diameter and had a 12 cm departure from the best-fit sphere. The second experiment was the generation of a purely astigmatic surface to demonstrate the feasibility of producing axially symmetric asphe.rics while mounted and rotated about any off-axis point. Measurements of the latter (the first experiment had relatively loose tolerances) indicate an accuracy only 3 or 4 times that achieved by conventional two-axis contouring (10 AM as opposed to 3 pm rms) The successful completion of these projects demonstrates the successful application of three-axis contouring with the LOG. Toroidal cutters have also solved many of the drawbacks of spherical wheels. Work remains to be done in improving machine response and decreasing the contribution of backlash errors.

Process based analysis of manually controlled drilling processes for bone

NASA Astrophysics Data System (ADS)

Teicher, Uwe; Achour, Anas Ben; Nestler, Andreas; Brosius, Alexander; Lauer, Günter

2018-05-01

The machining operation drilling is part of the standard repertoire for medical applications. This machining cycle, which is usually a multi-stage process, generates the geometric element for the subsequent integration of implants, which are screwed into the bone in subsequent processes. In addition to the form, shape and position of the generated drill hole, it is also necessary to use a technology that ensures an operation with minimal damage. A surface damaged by excessive mechanical and thermal energy input shows a deterioration in the healing capacity of implants and represents a structure with complications for inflammatory reactions. The resulting loads are influenced by the material properties of the bone, the used technology and the tool properties. An important aspect of the process analysis is the fact that machining of bone is in most of the cases a manual process that depends mainly on the skills of the operator. This includes, among other things, the machining time for the production of a drill hole, since manual drilling is a force-controlled process. Experimental work was carried out on the bone of a porcine mandible in order to investigate the interrelation of the applied load during drilling. It can be shown that the load application can be subdivided according to the working feed direction. The entire drilling process thus consists of several time domains, which can be divided into the geometry-generating feed motion and a retraction movement of the tool. It has been shown that the removal of the tool from the drill hole has a significant influence on the mechanical load input. This fact is proven in detail by a new evaluation methodology. The causes of this characteristic can also be identified, as well as possible ways of reducing the load input.

Feasibility investigations on multi-cutter milling process: A novel fabrication method for microreactors with multiple microchannels

NASA Astrophysics Data System (ADS)

Pan, Minqiang; Zeng, Dehuai; Tang, Yong

A novel multi-cutter milling process for multiple parallel microchannels with manifolds is proposed to address the challenge of mass manufacture as required for cost-effective commercial applications. Several slotting cutters are stacked together to form a composite tool for machining microchannels simultaneously. The feasibility of this new fabrication process is experimentally investigated under different machining conditions and reaction characteristics of methanol steam reforming for hydrogen production. The influences of cutting parameters and the composite tool on the microchannel qualities and burr formation are analyzed. Experimental results indicate that larger cutting speed, smaller feed rate and cutting depth are in favor of obtaining relatively good microchannel qualities and small burrs. Of all the cutting parameters considered in these experiments, 94.2 m min -1 cutting speed, 23.5 mm min -1 feed rate and 0.5 mm cutting depth are found to be the optimum value. According to the comparisons of experimental results of multi-cutter milling process and estimated one of other alternative methods, it is found that multi-cutter milling process shows much shorter machining time and higher work removal rate than that of other alternative methods. Reaction characteristics of methanol steam reforming in microchannels also indicate that multi-cutter milling process is probably suitable for a commercial application.

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.

A low-cost machine vision system for the recognition and sorting of small parts

NASA Astrophysics Data System (ADS)

Barea, Gustavo; Surgenor, Brian W.; Chauhan, Vedang; Joshi, Keyur D.

2018-04-01

An automated machine vision-based system for the recognition and sorting of small parts was designed, assembled and tested. The system was developed to address a need to expose engineering students to the issues of machine vision and assembly automation technology, with readily available and relatively low-cost hardware and software. This paper outlines the design of the system and presents experimental performance results. Three different styles of plastic gears, together with three different styles of defective gears, were used to test the system. A pattern matching tool was used for part classification. Nine experiments were conducted to demonstrate the effects of changing various hardware and software parameters, including: conveyor speed, gear feed rate, classification, and identification score thresholds. It was found that the system could achieve a maximum system accuracy of 95% at a feed rate of 60 parts/min, for a given set of parameter settings. Future work will be looking at the effect of lighting.

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.

Neural networks with fuzzy Petri nets for modeling a machining process

NASA Astrophysics Data System (ADS)

Hanna, Moheb M.

1998-03-01

The paper presents an intelligent architecture based a feedforward neural network with fuzzy Petri nets for modeling product quality in a CNC machining center. It discusses how the proposed architecture can be used for modeling, monitoring and control a product quality specification such as surface roughness. The surface roughness represents the output quality specification manufactured by a CNC machining center as a result of a milling process. The neural network approach employed the selected input parameters which defined by the machine operator via the CNC code. The fuzzy Petri nets approach utilized the exact input milling parameters, such as spindle speed, feed rate, tool diameter and coolant (off/on), which can be obtained via the machine or sensors system. An aim of the proposed architecture is to model the demanded quality of surface roughness as high, medium or low.

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.

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.

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

PubMed

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

2015-11-01

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

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.

Modeling and Analysis of CNC Milling Process Parameters on Al3030 based Composite

NASA Astrophysics Data System (ADS)

Gupta, Anand; Soni, P. K.; Krishna, C. M.

2018-04-01

The machining of Al3030 based composites on Computer Numerical Control (CNC) high speed milling machine have assumed importance because of their wide application in aerospace industries, marine industries and automotive industries etc. Industries mainly focus on surface irregularities; material removal rate (MRR) and tool wear rate (TWR) which usually depends on input process parameters namely cutting speed, feed in mm/min, depth of cut and step over ratio. Many researchers have carried out researches in this area but very few have taken step over ratio or radial depth of cut also as one of the input variables. In this research work, the study of characteristics of Al3030 is carried out at high speed CNC milling machine over the speed range of 3000 to 5000 r.p.m. Step over ratio, depth of cut and feed rate are other input variables taken into consideration in this research work. A total nine experiments are conducted according to Taguchi L9 orthogonal array. The machining is carried out on high speed CNC milling machine using flat end mill of diameter 10mm. Flatness, MRR and TWR are taken as output parameters. Flatness has been measured using portable Coordinate Measuring Machine (CMM). Linear regression models have been developed using Minitab 18 software and result are validated by conducting selected additional set of experiments. Selection of input process parameters in order to get best machining outputs is the key contributions of this research work.

Investigations on high speed machining of EN-353 steel alloy under different machining environments

NASA Astrophysics Data System (ADS)

Venkata Vishnu, A.; Jamaleswara Kumar, P.

2018-03-01

The addition of Nano Particles into conventional cutting fluids enhances its cooling capabilities; in the present paper an attempt is made by adding nano sized particles into conventional cutting fluids. Taguchi Robust Design Methodology is employed in order to study the performance characteristics of different turning parameters i.e. cutting speed, feed rate, depth of cut and type of tool under different machining environments i.e. dry machining, machining with lubricant - SAE 40 and machining with mixture of nano sized particles of Boric acid and base fluid SAE 40. A series of turning operations were performed using L27 (3)13 orthogonal array, considering high cutting speeds and the other machining parameters to measure hardness. The results are compared among the different machining environments, and it is concluded that there is considerable improvement in the machining performance using lubricant SAE 40 and mixture of SAE 40 + boric acid compared with dry machining. The ANOVA suggests that the selected parameters and the interactions are significant and cutting speed has most significant effect on hardness.

The development of mixer machine for organic animal feed production: Proposed study

NASA Astrophysics Data System (ADS)

Leman, A. M.; Wahab, R. Abdul; Zakaria, Supaat; Feriyanto, Dafit; Nor, M. I. F. Che Mohd; Muzarpar, Syafiq

2017-09-01

Mixer machine plays a major role in producing homogenous composition of animal feed. Long time production, inhomogeneous and minor agglomeration has been observed by existing mixer. Therefore, this paper proposed continuous mixer to enhance mixing efficiency with shorter time of mixing process in order to abbreviate the whole process in animal feed production. Through calculation of torque, torsion, bending, power and energy consumption will perform in mixer machine process. Proposed mixer machine is designed by two layer buckets with purpose for continuity of mixing process. Mixing process was performed by 4 blades which consists of various arm length such as 50, 100,150 and 225 mm in 60 rpm velocity clockwise rotation. Therefore by using this machine will produce the homogenous composition of animal feed through nutrition analysis and short operation time of mixing process approximately of 5 minutes. Therefore, the production of animal feed will suitable for various animals including poultry and aquatic fish. This mixer will available for various organic material in animal feed production. Therefore, this paper will highlights some areas such as continues animal feed supply chain and bio-based animal feed.

Machinability assessment of commercially pure titanium (CP-Ti) during turning operation: Application potential of GRA method

NASA Astrophysics Data System (ADS)

Khan, Akhtar; Maity, Kalipada

2018-03-01

This paper explores some of the vital machinability characteristics of commercially pure titanium (CP-Ti) grade 2. Experiments were conducted based on Taguchi’s L9 orthogonal array. The selected material was machined on a heavy duty lathe (Model: HMT NH26) using uncoated carbide inserts in dry cutting environment. The selected inserts were designated by ISO as SNMG 120408 (Model: K313) and manufactured by Kennametal. These inserts were rigidly mounted on a right handed tool holder PSBNR 2020K12. Cutting speed, feed rate and depth of cut were selected as three input variables whereas tool wear (VBc) and surface roughness (Ra) were the major attentions. In order to confirm an appreciable machinability of the work part, an optimal parametric combination was attained with the help of grey relational analysis (GRA) approach. Finally, a mathematical model was developed to exhibit the accuracy and acceptability of the proposed methodology using multiple regression equations. The results indicated that, the suggested model is capable of predicting overall grey relational grade within acceptable range.

Modeling the milling tool wear by using an evolutionary SVM-based model from milling runs experimental data

NASA Astrophysics Data System (ADS)

Nieto, Paulino José García; García-Gonzalo, Esperanza; Vilán, José Antonio Vilán; Robleda, Abraham Segade

2015-12-01

The main aim of this research work is to build a new practical hybrid regression model to predict the milling tool wear in a regular cut as well as entry cut and exit cut of a milling tool. The model was based on Particle Swarm Optimization (PSO) in combination with support vector machines (SVMs). This optimization mechanism involved kernel parameter setting in the SVM training procedure, which significantly influences the regression accuracy. Bearing this in mind, a PSO-SVM-based model, which is based on the statistical learning theory, 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. To accomplish the objective of this study, the experimental dataset represents experiments from runs on a milling machine under various operating conditions. In this way, data sampled by three different types of sensors (acoustic emission sensor, vibration sensor and current sensor) were acquired at several positions. A second aim is to determine the factors with the greatest bearing on the milling tool flank wear with a view to proposing milling machine's improvements. Firstly, this hybrid PSO-SVM-based regression model captures the main perception of statistical learning theory in order to obtain a good prediction of the dependence among the flank wear (output variable) and input variables (time, depth of cut, feed, etc.). Indeed, regression with optimal hyperparameters was performed and a determination coefficient of 0.95 was obtained. The agreement of this model with experimental data confirmed its good performance. Secondly, the main advantages of this PSO-SVM-based model are its capacity to produce a simple, easy-to-interpret model, its ability to estimate the contributions of the input variables, and its computational efficiency. Finally, the main conclusions of this study are exposed.

Optimization of Cvd Diamond Coating Type on Micro Drills in Pcb Machining

NASA Astrophysics Data System (ADS)

Lei, X. L.; He, Y.; Sun, F. H.

2016-12-01

The demand for better tools for machining printed circuit boards (PCBs) is increasing due to the extensive usage of these boards in digital electronic products. This paper is aimed at optimizing coating type on micro drills in order to extend their lifetime in PCB machining. First, the tribotests involving micro crystalline diamond (MCD), nano crystalline diamond (NCD) and bare tungsten carbide (WC-Co) against PCBs show that NCD-PCB tribopair exhibits the lowest friction coefficient (0.35) due to the unique nano structure and low surface roughness of NCD films. Thereafter, the dry machining performance of the MCD- and NCD-coated micro drills on PCBs is systematically studied, using diamond-like coating (DLC) and TiAlN-coated micro drills as comparison. The experiments show that the working lives of these micro drills can be ranked as: NCD>TiAlN>DLC>MCD>bare WC-Co. The superior cutting performance of NCD-coated micro drills in terms of the lowest flank wear growth rate, no tool degradation (e.g. chipping, tool tipping) appearance, the best hole quality as well as the lowest feed force may come from the excellent wear resistance, lower friction coefficient against PCB as well as the high adhesive strength on the underneath substrate of NCD films.

Research on the processing technology of elongated holes based on rotary ultrasonic drilling

NASA Astrophysics Data System (ADS)

Tong, Yi; Chen, Jianhua; Sun, Lipeng; Yu, Xin; Wang, Xin

2014-08-01

The optical glass is hard, brittle and difficult to process. Based on the method of rotating ultrasonic drilling, the study of single factor on drilling elongated holes was made in optical glass. The processing equipment was DAMA ultrasonic machine, and the machining tools were electroplated with diamond. Through the detection and analysis on the processing quality and surface roughness, the process parameters (the spindle speed, amplitude, feed rate) of rotary ultrasonic drilling were researched, and the influence of processing parameters on surface roughness was obtained, which will provide reference and basis for the actual processing.

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 infrared camera application for calculating the impact of the feed screw thermal expansion on machining accuracy

NASA Astrophysics Data System (ADS)

Matras, A.

2017-08-01

The paper discusses the impact of the feed screw heating on the machining accuracy. The test stand was built based on HASS Mini Mill 2 CNC milling machine and a Flir SC620 infrared camera. Measurements of workpiece were performed on Talysurf Intra 50 Taylor Hobson profilometer. The research proved that the intensive work of the milling machine lasted 60 minutes, causing thermal expansion of the feed screw what influence on the dimension error of the workpiece.

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

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.

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.

Process Parameters Optimization in Single Point Incremental Forming

NASA Astrophysics Data System (ADS)

Gulati, Vishal; Aryal, Ashmin; Katyal, Puneet; Goswami, Amitesh

2016-04-01

This work aims to optimize the formability and surface roughness of parts formed by the single-point incremental forming process for an Aluminium-6063 alloy. The tests are based on Taguchi's L18 orthogonal array selected on the basis of DOF. The tests have been carried out on vertical machining center (DMC70V); using CAD/CAM software (SolidWorks V5/MasterCAM). Two levels of tool radius, three levels of sheet thickness, step size, tool rotational speed, feed rate and lubrication have been considered as the input process parameters. Wall angle and surface roughness have been considered process responses. The influential process parameters for the formability and surface roughness have been identified with the help of statistical tool (response table, main effect plot and ANOVA). The parameter that has the utmost influence on formability and surface roughness is lubrication. In the case of formability, lubrication followed by the tool rotational speed, feed rate, sheet thickness, step size and tool radius have the influence in descending order. Whereas in surface roughness, lubrication followed by feed rate, step size, tool radius, sheet thickness and tool rotational speed have the influence in descending order. The predicted optimal values for the wall angle and surface roughness are found to be 88.29° and 1.03225 µm. The confirmation experiments were conducted thrice and the value of wall angle and surface roughness were found to be 85.76° and 1.15 µm respectively.

Effects of Process Parameters on Ultrasonic Micro-Hole Drilling in Glass and Ruby

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

Schorderet, Alain; Deghilage, Emmanuel; Agbeviade, Kossi

2011-05-04

Brittle materials such as ceramics, glasses and oxide single crystals find increasing applications in advanced micro-engineering products. Machining small features in such materials represents a manufacturing challenge. Ultrasonic drilling constitutes a promising technique for realizing simple micro-holes of high diameter-to-depth ratio. The process involves impacting abrasive particles in suspension in a liquid slurry between tool and work piece. Among the process performance criteria, the drilling time (productivity) is one of the most important quantities to evaluate the suitability of the process for industrial applications.This paper summarizes recent results pertaining to the ultrasonic micro-drilling process obtained with a semi-industrial 3-axis machine.more » The workpiece is vibrated at 40 kHz frequency with an amplitude of several micrometers. A voice-coil actuator and a control loop based on the drilling force impose the tool feed. In addition, the tool is rotated at a prescribed speed to improve the drilling speed as well as the hole geometry. Typically, a WC wire serves as tool to bore 200 {mu}m diameter micro-holes of 300 to 1,000 {mu}m depth in glass and ruby. The abrasive slurry contains B4C particles of 1 {mu}m to 5 {mu}m diameter in various concentrations.This paper discusses, on the basis of the experimental results, the influence of several parameters on the drilling time. First, the results show that the control strategy based on the drilling force allows to reach higher feed rates (avoiding tool breakage). Typically, a 8 um/s feed rate is achieved with glass and 0.9 {mu}m/s with ruby. Tool rotation, even for values as low as 50 rpm, increases productivity and improves holes geometry. Drilling with 1 {mu}m and 5 {mu}m B4C particles yields similar productivity results. Our future research will focus on using the presented results to develop a model that can serve to optimize the process for different applications.« less

Rapid fabrication of miniature lens arrays by four-axis single point diamond machining

PubMed Central

McCall, Brian; Tkaczyk, Tomasz S.

2013-01-01

A novel method for fabricating lens arrays and other non-rotationally symmetric free-form optics is presented. This is a diamond machining technique using 4 controlled axes of motion – X, Y, Z, and C. As in 3-axis diamond micro-milling, a diamond ball endmill is mounted to the work spindle of a 4-axis ultra-precision computer numerical control (CNC) machine. Unlike 3-axis micro-milling, the C-axis is used to hold the cutting edge of the tool in contact with the lens surface for the entire cut. This allows the feed rates to be doubled compared to the current state of the art of micro-milling while producing an optically smooth surface with very low surface form error and exceptionally low radius error. PMID:23481813

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].

Optimization of Processing Parameters in ECM of Die Tool Steel Using Nanofluid by Multiobjective Genetic Algorithm.

PubMed

Sathiyamoorthy, V; Sekar, T; Elango, N

2015-01-01

Formation of spikes prevents achievement of the better material removal rate (MRR) and surface finish while using plain NaNO3 aqueous electrolyte in electrochemical machining (ECM) of die tool steel. Hence this research work attempts to minimize the formation of spikes in the selected workpiece of high carbon high chromium die tool steel using copper nanoparticles suspended in NaNO3 aqueous electrolyte, that is, nanofluid. The selected influencing parameters are applied voltage and electrolyte discharge rate with three levels and tool feed rate with four levels. Thirty-six experiments were designed using Design Expert 7.0 software and optimization was done using multiobjective genetic algorithm (MOGA). This tool identified the best possible combination for achieving the better MRR and surface roughness. The results reveal that voltage of 18 V, tool feed rate of 0.54 mm/min, and nanofluid discharge rate of 12 lit/min would be the optimum values in ECM of HCHCr die tool steel. For checking the optimality obtained from the MOGA in MATLAB software, the maximum MRR of 375.78277 mm(3)/min and respective surface roughness Ra of 2.339779 μm were predicted at applied voltage of 17.688986 V, tool feed rate of 0.5399705 mm/min, and nanofluid discharge rate of 11.998816 lit/min. Confirmatory tests showed that the actual performance at the optimum conditions was 361.214 mm(3)/min and 2.41 μm; the deviation from the predicted performance is less than 4% which proves the composite desirability of the developed models.

Nd:YAG Pulsed Laser Assisted Machining of AMS 5708 Waspaloy Alloy

NASA Astrophysics Data System (ADS)

Sharifi, Zahra; Shoja-Razavi, Reza; Vafaei, Reza; Hashemi, Sayed Hamid

2018-03-01

Due to very high strenght, low thermal conductivity, and high work hardening rate, the machinability of nickel-based superalloys is poor at room temperature. Laser-assisted machining (LAM) can provide a better aspect of machining such alloys. Since the wavelength of Nd:YAG laser is about 1/10th of that of CO2 laser, absorption and heating efficiency of Nd:YAG laser is much higher on metals and especially superalloys. Transmission of Nd:YAG laser through fiber optics to the heating point on the workpiece is a simple task during machining. This makes the LAM process more convenient and practical than the CM process. In this study a model is introduced for LAM of waspaloy, and its machinability is evaluated in terms of ease of material removal. Also, a temperature generation model is introduced for the Nd:YAG laser beam. Furthemore, wear behavior of an uncoated tungsten carbide and the formed chips were compared during the LAM and the CM of waspolay. To study the wear mechanism, the worn cutting tool was studied via scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS). The formed chips were also evaluated via SEM and optical microscopy. Based on the results, the optimum LAM conditions were obtained at a cutting speed of 24 m/min and a feed rate of 0.06 mm/rev when a 400 W laser mean power and 80 Hz frequency are applied. Under these conditions, the temperature ahead of the cutting tool edge on the surface of workpiece was estimated to be 524°C. In comparison with CM, a significant improvement in tool wear and a better chip morphology were achieved through LAM, and also specific cutting energy and surface roughness were reduced by 25 and 20%, respectively.

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.

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.

Influence of particle size on Cutting Forces and Surface Roughness in Machining of B4Cp - 6061 Aluminium Matrix Composites

NASA Astrophysics Data System (ADS)

Hiremath, Vijaykumar; Badiger, Pradeep; Auradi, V.; Dundur, S. T.; Kori, S. A.

2016-02-01

Amongst advanced materials, metal matrix composites (MMC) are gaining importance as materials for structural applications in particular, particulate reinforced aluminium MMCs have received considerable attention due to their superior properties such as high strength to weight ratio, excellent low-temperature performance, high wear resistance, high thermal conductivity. The present study aims at studying and comparing the machinability aspects of B4Cp reinforced 6061Al alloy metal matrix composites reinforced with 37μm and 88μm particulates produced by stir casting method. The micro structural characterization of the prepared composites is done using Scanning Electron Microscopy equipped with EDX analysis (Hitachi Su-1500 model) to identify morphology and distribution of B4C particles in the 6061Al matrix. The specimens are turned on a conventional lathe machine using a Polly crystalline Diamond (PCD) tool to study the effect of particle size on the cutting forces and the surface roughness under varying machinability parameters viz., Cutting speed (29-45 m/min.), Feed rate (0.11-0.33 mm/rev.) and depth of cut (0.5-1mm). Results of micro structural characterization revealed fairly uniform distribution of B4C particles (in both cases i.e., 37μm and 88μm) in 6061Al matrix. The surface roughness of the composite is influenced by cutting speed. The feed rate and depth of cut have a negative influence on surface roughness. The cutting forces decreased with increase in cutting speed whereas cutting forces increased with increase in feed and depth of cut. Higher cutting forces are noticed while machining Al6061 base alloy compared to reinforced composites. Surface finish is high during turning of the 6061Al base alloy and surface roughness is high with 88μm size particle reinforced composites. As the particle size increases Surface roughness also increases.

A Virtual Sensor for Online Fault Detection of Multitooth-Tools

PubMed Central

Bustillo, Andres; Correa, Maritza; Reñones, Anibal

2011-01-01

The installation of suitable sensors close to the tool tip on milling centres is not possible in industrial environments. It is therefore necessary to design virtual sensors for these machines to perform online fault detection in many industrial tasks. This paper presents a virtual sensor for online fault detection of multitooth tools based on a Bayesian classifier. The device that performs this task applies mathematical models that function in conjunction with physical sensors. Only two experimental variables are collected from the milling centre that performs the machining operations: the electrical power consumption of the feed drive and the time required for machining each workpiece. The task of achieving reliable signals from a milling process is especially complex when multitooth tools are used, because each kind of cutting insert in the milling centre only works on each workpiece during a certain time window. Great effort has gone into designing a robust virtual sensor that can avoid re-calibration due to, e.g., maintenance operations. The virtual sensor developed as a result of this research is successfully validated under real conditions on a milling centre used for the mass production of automobile engine crankshafts. Recognition accuracy, calculated with a k-fold cross validation, had on average 0.957 of true positives and 0.986 of true negatives. Moreover, measured accuracy was 98%, which suggests that the virtual sensor correctly identifies new cases. PMID:22163766

A virtual sensor for online fault detection of multitooth-tools.

PubMed

Bustillo, Andres; Correa, Maritza; Reñones, Anibal

2011-01-01

The installation of suitable sensors close to the tool tip on milling centres is not possible in industrial environments. It is therefore necessary to design virtual sensors for these machines to perform online fault detection in many industrial tasks. This paper presents a virtual sensor for online fault detection of multitooth tools based on a bayesian classifier. The device that performs this task applies mathematical models that function in conjunction with physical sensors. Only two experimental variables are collected from the milling centre that performs the machining operations: the electrical power consumption of the feed drive and the time required for machining each workpiece. The task of achieving reliable signals from a milling process is especially complex when multitooth tools are used, because each kind of cutting insert in the milling centre only works on each workpiece during a certain time window. Great effort has gone into designing a robust virtual sensor that can avoid re-calibration due to, e.g., maintenance operations. The virtual sensor developed as a result of this research is successfully validated under real conditions on a milling centre used for the mass production of automobile engine crankshafts. Recognition accuracy, calculated with a k-fold cross validation, had on average 0.957 of true positives and 0.986 of true negatives. Moreover, measured accuracy was 98%, which suggests that the virtual sensor correctly identifies new cases.

Determination of Optimum Cutting Parameters for Surface Roughness in Turning AL-B4C Composites

NASA Astrophysics Data System (ADS)

Channabasavaraja, H. K.; Nagaraj, P. M.; Srinivasan, D.

2016-09-01

Many materials such as alloys, composites find their applications on the basis of machinability, cost and availability. In the present work, machinability of Aluminium 1100 and Boron carbide (AL+ B4C) composite material is examined by using lathe tool dynometers (BANKA Lathe) by varying the cutting parameters like spindle speed, Depth of cut and Feed rate in 3 levels. Also, surface roughness is measured against the weight % of reinforcement in the composite (0, 4 and 8 %). From the study it is observed that the hardness of a composite material increases with increase in weight % of reinforcement material (B4C) by 26.27 and 66.7 % respectively. The addition of reinforcement materials influences the machinability. The cutting force in both X and Z direction were also found increment with the reinforcement percentage.

Research on operation mode of abrasive grain during grinding

NASA Astrophysics Data System (ADS)

Ivanova, T. N.; Dement’ev, V. B.; Nikitina, O. V.

2018-03-01

The processing of materials by cutting with an abrasive tool is carried out by means of thousands of grains bonded together as a single whole. The quality of the abrasive tool is defined by cutting properties of abrasive grains and depends on features of spreading the temperature field in time and in the abrasive grain volume. Grains are exposed to heating and cooling during work. It leads to undesired effects such as a decrease of durability of grain retention in the binder, hardness, intensification of diffusion and oxidation processes between the binder and the grain, the occurrence of considerable temperature stresses in the grain itself. The obtained equation which allows calculation of temperature field of grain for one rotation of grinding wheel shows that the temperature of the wheel depends on grinding modes and thermophysical properties of abrasive material. Thus, as the time of contact of grain with processed material increases, the temperature in the cutting area rises. As thermophysical properties increase, the temperature in cutting area decreases. Thermal working conditions are determined to be different from each other depending on contact time of the grain and the material. For example, in case of creep-feed grinding, the peak value of temperature is higher than during multistep grinding; the depth of expansion is greater. While the speed of the thermal process in creep-feed grinding is 2-3 times lower than in multistep grinding, the gradient reduces 3-4 times. The analysis of machining methods shows that creep-feed grinding ensures greater depth of grain heating, a smaller heating rate and a reduced velocity gradient. It causes a decrease of probable allotropic modifications and prevents from occurring of heat strokes - cracking of grains due to high temperature falls. Consequently, it is necessary to employ creep-feed grinding to increase the efficiency of abrasive tool employing. Three operation modes of grinding wheel including blunting, full self-sharpening, emergency wear and tear are determined as the result of the research on evaluation of cutting ability of grinding wheels. Recommendations for working capacity of grinding wheels in each operation mode and with a transition from one mode to another are given. As a result of the research, different dependencies were determined. They include dependencies, governing the extent of influence of granularity, difference in height and concentration of grains, geometry parameters of the detail to be machined and the grinding wheel on machining modes and the thickness of the layer cutoff by one grain. They have an influence on the grinding process.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Sustainable manufacturing by calculating the energy demand during turning of AISI 1045 steel

NASA Astrophysics Data System (ADS)

Nur, R.; Nasrullah, B.; Suyuti, M. A.; Apollo

2018-01-01

Sustainable development will become important issues for many fields, including production, industry, and manufacturing. In order to achieve sustainable development, industry should be able to perform of sustainable production processes and environmentally friendly. Therefore, there is need to minimize the energy demand in the machining process. This paper presents a calculation method of energy consumption in the machining process, especially turning process which calculated by summing the number of energy consumption, such as the electric energy consumed during the machining preparation, the electrical energy during the cutting processes, and the electrical energy to produce a cutting tool. A case study was performed on dry turning of mild carbon steel using coated carbide. This approach can be used to determine the total amount of electrical energy consumed in the specific machining process. It concluded that the energy consumption will be an increase for using the high cutting speed as well as for the feed rate was increased.

Selection of Wire Electrical Discharge Machining Process Parameters on Stainless Steel AISI Grade-304 using Design of Experiments Approach

NASA Astrophysics Data System (ADS)

Lingadurai, K.; Nagasivamuni, B.; Muthu Kamatchi, M.; Palavesam, J.

2012-06-01

Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. Parts having sharp edges that pose difficulties to be machined by the main stream machining processes can be easily machined by WEDM process. Design of Experiments approach (DOE) has been reported in this work for stainless steel AISI grade-304 which is used in cryogenic vessels, evaporators, hospital surgical equipment, marine equipment, fasteners, nuclear vessels, feed water tubing, valves, refrigeration equipment, etc., is machined by WEDM with brass wire electrode. The DOE method is used to formulate the experimental layout, to analyze the effect of each parameter on the machining characteristics, and to predict the optimal choice for each WEDM parameter such as voltage, pulse ON, pulse OFF and wire feed. It is found that these parameters have a significant influence on machining characteristic such as metal removal rate (MRR), kerf width and surface roughness (SR). The analysis of the DOE reveals that, in general the pulse ON time significantly affects the kerf width and the wire feed rate affects SR, while, the input voltage mainly affects the MRR.

Diamond Tool Specific Wear Rate Assessment in Granite Machining by Means of Knoop Micro-Hardness and Process Parameters

NASA Astrophysics Data System (ADS)

Goktan, R. M.; Gunes Yılmaz, N.

2017-09-01

The present study was undertaken to investigate the potential usability of Knoop micro-hardness, both as a single parameter and in combination with operational parameters, for sawblade specific wear rate (SWR) assessment in the machining of ornamental granites. The sawing tests were performed on different commercially available granite varieties by using a fully instrumented side-cutting machine. During the sawing tests, two fundamental productivity parameters, namely the workpiece feed rate and cutting depth, were varied at different levels. The good correspondence observed between the measured Knoop hardness and SWR values for different operational conditions indicates that it has the potential to be used as a rock material property that can be employed in preliminary wear estimations of diamond sawblades. Also, a multiple regression model directed to SWR prediction was developed which takes into account the Knoop hardness, cutting depth and workpiece feed rate. The relative contribution of each independent variable in the prediction of SWR was determined by using test statistics. The prediction accuracy of the established model was checked against new observations. The strong prediction performance of the model suggests that its framework may be applied to other granites and operational conditions for quantifying or differentiating the relative wear performance of diamond sawblades.

Characteristics of the Arcing Plasma Formation Effect in Spark-Assisted Chemical Engraving of Glass, Based on Machine Vision

PubMed Central

Wu, Dung-Sheng

2018-01-01

Spark-assisted chemical engraving (SACE) is a non-traditional machining technology that is used to machine electrically non-conducting materials including glass, ceramics, and quartz. The processing accuracy, machining efficiency, and reproducibility are the key factors in the SACE process. In the present study, a machine vision method is applied to monitor and estimate the status of a SACE-drilled hole in quartz glass. During the machining of quartz glass, the spring-fed tool electrode was pre-pressured on the quartz glass surface to feed the electrode that was in contact with the machining surface of the quartz glass. In situ image acquisition and analysis of the SACE drilling processes were used to analyze the captured image of the state of the spark discharge at the tip and sidewall of the electrode. The results indicated an association between the accumulative size of the SACE-induced spark area and deepness of the hole. The results indicated that the evaluated depths of the SACE-machined holes were a proportional function of the accumulative spark size with a high degree of correlation. The study proposes an innovative computer vision-based method to estimate the deepness and status of SACE-drilled holes in real time. PMID:29565303

Characteristics of the Arcing Plasma Formation Effect in Spark-Assisted Chemical Engraving of Glass, Based on Machine Vision.

PubMed

Ho, Chao-Ching; Wu, Dung-Sheng

2018-03-22

Spark-assisted chemical engraving (SACE) is a non-traditional machining technology that is used to machine electrically non-conducting materials including glass, ceramics, and quartz. The processing accuracy, machining efficiency, and reproducibility are the key factors in the SACE process. In the present study, a machine vision method is applied to monitor and estimate the status of a SACE-drilled hole in quartz glass. During the machining of quartz glass, the spring-fed tool electrode was pre-pressured on the quartz glass surface to feed the electrode that was in contact with the machining surface of the quartz glass. In situ image acquisition and analysis of the SACE drilling processes were used to analyze the captured image of the state of the spark discharge at the tip and sidewall of the electrode. The results indicated an association between the accumulative size of the SACE-induced spark area and deepness of the hole. The results indicated that the evaluated depths of the SACE-machined holes were a proportional function of the accumulative spark size with a high degree of correlation. The study proposes an innovative computer vision-based method to estimate the deepness and status of SACE-drilled holes in real time.

On-machine precision preparation and dressing of ball-headed diamond wheel for the grinding of fused silica

NASA Astrophysics Data System (ADS)

Chen, Mingjun; Li, Ziang; Yu, Bo; Peng, Hui; Fang, Zhen

2013-09-01

In the grinding of high quality fused silica parts with complex surface or structure using ball-headed metal bonded diamond wheel with small diameter, the existing dressing methods are not suitable to dress the ball-headed diamond wheel precisely due to that they are either on-line in process dressing which may causes collision problem or without consideration for the effects of the tool setting error and electrode wear. An on-machine precision preparation and dressing method is proposed for ball-headed diamond wheel based on electrical discharge machining. By using this method the cylindrical diamond wheel with small diameter is manufactured to hemispherical-headed form. The obtained ball-headed diamond wheel is dressed after several grinding passes to recover geometrical accuracy and sharpness which is lost due to the wheel wear. A tool setting method based on high precision optical system is presented to reduce the wheel center setting error and dimension error. The effect of electrode tool wear is investigated by electrical dressing experiments, and the electrode tool wear compensation model is established based on the experimental results which show that the value of wear ratio coefficient K' tends to be constant with the increasing of the feed length of electrode and the mean value of K' is 0.156. Grinding experiments of fused silica are carried out on a test bench to evaluate the performance of the preparation and dressing method. The experimental results show that the surface roughness of the finished workpiece is 0.03 μm. The effect of the grinding parameter and dressing frequency on the surface roughness is investigated based on the measurement results of the surface roughness. This research provides an on-machine preparation and dressing method for ball-headed metal bonded diamond wheel used in the grinding of fused silica, which provides a solution to the tool setting method and the effect of electrode tool wear.

Parametric analysis of plastic strain and force distribution in single pass metal spinning

NASA Astrophysics Data System (ADS)

Choudhary, Shashank; Tejesh, Chiruvolu Mohan; Regalla, Srinivasa Prakash; Suresh, Kurra

2013-12-01

Metal spinning also known as spin forming is one of the sheet metal working processes by which an axis-symmetric part can be formed from a flat sheet metal blank. Parts are produced by pressing a blunt edged tool or roller on to the blank which in turn is mounted on a rotating mandrel. This paper discusses about the setting up a 3-D finite element simulation of single pass metal spinning in LS-Dyna. Four parameters were considered namely blank thickness, roller nose radius, feed ratio and mandrel speed and the variation in forces and plastic strain were analysed using the full-factorial design of experiments (DOE) method of simulation experiments. For some of these DOE runs, physical experiments on extra deep drawing (EDD) sheet metal were carried out using En31 tool on a lathe machine. Simulation results are able to predict the zone of unsafe thinning in the sheet and high forming forces that are hint to the necessity for less-expensive and semi-automated machine tools to help the household and small scale spinning workers widely prevalent in India.

Optimization of Coolant Technique Conditions for Machining A319 Aluminium Alloy Using Response Surface Method (RSM)

NASA Astrophysics Data System (ADS)

Zainal Ariffin, S.; Razlan, A.; Ali, M. Mohd; Efendee, A. M.; Rahman, M. M.

2018-03-01

Background/Objectives: The paper discusses about the optimum cutting parameters with coolant techniques condition (1.0 mm nozzle orifice, wet and dry) to optimize surface roughness, temperature and tool wear in the machining process based on the selected setting parameters. The selected cutting parameters for this study were the cutting speed, feed rate, depth of cut and coolant techniques condition. Methods/Statistical Analysis Experiments were conducted and investigated based on Design of Experiment (DOE) with Response Surface Method. The research of the aggressive machining process on aluminum alloy (A319) for automotive applications is an effort to understand the machining concept, which widely used in a variety of manufacturing industries especially in the automotive industry. Findings: The results show that the dominant failure mode is the surface roughness, temperature and tool wear when using 1.0 mm nozzle orifice, increases during machining and also can be alternative minimize built up edge of the A319. The exploration for surface roughness, productivity and the optimization of cutting speed in the technical and commercial aspects of the manufacturing processes of A319 are discussed in automotive components industries for further work Applications/Improvements: The research result also beneficial in minimizing the costs incurred and improving productivity of manufacturing firms. According to the mathematical model and equations, generated by CCD based RSM, experiments were performed and cutting coolant condition technique using size nozzle can reduces tool wear, surface roughness and temperature was obtained. Results have been analyzed and optimization has been carried out for selecting cutting parameters, shows that the effectiveness and efficiency of the system can be identified and helps to solve potential problems.

Experimental investigation of the tip based micro/nano machining

NASA Astrophysics Data System (ADS)

Guo, Z.; Tian, Y.; Liu, X.; Wang, F.; Zhou, C.; Zhang, D.

2017-12-01

Based on the self-developed three dimensional micro/nano machining system, the effects of machining parameters and sample material on micro/nano machining are investigated. The micro/nano machining system is mainly composed of the probe system and micro/nano positioning stage. The former is applied to control the normal load and the latter is utilized to realize high precision motion in the xy plane. A sample examination method is firstly introduced to estimate whether the sample is placed horizontally. The machining parameters include scratching direction, speed, cycles, normal load and feed. According to the experimental results, the scratching depth is significantly affected by the normal load in all four defined scratching directions but is rarely influenced by the scratching speed. The increase of scratching cycle number can increase the scratching depth as well as smooth the groove wall. In addition, the scratching tests of silicon and copper attest that the harder material is easier to be removed. In the scratching with different feed amount, the machining results indicate that the machined depth increases as the feed reduces. Further, a cubic polynomial is used to fit the experimental results to predict the scratching depth. With the selected machining parameters of scratching direction d3/d4, scratching speed 5 μm/s and feed 0.06 μm, some more micro structures including stair, sinusoidal groove, Chinese character '田', 'TJU' and Chinese panda have been fabricated on the silicon substrate.

Efficiently modeling neural networks on massively parallel computers

NASA Technical Reports Server (NTRS)

Farber, Robert M.

1993-01-01

Neural networks are a very useful tool for analyzing and modeling complex real world systems. Applying neural network simulations to real world problems generally involves large amounts of data and massive amounts of computation. To efficiently handle the computational requirements of large problems, we have implemented at Los Alamos a highly efficient neural network compiler for serial computers, vector computers, vector parallel computers, and fine grain SIMD computers such as the CM-2 connection machine. This paper describes the mapping used by the compiler to implement feed-forward backpropagation neural networks for a SIMD (Single Instruction Multiple Data) architecture parallel computer. Thinking Machines Corporation has benchmarked our code at 1.3 billion interconnects per second (approximately 3 gigaflops) on a 64,000 processor CM-2 connection machine (Singer 1990). This mapping is applicable to other SIMD computers and can be implemented on MIMD computers such as the CM-5 connection machine. Our mapping has virtually no communications overhead with the exception of the communications required for a global summation across the processors (which has a sub-linear runtime growth on the order of O(log(number of processors)). We can efficiently model very large neural networks which have many neurons and interconnects and our mapping can extend to arbitrarily large networks (within memory limitations) by merging the memory space of separate processors with fast adjacent processor interprocessor communications. This paper will consider the simulation of only feed forward neural network although this method is extendable to recurrent networks.

A comparison RSM and ANN surface roughness models in thin-wall machining of Ti6Al4V using vegetable oils under MQL-condition

NASA Astrophysics Data System (ADS)

Mohruni, Amrifan Saladin; Yanis, Muhammad; Sharif, Safian; Yani, Irsyadi; Yuliwati, Erna; Ismail, Ahmad Fauzi; Shayfull, Zamree

2017-09-01

Thin-wall components as usually applied in the structural parts of aeronautical industry require significant challenges in machining. Unacceptable surface roughness can occur during machining of thin-wall. Titanium product such Ti6Al4V is mostly applied to get the appropriate surface texture in thin wall designed requirements. In this study, the comparison of the accuracy between Response Surface Methodology (RSM) and Artificial Neural Networks (ANN) in the prediction of surface roughness was conducted. Furthermore, the machining tests were carried out under Minimum Quantity Lubrication (MQL) using AlCrN-coated carbide tools. The use of Coconut oil as cutting fluids was also chosen in order to evaluate its performance when involved in end milling. This selection of cutting fluids is based on the better performance of oxidative stability than that of other vegetable based cutting fluids. The cutting speed, feed rate, radial and axial depth of cut were used as independent variables, while surface roughness is evaluated as the dependent variable or output. The results showed that the feed rate is the most significant factors in increasing the surface roughness value followed by the radial depth of cut and lastly the axial depth of cut. In contrary, the surface becomes smoother with increasing the cutting speed. From a comparison of both methods, the ANN model delivered a better accuracy than the RSM model.

Confessions of a robot lobotomist

NASA Technical Reports Server (NTRS)

Gottshall, R. Marc

1994-01-01

Since its inception, numerically controlled (NC) machining methods have been used throughout the aerospace industry to mill, drill, and turn complex shapes by sequentially stepping through motion programs. However, the recent demand for more precision, faster feeds, exotic sensors, and branching execution have existing computer numerical control (CNC) and distributed numerical control (DNC) systems running at maximum controller capacity. Typical disadvantages of current CNC's include fixed memory capacities, limited communication ports, and the use of multiple control languages. The need to tailor CNC's to meet specific applications, whether it be expanded memory, additional communications, or integrated vision, often requires replacing the original controller supplied with the commercial machine tool with a more powerful and capable system. This paper briefly describes the process and equipment requirements for new controllers and their evolutionary implementation in an aerospace environment. The process of controller retrofit with currently available machines is examined, along with several case studies and their computational and architectural implications.

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.

Design and development of solid carbide step drill K34 for machining of CFRP and GFRP composite laminates

NASA Astrophysics Data System (ADS)

Rangaswamy, T.; Nagaraja, R.

2018-04-01

The Study focused on design and development of solid carbide step drill K34 to drill holes on composite materials such as Carbon Fiber Reinforced Plastic (CFRP) and Glass Fiber Reinforced Plastic (GFRP). The step drill K34 replaces step wise drilling of diameter 6.5mm and 9 mm holes that reduces the setup time, cutting speed, feed rate cost, delamination and increase the production rate. Several researchers have analyzed the effect of drilling process on various fiber reinforced plastic composites by carrying out using conventional tools and machinery. However, this process operation can lead to different kind of damages such as delamination, fiber pullout, and local cracks. To avoid the problems encountered at the time of drilling, suitable tool material and geometry is essential. This paper deals with the design and development of K34 Carbide step drill used to drill holes on CFRP and GFRP laminates. An Experimental study carried out to investigate the tool geometry, feed rate and cutting speed that avoids delamination and fiber breakage.

Desktop Genetics.

PubMed

Hough, Soren H; Ajetunmobi, Ayokunmi; Brody, Leigh; Humphryes-Kirilov, Neil; Perello, Edward

2016-11-01

Desktop Genetics is a bioinformatics company building a gene-editing platform for personalized medicine. The company works with scientists around the world to design and execute state-of-the-art clustered regularly interspaced short palindromic repeats (CRISPR) experiments. Desktop Genetics feeds the lessons learned about experimental intent, single-guide RNA design and data from international genomics projects into a novel CRISPR artificial intelligence system. We believe that machine learning techniques can transform this information into a cognitive therapeutic development tool that will revolutionize medicine.

Optimization of turning process through the analytic flank wear modelling

NASA Astrophysics Data System (ADS)

Del Prete, A.; Franchi, R.; De Lorenzis, D.

2018-05-01

In the present work, the approach used for the optimization of the process capabilities for Oil&Gas components machining will be described. These components are machined by turning of stainless steel castings workpieces. For this purpose, a proper Design Of Experiments (DOE) plan has been designed and executed: as output of the experimentation, data about tool wear have been collected. The DOE has been designed starting from the cutting speed and feed values recommended by the tools manufacturer; the depth of cut parameter has been maintained as a constant. Wear data has been obtained by means the observation of the tool flank wear under an optical microscope: the data acquisition has been carried out at regular intervals of working times. Through a statistical data and regression analysis, analytical models of the flank wear and the tool life have been obtained. The optimization approach used is a multi-objective optimization, which minimizes the production time and the number of cutting tools used, under the constraint on a defined flank wear level. The technique used to solve the optimization problem is a Multi Objective Particle Swarm Optimization (MOPS). The optimization results, validated by the execution of a further experimental campaign, highlighted the reliability of the work and confirmed the usability of the optimized process parameters and the potential benefit for the company.

Brain-state invariant thalamo-cortical coordination revealed by non-linear encoders.

PubMed

Viejo, Guillaume; Cortier, Thomas; Peyrache, Adrien

2018-03-01

Understanding how neurons cooperate to integrate sensory inputs and guide behavior is a fundamental problem in neuroscience. A large body of methods have been developed to study neuronal firing at the single cell and population levels, generally seeking interpretability as well as predictivity. However, these methods are usually confronted with the lack of ground-truth necessary to validate the approach. Here, using neuronal data from the head-direction (HD) system, we present evidence demonstrating how gradient boosted trees, a non-linear and supervised Machine Learning tool, can learn the relationship between behavioral parameters and neuronal responses with high accuracy by optimizing the information rate. Interestingly, and unlike other classes of Machine Learning methods, the intrinsic structure of the trees can be interpreted in relation to behavior (e.g. to recover the tuning curves) or to study how neurons cooperate with their peers in the network. We show how the method, unlike linear analysis, reveals that the coordination in thalamo-cortical circuits is qualitatively the same during wakefulness and sleep, indicating a brain-state independent feed-forward circuit. Machine Learning tools thus open new avenues for benchmarking model-based characterization of spike trains.

Brain-state invariant thalamo-cortical coordination revealed by non-linear encoders

PubMed Central

Cortier, Thomas; Peyrache, Adrien

2018-01-01

Understanding how neurons cooperate to integrate sensory inputs and guide behavior is a fundamental problem in neuroscience. A large body of methods have been developed to study neuronal firing at the single cell and population levels, generally seeking interpretability as well as predictivity. However, these methods are usually confronted with the lack of ground-truth necessary to validate the approach. Here, using neuronal data from the head-direction (HD) system, we present evidence demonstrating how gradient boosted trees, a non-linear and supervised Machine Learning tool, can learn the relationship between behavioral parameters and neuronal responses with high accuracy by optimizing the information rate. Interestingly, and unlike other classes of Machine Learning methods, the intrinsic structure of the trees can be interpreted in relation to behavior (e.g. to recover the tuning curves) or to study how neurons cooperate with their peers in the network. We show how the method, unlike linear analysis, reveals that the coordination in thalamo-cortical circuits is qualitatively the same during wakefulness and sleep, indicating a brain-state independent feed-forward circuit. Machine Learning tools thus open new avenues for benchmarking model-based characterization of spike trains. PMID:29565979

Roundness and taper of holes during drilling composites of various thickness by HSS drill bit under dry condition

NASA Astrophysics Data System (ADS)

Sakib, M. S.; Rahman, Motiur; Ferdous, M.; Dhar, N. R.

2017-12-01

Polymer Matrix Composites are extending a wide range of applications in aviation in recent eras because of their better economics, well established processing, high temperature properties, high resistance to corrosion and fatigue. Directional properties of composites are dependent on the fibre orientation. Composites being anisotropic in nature are difficult to drill and machining and tooling of the composites remained a great challenge over time. This paper addresses the issues of various machining problems such as delamination, fibre pull-out, cracks on varying drilling parameters like feed rate and drilling speed. Experimental drilling was carried out on Fibre Reinforced Plastic composites with HSS drill bit. Results reveal that as the number of holes increases the entry and exit diameter and tapper of holes vary and also varying composite thickness results in a difference in hole roundness and tapper. This experiment summarizes that for achieving acceptable tool life and hole quality demands a drill designed with composites.

Effects on Vibration and Surface Roughness in High Speed Micro End-Milling of Inconel 718 with Minimum Quantity Lubrication

NASA Astrophysics Data System (ADS)

Rahman, Mohamed Abd; Yeakub Ali, Mohammad; Saddam Khairuddin, Amir

2017-03-01

This paper presents the study on vibration and surface roughness of Inconel 718 workpiece produced by micro end-milling using Mikrotools Integrated Multi-Process machine tool DT-110 with control parameters; spindle speed (15000 rpm and 30000 rpm), feed rate (2 mm/min and 4 mm/min) and depth of cut (0.10 mm and 0.15mm). The vibration was measured using DYTRAN accelerometer instrument and the average surface roughness Ra was measured using Wyko NT1100. The analysis of variance (ANOVA) by using Design Expert software revealed that feed rate and depth of cut are the most significant factors on vibration meanwhile for average surface roughness, Ra, spindle speed is the most significant factor.

Finite Element Analysis Of Influence Of Flank Wear Evolution On Forces In Orthogonal Cutting Of 42CrMo4 Steel

NASA Astrophysics Data System (ADS)

Madajewski, Marek; Nowakowski, Zbigniew

2017-01-01

This paper presents analysis of flank wear influence on forces in orthogonal turning of 42CrMo4 steel and evaluates capacity of finite element model to provide such force values. Data about magnitude of feed and cutting force were obtained from measurements with force tensiometer in experimental test as well as from finite element analysis of chip formation process in ABAQUS/Explicit software. For studies an insert with complex rake face was selected and flank wear was simulated by grinding operation on its flank face. The aim of grinding inset surface was to obtain even flat wear along cutting edge, which after the measurement could be modeled with CAD program and applied in FE analysis for selected range of wear width. By comparing both sets of force values as function of flank wear in given cutting conditions FEA model was validated and it was established that it can be applied to analyze other physical aspects of machining. Force analysis found that progression of wear causes increase in cutting force magnitude and steep boost to feed force magnitude. Analysis of Fc/Ff force ratio revealed that flank wear has significant impact on resultant force in orthogonal cutting and magnitude of this force components in cutting and feed direction. Surge in force values can result in transfer of substantial loads to machine-tool interface.

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.

Development of system decision support tools for behavioral trends monitoring of machinery maintenance in a competitive environment

NASA Astrophysics Data System (ADS)

Adeyeri, Michael Kanisuru; Mpofu, Khumbulani

2017-06-01

The article is centred on software system development for manufacturing company that produces polyethylene bags using mostly conventional machines in a competitive world where each business enterprise desires to stand tall. This is meant to assist in gaining market shares, taking maintenance and production decisions by the dynamism and flexibilities embedded in the package as customers' demand varies under the duress of meeting the set goals. The production and machine condition monitoring software (PMCMS) is programmed in C# and designed in such a way to support hardware integration, real-time machine conditions monitoring, which is based on condition maintenance approach, maintenance decision suggestions and suitable production strategies as the demand for products keeps changing in a highly competitive environment. PMCMS works with an embedded device which feeds it with data from the various machines being monitored at the workstation, and the data are read at the base station through transmission via a wireless transceiver and stored in a database. A case study was used in the implementation of the developed system, and the results show that it can monitor the machine's health condition effectively by displaying machines' health status, gives repair suggestions to probable faults, decides strategy for both production methods and maintenance, and, thus, can enhance maintenance performance obviously.

Temperature Measurement and Numerical Prediction in Machining Inconel 718.

PubMed

Díaz-Álvarez, José; Tapetado, Alberto; Vázquez, Carmen; Miguélez, Henar

2017-06-30

Thermal issues are critical when machining Ni-based superalloy components designed for high temperature applications. The low thermal conductivity and extreme strain hardening of this family of materials results in elevated temperatures around the cutting area. This elevated temperature could lead to machining-induced damage such as phase changes and residual stresses, resulting in reduced service life of the component. Measurement of temperature during machining is crucial in order to control the cutting process, avoiding workpiece damage. On the other hand, the development of predictive tools based on numerical models helps in the definition of machining processes and the obtainment of difficult to measure parameters such as the penetration of the heated layer. However, the validation of numerical models strongly depends on the accurate measurement of physical parameters such as temperature, ensuring the calibration of the model. This paper focuses on the measurement and prediction of temperature during the machining of Ni-based superalloys. The temperature sensor was based on a fiber-optic two-color pyrometer developed for localized temperature measurements in turning of Inconel 718. The sensor is capable of measuring temperature in the range of 250 to 1200 °C. Temperature evolution is recorded in a lathe at different feed rates and cutting speeds. Measurements were used to calibrate a simplified numerical model for prediction of temperature fields during turning.

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.

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

DOEpatents

Barkman, William E; Babelay, Jr., Edwin F

2013-12-17

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

Path planning and parameter optimization of uniform removal in active feed polishing

NASA Astrophysics Data System (ADS)

Liu, Jian; Wang, Shaozhi; Zhang, Chunlei; Zhang, Linghua; Chen, Huanan

2015-06-01

A high-quality ultrasmooth surface is demanded in short-wave optical systems. However, the existing polishing methods have difficulties meeting the requirement on spherical or aspheric surfaces. As a new kind of small tool polishing method, active feed polishing (AFP) could attain a surface roughness of less than 0.3 nm (RMS) on spherical elements, although AFP may magnify the residual figure error or mid-frequency error. The purpose of this work is to propose an effective algorithm to realize uniform removal of the surface in the processing. At first, the principle of the AFP and the mechanism of the polishing machine are introduced. In order to maintain the processed figure error, a variable pitch spiral path planning algorithm and the dwell time-solving model are proposed. For suppressing the possible mid-frequency error, the uniformity of the synthesis tool path, which is generated by an arbitrary point at the polishing tool bottom, is analyzed and evaluated, and the angular velocity ratio of the tool spinning motion to the revolution motion is optimized. Finally, an experiment is conducted on a convex spherical surface and an ultrasmooth surface is finally acquired. In conclusion, a high-quality ultrasmooth surface can be successfully obtained with little degradation of the figure and mid-frequency errors by the algorithm.

The Identification of Hunger Behaviour of Lates Calcarifer through the Integration of Image Processing Technique and Support Vector Machine

NASA Astrophysics Data System (ADS)

Taha, Z.; Razman, M. A. M.; Adnan, F. A.; Ghani, A. S. Abdul; Majeed, A. P. P. Abdul; Musa, R. M.; Sallehudin, M. F.; Mukai, Y.

2018-03-01

Fish Hunger behaviour is one of the important element in determining the fish feeding routine, especially for farmed fishes. Inaccurate feeding routines (under-feeding or over-feeding) lead the fishes to die and thus, reduces the total production of fishes. The excessive food which is not eaten by fish will be dissolved in the water and thus, reduce the water quality (oxygen quantity in the water will be reduced). The reduction of oxygen (water quality) leads the fish to die and in some cases, may lead to fish diseases. This study correlates Barramundi fish-school behaviour with hunger condition through the hybrid data integration of image processing technique. The behaviour is clustered with respect to the position of the centre of gravity of the school of fish prior feeding, during feeding and after feeding. The clustered fish behaviour is then classified by means of a machine learning technique namely Support vector machine (SVM). It has been shown from the study that the Fine Gaussian variation of SVM is able to provide a reasonably accurate classification of fish feeding behaviour with a classification accuracy of 79.7%. The proposed integration technique may increase the usefulness of the captured data and thus better differentiates the various behaviour of farmed fishes.

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.

Engineering specification and system design for CAD/CAM of custom shoes: UMC project effort

NASA Technical Reports Server (NTRS)

Bao, Han P.

1990-01-01

Further experimentations were made to improve the design and fabrication techniques of the integrated sole. The sole design is shown to be related to the foot position requirements and the actual shape of the foot including presence of neurotropic ulcers or other infections. Factors for consideration were: heel pitch, balance line, and rigidity conditions of the foot. Machining considerations were also part of the design problem. Among these considerations, widths of each contour, tool motion, tool feed rate, depths of cut, and slopes of cut at the boundary were the key elements. The essential fabrication techniques evolved around the idea of machining a mold then, using quick-firm latex material, casting the sole through the mold. Two main mold materials were experimented with: plaster and wood. Plaster was very easy to machine and shape but could barely support the pressure in the hydraulic press required by the casting process. Wood was found to be quite effective in terms of relative cost, strength, and surface smoothness except for the problem of cutting against the fibers which could generate ragged surfaces. The programming efforts to convert the original dBase programs into C programs so that they could be executed on the SUN Computer at North Carolina State University are discussed.

Control system to reduce the effects of friction in drive trains of continuous-path-positioning systems. [Patent application

DOEpatents

Green, W.L.

1980-12-01

An improved continuous-path-positioning servo-control system is provided for reducing the effects of friction arising at very low cutting speeds in the drive trains of numerically controlled cutting machines, and the like. The improvement comprises a feed forward network for altering the gain of the servo-control loop at low positioning velocities to prevent stick-slip movement of the cutting tool holder being positioned by the control system. The feed forward network shunts conventional lag-compensators in the control loop, or loops, so that the error signal used for positioning varies linearly when the value is small, but being limited for larger values. Thus, at higher positioning speeds there is little effect of the added component upon the control being achieved.

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

Zhu, Bo; Zhao, Hongwei, E-mail: hwzhao@jlu.edu.cn, E-mail: khl69@163.com; Zhao, Dan

It has always been a critical issue to understand the material removal behavior of Vibration-Assisted Machining (VAM), especially on atomic level. To find out the effects of vibration frequency on material removal response, a three-dimensional molecular dynamics (MD) model has been established in this research to investigate the effects of scratched groove, crystal defects on the surface quality, comparing with the Von Mises shear strain and tangential force in simulations during nano-scratching process. Comparisons are made among the results of simulations from different vibration frequency with the same scratching feed, depth, amplitude and crystal orientation. Copper potential in this simulationmore » is Embedded-Atom Method (EAM) potential. Interaction between copper and carbon atoms is Morse potential. Simulational results show that higher frequency can make groove smoother. Simulation with high frequency creates more dislocations to improve the machinability of copper specimen. The changing frequency does not have evident effects on Von Mises shear strain. Higher frequency can decrease the tangential force to reduce the consumption of cutting energy and tool wear. In conclusion, higher vibration frequency in VAM on mono-crystalline copper has positive effects on surface finish, machinablility and tool wear reduction.« less

Comparison of surface roughness and chip characteristics obtained under different modes of lubrication during hard turning of AISI H13 tool work steel.

NASA Astrophysics Data System (ADS)

Raj, Anil; Wins, K. Leo Dev; Varadarajan, A. S.

2016-09-01

Surface roughness is one of the important parameters, which not only affects the service life of a component but also serves as a good index of machinability. Near Dry Machining, methods (NDM) are considered as sustainable alternative for workshops trying to bring down their dependence on cutting fluids and the hazards associated with their indiscriminate usage. The present work presents a comparison of the surface roughness and chip characteristics during hard turning of AISI H13 tool work steel using hard metal inserts under two popular NDM techniques namely the minimal fluid application and the Minimum Quantity Lubrication technique(MQL) using an experiment designed based on Taguchi's techniques. The statistical method of analysis of variance (ANOVA) was used to determine the relative significance of input parameters consisting of cutting speed, feed and depth of cut on the attainable surface finish and the chip characteristics. It was observed that the performance during minimal fluid application was better than that during MQL application.

Mathematical simulation and optimization of cutting mode in turning of workpieces made of nickel-based heat-resistant alloy

NASA Astrophysics Data System (ADS)

Bogoljubova, M. N.; Afonasov, A. I.; Kozlov, B. N.; Shavdurov, D. E.

2018-05-01

A predictive simulation technique of optimal cutting modes in the turning of workpieces made of nickel-based heat-resistant alloys, different from the well-known ones, is proposed. The impact of various factors on the cutting process with the purpose of determining optimal parameters of machining in concordance with certain effectiveness criteria is analyzed in the paper. A mathematical model of optimization, algorithms and computer programmes, visual graphical forms reflecting dependences of the effectiveness criteria – productivity, net cost, and tool life on parameters of the technological process - have been worked out. A nonlinear model for multidimensional functions, “solution of the equation with multiple unknowns”, “a coordinate descent method” and heuristic algorithms are accepted to solve the problem of optimization of cutting mode parameters. Research shows that in machining of workpieces made from heat-resistant alloy AISI N07263, the highest possible productivity will be achieved with the following parameters: cutting speed v = 22.1 m/min., feed rate s=0.26 mm/rev; tool life T = 18 min.; net cost – 2.45 per hour.

SwarmSight: Measuring the Temporal Progression of Animal Group Activity Levels from Natural Scene and Laboratory Videos

PubMed Central

Birgiolas, Justas; Jernigan, Christopher M.; Smith, Brian H.; Crook, Sharon M.

2016-01-01

We describe SwarmSight (available at: https://github.com/justasb/SwarmSight), a novel, open-source, Microsoft Windows software tool for quantitative assessment of the temporal progression of animal group activity levels from recorded videos. The tool utilizes a background subtraction machine vision algorithm and provides an activity metric that can be used to quantitatively assess and compare animal group behavior. Here we demonstrate the tool utility by analyzing defensive bee behavior as modulated by alarm pheromones, wild bird feeding onset and interruption, and cockroach nest finding activity. While more sophisticated, commercial software packages are available, SwarmSight provides a low-cost, open-source, and easy-to-use alternative that is suitable for a wide range of users, including minimally trained research technicians and behavioral science undergraduate students in classroom laboratory settings. PMID:27130170

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

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

The effect of CNC and manual laser machining on electrical resistance of HDPE/MWCNT composite

NASA Astrophysics Data System (ADS)

Mohammadi, Fatemeh; Farshbaf Zinati, Reza; Fattahi, A. M.

2018-05-01

In this study, electrical conductivity of high-density polyethylene (HDPE)/multi-walled carbon nanotube (MWCNT) composite was investigated after laser machining. To this end, produced using plastic injection process, nano-composite samples were laser machined with various combinations of input parameters such as feed rate (35, 45, and 55 mm/min), feed angle with injection flow direction (0°, 45°, and 90°), and MWCNT content (0.5, 1, and 1.5 wt%). The angle between laser feed and injected flow direction was set via either of two different methods: CNC programming and manual setting. The results showed that the parameters of angle between laser line and melt flow direction and feed rate were both found to have statistically significance and physical impacts on electrical resistance of the samples in manual setting. Also, maximum conductivity was seen when the angle between laser line and melt flow direction was set to 90° in manual setting, and maximum conductivity was seen at feed rate of 55 mm/min in both of CNC programming and manual setting.

Temperature Measurement and Numerical Prediction in Machining Inconel 718

PubMed Central

Tapetado, Alberto; Vázquez, Carmen; Miguélez, Henar

2017-01-01

Thermal issues are critical when machining Ni-based superalloy components designed for high temperature applications. The low thermal conductivity and extreme strain hardening of this family of materials results in elevated temperatures around the cutting area. This elevated temperature could lead to machining-induced damage such as phase changes and residual stresses, resulting in reduced service life of the component. Measurement of temperature during machining is crucial in order to control the cutting process, avoiding workpiece damage. On the other hand, the development of predictive tools based on numerical models helps in the definition of machining processes and the obtainment of difficult to measure parameters such as the penetration of the heated layer. However, the validation of numerical models strongly depends on the accurate measurement of physical parameters such as temperature, ensuring the calibration of the model. This paper focuses on the measurement and prediction of temperature during the machining of Ni-based superalloys. The temperature sensor was based on a fiber-optic two-color pyrometer developed for localized temperature measurements in turning of Inconel 718. The sensor is capable of measuring temperature in the range of 250 to 1200 °C. Temperature evolution is recorded in a lathe at different feed rates and cutting speeds. Measurements were used to calibrate a simplified numerical model for prediction of temperature fields during turning. PMID:28665312

Actualities and Development of Heavy-Duty CNC Machine Tool Thermal Error Monitoring Technology

NASA Astrophysics Data System (ADS)

Zhou, Zu-De; Gui, Lin; Tan, Yue-Gang; Liu, Ming-Yao; Liu, Yi; Li, Rui-Ya

2017-09-01

Thermal error monitoring technology is the key technological support to solve the thermal error problem of heavy-duty CNC (computer numerical control) machine tools. Currently, there are many review literatures introducing the thermal error research of CNC machine tools, but those mainly focus on the thermal issues in small and medium-sized CNC machine tools and seldom introduce thermal error monitoring technologies. This paper gives an overview of the research on the thermal error of CNC machine tools and emphasizes the study of thermal error of the heavy-duty CNC machine tool in three areas. These areas are the causes of thermal error of heavy-duty CNC machine tool and the issues with the temperature monitoring technology and thermal deformation monitoring technology. A new optical measurement technology called the "fiber Bragg grating (FBG) distributed sensing technology" for heavy-duty CNC machine tools is introduced in detail. This technology forms an intelligent sensing and monitoring system for heavy-duty CNC machine tools. This paper fills in the blank of this kind of review articles to guide the development of this industry field and opens up new areas of research on the heavy-duty CNC machine tool thermal error.

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

[Research on infrared safety protection system for machine tool].

PubMed

Zhang, Shuan-Ji; Zhang, Zhi-Ling; Yan, Hui-Ying; Wang, Song-De

2008-04-01

In order to ensure personal safety and prevent injury accident in machine tool operation, an infrared machine tool safety system was designed with infrared transmitting-receiving module, memory self-locked relay and voice recording-playing module. When the operator does not enter the danger area, the system has no response. Once the operator's whole or part of body enters the danger area and shades the infrared beam, the system will alarm and output an control signal to the machine tool executive element, and at the same time, the system makes the machine tool emergency stop to prevent equipment damaged and person injured. The system has a module framework, and has many advantages including safety, reliability, common use, circuit simplicity, maintenance convenience, low power consumption, low costs, working stability, easy debugging, vibration resistance and interference resistance. It is suitable for being installed and used in different machine tools such as punch machine, pour plastic machine, digital control machine, armor plate cutting machine, pipe bending machine, oil pressure machine etc.

Machine tool task force

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

Sutton, G.P.

1980-10-22

The Machine Tool Task Force (MTTF) is a multidisciplined team of international experts, whose mission was to investigate the state of the art of machine tool technology, to identify promising future directions of that technology for both the US government and private industry, and to disseminate the findings of its research in a conference and through the publication of a final report. MTTF was a two and one-half year effort that involved the participation of 122 experts in the specialized technologies of machine tools and in the management of machine tool operations. The scope of the MTTF was limited tomore » cutting-type or material-removal-type machine tools, because they represent the major share and value of all machine tools now installed or being built. The activities of the MTTF and the technical, commercial and economic signifiance of recommended activities for improving machine tool technology are discussed. (LCL)« less

Towards a generalized energy prediction model for machine tools

PubMed Central

Bhinge, Raunak; Park, Jinkyoo; Law, Kincho H.; Dornfeld, David A.; Helu, Moneer; Rachuri, Sudarsan

2017-01-01

Energy prediction of machine tools can deliver many advantages to a manufacturing enterprise, ranging from energy-efficient process planning to machine tool monitoring. Physics-based, energy prediction models have been proposed in the past to understand the energy usage pattern of a machine tool. However, uncertainties in both the machine and the operating environment make it difficult to predict the energy consumption of the target machine reliably. Taking advantage of the opportunity to collect extensive, contextual, energy-consumption data, we discuss a data-driven approach to develop an energy prediction model of a machine tool in this paper. First, we present a methodology that can efficiently and effectively collect and process data extracted from a machine tool and its sensors. We then present a data-driven model that can be used to predict the energy consumption of the machine tool for machining a generic part. Specifically, we use Gaussian Process (GP) Regression, a non-parametric machine-learning technique, to develop the prediction model. The energy prediction model is then generalized over multiple process parameters and operations. Finally, we apply this generalized model with a method to assess uncertainty intervals to predict the energy consumed to machine any part using a Mori Seiki NVD1500 machine tool. Furthermore, the same model can be used during process planning to optimize the energy-efficiency of a machining process. PMID:28652687

Towards a generalized energy prediction model for machine tools.

PubMed

Bhinge, Raunak; Park, Jinkyoo; Law, Kincho H; Dornfeld, David A; Helu, Moneer; Rachuri, Sudarsan

2017-04-01

Energy prediction of machine tools can deliver many advantages to a manufacturing enterprise, ranging from energy-efficient process planning to machine tool monitoring. Physics-based, energy prediction models have been proposed in the past to understand the energy usage pattern of a machine tool. However, uncertainties in both the machine and the operating environment make it difficult to predict the energy consumption of the target machine reliably. Taking advantage of the opportunity to collect extensive, contextual, energy-consumption data, we discuss a data-driven approach to develop an energy prediction model of a machine tool in this paper. First, we present a methodology that can efficiently and effectively collect and process data extracted from a machine tool and its sensors. We then present a data-driven model that can be used to predict the energy consumption of the machine tool for machining a generic part. Specifically, we use Gaussian Process (GP) Regression, a non-parametric machine-learning technique, to develop the prediction model. The energy prediction model is then generalized over multiple process parameters and operations. Finally, we apply this generalized model with a method to assess uncertainty intervals to predict the energy consumed to machine any part using a Mori Seiki NVD1500 machine tool. Furthermore, the same model can be used during process planning to optimize the energy-efficiency of a machining process.

Mississippi Curriculum Framework for Machine Tool Operation/Machine Shop and Tool and Die Making Technology Cluster (Program CIP: 48.0507--Tool and Die Maker/Technologist) (Program CIP: 48.0503--Machine Shop Assistant). Postsecondary Programs.

ERIC Educational Resources Information Center

Mississippi Research and Curriculum Unit for Vocational and Technical Education, State College.

This document, which is intended for use by community and junior colleges throughout Mississippi, contains curriculum frameworks for the course sequences in the machine tool operation/machine tool and tool and die making technology programs cluster. Presented in the introductory section are a framework of courses and programs, description of the…

Chip breaking system for automated machine tool

DOEpatents

Arehart, Theodore A.; Carey, Donald O.

1987-01-01

The invention is a rotary selectively directional valve assembly for use in an automated turret lathe for directing a stream of high pressure liquid machining coolant to the interface of a machine tool and workpiece for breaking up ribbon-shaped chips during the formation thereof so as to inhibit scratching or other marring of the machined surfaces by these ribbon-shaped chips. The valve assembly is provided by a manifold arrangement having a plurality of circumferentially spaced apart ports each coupled to a machine tool. The manifold is rotatable with the turret when the turret is positioned for alignment of a machine tool in a machining relationship with the workpiece. The manifold is connected to a non-rotational header having a single passageway therethrough which conveys the high pressure coolant to only the port in the manifold which is in registry with the tool disposed in a working relationship with the workpiece. To position the machine tools the turret is rotated and one of the tools is placed in a material-removing relationship of the workpiece. The passageway in the header and one of the ports in the manifold arrangement are then automatically aligned to supply the machining coolant to the machine tool workpiece interface for breaking up of the chips as well as cooling the tool and workpiece during the machining operation.

High efficiency machining technology and equipment for edge chamfer of KDP crystals

NASA Astrophysics Data System (ADS)

Chen, Dongsheng; Wang, Baorui; Chen, Jihong

2016-10-01

Potassium dihydrogen phosphate (KDP) is a type of nonlinear optical crystal material. To Inhibit the transverse stimulated Raman scattering of laser beam and then enhance the optical performance of the optics, the edges of the large-sized KDP crystal needs to be removed to form chamfered faces with high surface quality (RMS<5 nm). However, as the depth of cut (DOC) of fly cutting is usually several, its machining efficiency is too low to be accepted for chamfering of the KDP crystal as the amount of materials to be removed is in the order of millimeter. This paper proposes a novel hybrid machining method, which combines precision grinding with fly cutting, for crackless and high efficiency chamfer of KDP crystal. A specialized machine tool, which adopts aerostatic bearing linear slide and aerostatic bearing spindle, was developed for chamfer of the KDP crystal. The aerostatic bearing linear slide consists of an aerostatic bearing guide with linearity of 0.1 μm/100mm and a linear motor to achieve linear feeding with high precision and high dynamic performance. The vertical spindle consists of an aerostatic bearing spindle with the rotation accuracy (axial) of 0.05 microns and Fork type flexible connection precision driving mechanism. The machining experiment on flying and grinding was carried out, the optimize machining parameters was gained by a series of experiment. Surface roughness of 2.4 nm has been obtained. The machining efficiency can be improved by six times using the combined method to produce the same machined surface quality.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Bidirectional, Automatic Coal-Mining Machine

NASA Technical Reports Server (NTRS)

Collins, Earl R., Jr.

1986-01-01

Proposed coal-mining machine operates in both forward and reverse directions along mine face. New design increases efficiency and productivity, because does not stop cutting as it retreats to starting position after completing pass along face. To further increase efficiency, automatic miner carries its own machinery for crushing coal and feeding it to slurry-transport tube. Dual-drum mining machine cuts coal in two layers, crushes, mixes with water, and feeds it as slurry to haulage tube. At end of pass, foward drum raised so it becomes rear drum, and rear drum lowered, becoming forward drum for return pass.

Research on the tool holder mode in high speed machining

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Dropout Prediction in E-Learning Courses through the Combination of Machine Learning Techniques

ERIC Educational Resources Information Center

Lykourentzou, Ioanna; Giannoukos, Ioannis; Nikolopoulos, Vassilis; Mpardis, George; Loumos, Vassili

2009-01-01

In this paper, a dropout prediction method for e-learning courses, based on three popular machine learning techniques and detailed student data, is proposed. The machine learning techniques used are feed-forward neural networks, support vector machines and probabilistic ensemble simplified fuzzy ARTMAP. Since a single technique may fail to…

Machine tool locator

DOEpatents

Hanlon, John A.; Gill, Timothy J.

2001-01-01

Machine tools can be accurately measured and positioned on manufacturing machines within very small tolerances by use of an autocollimator on a 3-axis mount on a manufacturing machine and positioned so as to focus on a reference tooling ball or a machine tool, a digital camera connected to the viewing end of the autocollimator, and a marker and measure generator for receiving digital images from the camera, then displaying or measuring distances between the projection reticle and the reference reticle on the monitoring screen, and relating the distances to the actual position of the autocollimator relative to the reference tooling ball. The images and measurements are used to set the position of the machine tool and to measure the size and shape of the machine tool tip, and examine cutting edge wear. patent

Micro electrical discharge milling using deionized water as a dielectric fluid

NASA Astrophysics Data System (ADS)

Chung, Do Kwan; Kim, Bo Hyun; Chu, Chong Nam

2007-05-01

In electrical discharge machining, dielectric fluid is an important factor affecting machining characteristics. Generally, kerosene and deionized water have been used as dielectric fluids. In micro electrical discharge milling, which uses a micro electrode as a tool, the wear of the tool electrode decreases the machining accuracy. However, the use of deionized water instead of kerosene can reduce the tool wear and increase the machining speed. This paper investigates micro electrical discharge milling using deionized water. Deionized water with high resistivity was used to minimize the machining gap. Machining characteristics such as the tool wear, machining gap and machining rate were investigated according to resistivity of deionized water. As the resistivity of deionized water decreased, the tool wear was reduced, but the machining gap increased due to electrochemical dissolution. Micro hemispheres were machined for the purpose of investigating machining efficiency between dielectric fluids, kerosene and deionized water.

Minimization of the hole overcut and cylindricity errors during rotary ultrasonic drilling of Ti-6Al-4V

NASA Astrophysics Data System (ADS)

Nasr, M.; Anwar, S.; El-Tamimi, A.; Pervaiz, S.

2018-04-01

Titanium and its alloys e.g. Ti6Al4V have widespread applications in aerospace, automotive and medical industry. At the same time titanium and its alloys are regarded as difficult to machine materials due to their high strength and low thermal conductivity. Significant efforts have been dispensed to improve the accuracy of the machining processes for Ti6Al4V. The current study present the use of the rotary ultrasonic drilling (RUD) process for machining high quality holes in Ti6Al4V. The study takes into account the effects of the main RUD input parameters including spindle speed, ultrasonic power, feed rate and tool diameter on the key output responses related to the accuracy of the drilled holes including cylindricity and overcut errors. Analysis of variance (ANOVA) was employed to study the influence of the input parameters on cylindricity and overcut error. Later, regression models were developed to find the optimal set of input parameters to minimize the cylindricity and overcut errors.

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

DOEpatents

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

2013-04-30

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

Nanocomposites for Machining Tools

PubMed Central

Loginov, Pavel; Mishnaevsky, Leon; Levashov, Evgeny

2017-01-01

Machining tools are used in many areas of production. To a considerable extent, the performance characteristics of the tools determine the quality and cost of obtained products. The main materials used for producing machining tools are steel, cemented carbides, ceramics and superhard materials. A promising way to improve the performance characteristics of these materials is to design new nanocomposites based on them. The application of micromechanical modeling during the elaboration of composite materials for machining tools can reduce the financial and time costs for development of new tools, with enhanced performance. This article reviews the main groups of nanocomposites for machining tools and their performance. PMID:29027926

Permutation parity machines for neural cryptography.

PubMed

Reyes, Oscar Mauricio; Zimmermann, Karl-Heinz

2010-06-01

Recently, synchronization was proved for permutation parity machines, multilayer feed-forward neural networks proposed as a binary variant of the tree parity machines. This ability was already used in the case of tree parity machines to introduce a key-exchange protocol. In this paper, a protocol based on permutation parity machines is proposed and its performance against common attacks (simple, geometric, majority and genetic) is studied.

Permutation parity machines for neural cryptography

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

Reyes, Oscar Mauricio; Escuela de Ingenieria Electrica, Electronica y Telecomunicaciones, Universidad Industrial de Santander, Bucaramanga; Zimmermann, Karl-Heinz

2010-06-15

Recently, synchronization was proved for permutation parity machines, multilayer feed-forward neural networks proposed as a binary variant of the tree parity machines. This ability was already used in the case of tree parity machines to introduce a key-exchange protocol. In this paper, a protocol based on permutation parity machines is proposed and its performance against common attacks (simple, geometric, majority and genetic) is studied.

Machine learning for characterization of insect vector feeding

USDA-ARS?s Scientific Manuscript database

Insects that feed by ingesting plant and animal fluids cause devastating damage to humans, livestock, and agriculture worldwide, primarily by transmitting phytopathogenic and zoonotic pathogens. The feeding processes required for successful disease transmission by sucking insects can be recorded by ...

Virtual Manufacturing Techniques Designed and Applied to Manufacturing Activities in the Manufacturing Integration and Technology Branch

NASA Technical Reports Server (NTRS)

Shearrow, Charles A.

1999-01-01

One of the identified goals of EM3 is to implement virtual manufacturing by the time the year 2000 has ended. To realize this goal of a true virtual manufacturing enterprise the initial development of a machinability database and the infrastructure must be completed. This will consist of the containment of the existing EM-NET problems and developing machine, tooling, and common materials databases. To integrate the virtual manufacturing enterprise with normal day to day operations the development of a parallel virtual manufacturing machinability database, virtual manufacturing database, virtual manufacturing paradigm, implementation/integration procedure, and testable verification models must be constructed. Common and virtual machinability databases will include the four distinct areas of machine tools, available tooling, common machine tool loads, and a materials database. The machine tools database will include the machine envelope, special machine attachments, tooling capacity, location within NASA-JSC or with a contractor, and availability/scheduling. The tooling database will include available standard tooling, custom in-house tooling, tool properties, and availability. The common materials database will include materials thickness ranges, strengths, types, and their availability. The virtual manufacturing databases will consist of virtual machines and virtual tooling directly related to the common and machinability databases. The items to be completed are the design and construction of the machinability databases, virtual manufacturing paradigm for NASA-JSC, implementation timeline, VNC model of one bridge mill and troubleshoot existing software and hardware problems with EN4NET. The final step of this virtual manufacturing project will be to integrate other production sites into the databases bringing JSC's EM3 into a position of becoming a clearing house for NASA's digital manufacturing needs creating a true virtual manufacturing enterprise.

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

A noncontact laser technique for circular contouring accuracy measurement

NASA Astrophysics Data System (ADS)

Wang, Charles; Griffin, Bob

2001-02-01

The worldwide competition in manufacturing frequently requires the high-speed machine tools to deliver contouring accuracy in the order of a few micrometers, while moving at relatively high feed rates. Traditional test equipment is rather limited in its capability to measure contours of small radius at high speed. Described here is a new noncontact laser measurement technique for the test of circular contouring accuracy. This technique is based on a single-aperture laser Doppler displacement meter with a flat mirror as the target. It is of a noncontact type with the ability to vary the circular path radius continuously at data rates of up to 1000 Hz. Using this instrument, the actual radius, feed rate, velocity, and acceleration profiles can also be determined. The basic theory of operation, the hardware setup, the data collection, the data processing, and the error budget are discussed.

Machine tools and fixtures: A compilation

NASA Technical Reports Server (NTRS)

1971-01-01

As part of NASA's Technology Utilizations Program, a compilation was made of technological developments regarding machine tools, jigs, and fixtures that have been produced, modified, or adapted to meet requirements of the aerospace program. The compilation is divided into three sections that include: (1) a variety of machine tool applications that offer easier and more efficient production techniques; (2) methods, techniques, and hardware that aid in the setup, alignment, and control of machines and machine tools to further quality assurance in finished products: and (3) jigs, fixtures, and adapters that are ancillary to basic machine tools and aid in realizing their greatest potential.

Overview of the Machine-Tool Task Force

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

Sutton, G.P.

1981-06-08

The Machine Tool Task Force, (MTTF) surveyed the state of the art of machine tool technology for material removal for two and one-half years. This overview gives a brief summary of the approach, specific subjects covered, principal conclusions and some of the key recommendations aimed at improving the technology and advancing the productivity of machine tools. The Task Force consisted of 123 experts from the US and other countries. Their findings are documented in a five-volume report, Technology of Machine Tools.

Machine learning for characterization of insect vector feeding

USDA-ARS?s Scientific Manuscript database

Insects that feed by ingesting plant and animal fluids cause devastating damage to humans, livestock, and agriculture worldwide, primarily by transmitting pathogens of plants and animals. The feeding processes required for successful pathogen transmission by sucking insects can be recorded by monito...

A method to identify the main mode of machine tool under operating conditions

NASA Astrophysics Data System (ADS)

Wang, Daming; Pan, Yabing

2017-04-01

The identification of the modal parameters under experimental conditions is the most common procedure when solving the problem of machine tool structure vibration. However, the influence of each mode on the machine tool vibration in real working conditions remains unknown. In fact, the contributions each mode makes to the machine tool vibration during machining process are different. In this article, an active excitation modal analysis is applied to identify the modal parameters in operational condition, and the Operating Deflection Shapes (ODS) in frequencies of high level vibration that affect the quality of machining in real working conditions are obtained. Then, the ODS is decomposed by the mode shapes which are identified in operational conditions. So, the contributions each mode makes to machine tool vibration during machining process are got by decomposition coefficients. From the previous steps, we can find out the main modes which effect the machine tool more significantly in working conditions. This method was also verified to be effective by experiments.

Linear positioning laser calibration setup of CNC machine tools

NASA Astrophysics Data System (ADS)

Sui, Xiulin; Yang, Congjing

2002-10-01

The linear positioning laser calibration setup of CNC machine tools is capable of executing machine tool laser calibraiotn and backlash compensation. Using this setup, hole locations on CNC machien tools will be correct and machien tool geometry will be evaluated and adjusted. Machien tool laser calibration and backlash compensation is a simple and straightforward process. First the setup is to 'find' the stroke limits of the axis. Then the laser head is then brought into correct alignment. Second is to move the machine axis to the other extreme, the laser head is now aligned, using rotation and elevation adjustments. Finally the machine is moved to the start position and final alignment is verified. The stroke of the machine, and the machine compensation interval dictate the amount of data required for each axis. These factors determine the amount of time required for a through compensation of the linear positioning accuracy. The Laser Calibrator System monitors the material temperature and the air density; this takes into consideration machine thermal growth and laser beam frequency. This linear positioning laser calibration setup can be used on CNC machine tools, CNC lathes, horizontal centers and vertical machining centers.

Standardized Curriculum for Machine Tool Operation/Machine Shop.

ERIC Educational Resources Information Center

Mississippi State Dept. of Education, Jackson. Office of Vocational, Technical and Adult Education.

Standardized vocational education course titles and core contents for two courses in Mississippi are provided: machine tool operation/machine shop I and II. The first course contains the following units: (1) orientation; (2) shop safety; (3) shop math; (4) measuring tools and instruments; (5) hand and bench tools; (6) blueprint reading; (7)…

Contributions a la caracterisation et a l'amelioration de l'usinabilite de pieces d'acier elaborees par metallurgie des poudres

NASA Astrophysics Data System (ADS)

Boilard, Patrick

Even though powder metallurgy (P/M) is a near net shape process, a large number of parts still require one or more machining operations during the course of their elaboration and/or their finishing. The main objectives of the work presented in this thesis are centered on the elaboration of blends with enhanced machinability, as well as helping with the definition and in the characterization of the machinability of P/M parts. Enhancing machinability can be done in various ways, through the use of machinability additives and by decreasing the amount of porosity of the parts. These different ways of enhancing machinability have been investigated thoroughly, by systematically planning and preparing series of samples in order to obtain valid and repeatable results leading to meaningful conclusions relevant to the P/M domain. Results obtained during the course of the work are divided into three main chapters: (1) the effect of machining parameters on machinability, (2) the effect of additives on machinability, and (3) the development and the characterization of high density parts obtained by liquid phase sintering. Regarding the effect of machining parameters on machinability, studies were performed on parameters such as rotating speed, feed, tool position and diameter of the tool. Optimal cutting parameters are found for drilling operations performed on a standard FC-0208 blend, for different machinability criteria. Moreover, study of material removal rates shows the sensitivity of the machinability criteria for different machining parameters and indicates that thrust force is more regular than tool wear and slope of the drillability curve in the characterization of machinability. The chapter discussing the effect of various additives on machinability reveals many interesting results. First, work carried out on MoS2 additions reveals the dissociation of this additive and the creation of metallic sulphides (namely CuxS sulphides) when copper is present. Results also show that it is possible to reduce the amount of MoS2 in the blend so as to lower the dimensional change and the cost (blend Mo8A), while enhancing machinability and keeping hardness values within the same range (70 HRB). Second, adding enstatite (MgO·SiO2) permits the observation of the mechanisms occurring with the use of this additive. It is found that the stability of enstatite limits the diffusion of graphite during sintering, leading to the presence of free graphite in the pores, thus enhancing machinability. Furthermore, a lower amount of graphite in the matrix leads to a lower hardness, which is also beneficial to machinability. It is also found that the presence of copper enhances the diffusion of graphite, through the formation of a liquid phase during sintering. With the objective of improving machinability by reaching higher densities, blends were developed for densification through liquid phase sintering. High density samples are obtained (>7.5 g/cm3) for blends prepared with Fe-C-P constituents, namely with 0.5%P and 2.4%C. By systematically studying the effect of different parameters, the importance of the chemical composition (mainly the carbon content) and the importance of the sintering cycle (particularly the cooling rate) are demonstrated. Moreover, various heat treatments studied illustrate the different microstructures achievable for this system, showing various amounts of cementite, pearlite and free graphite. Although the machinability is limited for samples containing large amounts of cementite, it can be greatly improved with very slow cooling, leading to graphitization of the carbon in presence of phosphorus. Adequate control of the sintering cycle on samples made from FGS1625 powder leads to the obtention of high density (≥7.0 g/cm 3) microstructures containing various amounts of pearlite, ferrite and free graphite. Obtaining ferritic microstructures with free graphite designed for very high machinability (tool wear <1.0%) or fine pearlitic microstructures with excellent mechanical properties (transverse rupture strength >1600 MPa) is therefore possible. These results show that improvement of machinability through higher densities is limited by microstructure. Indeed, for the studied samples, microstructure is dominant in the determination of machinability, far more important than density, judging by the influence of cementite or of the volume fraction of free graphite on machinability for example. (Abstract shortened by UMI.)

Technology of machine tools. Volume 4. Machine tool controls

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

Not Available

1980-10-01

The Machine Tool Task Force (MTTF) was formed to characterize the state of the art of machine tool technology and to identify promising future directions of this technology. This volume is one of a five-volume series that presents the MTTF findings; reports on various areas of the technology were contributed by experts in those areas.

Technology of machine tools. Volume 3. Machine tool mechanics

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

Tlusty, J.

1980-10-01

The Machine Tool Task Force (MTTF) was formed to characterize the state of the art of machine tool technology and to identify promising future directions of this technology. This volume is one of a five-volume series that presents the MTTF findings; reports on various areas of the technology were contributed by experts in those areas.

Technology of machine tools. Volume 5. Machine tool accuracy

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

Hocken, R.J.

1980-10-01

The Machine Tool Task Force (MTTF) was formed to characterize the state of the art of machine tool technology and to identify promising future directions of this technology. This volume is one of a five-volume series that presents the MTTF findings; reports on various areas of the technology were contributed by experts in those areas.

76 FR 27668 - ASC Machine Tools, Inc., Spokane Valley, WA; Notice of Negative Determination on Reconsideration

Federal Register 2010, 2011, 2012, 2013, 2014

2011-05-12

... DEPARTMENT OF LABOR Employment and Training Administration [TA-W-72,971] ASC Machine Tools, Inc... workers and former workers of ASC Machine Tools, Inc., Spokane Valley, Washington (the subject firm). The... workers of ASC Machine Tools, Inc., Spokane Valley, Washington. Signed in Washington, DC, on this 2nd day...

Fabrication Characterization of Solar-Cell Silicon Wafers Using a Circular-Rhombus Tool

NASA Astrophysics Data System (ADS)

Pa, Pai-Shan

2010-01-01

A new recycling fabrication method using a custom-built designed circular-rhombus tool for a process combining of micro-electroetching and electrochemical machining for removal of the surface layers from silicon wafers of solar cells is demonstrated. The low yields of epoxy film and Si3N4 thin-film depositions are important factors in semiconductor production. The aim of the proposed recycling fabrication method is to replace the current approach, which uses strong acid and grinding and may damage the physical structure of silicon wafers and pollute to the environment. A precisely engineered clean production approach for removal of surface microstructure layers from silicon wafers is to develop a mass production system for recycling defective or discarded silicon wafers of solar cells that can reduce pollution and cost. A large diameter cathode of the circular-rhombus tool (with a small gap between the anode and the cathode) corresponds to a high rate of epoxy film removal. A high feed rate of the silicon wafers combined with a high continuous DC electric voltage results in a high removal rate. The high rotational speed of the circular-rhombus tool increases the discharge mobility and improves the removal effect associated with the high feed rate of the workpiece. A small port radius or large end angle of the rhombus anode provides a large discharge space and good removal effect only a short period of time is required to remove the Si3N4 layer and epoxy film easily and cleanly.

Tool setting device

DOEpatents

Brown, Raymond J.

1977-01-01

The present invention relates to a tool setting device for use with numerically controlled machine tools, such as lathes and milling machines. A reference position of the machine tool relative to the workpiece along both the X and Y axes is utilized by the control circuit for driving the tool through its program. This reference position is determined for both axes by displacing a single linear variable displacement transducer (LVDT) with the machine tool through a T-shaped pivotal bar. The use of the T-shaped bar allows the cutting tool to be moved sequentially in the X or Y direction for indicating the actual position of the machine tool relative to the predetermined desired position in the numerical control circuit by using a single LVDT.

Machinability of Green Powder Metallurgy Components: Part I. Characterization of the Influence of Tool Wear

NASA Astrophysics Data System (ADS)

Robert-Perron, Etienne; Blais, Carl; Pelletier, Sylvain; Thomas, Yannig

2007-06-01

The green machining process is an interesting approach for solving the mediocre machining behavior of high-performance powder metallurgy (PM) steels. This process appears as a promising method for extending tool life and reducing machining costs. Recent improvements in binder/lubricant technologies have led to high green strength systems that enable green machining. So far, tool wear has been considered negligible when characterizing the machinability of green PM specimens. This inaccurate assumption may lead to the selection of suboptimum cutting conditions. The first part of this study involves the optimization of the machining parameters to minimize the effects of tool wear on the machinability in turning of green PM components. The second part of our work compares the sintered mechanical properties of components machined in green state with other machined after sintering.

Experimental study of surface integrity and fatigue life in the face milling of inconel 718

NASA Astrophysics Data System (ADS)

Wang, Xiangyu; Huang, Chuanzhen; Zou, Bin; Liu, Guoliang; Zhu, Hongtao; Wang, Jun

2018-06-01

The Inconel 718 alloy is widely used in the aerospace and power industries. The machining-induced surface integrity and fatigue life of this material are important factors for consideration due to high reliability and safety requirements. In this work, the milling of Inconel 718 was conducted at different cutting speeds and feed rates. Surface integrity and fatigue life were measured directly. The effects of cutting speed and feed rate on surface integrity and their further influences on fatigue life were analyzed. Within the chosen parameter range, the cutting speed barely affected the surface roughness, whereas the feed rate increased the surface roughness through the ideal residual height. The surface hardness increased as the cutting speed and feed rate increased. Tensile residual stress was observed on the machined surface, which showed improvement with the increasing feed rate. The cutting speed was not an influencing factor on fatigue life, but the feed rate affected fatigue life through the surface roughness. The high surface roughness resulting from the high feed rate could result in a high stress concentration factor and lead to a low fatigue life.

Strength of inserts in titanium alloy machining

NASA Astrophysics Data System (ADS)

Kozlov, V.; Huang, Z.; Zhang, J.

2016-04-01

In this paper, a stressed state of a non-worn cutting wedge in a machined titanium alloy (Ti6Al2Mo2Cr) is analyzed. The distribution of contact loads on the face of a cutting tool was obtained experimentally with the use of a ‘split cutting tool’. Calculation of internal stresses in the indexable insert made from cemented carbide (WC8Co) was carried out with the help of ANSYS 14.0 software. Investigations showed that a small thickness of the cutting insert leads to extremely high compressive stresses near the cutting edge, stresses that exceed the ultimate compressive strength of cemented carbide. The face and the base of the insert experience high tensile stresses, which approach the ultimate tensile strength of cemented carbide and increase a probability of cutting insert destruction. If the thickness of the cutting insert is bigger than 5 mm, compressive stresses near the cutting edge decrease, and tensile stresses on the face and base decrease to zero. The dependences of the greatest normal and tangential stresses on thickness of the cutting insert were found. Abbreviation and symbols: m/s - meter per second (cutting speed v); mm/r - millimeter per revolution (feed rate f); MPa - mega Pascal (dimension of specific contact loads and stresses); γ - rake angle of the cutting tool [°] α - clearance angle of the sharp cutting tool [°].

EQUIPMENT FOR SPARK-ASSISTED MACHINING (OBORUDOVANIE DLYA ELEKTROISKROVOI OBRABOTKI),

DTIC Science & Technology

MACHINE TOOLS, * ELECTROEROSIVE MACHINING), MACHINE TOOL INDUSTRY, ELECTROFORMING, ELECTRODES, ELECTROLYTIC CAPACITORS, ELECTRIC DISCHARGES, TOLERANCES(MECHANICS), SURFACE ROUGHNESS, DIES, MOLDINGS, SYNTHETIC FIBERS, USSR

Technology of machine tools. Volume 2. Machine tool systems management and utilization

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

Thomson, A.R.

1980-10-01

The Machine Tool Task Force (MTTF) was formed to characterize the state of the art of machine tool technology and to identify promising future directions of this technology. This volume is one of a five-volume series that presents the MTTF findings; reports on various areas of the technology were contributed by experts in those areas.

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.

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.

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 13: Laser Machining, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 3: Machining, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Assessment Tools for Evaluation of Oral Feeding in Infants Less than Six Months Old

PubMed Central

Pados, Britt F.; Park, Jinhee; Estrem, Hayley; Awotwi, Araba

2015-01-01

Background Feeding difficulty is common in infants less than six months old. Identification of infants in need of specialized treatment is critical to ensure appropriate nutrition and feeding skill development. Valid and reliable assessment tools help clinicians objectively evaluate feeding. Purpose To identify and evaluate assessment tools available for clinical assessment of bottle- and breast-feeding in infants less than six months old. Methods/Search Strategy CINAHL, HaPI, PubMed, and Web of Science were searched for “infant feeding” and “assessment tool.” The literature (n=237) was reviewed for relevant assessment tools. A secondary search was conducted in CINAHL and PubMed for additional literature on identified tools. Findings/Results Eighteen assessment tools met inclusion criteria. Of these, seven were excluded because of limited available literature or because they were intended for use with a specific diagnosis or in research only. There are 11 assessment tools available for clinical practice. Only two of these were intended for bottle-feeding. All 11 indicated they were appropriate for use with breast-feeding. None of the available tools have adequate psychometric development and testing. Implications for Practice All of the tools should be used with caution. The Early Feeding Skills Assessment and Bristol Breastfeeding Assessment Tool had the most supportive psychometric development and testing. Implications for Research Feeding assessment tools need to be developed and tested to guide optimal clinical care of infants from birth through six months. A tool that assesses both bottle- and breast-feeding would allow for consistent assessment across feeding methods. PMID:26945280

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.

Surface Roughness Optimization Using Taguchi Method of High Speed End Milling For Hardened Steel D2

NASA Astrophysics Data System (ADS)

Hazza Faizi Al-Hazza, Muataz; Ibrahim, Nur Asmawiyah bt; Adesta, Erry T. Y.; Khan, Ahsan Ali; Abdullah Sidek, Atiah Bt.

2017-03-01

The main challenge for any manufacturer is to achieve higher quality of their final products with maintains minimum machining time. In this research final surface roughness analysed and optimized with maximum 0.3 mm flank wear length. The experiment was investigated the effect of cutting speed, feed rate and depth of cut on the final surface roughness using D2 as a work piece hardened to 52-56 HRC, and coated carbide as cutting tool with higher cutting speed 120-240 mm/min. The experiment has been conducted using L9 design of Taguchi collection. The results have been analysed using JMP software.

Plan for conducting an international machine tool task force

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

Sutton, G.P.; McClure, E.R.; Schuman, J.F.

1978-08-28

The basic objectives of the Machine Tool Task Force (MTTF) are to characterize and summarize the state of the art of cutting machine tool technology and to identify promising areas of future R and D. These goals will be accomplished with a series of multidisciplinary teams of prominent experts and individuals experienced in the specialized technologies of machine tools or in the management of machine tool operations. Experts will be drawn from all areas of the machine tool community: machine tool users or buyer organizations, builders, and R and D establishments including universities and government laboratories, both domestic and foreign.more » A plan for accomplishing this task is presented. The area of machine tool technology has been divided into about two dozen technology subjects on which teams of one or more experts will work. These teams are, in turn, organized into four principal working groups dealing, respectively, with machine tool accuracy, mechanics, control, and management systems/utilization. Details are presented on specific subjects to be covered, the organization of the Task Force and its four working groups, and the basic approach to determining the state of the art of technology and the future directions of this technology. The planned review procedure, the potential benefits, our management approach, and the schedule, as well as the key participating personnel and their background are discussed. The initial meeting of MTTF members will be held at a plenary session on October 16 and 17, 1978, in Scottsdale, AZ. The MTTF study will culminate in a conference on September 1, 1980, in Chicago, IL, immediately preceeding the 1980 International Machine Tool Show. At this time, our results will be released to the public; a series of reports will be published in late 1980.« less

37. MILL NO. 2, 2nd FLOOR, CLOSE SHOT OF 2 ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

37. MILL NO. 2, 2nd FLOOR, CLOSE SHOT OF 2 CREEL MACHINES, WHICH FEED YARN INTO KNITTING MACHINES. - Prattville Manufacturing Company, Number One, 242 South Court Street, Prattville, Autauga County, AL

Selected aspects of microelectronics technology and applications: Numerically controlled machine tools. Technology trends series no. 2

NASA Astrophysics Data System (ADS)

Sigurdson, J.; Tagerud, J.

1986-05-01

A UNIDO publication about machine tools with automatic control discusses the following: (1) numerical control (NC) machine tool perspectives, definition of NC, flexible manufacturing systems, robots and their industrial application, research and development, and sensors; (2) experience in developing a capability in NC machine tools; (3) policy issues; (4) procedures for retrieval of relevant documentation from data bases. Diagrams, statistics, bibliography are included.

Design and milling manufacture of polyurethane custom contoured cushions for wheelchair users.

PubMed

da Silva, Fabio Pinto; Beretta, Elisa Marangon; Prestes, Rafael Cavalli; Kindlein Junior, Wilson

2011-01-01

The design of custom contoured cushions manufactured in flexible polyurethane foams is an option to improve positioning and comfort for people with disabilities that spend most of the day seated in the same position. These surfaces increase the contact area between the seat and the user. This fact contributes to minimise the local pressures that can generate problems like decubitus ulcers. The present research aims at establishing development routes for custom cushion production to wheelchair users. This study also contributes to the investigation of Computer Numerical Control (CNC) machining of flexible polyurethane foams. The proposed route to obtain the customised seat began with acquiring the user's contour in adequate posture through plaster cast. To collect the surface geometry, the cast was three-dimensionally scanned and manipulated in CAD/CAM software. CNC milling parameters such as tools, spindle speeds and feed rates to machine flexible polyurethane foams were tested. These parameters were analysed regarding the surface quality. The best parameters were then tested in a customised seat. The possible dimensional changes generated during foam cutting were analysed through 3D scanning. Also, the customised seat pressure and temperature distribution was tested. The best parameters found for foams with a density of 50kg/cm(3) were high spindle speeds (24000 rpm) and feed rates between 2400-4000mm/min. Those parameters did not generate significant deformities in the machined cushions. The custom contoured cushion satisfactorily increased the contact area between wheelchair and user, as it distributed pressure and heat evenly. Through this study it was possible to define routes for the development and manufacturing of customised seats using direct CNC milling in flexible polyurethane foams. It also showed that custom contoured cushions efficiently distribute pressure and temperature, which is believed to minimise tissue lesions such as pressure ulcers.

Short communication: Measuring feed volume and weight by machine vision.

PubMed

Shelley, A N; Lau, D L; Stone, A E; Bewley, J M

2016-01-01

Individual dairy cow feed intake is closely related to the health and productive output of each cow, with healthy cows generally eating more feed than unhealthy cows. Incorporating the use of an automated system to monitor feed consumption for each cow may be beneficial for dairy farm management. This study examined the use of an inexpensive 3-dimensional video camera to measure feed volume, from which we derived feed weight. Proof-of-concept testing was conducted to determine the effectiveness and capability of the machine vision feed-scanning system and its possible use in feed intake monitoring. Such systems are ideal because they do not impede the workflow of the farm or interrupt feeding behavior. This is an improvement over existing systems that are labor and cost intensive. Our conducted experiments involve measuring feed volume at known weights, up to 22.68 kg, with the resulting volume and weight values analyzed by means of linear and quadratic least squares t-test regression analysis. The effects of feed positioning in the bin and near-range sensor limitations were also examined. The results showed that an estimation of feed weight from 3-dimensional scan of volume measurements could be made to within 0.5 kg of the physically measured feed weight using a digital scale. Future efforts will focus on extending this work to active bunks with multiple cows eating throughout the day and testing total mixed rations of varied composition. Copyright © 2016 American Dairy Science Association. Published by Elsevier Inc. All rights reserved.

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.

A hybrid prognostic model for multistep ahead prediction of machine condition

NASA Astrophysics Data System (ADS)

Roulias, D.; Loutas, T. H.; Kostopoulos, V.

2012-05-01

Prognostics are the future trend in condition based maintenance. In the current framework a data driven prognostic model is developed. The typical procedure of developing such a model comprises a) the selection of features which correlate well with the gradual degradation of the machine and b) the training of a mathematical tool. In this work the data are taken from a laboratory scale single stage gearbox under multi-sensor monitoring. Tests monitoring the condition of the gear pair from healthy state until total brake down following several days of continuous operation were conducted. After basic pre-processing of the derived data, an indicator that correlated well with the gearbox condition was obtained. Consecutively the time series is split in few distinguishable time regions via an intelligent data clustering scheme. Each operating region is modelled with a feed-forward artificial neural network (FFANN) scheme. The performance of the proposed model is tested by applying the system to predict the machine degradation level on unseen data. The results show the plausibility and effectiveness of the model in following the trend of the timeseries even in the case that a sudden change occurs. Moreover the model shows ability to generalise for application in similar mechanical assets.

The in-situ 3D measurement system combined with CNC machine tools

NASA Astrophysics Data System (ADS)

Zhao, Huijie; Jiang, Hongzhi; Li, Xudong; Sui, Shaochun; Tang, Limin; Liang, Xiaoyue; Diao, Xiaochun; Dai, Jiliang

2013-06-01

With the development of manufacturing industry, the in-situ 3D measurement for the machining workpieces in CNC machine tools is regarded as the new trend of efficient measurement. We introduce a 3D measurement system based on the stereovision and phase-shifting method combined with CNC machine tools, which can measure 3D profile of the machining workpieces between the key machining processes. The measurement system utilizes the method of high dynamic range fringe acquisition to solve the problem of saturation induced by specular lights reflected from shiny surfaces such as aluminum alloy workpiece or titanium alloy workpiece. We measured two workpieces of aluminum alloy on the CNC machine tools to demonstrate the effectiveness of the developed measurement system.

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.

Assessment Tools for Evaluation of Oral Feeding in Infants Younger Than 6 Months.

PubMed

Pados, Britt F; Park, Jinhee; Estrem, Hayley; Awotwi, Araba

2016-04-01

Feeding difficulty is common in infants younger than 6 months. Identification of infants in need of specialized treatment is critical to ensure appropriate nutrition and feeding skill development. Valid and reliable assessment tools help clinicians objectively evaluate feeding. To identify and evaluate assessment tools available for clinical assessment of bottle- and breastfeeding in infants younger than 6 months. CINAHL, HaPI, PubMed, and Web of Science were searched for "infant feeding" and "assessment tool." The literature (n = 237) was reviewed for relevant assessment tools. A secondary search was conducted in CINAHL and PubMed for additional literature on identified tools. Eighteen assessment tools met inclusion criteria. Of these, 7 were excluded because of limited available literature or because they were intended for use with a specific diagnosis or in research only. There are 11 assessment tools available for clinical practice. Only 2 of these were intended for bottle-feeding. All 11 indicated that they were appropriate for use with breastfeeding. None of the available tools have adequate psychometric development and testing. All of the tools should be used with caution. The Early Feeding Skills Assessment and Bristol Breastfeeding Assessment Tool had the most supportive psychometric development and testing. Feeding assessment tools need to be developed and tested to guide optimal clinical care of infants from birth through 6 months. A tool that assesses both bottle- and breastfeeding would allow for consistent assessment across feeding methods.

Community-driven computational biology with Debian Linux.

PubMed

Möller, Steffen; Krabbenhöft, Hajo Nils; Tille, Andreas; Paleino, David; Williams, Alan; Wolstencroft, Katy; Goble, Carole; Holland, Richard; Belhachemi, Dominique; Plessy, Charles

2010-12-21

The Open Source movement and its technologies are popular in the bioinformatics community because they provide freely available tools and resources for research. In order to feed the steady demand for updates on software and associated data, a service infrastructure is required for sharing and providing these tools to heterogeneous computing environments. The Debian Med initiative provides ready and coherent software packages for medical informatics and bioinformatics. These packages can be used together in Taverna workflows via the UseCase plugin to manage execution on local or remote machines. If such packages are available in cloud computing environments, the underlying hardware and the analysis pipelines can be shared along with the software. Debian Med closes the gap between developers and users. It provides a simple method for offering new releases of software and data resources, thus provisioning a local infrastructure for computational biology. For geographically distributed teams it can ensure they are working on the same versions of tools, in the same conditions. This contributes to the world-wide networking of researchers.

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).

Telepresence and telerobotics

NASA Technical Reports Server (NTRS)

Garin, John; Matteo, Joseph; Jennings, Von Ayre

1988-01-01

The capability for a single operator to simultaneously control complex remote multi degree of freedom robotic arms and associated dextrous end effectors is being developed. An optimal solution within the realm of current technology, can be achieved by recognizing that: (1) machines/computer systems are more effective than humans when the task is routine and specified, and (2) humans process complex data sets and deal with the unpredictable better than machines. These observations lead naturally to a philosophy in which the human's role becomes a higher level function associated with planning, teaching, initiating, monitoring, and intervening when the machine gets into trouble, while the machine performs the codifiable tasks with deliberate efficiency. This concept forms the basis for the integration of man and telerobotics, i.e., robotics with the operator in the control loop. The concept of integration of the human in the loop and maximizing the feed-forward and feed-back data flow is referred to as telepresence.

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.

The development of a new breast feeding assessment tool and the relationship with breast feeding self-efficacy

PubMed Central

Ingram, Jenny; Johnson, Debbie; Copeland, Marion; Churchill, Cathy; Taylor, Hazel

2015-01-01

Objective to develop a breast feeding assessment tool to facilitate improved targeting of optimum positioning and attachment advice and to describe the changes seen following the release of a tongue-tie. Design development and validation of the Bristol Breastfeeding Assessment Tool (BBAT) and correlation with breast feeding self-efficacy. Setting maternity hospital in South West England. Participants 218 breast feeds (160 mother–infant dyads); seven midwife assessors. Findings the tool has more explanation than other tools to remind those supporting breast-feeding women about the components of an efficient breast feed. There was good internal reliability for the final 4-item BBAT (Cronbach׳s alpha=0.668) and the midwives who used it showed a high correlation in the consistency of its use (ICC=0.782). Midwives were able to score a breast feed consistently using the BBAT and felt that it helped them with advice to mothers about improving positioning and attachment to make breast feeding less painful, particularly with a tongue-tied infant. The tool showed strong correlation with breast feeding self-efficacy, indicating that more efficient breast feeding technique is associated with increased confidence in breast feeding an infant. Conclusions the BBAT is a concise breast feeding assessment tool facilitating accurate, rapid breast feeding appraisal, and targeting breast feeding advice to mothers acquiring early breast feeding skills or for those experiencing problems with an older infant. Accurate assessment is essential to ensure enhanced breast feeding efficiency and increased maternal self-confidence. Implications for practice the BBAT could be used both clinically and in research to target advice to improve breast feeding efficacy. Further research is needed to establish its wider usefulness. PMID:25061006

The development of a new breast feeding assessment tool and the relationship with breast feeding self-efficacy.

PubMed

Ingram, Jenny; Johnson, Debbie; Copeland, Marion; Churchill, Cathy; Taylor, Hazel

2015-01-01

to develop a breast feeding assessment tool to facilitate improved targeting of optimum positioning and attachment advice and to describe the changes seen following the release of a tongue-tie. development and validation of the Bristol Breastfeeding Assessment Tool (BBAT) and correlation with breast feeding self-efficacy. maternity hospital in South West England. 218 breast feeds (160 mother-infant dyads); seven midwife assessors. the tool has more explanation than other tools to remind those supporting breast-feeding women about the components of an efficient breast feed. There was good internal reliability for the final 4-item BBAT (Cronbach's alpha=0.668) and the midwives who used it showed a high correlation in the consistency of its use (ICC=0.782). Midwives were able to score a breast feed consistently using the BBAT and felt that it helped them with advice to mothers about improving positioning and attachment to make breast feeding less painful, particularly with a tongue-tied infant. The tool showed strong correlation with breast feeding self-efficacy, indicating that more efficient breast feeding technique is associated with increased confidence in breast feeding an infant. the BBAT is a concise breast feeding assessment tool facilitating accurate, rapid breast feeding appraisal, and targeting breast feeding advice to mothers acquiring early breast feeding skills or for those experiencing problems with an older infant. Accurate assessment is essential to ensure enhanced breast feeding efficiency and increased maternal self-confidence. the BBAT could be used both clinically and in research to target advice to improve breast feeding efficacy. Further research is needed to establish its wider usefulness. Copyright © 2014 The Authors. Published by Elsevier Ltd.. All rights reserved.

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

High speed machining of space shuttle external tank liquid hydrogen barrel panel

NASA Technical Reports Server (NTRS)

Hankins, J. D.

1983-01-01

Actual and projected optimum High Speed Machining data for producing shuttle external tank liquid hydrogen barrel panels of aluminum alloy 2219-T87 are reported. The data included various machining parameters; e.g., spindle speeds, cutting speed, table feed, chip load, metal removal rate, horsepower, cutting efficiency, cutter wear (lack of) and chip removal methods.

High speed machining of space shuttle external tank liquid hydrogen barrel panel

NASA Astrophysics Data System (ADS)

Hankins, J. D.

1983-11-01

Actual and projected optimum High Speed Machining data for producing shuttle external tank liquid hydrogen barrel panels of aluminum alloy 2219-T87 are reported. The data included various machining parameters; e.g., spindle speeds, cutting speed, table feed, chip load, metal removal rate, horsepower, cutting efficiency, cutter wear (lack of) and chip removal methods.

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.

Contributions on Optimizing Approximations in the Study of Melting and Solidification Processes That Occur in Processing by Electro-Erosion

NASA Astrophysics Data System (ADS)

Potra, F. L.; Potra, T.; Soporan, V. F.

We propose two optimization methods of the processes which appear in EDM (Electrical Discharge Machining). First refers to the introduction of a new function approximating the thermal flux energy in EDM machine. Classical researches approximate this energy with the Gauss' function. In the case of unconventional technology the Gauss' bell became null only for r → +∞, where r is the radius of crater produced by EDM. We introduce a cubic spline regression which descends to zero at the crater's boundary. In the second optimization we propose modifications in technologies' work regarding the displacement of the tool electrode to the piece electrode such that the material melting to be realized in optimal time and the feeding speed with dielectric liquid regarding the solidification of the expulsed material. This we realize using the FAHP algorithm based on the theory of eigenvalues and eigenvectors, which lead to mean values of best approximation. [6

The effect of cutting conditions on power inputs when machining

NASA Astrophysics Data System (ADS)

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

2016-08-01

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

2D simulations of orthogonal cutting of CFRP: Effect of tool angles on parameters of cut and chip morphology

NASA Astrophysics Data System (ADS)

Benhassine, Mehdi; Rivière-Lorphèvre, Edouard; Arrazola, Pedro-Jose; Gobin, Pierre; Dumas, David; Madhavan, Vinay; Aizpuru, Ohian; Ducobu, François

2018-05-01

Carbon-fiber reinforced composites (CFRP) are attractive materials for lightweight designs in applications needing good mechanical properties. Machining of such materials can be harder than metals due to their anisotropic behavior. In addition, the combination of the fibers and resin mechanical properties must also include the fiber orientation. In the case of orthogonal cutting, the tool inclination, rake angle or cutting angle usually influence the cutting process but such a detailed investigation is currently lacking in a 2D configuration. To address this issue, a model has been developed with Abaqus Explicit including Hashin damage. This model has been validated with experimental results from the literature. The effects of the tool parameters (rake angle, clearance angle) on the tool cutting forces, CFRP chip morphology and surface damage are herewith studied. It is shown that 90° orientation for the CFRP increases the surface damage. The rake angle has a minimal effect on the cutting forces but modifies the chip formation times. The feed forces are increased with increasing rake angle.

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 9: Tool and Die, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Graphite fiber reinforced structure for supporting machine tools

DOEpatents

Knight, Jr., Charles E.; Kovach, Louis; Hurst, John S.

1978-01-01

Machine tools utilized in precision machine operations require tool support structures which exhibit minimal deflection, thermal expansion and vibration characteristics. The tool support structure of the present invention is a graphite fiber reinforced composite in which layers of the graphite fibers or yarn are disposed in a 0/90.degree. pattern and bonded together with an epoxy resin. The finished composite possesses a low coefficient of thermal expansion and a substantially greater elastic modulus, stiffness-to-weight ratio, and damping factor than a conventional steel tool support utilized in similar machining operations.

Machining and brazing of accelerating RF cavity

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

Ghodke, S.R.; Barnwal, Rajesh; Mondal, Jayant, E-mail: ghodke_barc@yahoo.co.in

2014-07-01

BARC has developed 2856 MHz accelerating cavities for 6 MeV, 9 MeV and 10 MeV RF Linac. New vendors are developed for mass production of accelerating cavity for future projects. New vendors are developing for diamond turning machining, cleaning and brazing processes. Fabrication involved material testing, CNC diamond turning of cavity, cavity cleaning and brazing. Before and after brazing resonance frequency (RF) of cavity was checked with vector network analyser (VNA). A power feed test setup is also fabricated to test power feed cavity before brazing. This test setup will be used to find out assembly performance of power feedmore » cavity and its coupler. This paper discusses about nano machining, cleaning and brazing processes of RF cavities. (author)« less

Powder Flux Regulation in the Laser Material Deposition Process

NASA Astrophysics Data System (ADS)

Arrizubieta, Jon Iñaki; Wegener, Maximiliam; Arntz, Kristian; Lamikiz, Aitzol; Ruiz, Jose Exequiel

In the present research work a powder flux regulation system has been designed, developed and validated with the aim of improving the Laser Material Deposition (LMD) process. In this process, the amount of deposited material per substrate surface unit area depends on the real feed rate of the nozzle. Therefore, a regulation system based on a solenoid valve has been installed at the nozzle entrance in order to control the powder flux. The powder flux control has been performed based on the machine real feed rate, which is compared with the programmed feed rate. An instantaneous velocity error is calculated and the powder flow is controlled as a function of this variation using Pulse Width Modulation (PWM) signals. Thereby, in zones where the Laser Material Deposition machine reduces the feed rate due to a trajectory change, powder accumulation can be avoided and the generated clads would present a homogeneous shape.

Traceability of On-Machine Tool Measurement: A Review.

PubMed

Mutilba, Unai; Gomez-Acedo, Eneko; Kortaberria, Gorka; Olarra, Aitor; Yagüe-Fabra, Jose A

2017-07-11

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Microstructure and Mechanical Properties of Laser Clad and Post-cladding Tempered AISI H13 Tool Steel

NASA Astrophysics Data System (ADS)

Telasang, Gururaj; Dutta Majumdar, Jyotsna; Wasekar, Nitin; Padmanabham, G.; Manna, Indranil

2015-05-01

This study reports a detailed investigation of the microstructure and mechanical properties (wear resistance and tensile strength) of hardened and tempered AISI H13 tool steel substrate following laser cladding with AISI H13 tool steel powder in as-clad and after post-cladding conventional bulk isothermal tempering [at 823 K (550 °C) for 2 hours] heat treatment. Laser cladding was carried out on AISI H13 tool steel substrate using a 6 kW continuous wave diode laser coupled with fiber delivering an energy density of 133 J/mm2 and equipped with a co-axial powder feeding nozzle capable of feeding powder at the rate of 13.3 × 10-3 g/mm2. Laser clad zone comprises martensite, retained austenite, and carbides, and measures an average hardness of 600 to 650 VHN. Subsequent isothermal tempering converted the microstructure into one with tempered martensite and uniform dispersion of carbides with a hardness of 550 to 650 VHN. Interestingly, laser cladding introduced residual compressive stress of 670 ± 15 MPa, which reduces to 580 ± 20 MPa following isothermal tempering. Micro-tensile testing with specimens machined from the clad zone across or transverse to cladding direction showed high strength but failure in brittle mode. On the other hand, similar testing with samples sectioned from the clad zone parallel or longitudinal to the direction of laser cladding prior to and after post-cladding tempering recorded lower strength but ductile failure with 4.7 and 8 pct elongation, respectively. Wear resistance of the laser surface clad and post-cladding tempered samples (evaluated by fretting wear testing) registered superior performance as compared to that of conventional hardened and tempered AISI H13 tool steel.

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.

Development of an Empirical Model for Optimization of Machining Parameters to Minimize Power Consumption

NASA Astrophysics Data System (ADS)

Kant Garg, Girish; Garg, Suman; Sangwan, K. S.

2018-04-01

The manufacturing sector consumes huge energy demand and the machine tools used in this sector have very less energy efficiency. Selection of the optimum machining parameters for machine tools is significant for energy saving and for reduction of environmental emission. In this work an empirical model is developed to minimize the power consumption using response surface methodology. The experiments are performed on a lathe machine tool during the turning of AISI 6061 Aluminum with coated tungsten inserts. The relationship between the power consumption and machining parameters is adequately modeled. This model is used for formulation of minimum power consumption criterion as a function of optimal machining parameters using desirability function approach. The influence of machining parameters on the energy consumption has been found using the analysis of variance. The validation of the developed empirical model is proved using the confirmation experiments. The results indicate that the developed model is effective and has potential to be adopted by the industry for minimum power consumption of machine tools.

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.

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.

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.

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 6: Welding, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 12: Instrumentation, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 1: Executive Summary, of a 15-Volume Set of Skills Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

The Machine Tool Advanced Skills Technology (MAST) consortium was formed to address the shortage of skilled workers for the machine tools and metals-related industries. Featuring six of the nation's leading advanced technology centers, the MAST consortium developed, tested, and disseminated industry-specific skill standards and model curricula for…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 15: Administrative Information, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This volume developed by the Machine Tool Advanced Skill Technology (MAST) program contains key administrative documents and provides additional sources for machine tool and precision manufacturing information and important points of contact in the industry. The document contains the following sections: a foreword; grant award letter; timeline for…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 5: Mold Making, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational speciality areas within the U.S. machine tool and metals-related…

Experimental investigations on the effect of process parameters with the use of minimum quantity solid lubrication in turning

NASA Astrophysics Data System (ADS)

Makhesana, Mayur A.; Patel, K. M.; Mawandiya, B. K.

2018-04-01

Turning process is a very basic process in any field of mechanical application. During turning process, most of the energy is converted into heat because of the friction between work piece and tool. Heat generation can affect the surface quality of the work piece and tool life. To reduce the heat generation, Conventional Lubrication process is used in most of the industry. Minimum quantity lubrication has been an effective alternative to improve the performance of machining process. In this present work, effort has been made to study the effect of various process parameters on the surface roughness and power consumption during turning of EN8 steel material. Result revealed the effect of depth of cut and feed on the obtained surface roughness value. Further the effect of solid lubricant has been also studied and optimization of process parameters is also done for the turning process.

Investigations of Effect of Rotary EDM Electrode on Machining Performance of Al6061 Alloy

NASA Astrophysics Data System (ADS)

Robinson Smart, D. S.; Jenish Smart, Joses; Periasamy, C.; Ratna Kumar, P. S. Samuel

2018-04-01

Electric Discharge Machining is an essential process which is being used for machining desired shape using electrical discharges which creates sparks. There will be electrodes subjected to electric voltage and which are separated by a dielectric liquid. Removing of material will be due to the continuous and rapid current discharges between two electrodes.. The spark is very carefully controlled and localized so that it only affects the surface of the material. Usually in order to prevent the defects which are arising due to the conventional machining, the Electric Discharge Machining (EDM) machining is preferred. Also intricate and complicated shapes can be machined effectively by use of Electric Discharge Machining (EDM). The EDM process usually does not affect the heat treat below the surface. This research work focus on the design and fabrication of rotary EDM tool for machining Al6061alloy and investigation of effect of rotary tool on surface finish, material removal rate and tool wear rate. Also the effect of machining parameters of EDM such as pulse on & off time, current on material Removal Rate (MRR), Surface Roughness (SR) and Electrode wear rate (EWR) have studied. Al6061 alloy can be used for marine and offshore applications by reinforcing some other elements. The investigations have revealed that MRR (material removal rate), surface roughness (Ra) have been improved with the reduction in the tool wear rate (TWR) when the tool is rotating instead of stationary. It was clear that as rotary speed of the tool is increasing the material removal rate is increasing with the reduction of surface finish and tool wear rate.

Slide system for machine tools

DOEpatents

Douglass, S.S.; Green, W.L.

1980-06-12

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

Slide system for machine tools

DOEpatents

Douglass, Spivey S.; Green, Walter L.

1982-01-01

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

Volumetric Verification of Multiaxis Machine Tool Using Laser Tracker

PubMed Central

Aguilar, Juan José

2014-01-01

This paper aims to present a method of volumetric verification in machine tools with linear and rotary axes using a laser tracker. Beyond a method for a particular machine, it presents a methodology that can be used in any machine type. Along this paper, the schema and kinematic model of a machine with three axes of movement, two linear and one rotational axes, including the measurement system and the nominal rotation matrix of the rotational axis are presented. Using this, the machine tool volumetric error is obtained and nonlinear optimization techniques are employed to improve the accuracy of the machine tool. The verification provides a mathematical, not physical, compensation, in less time than other methods of verification by means of the indirect measurement of geometric errors of the machine from the linear and rotary axes. This paper presents an extensive study about the appropriateness and drawbacks of the regression function employed depending on the types of movement of the axes of any machine. In the same way, strengths and weaknesses of measurement methods and optimization techniques depending on the space available to place the measurement system are presented. These studies provide the most appropriate strategies to verify each machine tool taking into consideration its configuration and its available work space. PMID:25202744

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.

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

NASA Astrophysics Data System (ADS)

Li, Xiaoda; Zhan, Xianghui

2018-04-01

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

Interferometric correction system for a numerically controlled machine

DOEpatents

Burleson, Robert R.

1978-01-01

An interferometric correction system for a numerically controlled machine is provided to improve the positioning accuracy of a machine tool, for example, for a high-precision numerically controlled machine. A laser interferometer feedback system is used to monitor the positioning of the machine tool which is being moved by command pulses to a positioning system to position the tool. The correction system compares the commanded position as indicated by a command pulse train applied to the positioning system with the actual position of the tool as monitored by the laser interferometer. If the tool position lags the commanded position by a preselected error, additional pulses are added to the pulse train applied to the positioning system to advance the tool closer to the commanded position, thereby reducing the lag error. If the actual tool position is leading in comparison to the commanded position, pulses are deleted from the pulse train where the advance error exceeds the preselected error magnitude to correct the position error of the tool relative to the commanded position.

Traceability of On-Machine Tool Measurement: A Review

PubMed Central

Gomez-Acedo, Eneko; Kortaberria, Gorka; Olarra, Aitor

2017-01-01

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand. PMID:28696358

Department of Defense Tri-Service Precision Machine-Tool Program. Quarterly report, February--April 1978

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

Not Available

1978-06-01

Following a planning period during which the Lawrence Livermore Laboratory and the Department of Defense managing sponsor, the USAF Materials Laboratory, agreed on work statements, the Department of Defense Tri-Service Precision Machine-Tool Program began in February 1978. Milestones scheduled for the first quarter have been met. Tasks and manpower requirements for two basic projects, precision-machining commercialization (PMC) and a machine-tool task force (MTTF), were defined. Progress by PMC includes: (1) documentation of existing precision machine-tool technology by initiation and compilation of a bibliography containing several hundred entries: (2) identification of the problems and needs of precision turning-machine builders and ofmore » precision turning-machine users interested in developing high-precision machining capability; and (3) organization of the schedule and content of the first seminar, to be held in October 1978, which will bring together representatives from the machine-tool and optics communities to address the problems and begin the process of high-precision machining commercialization. Progress by MTTF includes: (1) planning for the organization of a team effort of approximately 60 to 80 international experts to contribute in various ways to project objectives, namely, to summarize state-of-the-art cutting-machine-tool technology and to identify areas where future R and D should prove technically and economically profitable; (2) preparation of a comprehensive plan to achieve those objectives; and (3) preliminary arrangements for a plenary session, also in October, when the task force will meet to formalize the details for implementing the plan.« less

AN EIGHT WEEK SEMINAR IN AN INTRODUCTION TO NUMERICAL CONTROL ON TWO- AND THREE-AXIS MACHINE TOOLS FOR VOCATIONAL AND TECHNICAL MACHINE TOOL INSTRUCTORS. FINAL REPORT.

ERIC Educational Resources Information Center

BOLDT, MILTON; POKORNY, HARRY

THIRTY-THREE MACHINE SHOP INSTRUCTORS FROM 17 STATES PARTICIPATED IN AN 8-WEEK SEMINAR TO DEVELOP THE SKILLS AND KNOWLEDGE ESSENTIAL FOR TEACHING THE OPERATION OF NUMERICALLY CONTROLLED MACHINE TOOLS. THE SEMINAR WAS GIVEN FROM JUNE 20 TO AUGUST 12, 1966, WITH COLLEGE CREDIT AVAILABLE THROUGH STOUT STATE UNIVERSITY. THE PARTICIPANTS COMPLETED AN…

An iterative learning control method with application for CNC machine tools

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

Kim, D.I.; Kim, S.

1996-01-01

A proportional, integral, and derivative (PID) type iterative learning controller is proposed for precise tracking control of industrial robots and computer numerical controller (CNC) machine tools performing repetitive tasks. The convergence of the output error by the proposed learning controller is guaranteed under a certain condition even when the system parameters are not known exactly and unknown external disturbances exist. As the proposed learning controller is repeatedly applied to the industrial robot or the CNC machine tool with the path-dependent repetitive task, the distance difference between the desired path and the actual tracked or machined path, which is one ofmore » the most significant factors in the evaluation of control performance, is progressively reduced. The experimental results demonstrate that the proposed learning controller can improve machining accuracy when the CNC machine tool performs repetitive machining tasks.« less

Mississippi Curriculum Framework for Machine Tool Operation/Machine Shop (Program CIP: 48.0503--Machine Shop Assistant). Secondary Programs.

ERIC Educational Resources Information Center

Mississippi Research and Curriculum Unit for Vocational and Technical Education, State College.

This document, which reflects Mississippi's statutory requirement that instructional programs be based on core curricula and performance-based assessment, contains outlines of the instructional units required in local instructional management plans and daily lesson plans for machine tool operation/machine shop I and II. Presented first are a…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 8: Sheet Metal & Composites, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 4: Manufacturing Engineering Technology, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 14: Automated Equipment Technician (CIM), of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 10: Computer-Aided Drafting & Design, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 11: Computer-Aided Manufacturing & Advanced CNC, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 2: Career Development, General Education and Remediation, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Machine Tool Advanced Skills Technology (MAST). Common Ground: Toward a Standards-Based Training System for the U.S. Machine Tool and Metal Related Industries. Volume 7: Industrial Maintenance Technology, of a 15-Volume Set of Skill Standards and Curriculum Training Materials for the Precision Manufacturing Industry.

ERIC Educational Resources Information Center

Texas State Technical Coll., Waco.

This document is intended to help education and training institutions deliver the Machine Tool Advanced Skills Technology (MAST) curriculum to a variety of individuals and organizations. MAST consists of industry-specific skill standards and model curricula for 15 occupational specialty areas within the U.S. machine tool and metals-related…

Analysis of acoustic emission during abrasive waterjet machining of sheet metals

NASA Astrophysics Data System (ADS)

Mokhtar, Nazrin; Gebremariam, MA; Zohari, H.; Azhari, Azmir

2018-04-01

The present paper reports on the analysis of acoustic emission (AE) produced during abrasive waterjet (AWJ) machining process. This paper focuses on the relationship of AE and surface quality of sheet metals. The changes in acoustic emission signals recorded by the mean of power spectral density (PSD) via covariance method in relation to the surface quality of the cut are discussed. The test was made using two materials for comparison namely aluminium 6061 and stainless steel 304 with five different feed rates. The acoustic emission data were captured by Labview and later processed using MATLAB software. The results show that the AE spectrums correlated with different feed rates and surface qualities. It can be concluded that the AE is capable of monitoring the changes of feed rate and surface quality.

Taguchi Optimization of Cutting Parameters in Turning AISI 1020 MS with M2 HSS Tool

NASA Astrophysics Data System (ADS)

Sonowal, Dharindom; Sarma, Dhrupad; Bakul Barua, Parimal; Nath, Thuleswar

2017-08-01

In this paper the effect of three cutting parameters viz. Spindle speed, Feed and Depth of Cut on surface roughness of AISI 1020 mild steel bar in turning was investigated and optimized to obtain minimum surface roughness. All the experiments are conducted on HMT LB25 lathe machine using M2 HSS cutting tool. Ranges of parameters of interest have been decided through some preliminary experimentation (One Factor At a Time experiments). Finally a combined experiment has been carried out using Taguchi’s L27 Orthogonal Array (OA) to study the main effect and interaction effect of the all three parameters. The experimental results were analyzed with raw data ANOVA (Analysis of Variance) and S/N data (Signal to Noise ratio) ANOVA. Results show that Spindle speed, Feed and Depth of Cut have significant effects on both mean and variation of surface roughness in turning AISI 1020 mild steel. Mild two factors interactions are observed among the aforesaid factors with significant effects only on the mean of the output variable. From the Taguchi parameter optimization the optimum factor combination is found to be 630 rpm spindle speed, 0.05 mm/rev feed and 1.25 mm depth of cut with estimated surface roughness 2.358 ± 0.970 µm. A confirmatory experiment was conducted with the optimum factor combination to verify the results. In the confirmatory experiment the average value of surface roughness is found to be 2.408 µm which is well within the range (0.418 µm to 4.299 µm) predicted for confirmatory experiment.

A Real-Time Tool Positioning Sensor for Machine-Tools

PubMed Central

Ruiz, Antonio Ramon Jimenez; Rosas, Jorge Guevara; Granja, Fernando Seco; Honorato, Jose Carlos Prieto; Taboada, Jose Juan Esteve; Serrano, Vicente Mico; Jimenez, Teresa Molina

2009-01-01

In machining, natural oscillations, and elastic, gravitational or temperature deformations, are still a problem to guarantee the quality of fabricated parts. In this paper we present an optical measurement system designed to track and localize in 3D a reference retro-reflector close to the machine-tool's drill. The complete system and its components are described in detail. Several tests, some static (including impacts and rotations) and others dynamic (by executing linear and circular trajectories), were performed on two different machine tools. It has been integrated, for the first time, a laser tracking system into the position control loop of a machine-tool. Results indicate that oscillations and deformations close to the tool can be estimated with micrometric resolution and a bandwidth from 0 to more than 100 Hz. Therefore this sensor opens the possibility for on-line compensation of oscillations and deformations. PMID:22408472

Machinability of hypereutectic silicon-aluminum alloys

NASA Astrophysics Data System (ADS)

Tanaka, T.; Akasawa, T.

1999-08-01

The machinability of high-silicon aluminum alloys made by a P/M process and by casting was compared. The cutting test was conducted by turning on lathes with the use of cemented carbide tools. The tool wear by machining the P/M alloy was far smaller than the tool wear by machining the cast alloy. The roughness of the machined surface of the P/M alloy is far better than that of the cast alloy, and the turning speed did not affect it greatly at higher speeds. The P/M alloy produced long chips, so the disposal can cause trouble. The size effect of silicon grains on the machinability is discussed.

Apparatus for electrical-assisted incremental forming and process thereof

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

Roth, John; Cao, Jian

A process and apparatus for forming a sheet metal component using an electric current passing through the component. The process can include providing an incremental forming machine, the machine having at least one arcuate tipped tool and at least electrode spaced a predetermined distance from the arcuate tipped tool. The machine is operable to perform a plurality of incremental deformations on the sheet metal component using the arcuate tipped tool. The machine is also operable to apply an electric direct current through the electrode into the sheet metal component at the predetermined distance from the arcuate tipped tool while themore » machine is forming the sheet metal component.« less

Tube Alinement for Machining

NASA Technical Reports Server (NTRS)

Garcia, J.

1984-01-01

Tool with stepped shoulders alines tubes for machining in preparation for welding. Alinement with machine tool axis accurate to within 5 mils (0.13mm) and completed much faster than visual setup by machinist.

NASA's Software Bank (Cassegrain Feed System)

NASA Technical Reports Server (NTRS)

1991-01-01

When Scientific-Atlanta had to design a new Cassegrain antenna, they found that the COSMIC program, "Machine Design of Cassegrain Feed System" allowed for computer simulation of the antenna's performance enabling pre-construction changes to be made. Significant cost savings were effected by the program.

Reversible micromachining locator

DOEpatents

Salzer, Leander J.; Foreman, Larry R.

2002-01-01

A locator with a part support is used to hold a part onto the kinematic mount of a tooling machine so that the part can be held in or replaced in exactly the same position relative to the cutting tool for machining different surfaces of the part or for performing different machining operations on the same or different surfaces of the part. The locator has disposed therein a plurality of steel balls placed at equidistant positions around the planar surface of the locator and the kinematic mount has a plurality of magnets which alternate with grooves which accommodate the portions of the steel balls projecting from the locator. The part support holds the part to be machined securely in place in the locator. The locator can be easily detached from the kinematic mount, turned over, and replaced onto the same kinematic mount or another kinematic mount on another tooling machine without removing the part to be machined from the locator so that there is no need to touch or reposition the part within the locator, thereby assuring exact replication of the position of the part in relation to the cutting tool on the tooling machine for each machining operation on the part.

Articulated, Performance-Based Instruction Objectives Guide for Machine Shop Technology.

ERIC Educational Resources Information Center

Henderson, William Edward, Jr., Ed.

This articulation guide contains 21 units of instruction for two years of machine shop. The objectives of the program are to provide the student with the basic terminology and fundamental knowledge and skills in machining (year 1) and to teach him/her to set up and operate machine tools and make or repair metal parts, tools, and machines (year 2).…

MATC Machine Shop '84: Specific Skill Needs Assessment for Machine Shops in the Milwaukee Area.

ERIC Educational Resources Information Center

Roberts, Keith J.

Building on previous research on the future skill needs of workers in southeastern Wisconsin, a study was conducted at Milwaukee Area Technical College (MATC) to gather information on the machine tool industry in the Milwaukee area. Interviews were conducted by MATC Machine Shop and Tool and Die faculty with representatives from 135 machine shops,…

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.

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.

Comparison between laser interferometric and calibrated artifacts for the geometric test of machine tools

NASA Astrophysics Data System (ADS)

Sousa, Andre R.; Schneider, Carlos A.

2001-09-01

A touch probe is used on a 3-axis vertical machine center to check against a hole plate, calibrated on a coordinate measuring machine (CMM). By comparing the results obtained from the machine tool and CMM, the main machine tool error components are measured, attesting the machine accuracy. The error values can b used also t update the error compensation table at the CNC, enhancing the machine accuracy. The method is easy to us, has a lower cost than classical test techniques, and preliminary results have shown that its uncertainty is comparable to well established techniques. In this paper the method is compared with the laser interferometric system, regarding reliability, cost and time efficiency.

75 FR 65516 - ASC Machine Tools, Inc., Spokane Valley, WA; Notice of Affirmative Determination Regarding...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-10-25

... DEPARTMENT OF LABOR Employment and Training Administration [TA-W-72,971] ASC Machine Tools, Inc... workers and former workers of ASC Machine Tools, Inc., Spokane Valley, Washington (the subject firm). The... cut metal, including assembled equipment, component parts of equipment, and spare parts. The negative...

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.

High-precision micro/nano-scale machining system

DOEpatents

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

2014-08-19

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

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.

Diamond machine tool face lapping machine

DOEpatents

Yetter, H.H.

1985-05-06

An apparatus for shaping, sharpening and polishing diamond-tipped single-point machine tools. The isolation of a rotating grinding wheel from its driving apparatus using an air bearing and causing the tool to be shaped, polished or sharpened to be moved across the surface of the grinding wheel so that it does not remain at one radius for more than a single rotation of the grinding wheel has been found to readily result in machine tools of a quality which can only be obtained by the most tedious and costly processing procedures, and previously unattainable by simple lapping techniques.

Controlling the type and the form of chip when machining steel

NASA Astrophysics Data System (ADS)

Gruby, S. V.; Lasukov, A. A.; Nekrasov, R. Yu; Politsinsky, E. V.; Arkhipova, D. A.

2016-08-01

The type of the chip produced in the process of machining influences many factors of production process. Controlling the type of chip when cutting metals is important for producing swarf chips and for easing its utilization as well as for protecting the machined surface, cutting tool and the worker. In the given work we provide the experimental data on machining structural steel with implanted tool. The authors show that it is possible to control the chip formation process to produce the required type of chip by selecting the material for machining the tool surface.

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.

AFM surface imaging of AISI D2 tool steel machined by the EDM process

NASA Astrophysics Data System (ADS)

Guu, Y. H.

2005-04-01

The surface morphology, surface roughness and micro-crack of AISI D2 tool steel machined by the electrical discharge machining (EDM) process were analyzed by means of the atomic force microscopy (AFM) technique. Experimental results indicate that the surface texture after EDM is determined by the discharge energy during processing. An excellent machined finish can be obtained by setting the machine parameters at a low pulse energy. The surface roughness and the depth of the micro-cracks were proportional to the power input. Furthermore, the AFM application yielded information about the depth of the micro-cracks is particularly important in the post treatment of AISI D2 tool steel machined by EDM.

The U.S. Machine Tool Industry and the Defense Industrial Base

DTIC Science & Technology

1983-01-01

GOLD, Director, Research Program in Industrial Economics , Case Western Reserve University HAMILTON HERMAN, Management Consultant NATHANIEL S. HOWE...Traditional U.S. Machine Tool Industry ........ 8 Technological Trends Shaping the Industry ........ 18 Economic Trends .................................. 23...sustained economic recovery and aggressive steps by both government and industry, an effectively com- petitive domestic machine tool industry can emerge

Technology of machine tools. Volume 1. Executive summary

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

Sutton, G.P.

1980-10-01

The Machine Tool Task Force (MTTF) was formed to characterize the state of the art of machine tool technology and to identify promising future directions of this technology. This volume is one of a five-volume series that presents the MTTF findings; reports on various areas of the technology were contributed by experts in those areas.

PCD tool wear and its monitoring in machining tungsten

NASA Astrophysics Data System (ADS)

Wang, Lijiang; Zhang, Zhenlie; Sun, Qi; Liu, Pin

The views of Chinese and foreign researchers are quite different as to whether or not polycrystalline diamond (PCD) tools can machine tungsten that is used in the aerospace and electronic industries. A study is presented that shows the possibility of machining tungsten, and a new method is developed for monitoring the tool wear in production.

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

ERIC Educational Resources Information Center

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

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

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.

Simulation on turning aspheric surface method via oscillating feed

NASA Astrophysics Data System (ADS)

Kong, Fanxing; Li, Zengqiang; Sun, Tao

2014-08-01

It is quite difficult to manufacturing optical components, the combination of high gradient ellipsoid and hyperboloid, with high machining surface requirements. To solve the problem, in this paper we present a turning and forming method via oscillating feed of R-θ layout lathe, analyze machining ellipsoid segment and hyperboloid segment separately through oscillating feed. Also calculate parameters on each trajectory during processing respectively and obtain displacement, velocity, acceleration and other parameters. The simulation result shows that this rotary turning method is capable of ensuring that the cutter is on the equidistance line of meridian cross section curve of work piece during processing high gradient aspheric surface, which helps getting high quality surface. Also the method provides a new approach and a theory basis for manufacturing high quality aspheric surface and extending function of the available twin-spindle lathe as well.

Operating System For Numerically Controlled Milling Machine

NASA Technical Reports Server (NTRS)

Ray, R. B.

1992-01-01

OPMILL program is operating system for Kearney and Trecker milling machine providing fast easy way to program manufacture of machine parts with IBM-compatible personal computer. Gives machinist "equation plotter" feature, which plots equations that define movements and converts equations to milling-machine-controlling program moving cutter along defined path. System includes tool-manager software handling up to 25 tools and automatically adjusts to account for each tool. Developed on IBM PS/2 computer running DOS 3.3 with 1 MB of random-access memory.

UIVerify: A Web-Based Tool for Verification and Automatic Generation of User Interfaces

NASA Technical Reports Server (NTRS)

Shiffman, Smadar; Degani, Asaf; Heymann, Michael

2004-01-01

In this poster, we describe a web-based tool for verification and automatic generation of user interfaces. The verification component of the tool accepts as input a model of a machine and a model of its interface, and checks that the interface is adequate (correct). The generation component of the tool accepts a model of a given machine and the user's task, and then generates a correct and succinct interface. This write-up will demonstrate the usefulness of the tool by verifying the correctness of a user interface to a flight-control system. The poster will include two more examples of using the tool: verification of the interface to an espresso machine, and automatic generation of a succinct interface to a large hypothetical machine.

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

[Present-day metal-cutting tools and working conditions].

PubMed

Kondratiuk, V P

1990-01-01

Polyfunctional machine-tools of a processing centre type are characterized by a set of hygienic advantages as compared to universal machine-tools. But low degree of mechanization and automation of some auxiliary processes, and constructional defects which decrease the ergonomic characteristics of the tools, involve labour intensity in multi-machine processing. The article specifies techniques of allowable noise level assessment, and proposes hygienic recommendations, some of which have been introduced into practice.

Community-driven computational biology with Debian Linux

PubMed Central

2010-01-01

Background The Open Source movement and its technologies are popular in the bioinformatics community because they provide freely available tools and resources for research. In order to feed the steady demand for updates on software and associated data, a service infrastructure is required for sharing and providing these tools to heterogeneous computing environments. Results The Debian Med initiative provides ready and coherent software packages for medical informatics and bioinformatics. These packages can be used together in Taverna workflows via the UseCase plugin to manage execution on local or remote machines. If such packages are available in cloud computing environments, the underlying hardware and the analysis pipelines can be shared along with the software. Conclusions Debian Med closes the gap between developers and users. It provides a simple method for offering new releases of software and data resources, thus provisioning a local infrastructure for computational biology. For geographically distributed teams it can ensure they are working on the same versions of tools, in the same conditions. This contributes to the world-wide networking of researchers. PMID:21210984

An easy-to-use calculating machine to simulate steady state and non-steady-state preparative separations by multiple dual mode counter-current chromatography with semi-continuous loading of feed mixtures.

PubMed

Kostanyan, Artak E; Shishilov, Oleg N

2018-06-01

Multiple dual mode counter-current chromatography (MDM CCC) separation processes with semi-continuous large sample loading consist of a succession of two counter-current steps: with "x" phase (first step) and "y" phase (second step) flow periods. A feed mixture dissolved in the "x" phase is continuously loaded into a CCC machine at the beginning of the first step of each cycle over a constant time with the volumetric rate equal to the flow rate of the pure "x" phase. An easy-to-use calculating machine is developed to simulate the chromatograms and the amounts of solutes eluted with the phases at each cycle for steady-state (the duration of the flow periods of the phases is kept constant for all the cycles) and non-steady-state (with variable duration of alternating phase elution steps) separations. Using the calculating machine, the separation of mixtures containing up to five components can be simulated and designed. Examples of the application of the calculating machine for the simulation of MDM CCC processes are discussed. Copyright © 2018 Elsevier B.V. All rights reserved.

Method for machining steel with diamond tools

DOEpatents

Casstevens, J.M.

1984-01-01

The present invention is directed to a method for machine optical quality finishes and contour accuracies of workpieces of carbon-containing metals such as steel with diamond tooling. The wear rate of the diamond tooling is significantly reduced by saturating the atmosphere at the interface of the workpiece and the diamond tool with a gaseous hydrocarbon during the machining operation. The presence of the gaseous hydrocarbon effectively eliminates the deterioration of the diamond tool by inhibiting or preventing the conversion of the diamond carbon to graphite carbon at the point of contact between the cutting tool and the workpiece.

Method for machining steel with diamond tools

DOEpatents

Casstevens, John M.

1986-01-01

The present invention is directed to a method for machining optical quality inishes and contour accuracies of workpieces of carbon-containing metals such as steel with diamond tooling. The wear rate of the diamond tooling is significantly reduced by saturating the atmosphere at the interface of the workpiece and the diamond tool with a gaseous hydrocarbon during the machining operation. The presence of the gaseous hydrocarbon effectively eliminates the deterioration of the diamond tool by inhibiting or preventing the conversion of the diamond carbon to graphite carbon at the point of contact between the cutting tool and the workpiece.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

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

ERIC Educational Resources Information Center

Crossley, Scott A.

2013-01-01

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

JPRS Report, China.

DTIC Science & Technology

1989-01-30

absolutely forbid the dealing of retaliatory blows to those of the masses who give their opinions. Fifth, on the basis of their analyses they pass on...Timber Artificial Board Cement Plate Glass Power Equipment Machine Tool Precision Machine Tool Large Machine Tool Automobile Truck Tractor Small...the State Bureau of Building Materials Industry said that the industry must manufacture more varieties of high quality cement, glass , pottery, and

Mechanism and experimental research on ultra-precision grinding of ferrite

NASA Astrophysics Data System (ADS)

Ban, Xinxing; Zhao, Huiying; Dong, Longchao; Zhu, Xueliang; Zhang, Chupeng; Gu, Yawen

2017-02-01

Ultra-precision grinding of ferrite is conducted to investigate the removal mechanism. Effect of the accuracy of machine tool key components on grinding surface quality is analyzed. The surface generation model of ferrite ultra-precision grinding machining is established. In order to reveal the surface formation mechanism of ferrite in the process of ultraprecision grinding, furthermore, the scientific and accurate of the calculation model are taken into account to verify the grinding surface roughness, which is proposed. Orthogonal experiment is designed using the high precision aerostatic turntable and aerostatic spindle for ferrite which is a typical hard brittle materials. Based on the experimental results, the influence factors and laws of ultra-precision grinding surface of ferrite are discussed through the analysis of the surface roughness. The results show that the quality of ferrite grinding surface is the optimal parameters, when the wheel speed of 20000r/mm, feed rate of 10mm/min, grinding depth of 0.005mm, and turntable rotary speed of 5r/min, the surface roughness Ra can up to 75nm.

High speed machinability of the aerospace alloy AA7075 T6 under different cooling conditions

NASA Astrophysics Data System (ADS)

Imbrogno, Stano; Rinaldi, Sergio; Suarez, Asier Gurruchaga; Arrazola, Pedro J.; Umbrello, Domenico

2018-05-01

This paper describes the results of an experimental investigation aimed to st udy the machinability of AA7075 T6 (160 HV) for aerospace industry at high cutting speeds. The paper investigates the effects of different lubri-cooling strategies (cryogenic, M QL and dry) during high speed turning process on cutting forces, tool wear, chip morphology and cutting temperatures. The cutting speeds selected were 1000m/min, 1250m/min and 1500 m/min, while the feed rate values used were 0.1mm/rev and 0.3 mm/rev. The results of cryogenic and M QL application is compared with dry application. It was found that the cryogenic and M QL lubri-cooling techniques could represent a functional alternative to the common dry cutting application in order to implement a more effect ive high speed turning process. Higher cuttingparameters would be able to increase the productivity and reduce the production costs. The effects of the cutting parameters and on the variables object of study were investigated and the role of the different lubri-cooling conditions was assessed.

Trajectory Tracking of a Planer Parallel Manipulator by Using Computed Force Control Method

NASA Astrophysics Data System (ADS)

Bayram, Atilla

2017-03-01

Despite small workspace, parallel manipulators have some advantages over their serial counterparts in terms of higher speed, acceleration, rigidity, accuracy, manufacturing cost and payload. Accordingly, this type of manipulators can be used in many applications such as in high-speed machine tools, tuning machine for feeding, sensitive cutting, assembly and packaging. This paper presents a special type of planar parallel manipulator with three degrees of freedom. It is constructed as a variable geometry truss generally known planar Stewart platform. The reachable and orientation workspaces are obtained for this manipulator. The inverse kinematic analysis is solved for the trajectory tracking according to the redundancy and joint limit avoidance. Then, the dynamics model of the manipulator is established by using Virtual Work method. The simulations are performed to follow the given planar trajectories by using the dynamic equations of the variable geometry truss manipulator and computed force control method. In computed force control method, the feedback gain matrices for PD control are tuned with fixed matrices by trail end error and variable ones by means of optimization with genetic algorithm.

Successful fabrication of a convex platform PMMA cell-counting slide using a high-precision perpendicular dual-spindle CNC machine tool

NASA Astrophysics Data System (ADS)

Chen, Shun-Tong; Chang, Chih-Hsien

2013-12-01

This study presents a novel approach to the fabrication of a biomedical-mold for producing convex platform PMMA (poly-methyl-meth-acrylate) slides for counting cells. These slides allow for the microscopic examination of urine sediment cells. Manufacturing of such slides incorporates three important procedures: (1) the development of a tabletop high-precision dual-spindle CNC (computerized numerical control) machine tool; (2) the formation of a boron-doped polycrystalline composite diamond (BD-PCD) wheel-tool on the machine tool developed in procedure (1); and (3) the cutting of a multi-groove-biomedical-mold array using the formed diamond wheel-tool in situ on the developed machine. The machine incorporates a hybrid working platform providing wheel-tool thinning using spark erosion to cut, polish, and deburr microgrooves on NAK80 steel directly. With consideration given for the electrical conductive properties of BD-PCD, the diamond wheel-tool is thinned to a thickness of 5 µm by rotary wire electrical discharge machining. The thinned wheel-tool can grind microgrooves 10 µm wide. An embedded design, which inserts a close fitting precision core into the biomedical-mold to create step-difference (concave inward) of 50 µm in height between the core and the mold, is also proposed and realized. The perpendicular dual-spindles and precision rotary stage are features that allow for biomedical-mold machining without the necessity of uploading and repositioning materials until all tasks are completed. A PMMA biomedical-slide with a plurality of juxtaposed counting chambers is formed and its usefulness verified.

A Sensor-Based Method for Diagnostics of Machine Tool Linear Axes.

PubMed

Vogl, Gregory W; Weiss, Brian A; Donmez, M Alkan

2015-01-01

A linear axis is a vital subsystem of machine tools, which are vital systems within many manufacturing operations. When installed and operating within a manufacturing facility, a machine tool needs to stay in good condition for parts production. All machine tools degrade during operations, yet knowledge of that degradation is illusive; specifically, accurately detecting degradation of linear axes is a manual and time-consuming process. Thus, manufacturers need automated and efficient methods to diagnose the condition of their machine tool linear axes without disruptions to production. The Prognostics and Health Management for Smart Manufacturing Systems (PHM4SMS) project at the National Institute of Standards and Technology (NIST) developed a sensor-based method to quickly estimate the performance degradation of linear axes. The multi-sensor-based method uses data collected from a 'sensor box' to identify changes in linear and angular errors due to axis degradation; the sensor box contains inclinometers, accelerometers, and rate gyroscopes to capture this data. The sensors are expected to be cost effective with respect to savings in production losses and scrapped parts for a machine tool. Numerical simulations, based on sensor bandwidth and noise specifications, show that changes in straightness and angular errors could be known with acceptable test uncertainty ratios. If a sensor box resides on a machine tool and data is collected periodically, then the degradation of the linear axes can be determined and used for diagnostics and prognostics to help optimize maintenance, production schedules, and ultimately part quality.

A Sensor-Based Method for Diagnostics of Machine Tool Linear Axes

PubMed Central

Vogl, Gregory W.; Weiss, Brian A.; Donmez, M. Alkan

2017-01-01

A linear axis is a vital subsystem of machine tools, which are vital systems within many manufacturing operations. When installed and operating within a manufacturing facility, a machine tool needs to stay in good condition for parts production. All machine tools degrade during operations, yet knowledge of that degradation is illusive; specifically, accurately detecting degradation of linear axes is a manual and time-consuming process. Thus, manufacturers need automated and efficient methods to diagnose the condition of their machine tool linear axes without disruptions to production. The Prognostics and Health Management for Smart Manufacturing Systems (PHM4SMS) project at the National Institute of Standards and Technology (NIST) developed a sensor-based method to quickly estimate the performance degradation of linear axes. The multi-sensor-based method uses data collected from a ‘sensor box’ to identify changes in linear and angular errors due to axis degradation; the sensor box contains inclinometers, accelerometers, and rate gyroscopes to capture this data. The sensors are expected to be cost effective with respect to savings in production losses and scrapped parts for a machine tool. Numerical simulations, based on sensor bandwidth and noise specifications, show that changes in straightness and angular errors could be known with acceptable test uncertainty ratios. If a sensor box resides on a machine tool and data is collected periodically, then the degradation of the linear axes can be determined and used for diagnostics and prognostics to help optimize maintenance, production schedules, and ultimately part quality. PMID:28691039

Prediction of the wear and evolution of cutting tools in a carbide / titanium-aluminum-vanadium machining tribosystem by volumetric tool wear characterization and modeling

NASA Astrophysics Data System (ADS)

Kuttolamadom, Mathew Abraham

The objective of this research work is to create a comprehensive microstructural wear mechanism-based predictive model of tool wear in the tungsten carbide / Ti-6Al-4V machining tribosystem, and to develop a new topology characterization method for worn cutting tools in order to validate the model predictions. This is accomplished by blending first principle wear mechanism models using a weighting scheme derived from scanning electron microscopy (SEM) imaging and energy dispersive x-ray spectroscopy (EDS) analysis of tools worn under different operational conditions. In addition, the topology of worn tools is characterized through scanning by white light interferometry (WLI), and then application of an algorithm to stitch and solidify data sets to calculate the volume of the tool worn away. The methodology was to first combine and weight dominant microstructural wear mechanism models, to be able to effectively predict the tool volume worn away. Then, by developing a new metrology method for accurately quantifying the bulk-3D wear, the model-predicted wear was validated against worn tool volumes obtained from corresponding machining experiments. On analyzing worn crater faces using SEM/EDS, adhesion was found dominant at lower surface speeds, while dissolution wear dominated with increasing speeds -- this is in conformance with the lower relative surface speed requirement for micro welds to form and rupture, essentially defining the mechanical load limit of the tool material. It also conforms to the known dominance of high temperature-controlled wear mechanisms with increasing surface speed, which is known to exponentially increase temperatures especially when machining Ti-6Al-4V due to its low thermal conductivity. Thus, straight tungsten carbide wear when machining Ti-6Al-4V is mechanically-driven at low surface speeds and thermally-driven at high surface speeds. Further, at high surface speeds, craters were formed due to carbon diffusing to the tool surface and being carried away by the rubbing action of the chips -- this left behind a smooth crater surface predominantly of tungsten and cobalt as observed from EDS analysis. Also, at high surface speeds, carbon from the tool was found diffused into the adhered titanium layer to form a titanium carbide (TiC) boundary layer -- this was observed as instances of TiC build-up on the tool edge from EDS analysis. A complex wear mechanism interaction was thus observed, i.e., titanium adhered on top of an earlier worn out crater trough, additional carbon diffused into this adhered titanium layer to create a more stable boundary layer (which could limit diffusion-rates on saturation), and then all were further worn away by dissolution wear as temperatures increased. At low and medium feeds, notch discoloration was observed -- this was detected to be carbon from EDS analysis, suggesting that it was deposited from the edges of the passing chips. Mapping the dominant wear mechanisms showed the increasing dominance of dissolution wear relative to adhesion, with increasing grain size -- this is because a 13% larger sub-micron grain results in a larger surface area of cobalt exposed to chemical action. On the macro-scale, wear quantification through topology characterization elevated wear from a 1D to 3D concept. From investigation, a second order dependence of volumetric tool wear (VTW) and VTW rate with the material removal rate (MRR) emerged, suggesting that MRR is a more consistent wear-controlling factor instead of the traditionally used cutting speed. A predictive model for VTW was developed which showed its exponential dependence with workpiece stock volume removed. Also, both VTW and VTW rate were found to be dependent on the accumulated cumulative wear on the tool. Further, a ratio metric of stock material removed to tool volume lost is now possible as a tool efficiency quantifier and energy-based productivity parameter, which was found to inversely depend on MRR - this led to a more comprehensive tool wear definition based on cutting tool efficiency. (Abstract shortened by UMI.)

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

NASA Astrophysics Data System (ADS)

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

2017-06-01

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

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

NASA Astrophysics Data System (ADS)

Gohil, Vikas; Puri, YM

2018-04-01

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

Recent developments in turning hardened steels - A review

NASA Astrophysics Data System (ADS)

Sivaraman, V.; Prakash, S.

2017-05-01

Hard materials ranging from HRC 45 - 68 such as hardened AISI H13, AISI 4340, AISI 52100, D2 STL, D3 STEEL Steel etc., need super hard tool materials to machine. Turning of these hard materials is termed as hard turning. Hard turning makes possible direct machining of the hard materials and also eliminates the lubricant requirement and thus favoring dry machining. Hard turning is a finish turning process and hence conventional grinding is not required. Development of the new advanced super hard tool materials such as ceramic inserts, Cubic Boron Nitride, Polycrystalline Cubic Boron Nitride etc. enabled the turning of these materials. PVD and CVD methods of coating have made easier the production of single and multi layered coated tool inserts. Coatings of TiN, TiAlN, TiC, Al2O3, AlCrN over cemented carbide inserts has lead to the machining of difficult to machine materials. Advancement in the process of hard machining paved way for better surface finish, long tool life, reduced tool wear, cutting force and cutting temperatures. Micro and Nano coated carbide inserts, nanocomposite coated PCBN inserts, micro and nano CBN coated carbide inserts and similar developments have made machining of hardened steels much easier and economical. In this paper, broad literature review on turning of hardened steels including optimizing process parameters, cooling requirements, different tool materials etc., are done.

Comparison between extreme learning machine and wavelet neural networks in data classification

NASA Astrophysics Data System (ADS)

Yahia, Siwar; Said, Salwa; Jemai, Olfa; Zaied, Mourad; Ben Amar, Chokri

2017-03-01

Extreme learning Machine is a well known learning algorithm in the field of machine learning. It's about a feed forward neural network with a single-hidden layer. It is an extremely fast learning algorithm with good generalization performance. In this paper, we aim to compare the Extreme learning Machine with wavelet neural networks, which is a very used algorithm. We have used six benchmark data sets to evaluate each technique. These datasets Including Wisconsin Breast Cancer, Glass Identification, Ionosphere, Pima Indians Diabetes, Wine Recognition and Iris Plant. Experimental results have shown that both extreme learning machine and wavelet neural networks have reached good results.

A Guide for Industrial Mobilization

DTIC Science & Technology

1989-03-01

packages; and cient, increased production controls may be needed. These actions include: i. Releasing machine tool trigger or- ders and increasing buys...710). the Department of Defense to maintain facili- 4. The National Defense Act authorizes: ties, machine tools , production equipment, and skilled...Defense Industrial Reserve Act pro- Room 3876, U.S. Departm nt of Commerce vides for the reserve of machine tools and other Washington, D.C. 20230 or

Coupling for joining a ball nut to a machine tool carriage

DOEpatents

Gerth, Howard L.

1979-01-01

The present invention relates to an improved coupling for joining a lead screw ball nut to a machine tool carriage. The ball nut is coupled to the machine tool carriage by a plurality of laterally flexible bolts which function as hinges during the rotation of the lead screw for substantially reducing lateral carriage movement due to wobble in the lead screw.

A Guide for Planning Facilities for Occupational Preparation Programs in the Machine Trades. Interim Report. Research 24.

ERIC Educational Resources Information Center

Larson, Milton E.

This guide is designed for use by any person or groups of persons responsible for planning occupational programs in the machine trades. Its major purpose is to elicit the necessary information for the writing of educational specifications for facilities to house needed vocational programs in machine tool operation, machine shop, and tool and die…

Determining the Effect of Material Hardness During the Hard Turning of AISI4340 Steel

NASA Astrophysics Data System (ADS)

Kambagowni, Venkatasubbaiah; Chitla, Raju; Challa, Suresh

2018-05-01

In the present manufacturing industries hardened steels are most widely used in the applications like tool design and mould design. It enhances the application range of hard turning of hardened steels in manufacturing industries. This study discusses the impact of workpiece hardness, feed and depth of cut on Arithmetic mean roughness (Ra), root mean square roughness (Rq), mean depth of roughness (Rz) and total roughness (Rt) during the hard turning. Experiments have been planned according to the Box-Behnken design and conducted on hardened AISI4340 steel at 45, 50 and 55 HRC with wiper ceramic cutting inserts. Cutting speed is kept constant during this study. The analysis of variance was used to determine the effects of the machining parameters. 3-D response surface plots drawn based on RSM were utilized to set up the input-output relationships. The results indicated that the feed rate has the most significant parameter for Ra, Rq and Rz and hardness has the most critical parameter for the Rt. Further, hardness shows its influence over all the surface roughness characteristics.

76 FR 11361 - Defense Federal Acquisition Regulation Supplement; Preservation of Tooling for Major Defense...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-03-02

... tooling, but should include ``all property, i.e., special test equipment, ground support equipment, machine tools and machines and other intangibles to maintain capability.'' Response: DoD is fully...

Modeling of Geometric Error in Linear Guide Way to Improved the vertical three-axis CNC Milling machine’s accuracy

NASA Astrophysics Data System (ADS)

Kwintarini, Widiyanti; Wibowo, Agung; Arthaya, Bagus M.; Yuwana Martawirya, Yatna

2018-03-01

The purpose of this study was to improve the accuracy of three-axis CNC Milling Vertical engines with a general approach by using mathematical modeling methods of machine tool geometric errors. The inaccuracy of CNC machines can be caused by geometric errors that are an important factor during the manufacturing process and during the assembly phase, and are factors for being able to build machines with high-accuracy. To improve the accuracy of the three-axis vertical milling machine, by knowing geometric errors and identifying the error position parameters in the machine tool by arranging the mathematical modeling. The geometric error in the machine tool consists of twenty-one error parameters consisting of nine linear error parameters, nine angle error parameters and three perpendicular error parameters. The mathematical modeling approach of geometric error with the calculated alignment error and angle error in the supporting components of the machine motion is linear guide way and linear motion. The purpose of using this mathematical modeling approach is the identification of geometric errors that can be helpful as reference during the design, assembly and maintenance stages to improve the accuracy of CNC machines. Mathematically modeling geometric errors in CNC machine tools can illustrate the relationship between alignment error, position and angle on a linear guide way of three-axis vertical milling machines.

Agile Machining and Inspection Non-Nuclear Report (NNR) Project

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

Lazarus, Lloyd

This report is a high level summary of the eight major projects funded by the Agile Machining and Inspection Non-Nuclear Readiness (NNR) project (FY06.0422.3.04.R1). The largest project of the group is the Rapid Response project in which the six major sub categories are summarized. This project focused on the operations of the machining departments that will comprise Special Applications Machining (SAM) in the Kansas City Responsive Infrastructure Manufacturing & Sourcing (KCRIMS) project. This project was aimed at upgrading older machine tools, developing new inspection tools, eliminating Classified Removable Electronic Media (CREM) in the handling of classified Numerical Control (NC) programsmore » by installing the CRONOS network, and developing methods to automatically load Coordinated-Measuring Machine (CMM) inspection data into bomb books and product score cards. Finally, the project personnel leaned perations of some of the machine tool cells, and now have the model to continue this activity.« less

Method for producing hard-surfaced tools and machine components

DOEpatents

McHargue, Carl J.

1985-01-01

In one aspect, the invention comprises a method for producing tools and machine components having superhard crystalline-ceramic work surfaces. Broadly, the method comprises two steps: A tool or machine component having a ceramic near-surface region is mounted in ion-implantation apparatus. The region then is implanted with metal ions to form, in the region, a metastable alloy of the ions and said ceramic. The region containing the alloy is characterized by a significant increase in hardness properties, such as microhardness, fracture-toughness, and/or scratch-resistance. The resulting improved article has good thermal stability at temperatures characteristic of typical tool and machine-component uses. The method is relatively simple and reproducible.

Method for producing hard-surfaced tools and machine components

DOEpatents

McHargue, C.J.

1981-10-21

In one aspect, the invention comprises a method for producing tools and machine components having superhard crystalline-ceramic work surfaces. Broadly, the method comprises two steps: a tool or machine component having a ceramic near-surface region is mounted in ion-implantation apparatus. The region then is implanted with metal ions to form, in the region, a metastable alloy of the ions and said ceramic. The region containing the alloy is characterized by a significant increase in hardness properties, such as microhardness, fracture-toughness, and/or scratch-resistance. The resulting improved article has good thermal stability at temperatures characteristic of typical tool and machine-component uses. The method is relatively simple and reproducible.

Research on the EDM Technology for Micro-holes at Complex Spatial Locations

NASA Astrophysics Data System (ADS)

Y Liu, J.; Guo, J. M.; Sun, D. J.; Cai, Y. H.; Ding, L. T.; Jiang, H.

2017-12-01

For the demands on machining micro-holes at complex spatial location, several key technical problems are conquered such as micro-Electron Discharge Machining (micro-EDM) power supply system’s development, the host structure’s design and machining process technical. Through developing low-voltage power supply circuit, high-voltage circuit, micro and precision machining circuit and clearance detection system, the narrow pulse and high frequency six-axis EDM machining power supply system is developed to meet the demands on micro-hole discharging machining. With the method of combining the CAD structure design, CAE simulation analysis, modal test, ODS (Operational Deflection Shapes) test and theoretical analysis, the host construction and key axes of the machine tool are optimized to meet the position demands of the micro-holes. Through developing the special deionized water filtration system to make sure that the machining process is stable enough. To verify the machining equipment and processing technical developed in this paper through developing the micro-hole’s processing flow and test on the real machine tool. As shown in the final test results: the efficient micro-EDM machining pulse power supply system, machine tool host system, deionized filtration system and processing method developed in this paper meet the demands on machining micro-holes at complex spatial locations.

Open architecture CNC system

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

Tal, J.; Lopez, A.; Edwards, J.M.

1995-04-01

In this paper, an alternative solution to the traditional CNC machine tool controller has been introduced. Software and hardware modules have been described and their incorporation in a CNC control system has been outlined. This type of CNC machine tool controller demonstrates that technology is accessible and can be readily implemented into an open architecture machine tool controller. Benefit to the user is greater controller flexibility, while being economically achievable. PC based, motion as well as non-motion features will provide flexibility through a Windows environment. Up-grading this type of controller system through software revisions will keep the machine tool inmore » a competitive state with minimal effort. Software and hardware modules are mass produced permitting competitive procurement and incorporation. Open architecture CNC systems provide diagnostics thus enhancing maintainability, and machine tool up-time. A major concern of traditional CNC systems has been operator training time. Training time can be greatly minimized by making use of Windows environment features.« less

Study of tapping process of carbon fiber reinforced plastic composites/AA7075 stacks

NASA Astrophysics Data System (ADS)

D'Orazio, Alessio; Mehtedi, Mohamad El; Forcellese, Archimede; Nardinocchi, Alessia; Simoncini, Michela

2018-05-01

The present investigation aims at studying the tapping process of a three-layer stack constituted by two CFRP layers and a core plate in AA7075 aluminum alloy. The CFRP laminates were obtained by a pre-impregnated woven sample made up of T700 carbon fibers and a thermoset epoxy matrix. Tapping experiments were performed on a 5-axis machining center instrumented with a dynamometer to measure thrust force generated during process. A high-speed steel tool, coated with nanocomposite TiAlN, was used. According to the tool manufacturer recommendations, rotational speed and feed rate were 800 rpm and 1000 mm/min, respectively. Similar thrust force time history responses were obtained by tapping different holes, even though the vertical force increases with number of threaded holes. Furthermore, a quantitative evaluation of delamination at the periphery of entry holes was carried out. The delamination at the entry hole strongly increases with number of threaded holes.

Application of dragonfly algorithm for optimal performance analysis of process parameters in turn-mill operations- A case study

NASA Astrophysics Data System (ADS)

Vikram, K. Arun; Ratnam, Ch; Lakshmi, VVK; Kumar, A. Sunny; Ramakanth, RT

2018-02-01

Meta-heuristic multi-response optimization methods are widely in use to solve multi-objective problems to obtain Pareto optimal solutions during optimization. This work focuses on optimal multi-response evaluation of process parameters in generating responses like surface roughness (Ra), surface hardness (H) and tool vibration displacement amplitude (Vib) while performing operations like tangential and orthogonal turn-mill processes on A-axis Computer Numerical Control vertical milling center. Process parameters like tool speed, feed rate and depth of cut are considered as process parameters machined over brass material under dry condition with high speed steel end milling cutters using Taguchi design of experiments (DOE). Meta-heuristic like Dragonfly algorithm is used to optimize the multi-objectives like ‘Ra’, ‘H’ and ‘Vib’ to identify the optimal multi-response process parameters combination. Later, the results thus obtained from multi-objective dragonfly algorithm (MODA) are compared with another multi-response optimization technique Viz. Grey relational analysis (GRA).

Predictive Surface Roughness Model for End Milling of Machinable Glass Ceramic

NASA Astrophysics Data System (ADS)

Mohan Reddy, M.; Gorin, Alexander; Abou-El-Hossein, K. A.

2011-02-01

Advanced ceramics of Machinable glass ceramic is attractive material to produce high accuracy miniaturized components for many applications in various industries such as aerospace, electronics, biomedical, automotive and environmental communications due to their wear resistance, high hardness, high compressive strength, good corrosion resistance and excellent high temperature properties. Many research works have been conducted in the last few years to investigate the performance of different machining operations when processing various advanced ceramics. Micro end-milling is one of the machining methods to meet the demand of micro parts. Selecting proper machining parameters are important to obtain good surface finish during machining of Machinable glass ceramic. Therefore, this paper describes the development of predictive model for the surface roughness of Machinable glass ceramic in terms of speed, feed rate by using micro end-milling operation.

JPRS Report, Science & Technology, Europe & Latin America.

DTIC Science & Technology

1988-01-22

Rex Malik; ZERO UN INFORMATIQUE, 31 Aug 87) 25 FACTORY AUTOMATION, ROBOTICS West Europe Seeks To Halt Japanese Inroads in Machine Tool Sector...aircraft. 25048 CSO: 3698/A014 26 FACTORY AUTOMATION, ROBOTICS vrEST EUROpE WEST EUROPE SEEKS TO HALT JAPANESE INROADS IN MACHINE TOOL SECTOR...Trumpf, by the same journalist; first paragraph is L’USINE NOUVELLE introduction] [Excerpts] European machine - tool builders are stepping up mutual

Translations on North Korea No. 622

DTIC Science & Technology

1978-10-13

Pyongyang Power Station 5 July Electric Factory Hamhung Machine Tool Factory Kosan Plastic Pipe Factory Sog’wangea Plastic Pipe Factory 8...August Factory Double Chollima Hamhung Disabled Veterans’ Plastic Goods Factory Mangyongdae Machine Tool Factory Kangso Coal Mine Tongdaewon Garment...21 Jul 78 p 4) innovating in machine tool production (NC 21 Jul 78 p 2) in 40 days of the 蔴 days of combat" raised coal production 10 percent

Pellet to Part Manufacturing System for CNCs

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

Roschli, Alex C.; Love, Lonnie J.; Post, Brian K.

Oak Ridge National Laboratory’s Manufacturing Demonstration Facility worked with Hybrid Manufacturing Technologies to develop a compact prototype composite additive manufacturing head that can effectively extrude injection molding pellets. The head interfaces with conventional CNC machine tools enabling rapid conversion of conventional machine tools to additive manufacturing tools. The intent was to enable wider adoption of Big Area Additive Manufacturing (BAAM) technology and combine BAAM technology with conventional machining systems.

A Comparative Study of Teacher Education Institutions and Machine Tool Manufacturers to Determine Course Content for a Machine Tool Maintenance Course in the Woodworking Area.

ERIC Educational Resources Information Center

Polette, Douglas Lee

To determine what type of maintenance training the prospective industrial arts teacher should receive in the woodworking area and how this information should be taught, a research instrument was constructed using information obtained from a review of relevant literature. Specific data on machine tool maintenance was gathered by the use of two…

Machining of AISI D2 Tool Steel with Multiple Hole Electrodes by EDM Process

NASA Astrophysics Data System (ADS)

Prasad Prathipati, R.; Devuri, Venkateswarlu; Cheepu, Muralimohan; Gudimetla, Kondaiah; Uzwal Kiran, R.

2018-03-01

In recent years, with the increasing of technology the demand for machining processes is increasing for the newly developed materials. The conventional machining processes are not adequate to meet the accuracy of the machining of these materials. The non-conventional machining processes of electrical discharge machining is one of the most efficient machining processes is being widely used to machining of high accuracy products of various industries. The optimum selection of process parameters is very important in machining processes as that of an electrical discharge machining as they determine surface quality and dimensional precision of the obtained parts, even though time consumption rate is higher for machining of large dimension features. In this work, D2 high carbon and chromium tool steel has been machined using electrical discharge machining with the multiple hole electrode technique. The D2 steel has several applications such as forming dies, extrusion dies and thread rolling. But the machining of this tool steel is very hard because of it shard alloyed elements of V, Cr and Mo which enhance its strength and wear properties. However, the machining is possible by using electrical discharge machining process and the present study implemented a new technique to reduce the machining time using a multiple hole copper electrode. In this technique, while machining with multiple holes electrode, fin like projections are obtained, which can be removed easily by chipping. Then the finishing is done by using solid electrode. The machining time is reduced to around 50% while using multiple hole electrode technique for electrical discharge machining.

12. TOOL ROOM SHOWING LANDIS MACHINE CO. BOL/T THREADER (L), ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

12. TOOL ROOM SHOWING LANDIS MACHINE CO. BOL/T THREADER (L), OSTER MANUFACTURING CO. PIPE MASTER (R), AND OLDMAN KINK, A SHOP-MADE WELDING STRENGTH TESTER (L, BACKGROUND). VIEW NORTHEAST - Oldman Boiler Works, Office/Machine Shop, 32 Illinois Street, Buffalo, Erie County, NY

Source localization in an ocean waveguide using supervised machine learning.

PubMed

Niu, Haiqiang; Reeves, Emma; Gerstoft, Peter

2017-09-01

Source localization in ocean acoustics is posed as a machine learning problem in which data-driven methods learn source ranges directly from observed acoustic data. The pressure received by a vertical linear array is preprocessed by constructing a normalized sample covariance matrix and used as the input for three machine learning methods: feed-forward neural networks (FNN), support vector machines (SVM), and random forests (RF). The range estimation problem is solved both as a classification problem and as a regression problem by these three machine learning algorithms. The results of range estimation for the Noise09 experiment are compared for FNN, SVM, RF, and conventional matched-field processing and demonstrate the potential of machine learning for underwater source localization.

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.

Large robotized turning centers described

NASA Astrophysics Data System (ADS)

Kirsanov, V. V.; Tsarenko, V. I.

1985-09-01

The introduction of numerical control (NC) machine tools has made it possible to automate machining in series and small series production. The organization of automated production sections merged NC machine tools with automated transport systems. However, both the one and the other require the presence of an operative at the machine for low skilled operations. Industrial robots perform a number of auxiliary operations, such as equipment loading-unloading and control, changing cutting and auxiliary tools, controlling workpieces and parts, and cleaning of location surfaces. When used with a group of equipment they perform transfer operations between the machine tools. Industrial robots eliminate the need for workers to form auxiliary operations. This underscores the importance of developing robotized manufacturing centers providing for minimal human participation in production and creating conditions for two and three shift operation of equipment. Work carried out at several robotized manufacturing centers for series and small series production is described.

Machining Parameters Optimization using Hybrid Firefly Algorithm and Particle Swarm Optimization

NASA Astrophysics Data System (ADS)

Farahlina Johari, Nur; Zain, Azlan Mohd; Haszlinna Mustaffa, Noorfa; Udin, Amirmudin

2017-09-01

Firefly Algorithm (FA) is a metaheuristic algorithm that is inspired by the flashing behavior of fireflies and the phenomenon of bioluminescent communication and the algorithm is used to optimize the machining parameters (feed rate, depth of cut, and spindle speed) in this research. The algorithm is hybridized with Particle Swarm Optimization (PSO) to discover better solution in exploring the search space. Objective function of previous research is used to optimize the machining parameters in turning operation. The optimal machining cutting parameters estimated by FA that lead to a minimum surface roughness are validated using ANOVA test.

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

PubMed Central

Erdakov, Ivan Nikolaevich; Taha, Mohamed~Adel; Soliman, Mahmoud Sayed; El Rayes, Magdy Mostafa

2018-01-01

Magnesium alloys are widely used in aerospace vehicles and modern cars, due to their rapid machinability at high cutting speeds. A novel Edgeworth–Pareto optimization of an artificial neural network (ANN) is presented in this paper for surface roughness (Ra) prediction of one component in computer numerical control (CNC) turning over minimal machining time (Tm) and at prime machining costs (C). An ANN is built in the Matlab programming environment, based on a 4-12-3 multi-layer perceptron (MLP), to predict Ra, Tm, and C, in relation to cutting speed, vc, depth of cut, ap, and feed per revolution, fr. For the first time, a profile of an AZ61 alloy workpiece after finish turning is constructed using an ANN for the range of experimental values vc, ap, and fr. The global minimum length of a three-dimensional estimation vector was defined with the following coordinates: Ra = 0.087 μm, Tm = 0.358 min/cm3, C = $8.2973. Likewise, the corresponding finish-turning parameters were also estimated: cutting speed vc = 250 m/min, cutting depth ap = 1.0 mm, and feed per revolution fr = 0.08 mm/rev. The ANN model achieved a reliable prediction accuracy of ±1.35% for surface roughness. PMID:29772670

Tool simplifies machining of pipe ends for precision welding

NASA Technical Reports Server (NTRS)

Matus, S. T.

1969-01-01

Single tool prepares a pipe end for precision welding by simultaneously performing internal machining, end facing, and bevel cutting to specification standards. The machining operation requires only one milling adjustment, can be performed quickly, and produces the high quality pipe-end configurations required to ensure precision-welded joints.

Machine Translation and Other Translation Technologies.

ERIC Educational Resources Information Center

Melby, Alan

1996-01-01

Examines the application of linguistic theory to machine translation and translator tools, discusses the use of machine translation and translator tools in the real world of translation, and addresses the impact of translation technology on conceptions of language and other issues. Findings indicate that the human mind is flexible and linguistic…

29 CFR 1926.303 - Abrasive wheels and tools.

Code of Federal Regulations, 2013 CFR

2013-07-01

... and tools. (a) Power. All grinding machines shall be supplied with sufficient power to maintain the spindle speed at safe levels under all conditions of normal operation. (b) Guarding. (1) Grinding machines..., nut, and outer flange may be exposed on machines designed as portable saws. (c) Use of abrasive wheels...

29 CFR 1926.303 - Abrasive wheels and tools.

Code of Federal Regulations, 2014 CFR

2014-07-01

... and tools. (a) Power. All grinding machines shall be supplied with sufficient power to maintain the spindle speed at safe levels under all conditions of normal operation. (b) Guarding. (1) Grinding machines..., nut, and outer flange may be exposed on machines designed as portable saws. (c) Use of abrasive wheels...

29 CFR 1926.303 - Abrasive wheels and tools.

Code of Federal Regulations, 2012 CFR

2012-07-01

... and tools. (a) Power. All grinding machines shall be supplied with sufficient power to maintain the spindle speed at safe levels under all conditions of normal operation. (b) Guarding. (1) Grinding machines..., nut, and outer flange may be exposed on machines designed as portable saws. (c) Use of abrasive wheels...

Optical alignment of electrodes on electrical discharge machines

NASA Technical Reports Server (NTRS)

Boissevain, A. G.; Nelson, B. W.

1972-01-01

Shadowgraph system projects magnified image on screen so that alignment of small electrodes mounted on electrical discharge machines can be corrected and verified. Technique may be adapted to other machine tool equipment where physical contact cannot be made during inspection and access to tool limits conventional runout checking procedures.

The Science of and Advanced Technology for Cost-Effective Manufacture of High Precision Engineering Products. Volume 4. Thermal Effects on the Accuracy of Numerically Controlled Machine Tools.

DTIC Science & Technology

1985-10-01

83K0385 FINAL REPORT D Vol. 4 00 THERMAL EFFECTS ON THE ACCURACY OF LD NUME" 1ICALLY CONTROLLED MACHINE TOOLS PREPARED BY I Raghunath Venugopal and M...OF NUMERICALLY CONTROLLED MACHINE TOOLS 12 PERSONAL AJ’HOR(S) Venunorial, Raghunath and M. M. Barash 13a TYPE OF REPORT 13b TIME COVERED 14 DATE OF...TOOLS Prepared by Raghunath Venugopal and M. M. Barash Accesion For Unannounced 0 Justification ........................................... October 1085

Speed-Selector Guard For Machine Tool

NASA Technical Reports Server (NTRS)

Shakhshir, Roda J.; Valentine, Richard L.

1992-01-01

Simple guardplate prevents accidental reversal of direction of rotation or sudden change of speed of lathe, milling machine, or other machine tool. Custom-made for specific machine and control settings. Allows control lever to be placed at only one setting. Operator uses handle to slide guard to engage or disengage control lever. Protects personnel from injury and equipment from damage occurring if speed- or direction-control lever inadvertently placed in wrong position.

20 CFR 404.1568 - Skill requirements.

Code of Federal Regulations, 2010 CFR

2010-04-01

... are handling, feeding and offbearing (that is, placing or removing materials from machines which are automatic or operated by others), or machine tending, and a person can usually learn to do the job in 30... judgment to do simple duties that can be learned on the job in a short period of time. The job may or may...

20 CFR 404.1568 - Skill requirements.

Code of Federal Regulations, 2011 CFR

2011-04-01

... are handling, feeding and offbearing (that is, placing or removing materials from machines which are automatic or operated by others), or machine tending, and a person can usually learn to do the job in 30... judgment to do simple duties that can be learned on the job in a short period of time. The job may or may...

20 CFR 404.1568 - Skill requirements.

Code of Federal Regulations, 2012 CFR

2012-04-01

... are handling, feeding and offbearing (that is, placing or removing materials from machines which are automatic or operated by others), or machine tending, and a person can usually learn to do the job in 30... judgment to do simple duties that can be learned on the job in a short period of time. The job may or may...

20 CFR 404.1568 - Skill requirements.

Code of Federal Regulations, 2014 CFR

2014-04-01

... are handling, feeding and offbearing (that is, placing or removing materials from machines which are automatic or operated by others), or machine tending, and a person can usually learn to do the job in 30... judgment to do simple duties that can be learned on the job in a short period of time. The job may or may...

20 CFR 404.1568 - Skill requirements.

Code of Federal Regulations, 2013 CFR

2013-04-01

... are handling, feeding and offbearing (that is, placing or removing materials from machines which are automatic or operated by others), or machine tending, and a person can usually learn to do the job in 30... judgment to do simple duties that can be learned on the job in a short period of time. The job may or may...

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.

New tool holder design for cryogenic machining of Ti6Al4V

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Machine tools error characterization and compensation by on-line measurement of artifact

NASA Astrophysics Data System (ADS)

Wahid Khan, Abdul; Chen, Wuyi; Wu, Lili

2009-11-01

Most manufacturing machine tools are utilized for mass production or batch production with high accuracy at a deterministic manufacturing principle. Volumetric accuracy of machine tools depends on the positional accuracy of the cutting tool, probe or end effector related to the workpiece in the workspace volume. In this research paper, a methodology is presented for volumetric calibration of machine tools by on-line measurement of an artifact or an object of a similar type. The machine tool geometric error characterization was carried out through a standard or an artifact, having similar geometry to the mass production or batch production product. The artifact was measured at an arbitrary position in the volumetric workspace with a calibrated Renishaw touch trigger probe system. Positional errors were stored into a computer for compensation purpose, to further run the manufacturing batch through compensated codes. This methodology was found quite effective to manufacture high precision components with more dimensional accuracy and reliability. Calibration by on-line measurement gives the advantage to improve the manufacturing process by use of deterministic manufacturing principle and found efficient and economical but limited to the workspace or envelop surface of the measured artifact's geometry or the profile.

Multi-category micro-milling tool wear monitoring with continuous hidden Markov models

NASA Astrophysics Data System (ADS)

Zhu, Kunpeng; Wong, Yoke San; Hong, Geok Soon

2009-02-01

In-process monitoring of tool conditions is important in micro-machining due to the high precision requirement and high tool wear rate. Tool condition monitoring in micro-machining poses new challenges compared to conventional machining. In this paper, a multi-category classification approach is proposed for tool flank wear state identification in micro-milling. Continuous Hidden Markov models (HMMs) are adapted for modeling of the tool wear process in micro-milling, and estimation of the tool wear state given the cutting force features. For a noise-robust approach, the HMM outputs are connected via a medium filter to minimize the tool state before entry into the next state due to high noise level. A detailed study on the selection of HMM structures for tool condition monitoring (TCM) is presented. Case studies on the tool state estimation in the micro-milling of pure copper and steel demonstrate the effectiveness and potential of these methods.

76 FR 5832 - International Business Machines (IBM), Software Group Business Unit, Optim Data Studio Tools QA...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-02-02

... DEPARTMENT OF LABOR Employment and Training Administration [TA-W-74,554] International Business Machines (IBM), Software Group Business Unit, Optim Data Studio Tools QA, San Jose, CA; Notice of... determination of the TAA petition filed on behalf of workers at International Business Machines (IBM), Software...

Production Engineering Program to Develop Improved Mass-Production Process for M42/M46 Grenade Bodies

DTIC Science & Technology

1978-03-01

J16 Photograph 3 Knurling Tool Installed in Machine . . ....... 16 Photograph 4 Shrapnel Pattern Being Knurled Into M42 Grenade Cylinder...body Fenn mill embossing rolls. Roehlen was awarded a cuxiu**L am’i labricated a knurling tool for use in the modified Tesker thread-rolling machine ...automatic grinding machine . IKratz-Wilde was not successful in developing tooling to produce domes to the inertia-welded assembly design. (See Figure

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.

ORACLE (Oversight of Resources and Capability for Logistics Effectiveness) and Requirements Forecasting. Volume 3. Predicting the Peacetime Spares Requirements.

DTIC Science & Technology

1988-05-01

Shearing Machines WR/MMI DG 3446 Forging Machinery and Hammers WR/MMI DG 3447 Wire and Metal Ribbon Forming Machines WR/MMI DG 3448 Riveting Machines ...R/MN1I DG 3449 Miscellaneous Secondary Metal Forming & Cutting WR/MMI DG Machinery 3450 Machine Tools, Portable WR/MMI DG 3455 Cutting Tools for...Secondary Metalworking Machinery WR/MMI DG WR 3465 Production Jigs, Fixtures and Templates WR/MMI DG WR 3470 Machine Shop Sets, Kits, and Outfits WR/MMI DG

Micro-optical fabrication by ultraprecision diamond machining and precision molding

NASA Astrophysics Data System (ADS)

Li, Hui; Li, Likai; Naples, Neil J.; Roblee, Jeffrey W.; Yi, Allen Y.

2017-06-01

Ultraprecision diamond machining and high volume molding for affordable high precision high performance optical elements are becoming a viable process in optical industry for low cost high quality microoptical component manufacturing. In this process, first high precision microoptical molds are fabricated using ultraprecision single point diamond machining followed by high volume production methods such as compression or injection molding. In the last two decades, there have been steady improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tool and fast tool servo. Today optical molds, including freeform surfaces and microlens arrays, are routinely diamond machined to final finish without post machining polishing. For consumers, compression molding or injection molding provide efficient and high quality optics at extremely low cost. In this paper, first ultraprecision machine design and machining processes such as slow tool and fast too servo are described then both compression molding and injection molding of polymer optics are discussed. To implement precision optical manufacturing by molding, numerical modeling can be included in the future as a critical part of the manufacturing process to ensure high product quality.

Estimation of tool wear length in finish milling using a fuzzy inference algorithm

NASA Astrophysics Data System (ADS)

Ko, Tae Jo; Cho, Dong Woo

1993-10-01

The geometric accuracy and surface roughness are mainly affected by the flank wear at the minor cutting edge in finish machining. A fuzzy estimator obtained by a fuzzy inference algorithm with a max-min composition rule to evaluate the minor flank wear length in finish milling is introduced. The features sensitive to minor flank wear are extracted from the dispersion analysis of a time series AR model of the feed directional acceleration of the spindle housing. Linguistic rules for fuzzy estimation are constructed using these features, and then fuzzy inferences are carried out with test data sets under various cutting conditions. The proposed system turns out to be effective for estimating minor flank wear length, and its mean error is less than 12%.

Material Choice for spindle of machine tools

NASA Astrophysics Data System (ADS)

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

2012-02-01

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

MISR Center Block Time Tool

Atmospheric Science Data Center

2013-04-01

  MISR Center Block Time Tool The misr_time tool calculates the block center times for MISR Level 1B2 files. This is ... version of the IDL package or by using the IDL Virtual Machine application. The IDL Virtual Machine is bundled with IDL and is ...

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.

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.

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.

Impact resistance of materials for guards on cutting machine tools--requirements in future European safety standards.

PubMed

Mewes, D; Trapp, R P

2000-01-01

Guards on machine tools are meant to protect operators from injuries caused by tools, workpieces, and fragments hurled out of the machine's working zone. This article presents the impact resistance requirements, which guards according to European safety standards for machine tools must satisfy. Based upon these standards the impact resistance of different guard materials was determined using cylindrical steel projectiles. Polycarbonate proves to be a suitable material for vision panels because of its high energy absorption capacity. The impact resistance of 8-mm thick polycarbonate is roughly equal to that of a 3-mm thick steel sheet Fe P01. The limited ageing stability, however, makes it necessary to protect polycarbonate against cooling lubricants by means of additional panes on both sides.

SKYNET: an efficient and robust neural network training tool for machine learning in astronomy

NASA Astrophysics Data System (ADS)

Graff, Philip; Feroz, Farhan; Hobson, Michael P.; Lasenby, Anthony

2014-06-01

We present the first public release of our generic neural network training algorithm, called SKYNET. This efficient and robust machine learning tool is able to train large and deep feed-forward neural networks, including autoencoders, for use in a wide range of supervised and unsupervised learning applications, such as regression, classification, density estimation, clustering and dimensionality reduction. SKYNET uses a `pre-training' method to obtain a set of network parameters that has empirically been shown to be close to a good solution, followed by further optimization using a regularized variant of Newton's method, where the level of regularization is determined and adjusted automatically; the latter uses second-order derivative information to improve convergence, but without the need to evaluate or store the full Hessian matrix, by using a fast approximate method to calculate Hessian-vector products. This combination of methods allows for the training of complicated networks that are difficult to optimize using standard backpropagation techniques. SKYNET employs convergence criteria that naturally prevent overfitting, and also includes a fast algorithm for estimating the accuracy of network outputs. The utility and flexibility of SKYNET are demonstrated by application to a number of toy problems, and to astronomical problems focusing on the recovery of structure from blurred and noisy images, the identification of gamma-ray bursters, and the compression and denoising of galaxy images. The SKYNET software, which is implemented in standard ANSI C and fully parallelized using MPI, is available at http://www.mrao.cam.ac.uk/software/skynet/.

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

NASA Astrophysics Data System (ADS)

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

2017-11-01

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

OPMILL - MICRO COMPUTER PROGRAMMING ENVIRONMENT FOR CNC MILLING MACHINES THREE AXIS EQUATION PLOTTING CAPABILITIES

NASA Technical Reports Server (NTRS)

Ray, R. B.

1994-01-01

OPMILL is a computer operating system for a Kearney and Trecker milling machine that provides a fast and easy way to program machine part manufacture with an IBM compatible PC. The program gives the machinist an "equation plotter" feature which plots any set of equations that define axis moves (up to three axes simultaneously) and converts those equations to a machine milling program that will move a cutter along a defined path. Other supported functions include: drill with peck, bolt circle, tap, mill arc, quarter circle, circle, circle 2 pass, frame, frame 2 pass, rotary frame, pocket, loop and repeat, and copy blocks. The system includes a tool manager that can handle up to 25 tools and automatically adjusts tool length for each tool. It will display all tool information and stop the milling machine at the appropriate time. Information for the program is entered via a series of menus and compiled to the Kearney and Trecker format. The program can then be loaded into the milling machine, the tool path graphically displayed, and tool change information or the program in Kearney and Trecker format viewed. The program has a complete file handling utility that allows the user to load the program into memory from the hard disk, save the program to the disk with comments, view directories, merge a program on the disk with one in memory, save a portion of a program in memory, and change directories. OPMILL was developed on an IBM PS/2 running DOS 3.3 with 1 MB of RAM. OPMILL was written for an IBM PC or compatible 8088 or 80286 machine connected via an RS-232 port to a Kearney and Trecker Data Mill 700/C Control milling machine. It requires a "D:" drive (fixed-disk or virtual), a browse or text display utility, and an EGA or better display. Users wishing to modify and recompile the source code will also need Turbo BASIC, Turbo C, and Crescent Software's QuickPak for Turbo BASIC. IBM PC and IBM PS/2 are registered trademarks of International Business Machines. Turbo BASIC and Turbo C are trademarks of Borland International.

HUMAN ENGINEERING FOR AN EFFECTIVE AIR-NAVIGATION AND TRAFFIC-CONTROL SYSTEM, AND APPENDIXES 1 THRU 3

DTIC Science & Technology

1951-03-14

human "We have been very much occupied In perfect. engineering to the improvement of the air-navigation ing the machines and the tools which the...a man-machine system which will ever, if he were only considered as an instrument, yield optimal results in the way of efficiency and a tool , a motor...operation of machines and equipment and system development, which will permit tools , the emphasis has been upon the adjustment of an orderly and

Development of superconducting links for the Large Hadron Collider machine

NASA Astrophysics Data System (ADS)

Ballarino, Amalia

2014-04-01

In the framework of the upgrade of the Large Hadron Collider (LHC) machine, new superconducting lines are being developed for the feeding of the LHC magnets. The proposed electrical layout envisages the location of the power converters in surface buildings, and the transfer of the current from the surface to the LHC tunnel, where the magnets are located, via superconducting links containing tens of cables feeding different circuits and transferring altogether more than 150 kA. Depending on the location, the links will have a length ranging from 300 m to 500 m, and they will span a vertical distance of about 80 m. An overview of the R&D program that has been launched by CERN is presented, with special attention to the development of novel types of cables made from MgB2 and high temperature superconductors (Bi-2223 and REBCO) and to the results of the tests performed on prototype links. Plans for future activities are presented, together with a timeline for potential future integration in the LHC machine.

Ship localization in Santa Barbara Channel using machine learning classifiers.

PubMed

Niu, Haiqiang; Ozanich, Emma; Gerstoft, Peter

2017-11-01

Machine learning classifiers are shown to outperform conventional matched field processing for a deep water (600 m depth) ocean acoustic-based ship range estimation problem in the Santa Barbara Channel Experiment when limited environmental information is known. Recordings of three different ships of opportunity on a vertical array were used as training and test data for the feed-forward neural network and support vector machine classifiers, demonstrating the feasibility of machine learning methods to locate unseen sources. The classifiers perform well up to 10 km range whereas the conventional matched field processing fails at about 4 km range without accurate environmental information.

Wire electric-discharge machining and other fabrication techniques

NASA Technical Reports Server (NTRS)

Morgan, W. H.

1983-01-01

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

Machine Tool Series. Duty Task List.

ERIC Educational Resources Information Center

Oklahoma State Dept. of Vocational and Technical Education, Stillwater. Curriculum and Instructional Materials Center.

This task list is intended for use in planning and/or evaluating a competency-based course to prepare machine tool, drill press, grinding machine, lathe, mill, and/or power saw operators. The listing is divided into six sections, with each one outlining the tasks required to perform the duties that have been identified for the given occupation.…

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.

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

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.

Shot and bead peening control

NASA Astrophysics Data System (ADS)

John, R.

The merits of the peening effect in improving the fatigue resistance of ferrous and non-ferrous media is discussed. The machines that perform the peening task are also discussed, including the rotating-wheel plant, pressure-type air-assisted peening machines, and suction systems. The peening process itself is discussed briefly, and an outline of the parameters that affect the product specification is presented. The merits of the Almen test strip as a measure of correct treatment are evaluated, and the two types of devices are discussed for monitoring the flow of peening media. The two types of feed control devices (one for ferrous media and the other for non-ferrous media) for accurately controlling the feed of peening media are also briefly examined.

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

PubMed

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

2011-10-01

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

A Catalog of Performance Objectives, Performance Conditions, and Performance Guides for Machine Tool Operations.

ERIC Educational Resources Information Center

Stadt, Ronald; And Others

This catalog provides performance objectives, tasks, standards, and performance guides associated with current occupational information relating to the job content of machinists, specifically tool grinder operators, production lathe operators, and production screw machine operators. The catalog is comprised of 262 performance objectives, tool and…

Laser machining of southern pine

Treesearch

C. W. McMillin; J. E. Harry

1971-01-01

When cutting with an air-jet-assisted carbon-dioxide laser of 240 watts output power, maximum feed speed at the point of full penetration of the beam decreased with increasing workpiece thickness in both wet and dry samples; the trend was curvilinear. Feed speeds averaged 99.1 and 14.6 inches per minute for samples 0.25 and 1.00 inch thick, respectively. Somewhat...

Multi-objective optimization model of CNC machining to minimize processing time and environmental impact

NASA Astrophysics Data System (ADS)

Hamada, Aulia; Rosyidi, Cucuk Nur; Jauhari, Wakhid Ahmad

2017-11-01

Minimizing processing time in a production system can increase the efficiency of a manufacturing company. Processing time are influenced by application of modern technology and machining parameter. Application of modern technology can be apply by use of CNC machining, one of the machining process can be done with a CNC machining is turning. However, the machining parameters not only affect the processing time but also affect the environmental impact. Hence, optimization model is needed to optimize the machining parameters to minimize the processing time and environmental impact. This research developed a multi-objective optimization to minimize the processing time and environmental impact in CNC turning process which will result in optimal decision variables of cutting speed and feed rate. Environmental impact is converted from environmental burden through the use of eco-indicator 99. The model were solved by using OptQuest optimization software from Oracle Crystal Ball.

Cutting Modeling of Hybrid CFRP/Ti Composite with Induced Damage Analysis

PubMed Central

Xu, Jinyang; El Mansori, Mohamed

2016-01-01

In hybrid carbon fiber reinforced polymer (CFRP)/Ti machining, the bi-material interface is the weakest region vulnerable to severe damage formation when the tool cutting from one phase to another phase and vice versa. The interface delamination as well as the composite-phase damage is the most serious failure dominating the bi-material machining. In this paper, an original finite element (FE) model was developed to inspect the key mechanisms governing the induced damage formation when cutting this multi-phase material. The hybrid composite model was constructed by establishing three disparate physical constituents, i.e., the Ti phase, the interface, and the CFRP phase. Different constitutive laws and damage criteria were implemented to build up the entire cutting behavior of the bi-material system. The developed orthogonal cutting (OC) model aims to characterize the dynamic mechanisms of interface delamination formation and the affected interface zone (AIZ). Special focus was made on the quantitative analyses of the parametric effects on the interface delamination and composite-phase damage. The numerical results highlighted the pivotal role of AIZ in affecting the formation of interface delamination, and the significant impacts of feed rate and cutting speed on delamination extent and fiber/matrix failure. PMID:28787824

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

PubMed

Abbas, Adel Taha; Pimenov, Danil Yurievich; Erdakov, Ivan Nikolaevich; Taha, Mohamed Adel; Soliman, Mahmoud Sayed; El Rayes, Magdy Mostafa

2018-05-16

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

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.

System technology for laser-assisted milling with tool integrated optics

NASA Astrophysics Data System (ADS)

Hermani, Jan-Patrick; Emonts, Michael; Brecher, Christian

2013-02-01

High strength metal alloys and ceramics offer a huge potential for increased efficiency (e. g. in engine components for aerospace or components for gas turbines). However, mass application is still hampered by cost- and time-consuming end-machining due to long processing times and high tool wear. Laser-induced heating shortly before machining can reduce the material strength and improve machinability significantly. The Fraunhofer IPT has developed and successfully realized a new approach for laser-assisted milling with spindle and tool integrated, co-rotating optics. The novel optical system inside the tool consists of one deflection prism to position the laser spot in front of the cutting insert and one focusing lens. Using a fiber laser with high beam quality the laser spot diameter can be precisely adjusted to the chip size. A high dynamic adaption of the laser power signal according to the engagement condition of the cutting tool was realized in order not to irradiate already machined work piece material. During the tool engagement the laser power is controlled in proportion to the current material removal rate, which has to be calculated continuously. The needed geometric values are generated by a CAD/CAM program and converted into a laser power signal by a real-time controller. The developed milling tool with integrated optics and the algorithm for laser power control enable a multi-axis laser-assisted machining of complex parts.

An Introduction to Intelligent Processing Programs Developed by the Air Force Manufacturing Technology Directorate

NASA Technical Reports Server (NTRS)

Sampson, Paul G.; Sny, Linda C.

1992-01-01

The Air Force has numerous on-going manufacturing and integration development programs (machine tools, composites, metals, assembly, and electronics) which are instrumental in improving productivity in the aerospace industry, but more importantly, have identified strategies and technologies required for the integration of advanced processing equipment. An introduction to four current Air Force Manufacturing Technology Directorate (ManTech) manufacturing areas is provided. Research is being carried out in the following areas: (1) machining initiatives for aerospace subcontractors which provide for advanced technology and innovative manufacturing strategies to increase the capabilities of small shops; (2) innovative approaches to advance machine tool products and manufacturing processes; (3) innovative approaches to advance sensors for process control in machine tools; and (4) efforts currently underway to develop, with the support of industry, the Next Generation Workstation/Machine Controller (Low-End Controller Task).

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

PubMed

Nguyen, Huu-Tho; Md Dawal, Siti Zawiah; Nukman, Yusoff; Aoyama, Hideki; Case, Keith

2015-01-01

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

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.

Multi-Cultural Competency-Based Vocational Curricula. Machine Trades. Multi-Cultural Competency-Based Vocational/Technical Curricula Series.

ERIC Educational Resources Information Center

Hepburn, Larry; Shin, Masako

This document, one of eight in a multi-cultural competency-based vocational/technical curricula series, is on machine trades. This program is designed to run 36 weeks and cover 6 instructional areas: use of measuring tools; benchwork/tool bit grinding; lathe work; milling work; precision grinding; and combination machine work. A duty-task index…

Precision tool holder with flexure-adjustable, three degrees of freedom for a four-axis lathe

DOEpatents

Bono, Matthew J [Pleasanton, CA; Hibbard, Robin L [Livermore, CA

2008-03-04

A precision tool holder for precisely positioning a single point cutting tool on 4-axis lathe, such that the center of the radius of the tool nose is aligned with the B-axis of the machine tool, so as to facilitate the machining of precision meso-scale components with complex three-dimensional shapes with sub-.mu.m accuracy on a four-axis lathe. The device is designed to fit on a commercial diamond turning machine and can adjust the cutting tool position in three orthogonal directions with sub-micrometer resolution. In particular, the tool holder adjusts the tool position using three flexure-based mechanisms, with two flexure mechanisms adjusting the lateral position of the tool to align the tool with the B-axis, and a third flexure mechanism adjusting the height of the tool. Preferably, the flexures are driven by manual micrometer adjusters. In this manner, this tool holder simplifies the process of setting a tool with sub-.mu.m accuracy, to substantially reduce the time required to set the tool.

Machinability of experimental Ti-Ag alloys.

PubMed

Kikuchi, Masafumi; Takahashi, Masatoshi; Okuno, Osamu

2008-03-01

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

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.

Curriculum Assessment Using Artificial Neural Network and Support Vector Machine Modeling Approaches: A Case Study. IR Applications. Volume 29

ERIC Educational Resources Information Center

Chen, Chau-Kuang

2010-01-01

Artificial Neural Network (ANN) and Support Vector Machine (SVM) approaches have been on the cutting edge of science and technology for pattern recognition and data classification. In the ANN model, classification accuracy can be achieved by using the feed-forward of inputs, back-propagation of errors, and the adjustment of connection weights. In…

Automated Rapid Prototyping of 3D Ceramic Parts

NASA Technical Reports Server (NTRS)

McMillin, Scott G.; Griffin, Eugene A.; Griffin, Curtis W.; Coles, Peter W. H.; Engle, James D.

2005-01-01

An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut into individual sheets, which are stacked in the sheet-feeding machine until used. The sheet-feeding machine can hold enough sheets for about 8 hours of continuous operation.

Machine learning and data science in soft materials engineering

NASA Astrophysics Data System (ADS)

Ferguson, Andrew L.

2018-01-01

In many branches of materials science it is now routine to generate data sets of such large size and dimensionality that conventional methods of analysis fail. Paradigms and tools from data science and machine learning can provide scalable approaches to identify and extract trends and patterns within voluminous data sets, perform guided traversals of high-dimensional phase spaces, and furnish data-driven strategies for inverse materials design. This topical review provides an accessible introduction to machine learning tools in the context of soft and biological materials by ‘de-jargonizing’ data science terminology, presenting a taxonomy of machine learning techniques, and surveying the mathematical underpinnings and software implementations of popular tools, including principal component analysis, independent component analysis, diffusion maps, support vector machines, and relative entropy. We present illustrative examples of machine learning applications in soft matter, including inverse design of self-assembling materials, nonlinear learning of protein folding landscapes, high-throughput antimicrobial peptide design, and data-driven materials design engines. We close with an outlook on the challenges and opportunities for the field.

Machine learning and data science in soft materials engineering.

PubMed

Ferguson, Andrew L

2018-01-31

In many branches of materials science it is now routine to generate data sets of such large size and dimensionality that conventional methods of analysis fail. Paradigms and tools from data science and machine learning can provide scalable approaches to identify and extract trends and patterns within voluminous data sets, perform guided traversals of high-dimensional phase spaces, and furnish data-driven strategies for inverse materials design. This topical review provides an accessible introduction to machine learning tools in the context of soft and biological materials by 'de-jargonizing' data science terminology, presenting a taxonomy of machine learning techniques, and surveying the mathematical underpinnings and software implementations of popular tools, including principal component analysis, independent component analysis, diffusion maps, support vector machines, and relative entropy. We present illustrative examples of machine learning applications in soft matter, including inverse design of self-assembling materials, nonlinear learning of protein folding landscapes, high-throughput antimicrobial peptide design, and data-driven materials design engines. We close with an outlook on the challenges and opportunities for the field.

Computer Simulation Of An In-Process Surface Finish Sensor.

NASA Astrophysics Data System (ADS)

Rakels, Jan H.

1987-01-01

It is generally accepted, that optical methods are the most promising for the in-process measurement of surface finish. These methods have the advantages of being non-contacting and fast data acquisition. Furthermore, these optical instruments can be easily retrofitted on existing machine-tools. In the Micro-Engineering Centre at the University of Warwick, an optical sensor has been developed which can measure the rms roughness, slope and wavelength of turned and precision ground surfaces during machining. The operation of this device is based upon the Kirchhoff-Fresnel diffraction integral. Application of this theory to ideal turned and ground surfaces is straightforward, and indeed the calculated diffraction patterns are in close agreement with patterns produced by an actual optical instrument. Since it is mathematically difficult to introduce real machine-tool behaviour into the diffraction integral, a computer program has been devised, which simulates the operation of the optical sensor. The program produces a diffraction pattern as a graphical output. Comparison between computer generated and actual diffraction patterns of the same surfaces show a high correlation. The main aim of this program is to construct an atlas, which maps known machine-tool errors versus optical diffraction patterns. This atlas can then be used for machine-tool condition diagnostics. It has been found that optical monitoring is very sensitive to minor defects. Therefore machine-tool detoriation can be detected before it is detrimental.

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.

Research Results Of Stress-Strain State Of Cutting Tool When Aviation Materials Turning

NASA Astrophysics Data System (ADS)

Serebrennikova, A. G.; Nikolaeva, E. P.; Savilov, A. V.; Timofeev, S. A.; Pyatykh, A. S.

2018-01-01

Titanium alloys and stainless steels are hard-to-machine of all the machining types. Cutting edge state of turning tool after machining titanium and high-strength aluminium alloys and corrosion-resistant high-alloy steel has been studied. Cutting forces and chip contact arears with the rake surface of cutter has been measured. The relationship of cutting forces and residual stresses are shown. Cutting forces and residual stresses vs value of cutting tool rake angle relation were obtained. Measurements of residual stresses were performed by x-ray diffraction.

A defect-driven diagnostic method for machine tool spindles

PubMed Central

Vogl, Gregory W.; Donmez, M. Alkan

2016-01-01

Simple vibration-based metrics are, in many cases, insufficient to diagnose machine tool spindle condition. These metrics couple defect-based motion with spindle dynamics; diagnostics should be defect-driven. A new method and spindle condition estimation device (SCED) were developed to acquire data and to separate system dynamics from defect geometry. Based on this method, a spindle condition metric relying only on defect geometry is proposed. Application of the SCED on various milling and turning spindles shows that the new approach is robust for diagnosing the machine tool spindle condition. PMID:28065985

Diamond Turning Of Infra-Red Components

NASA Astrophysics Data System (ADS)

Hodgson, B.; Lettington, A. H.; Stillwell, P. F. T. C.

1986-05-01

Single point diamond machining of infra-red optical components such as aluminium mirrors, germanium lenses and zinc sulphide domes is potentially the most cost effective method for their manufacture since components may be machined from the blanks to a high surface finish, requiring no subsequent polishing, in a few minutes. Machines for the production of flat surfaces are well established. Diamond turning lathes for curved surfaces however require a high capital investment which can be justified only for research purposes or high volume production. The present paper describes the development of a low cost production machine based on a Bryant Symons diamond turning lathe which is able to machine spherical components to the required form and finish. It employs two horizontal spindles one for the workpiece the other for the tool. The machined radius of curvature is set by the alignment of the axes and the radius of the tool motion, as in conventional generation. The diamond tool is always normal to the workpiece and does not need to be accurately profiled. There are two variants of this basic machine. For machining hemispherical domes the axes are at right angles while for lenses with positive or negative curvature these axes are adjustable. An aspherical machine is under development, based on the all mechanical spherical machine, but in which a ± 2 mm aspherecity may be imposed on the best fit sphere by moving the work spindle under numerical control.

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.

Nearly arc-length tool path generation and tool radius compensation algorithm research in FTS turning

NASA Astrophysics Data System (ADS)

Zhao, Minghui; Zhao, Xuesen; Li, Zengqiang; Sun, Tao

2014-08-01

In the non-rotational symmetrical microstrcture surfaces generation using turning method with Fast Tool Servo(FTS), non-uniform distribution of the interpolation data points will lead to long processing cycle and poor surface quality. To improve this situation, nearly arc-length tool path generation algorithm is proposed, which generates tool tip trajectory points in nearly arc-length instead of the traditional interpolation rule of equal angle and adds tool radius compensation. All the interpolation points are equidistant in radial distribution because of the constant feeding speed in X slider, the high frequency tool radius compensation components are in both X direction and Z direction, which makes X slider difficult to follow the input orders due to its large mass. Newton iterative method is used to calculate the neighboring contour tangent point coordinate value with the interpolation point X position as initial value, in this way, the new Z coordinate value is gotten, and the high frequency motion components in X direction is decomposed into Z direction. Taking a typical microstructure with 4μm PV value for test, which is mixed with two 70μm wave length sine-waves, the max profile error at the angle of fifteen is less than 0.01μm turning by a diamond tool with big radius of 80μm. The sinusoidal grid is machined on a ultra-precision lathe succesfully, the wavelength is 70.2278μm the Ra value is 22.81nm evaluated by data points generated by filtering out the first five harmonics.

Comparison of Artificial Immune System and Particle Swarm Optimization Techniques for Error Optimization of Machine Vision Based Tool Movements

NASA Astrophysics Data System (ADS)

Mahapatra, Prasant Kumar; Sethi, Spardha; Kumar, Amod

2015-10-01

In conventional tool positioning technique, sensors embedded in the motion stages provide the accurate tool position information. In this paper, a machine vision based system and image processing technique for motion measurement of lathe tool from two-dimensional sequential images captured using charge coupled device camera having a resolution of 250 microns has been described. An algorithm was developed to calculate the observed distance travelled by the tool from the captured images. As expected, error was observed in the value of the distance traversed by the tool calculated from these images. Optimization of errors due to machine vision system, calibration, environmental factors, etc. in lathe tool movement was carried out using two soft computing techniques, namely, artificial immune system (AIS) and particle swarm optimization (PSO). The results show better capability of AIS over PSO.

Computer-assisted framework for machine-learning-based delineation of GTV regions on datasets of planning CT and PET/CT images.

PubMed

Ikushima, Koujiro; Arimura, Hidetaka; Jin, Ze; Yabu-Uchi, Hidetake; Kuwazuru, Jumpei; Shioyama, Yoshiyuki; Sasaki, Tomonari; Honda, Hiroshi; Sasaki, Masayuki

2017-01-01

We have proposed a computer-assisted framework for machine-learning-based delineation of gross tumor volumes (GTVs) following an optimum contour selection (OCS) method. The key idea of the proposed framework was to feed image features around GTV contours (determined based on the knowledge of radiation oncologists) into a machine-learning classifier during the training step, after which the classifier produces the 'degree of GTV' for each voxel in the testing step. Initial GTV regions were extracted using a support vector machine (SVM) that learned the image features inside and outside each tumor region (determined by radiation oncologists). The leave-one-out-by-patient test was employed for training and testing the steps of the proposed framework. The final GTV regions were determined using the OCS method that can be used to select a global optimum object contour based on multiple active delineations with a LSM around the GTV. The efficacy of the proposed framework was evaluated in 14 lung cancer cases [solid: 6, ground-glass opacity (GGO): 4, mixed GGO: 4] using the 3D Dice similarity coefficient (DSC), which denotes the degree of region similarity between the GTVs contoured by radiation oncologists and those determined using the proposed framework. The proposed framework achieved an average DSC of 0.777 for 14 cases, whereas the OCS-based framework produced an average DSC of 0.507. The average DSCs for GGO and mixed GGO were 0.763 and 0.701, respectively, obtained by the proposed framework. The proposed framework can be employed as a tool to assist radiation oncologists in delineating various GTV regions. © The Author 2016. Published by Oxford University Press on behalf of The Japan Radiation Research Society and Japanese Society for Radiation Oncology.

Gravity Spy - Integrating LIGO detector characterization, citizen science, and machine learning

NASA Astrophysics Data System (ADS)

Zevin, Michael; Gravity Spy

2016-06-01

On September 14th 2015, the Advanced Laser Interferometer Gravitational-wave Observatory (aLIGO) made the first direct observation of gravitational waves and opened a new field of observational astronomy. However, being the most complicated and sensitve experiment ever undertaken in gravitational physics, aLIGO is susceptible to various sources of environmental and instrumental noise that hinder the search for more gravitational waves.Of particular concern are transient, non-Gaussian noise features known as glitches. Glitches can mimic true astrophysical gravitational waves, occur at a high enough frequency to be coherent between the two detectors, and generally worsen aLIGO's detection capabilities. The proper classification and charaterization of glitches is paramount in optimizing aLIGO's ability to detect gravitational waves. However, teaching computers to identify and morphologically classify these artifacts is exceedingly difficult.Human intuition has proven to be a useful tool in classifcation probelms such as this. Gravity Spy is an innovative, interdisciplinary project hosted by Zooniverse that combines aLIGO detector characterization, citizen science, machine learning, and social science. In this project, citizen scientists and computers will work together in a sybiotic relationship that leverages human pattern recognition and the ability of machine learning to process large amounts of data systematically: volunteers classify triggers from the aLIGO data steam that are constantly updated as aLIGO takes in new data, and these classifications are used to train machine learning algorithms which proceed to classify the bulk of aLIGO data and feed questionable glithces back to the users.In this talk, I will discuss the workflow and initial results of the Gravity Spy project with regard to aLIGO's future observing runs and highlight the potential of such citizen science projects in promoting nascent fields such as gravitational wave astrophysics.

Computer-aided design/computer-aided manufacturing skull base drill.

PubMed

Couldwell, William T; MacDonald, Joel D; Thomas, Charles L; Hansen, Bradley C; Lapalikar, Aniruddha; Thakkar, Bharat; Balaji, Alagar K

2017-05-01

The authors have developed a simple device for computer-aided design/computer-aided manufacturing (CAD-CAM) that uses an image-guided system to define a cutting tool path that is shared with a surgical machining system for drilling bone. Information from 2D images (obtained via CT and MRI) is transmitted to a processor that produces a 3D image. The processor generates code defining an optimized cutting tool path, which is sent to a surgical machining system that can drill the desired portion of bone. This tool has applications for bone removal in both cranial and spine neurosurgical approaches. Such applications have the potential to reduce surgical time and associated complications such as infection or blood loss. The device enables rapid removal of bone within 1 mm of vital structures. The validity of such a machining tool is exemplified in the rapid (< 3 minutes machining time) and accurate removal of bone for transtemporal (for example, translabyrinthine) approaches.

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

NASA Astrophysics Data System (ADS)

Naumann, Andreas; Ruprecht, Daniel; Wensch, Joerg

2018-01-01

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

Howitzer Ammunition System Procurement (HASP).

DTIC Science & Technology

1991-07-01

machine tools , etc.) * Most critical part of base to reassemble. IPP * Industry to plan round-specific...beyond allowed tolerances. - Conducting tolerance studies and funding machining studies at sul’on "’actors. " Facility development was controlled by the...Manufacturing Balimoy Mfg. of Venice, Inc. Action Manufacturing Co. Lanson Industries Inc. Hercules Aerospace Company CIMA Machine & Tool Co., Inc. Talley Defense Systems Tracor Aerospace Inc. BMY E49030APPBMAC

49 CFR 1242.28 - Roadway machines, small tools and supplies, and snow removal (accounts XX-19-36 to XX-19-38...

Code of Federal Regulations, 2011 CFR

2011-10-01

... 49 Transportation 9 2011-10-01 2011-10-01 false Roadway machines, small tools and supplies, and snow removal (accounts XX-19-36 to XX-19-38, inclusive). 1242.28 Section 1242.28 Transportation Other... PASSENGER SERVICE FOR RAILROADS 1 Operating Expenses-Way and Structures § 1242.28 Roadway machines, small...

Machine Tool Technology. Automatic Screw Machine Troubleshooting & Set-Up Training Outlines [and] Basic Operator's Skills Set List.

ERIC Educational Resources Information Center

Anoka-Hennepin Technical Coll., Minneapolis, MN.

This set of two training outlines and one basic skills set list are designed for a machine tool technology program developed during a project to retrain defense industry workers at risk of job loss or dislocation because of conversion of the defense industry. The first troubleshooting training outline lists the categories of problems that develop…

Translations on USSR Resources, Number 767.

DTIC Science & Technology

1978-01-19

photography and so on). The amount of data obtained as a result of additional surveys makes it possible to evaluate the intensity and configuration...machine tools , chemical products, refrigerators, as well as potatoes and products of livestock breeding. The Kazakh SSR made an enormous leap in its...of the fuel and water power resources of Georgia, Azerbaydzhan and Armenia. Petroleum, transport and electrical machine building, machine tool

Deep Learning Accurately Predicts Estrogen Receptor Status in Breast Cancer Metabolomics Data.

PubMed

Alakwaa, Fadhl M; Chaudhary, Kumardeep; Garmire, Lana X

2018-01-05

Metabolomics holds the promise as a new technology to diagnose highly heterogeneous diseases. Conventionally, metabolomics data analysis for diagnosis is done using various statistical and machine learning based classification methods. However, it remains unknown if deep neural network, a class of increasingly popular machine learning methods, is suitable to classify metabolomics data. Here we use a cohort of 271 breast cancer tissues, 204 positive estrogen receptor (ER+), and 67 negative estrogen receptor (ER-) to test the accuracies of feed-forward networks, a deep learning (DL) framework, as well as six widely used machine learning models, namely random forest (RF), support vector machines (SVM), recursive partitioning and regression trees (RPART), linear discriminant analysis (LDA), prediction analysis for microarrays (PAM), and generalized boosted models (GBM). DL framework has the highest area under the curve (AUC) of 0.93 in classifying ER+/ER- patients, compared to the other six machine learning algorithms. Furthermore, the biological interpretation of the first hidden layer reveals eight commonly enriched significant metabolomics pathways (adjusted P-value <0.05) that cannot be discovered by other machine learning methods. Among them, protein digestion and absorption and ATP-binding cassette (ABC) transporters pathways are also confirmed in integrated analysis between metabolomics and gene expression data in these samples. In summary, deep learning method shows advantages for metabolomics based breast cancer ER status classification, with both the highest prediction accuracy (AUC = 0.93) and better revelation of disease biology. We encourage the adoption of feed-forward networks based deep learning method in the metabolomics research community for classification.

Gambling with stimulus payments: feeding gaming machines with federal dollars.

PubMed

Lye, Jenny; Hirschberg, Joe

2014-09-01

In late 2008 and early 2009 the Australian Federal Government introduced a series of economic stimulus packages designed to maintain consumer spending in the early days of the Great Recession. When these packages were initiated the media suggested that the wide-spread availability of electronic gaming machines (EGMs, e.g. slot machines, poker machines, video lottery terminals) in Australia would result in stimulating the EGMs. Using state level monthly data we estimate that the stimulus packages led to an increase of 26 % in EGM revenues. This also resulted in over $60 million in additional tax revenue for State Governments. We also estimate a short-run aggregate income demand elasticity for EGMs to be approximately 2.

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.

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.

Safety issues in high speed machining

NASA Astrophysics Data System (ADS)

1994-05-01

There are several risks related to High-Speed Milling, but they have not been systematically determined or studied so far. Increased loads by high centrifugal forces may result in dramatic hazards. Flying tools or fragments from a tool with high kinetic energy may damage surrounding people, machines and devices. In the project, mechanical risks were evaluated, theoretic values for kinetic energies of rotating tools were calculated, possible damages of the flying objects were determined and terms to eliminate the risks were considered. The noise levels of the High-Speed Machining center owned by the Helsinki University of Technology (HUT) and the Technical Research Center of Finland (VTT) in practical machining situation were measured and the results were compared to those after basic preventive measures were taken.

Machinability of Stellite 6 hardfacing

NASA Astrophysics Data System (ADS)

Benghersallah, M.; Boulanouar, L.; Le Coz, G.; Devillez, A.; Dudzinski, D.

2010-06-01

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

Investigation of Machine-ability of Inconel 800 in EDM with Coated Electrode

NASA Astrophysics Data System (ADS)

Karunakaran, K.; Chandrasekaran, M.

2017-03-01

The Inconel 800 is a high temperature application alloy which is classified as a nickel based super alloy. It has wide scope in aerospace engineering, gas Turbine etc. The machine-ability studies were found limited on this material. Hence This research focuses on machine-ability studies on EDM of Inconel 800 with Silver Coated Electrolyte Copper Electrode. The purpose of coating on electrode is to reduce tool wear. The factors pulse on Time, Pulse off Time and Peck Current were considered to observe the responses of surface roughness, material removal rate, tool wear rate. Taguchi Full Factorial Design is employed for Design the experiment. Some specific findings were reported and the percentage of contribution of each parameter was furnished

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.

The Infant Feeding Genogram: a tool for exploring family infant feeding history and identifying support needs.

PubMed

Darwent, K L; McInnes, R J; Swanson, V

2016-10-19

Family culture and beliefs are passed through the generations within families and influence what constitutes appropriate infant care. This includes infant feeding decisions where a family history and support network congruent with women's infant feeding intentions has been shown to be important to women's breastfeeding experience. This is reflected in breastfeeding rates where women who were not breastfed themselves are less likely to initiate and continue with breastfeeding. Given the importance of family infant feeding history in the initiation and duration of breastfeeding, and the limited ability of some families to provide support; it is unclear why infant feeding family history and support networks are not explored during pregnancy. The Infant Feeding Genogram was adapted from a simple pictorial device that is widely used in psychotherapy and genetic counselling. This tool was developed as part of a study investigating the experience of women when they were the first to breastfeed in their family. Fourteen Scottish participants completed their Infant Feeding Genogram as part of a semi-structured interview. The tool was adapted alongside their narratives to give a visual representation of each participant's family infant feeding history. The utility of the genogram is illustrated through two contrasting case examples with very different family feeding histories. The genogram showed family structures, patterns of infant feeding over time, and supportive or conflicting relationships. In the research setting it assisted women to explore their infant feeding history, identify challenges and sources of support and build rapport with the interviewer. The infant feeding genogram is proposed as a time efficient tool that could assist health professionals and other breastfeeding workers to support women and their families and by stimulating discussion around breastfeeding, Bby identifying strengths or possible deficits in social support for each individual, the tool could inform tailored support and care interventions. The effectiveness and acceptability of the Infant Feeding Genogram requires testing in the clinical environment. However, its successful application in other clinical contexts, combined with the interest in genealogy in popular culture, mean this is likely to be an acceptable, family friendly way to develop more effective breastfeeding conversations.

Machine Learning for Characterization of Insect Vector Feeding

PubMed Central

Willett, Nora S.; Stelinski, Lukasz L.; Lapointe, Stephen L.

2016-01-01

Insects that feed by ingesting plant and animal fluids cause devastating damage to humans, livestock, and agriculture worldwide, primarily by transmitting pathogens of plants and animals. The feeding processes required for successful pathogen transmission by sucking insects can be recorded by monitoring voltage changes across an insect-food source feeding circuit. The output from such monitoring has traditionally been examined manually, a slow and onerous process. We taught a computer program to automatically classify previously described insect feeding patterns involved in transmission of the pathogen causing citrus greening disease. We also show how such analysis contributes to discovery of previously unrecognized feeding states and can be used to characterize plant resistance mechanisms. This advance greatly reduces the time and effort required to analyze insect feeding, and should facilitate developing, screening, and testing of novel intervention strategies to disrupt pathogen transmission affecting agriculture, livestock and human health. PMID:27832081

Measurement techniques for determining the static stiffness of foundations for machine tools

NASA Astrophysics Data System (ADS)

Myers, A.; Barrans, S. M.; Ford, D. G.

2005-01-01

The paper presents a novel technique for accurately measuring the static stiffness of a machine tool concrete foundation using various items of metrology equipment. The foundation was loaded in a number of different ways which simulated the erection of the machine, traversing of the axes and loading of the heaviest component. The results were compared with the stiffness tolerances specified for the foundation which were deemed necessary in order that the machine alignments could be achieved. This paper is a continuation of research previously published for a FEA of the foundation.

Triaxial Measurement Method for Analysis of Residual Stress after High Feed Milling by X-Ray Diffraction

NASA Astrophysics Data System (ADS)

Čuma, Matúš; Török, Jozef; Telišková, Monika

2016-12-01

Surface integrity is a broad term which includes various quality factors affecting the functional properties of parts. Residual stress is one of these factors. Machining generates residual stresses in the surface and subsurface layers of the structural elements. X-ray diffractometry is a non-destructive method applicable for the measurement of residual stresses in surface and subsurface layers of components. The article is focused on the non-destructive progressive method of triaxial measurement of residual stress after machining the surface of sample by high feed milling technology. Significance of triaxial measuring is the capability of measuring in different angles so it is possible to acquire stress tensor containing normal and shear stress components acting in the spot of measuring, using a Cartesian coordinate system.

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.

minimega

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

David Fritz, John Floren

2013-08-27

Minimega is a simple emulytics platform for creating testbeds of networked devices. The platform consists of easily deployable tools to facilitate bringing up large networks of virtual machines including Windows, Linux, and Android. Minimega attempts to allow experiments to be brought up quickly with nearly no configuration. Minimega also includes tools for simple cluster management, as well as tools for creating Linux based virtual machine images.

Web-Based Machine Translation as a Tool for Promoting Electronic Literacy and Language Awareness

ERIC Educational Resources Information Center

Williams, Lawrence

2006-01-01

This article addresses a pervasive problem of concern to teachers of many foreign languages: the use of Web-Based Machine Translation (WBMT) by students who do not understand the complexities of this relatively new tool. Although networked technologies have greatly increased access to many language and communication tools, WBMT is still…

Ultra precision machining

NASA Astrophysics Data System (ADS)

Debra, Daniel B.; Hesselink, Lambertus; Binford, Thomas

1990-05-01

There are a number of fields that require or can use to advantage very high precision in machining. For example, further development of high energy lasers and x ray astronomy depend critically on the manufacture of light weight reflecting metal optical components. To fabricate these optical components with machine tools they will be made of metal with mirror quality surface finish. By mirror quality surface finish, it is meant that the dimensions tolerances on the order of 0.02 microns and surface roughness of 0.07. These accuracy targets fall in the category of ultra precision machining. They cannot be achieved by a simple extension of conventional machining processes and techniques. They require single crystal diamond tools, special attention to vibration isolation, special isolation of machine metrology, and on line correction of imperfection in the motion of the machine carriages on their way.

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

PubMed Central

Nguyen, Huu-Tho; Md Dawal, Siti Zawiah; Nukman, Yusoff; Aoyama, Hideki; Case, Keith

2015-01-01

Globalization of business and competitiveness in manufacturing has forced companies to improve their manufacturing facilities to respond to market requirements. Machine tool evaluation involves an essential decision using imprecise and vague information, and plays a major role to improve the productivity and flexibility in manufacturing. The aim of this study is to present an integrated approach for decision-making in machine tool selection. This paper is focused on the integration of a consistent fuzzy AHP (Analytic Hierarchy Process) and a fuzzy COmplex PRoportional ASsessment (COPRAS) for multi-attribute decision-making in selecting the most suitable machine tool. In this method, the fuzzy linguistic reference relation is integrated into AHP to handle the imprecise and vague information, and to simplify the data collection for the pair-wise comparison matrix of the AHP which determines the weights of attributes. The output of the fuzzy AHP is imported into the fuzzy COPRAS method for ranking alternatives through the closeness coefficient. Presentation of the proposed model application is provided by a numerical example based on the collection of data by questionnaire and from the literature. The results highlight the integration of the improved fuzzy AHP and the fuzzy COPRAS as a precise tool and provide effective multi-attribute decision-making for evaluating the machine tool in the uncertain environment. PMID:26368541

Cybernetic prosthesis

NASA Technical Reports Server (NTRS)

Mann, R. W.

1974-01-01

Design and development of a prosthetic device fitted to an above elbow amputee is reported that derives control information from the human to modulate power to an actuator to drive the substitute limb. In turn, the artificial limb generates sensory information feedback to the human nervous system and brain. This synergetic unity feeds efferent or motor control information from the human to the machine, and the machine responds, delivering afferent or sensory information back to the man.

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.

25. VIEW OF THE MACHINE TOOL LAYOUT IN ROOMS 244 ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

25. VIEW OF THE MACHINE TOOL LAYOUT IN ROOMS 244 AND 296. MACHINES WERE USED FOR STAINLESS STEEL FABRICATION (THE J-LINE). THE ORIGINAL DRAWING HAS BEEN ARCHIVED ON MICROFILM. THE DRAWING WAS REPRODUCED AT THE BEST QUALITY POSSIBLE. LETTERS AND NUMBERS IN THE CIRCLES INDICATE FOOTER AND/OR COLUMN LOCATIONS. - Rocky Flats Plant, General Manufacturing, Support, Records-Central Computing, Southern portion of Plant, Golden, Jefferson County, CO

Spindle Thermal Error Optimization Modeling of a Five-axis Machine Tool

NASA Astrophysics Data System (ADS)

Guo, Qianjian; Fan, Shuo; Xu, Rufeng; Cheng, Xiang; Zhao, Guoyong; Yang, Jianguo

2017-05-01

Aiming at the problem of low machining accuracy and uncontrollable thermal errors of NC machine tools, spindle thermal error measurement, modeling and compensation of a two turntable five-axis machine tool are researched. Measurement experiment of heat sources and thermal errors are carried out, and GRA(grey relational analysis) method is introduced into the selection of temperature variables used for thermal error modeling. In order to analyze the influence of different heat sources on spindle thermal errors, an ANN (artificial neural network) model is presented, and ABC(artificial bee colony) algorithm is introduced to train the link weights of ANN, a new ABC-NN(Artificial bee colony-based neural network) modeling method is proposed and used in the prediction of spindle thermal errors. In order to test the prediction performance of ABC-NN model, an experiment system is developed, the prediction results of LSR (least squares regression), ANN and ABC-NN are compared with the measurement results of spindle thermal errors. Experiment results show that the prediction accuracy of ABC-NN model is higher than LSR and ANN, and the residual error is smaller than 3 μm, the new modeling method is feasible. The proposed research provides instruction to compensate thermal errors and improve machining accuracy of NC machine tools.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Osteoporosis risk prediction using machine learning and conventional methods.

PubMed

Kim, Sung Kean; Yoo, Tae Keun; Oh, Ein; Kim, Deok Won

2013-01-01

A number of clinical decision tools for osteoporosis risk assessment have been developed to select postmenopausal women for the measurement of bone mineral density. We developed and validated machine learning models with the aim of more accurately identifying the risk of osteoporosis in postmenopausal women, and compared with the ability of a conventional clinical decision tool, osteoporosis self-assessment tool (OST). We collected medical records from Korean postmenopausal women based on the Korea National Health and Nutrition Surveys (KNHANES V-1). The training data set was used to construct models based on popular machine learning algorithms such as support vector machines (SVM), random forests (RF), artificial neural networks (ANN), and logistic regression (LR) based on various predictors associated with low bone density. The learning models were compared with OST. SVM had significantly better area under the curve (AUC) of the receiver operating characteristic (ROC) than ANN, LR, and OST. Validation on the test set showed that SVM predicted osteoporosis risk with an AUC of 0.827, accuracy of 76.7%, sensitivity of 77.8%, and specificity of 76.0%. We were the first to perform comparisons of the performance of osteoporosis prediction between the machine learning and conventional methods using population-based epidemiological data. The machine learning methods may be effective tools for identifying postmenopausal women at high risk for osteoporosis.

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.

Omega-X micromachining system

DOEpatents

Miller, Donald M.

1978-01-01

A micromachining tool system with X- and omega-axes is used to machine spherical, aspherical, and irregular surfaces with a maximum contour error of 100 nonometers (nm) and surface waviness of no more than 0.8 nm RMS. The omega axis, named for the angular measurement of the rotation of an eccentric mechanism supporting one end of a tool bar, enables the pulse increments of the tool toward the workpiece to be as little as 0 to 4.4 nm. A dedicated computer coordinates motion in the two axes to produce the workpiece contour. Inertia is reduced by reducing the mass pulsed toward the workpiece to about one-fifth of its former value. The tool system includes calibration instruments to calibrate the micromachining tool system. Backlash is reduced and flexing decreased by using a rotary table and servomotor to pulse the tool in the omega-axis instead of a ball screw mechanism. A thermally-stabilized spindle rotates the workpiece and is driven by a motor not mounted on the micromachining tool base through a torque-smoothing pulley and vibrationless rotary coupling. Abbe offset errors are almost eliminated by tool setting and calibration at spindle center height. Tool contour and workpiece contour are gaged on the machine; this enables the source of machining errors to be determined more readily, because the workpiece is gaged before its shape can be changed by removal from the machine.

Industrial machine systems risk assessment: a critical review of concepts and methods.

PubMed

Etherton, John R

2007-02-01

Reducing the risk of work-related death and injury to machine operators and maintenance personnel poses a continuing occupational safety challenge. The risk of injury from machinery in U.S. workplaces is high. Between 1992 and 2001, there were, on average, 520 fatalities per year involving machines and, on average, 3.8 cases per 10,000 workers of nonfatal caught-in-running-machine injuries involving lost workdays. A U.S. task group recently developed a technical reference guideline, ANSI B11 TR3, "A Guide to Estimate, Evaluate, & Reduce Risks Associated with Machine Tools," that is intended to bring machine tool risk assessment practice in the United States up to or above the level now required by the international standard, ISO 14121. The ANSI guideline emphasizes identifying tasks and hazards not previously considered, particularly those associated with maintenance; and it further emphasizes teamwork among line workers, engineers, and safety professionals. The value of this critical review of concepts and methods resides in (1) its linking current risk theory to machine system risk assessment and (2) its exploration of how various risk estimation tools translate into risk-informed decisions on industrial machine system design and use. The review was undertaken to set the stage for a field evaluation study on machine risk assessment among users of the ANSI B11 TR3 method.

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.

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.

Determination of real machine-tool settings and minimization of real surface deviation by computerized inspection

NASA Technical Reports Server (NTRS)

Litvin, Faydor L.; Kuan, Chihping; Zhang, YI

1991-01-01

A numerical method is developed for the minimization of deviations of real tooth surfaces from the theoretical ones. The deviations are caused by errors of manufacturing, errors of installment of machine-tool settings and distortion of surfaces by heat-treatment. The deviations are determined by coordinate measurements of gear tooth surfaces. The minimization of deviations is based on the proper correction of initially applied machine-tool settings. The contents of accomplished research project cover the following topics: (1) Descriptions of the principle of coordinate measurements of gear tooth surfaces; (2) Deviation of theoretical tooth surfaces (with examples of surfaces of hypoid gears and references for spiral bevel gears); (3) Determination of the reference point and the grid; (4) Determination of the deviations of real tooth surfaces at the points of the grid; and (5) Determination of required corrections of machine-tool settings for minimization of deviations. The procedure for minimization of deviations is based on numerical solution of an overdetermined system of n linear equations in m unknowns (m much less than n ), where n is the number of points of measurements and m is the number of parameters of applied machine-tool settings to be corrected. The developed approach is illustrated with numerical examples.

Calibrated thermal microscopy of the tool-chip interface in machining

NASA Astrophysics Data System (ADS)

Yoon, Howard W.; Davies, Matthew A.; Burns, Timothy J.; Kennedy, M. D.

2000-03-01

A critical parameter in predicting tool wear during machining and in accurate computer simulations of machining is the spatially-resolved temperature at the tool-chip interface. We describe the development and the calibration of a nearly diffraction-limited thermal-imaging microscope to measure the spatially-resolved temperatures during the machining of an AISI 1045 steel with a tungsten-carbide tool bit. The microscope has a target area of 0.5 mm X 0.5 mm square region with a < 5 micrometers spatial resolution and is based on a commercial InSb 128 X 128 focal plane array with an all reflective microscope objective. The minimum frame image acquisition time is < 1 ms. The microscope is calibrated using a standard blackbody source from the radiance temperature calibration laboratory at the National Institute of Standards and Technology, and the emissivity of the machined material is deduced from the infrared reflectivity measurements. The steady-state thermal images from the machining of 1045 steel are compared to previous determinations of tool temperatures from micro-hardness measurements and are found to be in agreement with those studies. The measured average chip temperatures are also in agreement with the temperature rise estimated from energy balance considerations. From these calculations and the agreement between the experimental and the calculated determinations of the emissivity of the 1045 steel, the standard uncertainty of the temperature measurements is estimated to be about 45 degree(s)C at 900 degree(s)C.

Sustainable cooling method for machining titanium alloy

NASA Astrophysics Data System (ADS)

Boswell, B.; Islam, M. N.

2016-02-01

Hard to machine materials such as Titanium Alloy TI-6AI-4V Grade 5 are notoriously known to generate high temperatures and adverse reactions between the workpiece and the tool tip materials. These conditions all contribute to an increase in the wear mechanisms, reducing tool life. Titanium Alloy, for example always requires coolant to be used during machining. However, traditional flood cooling needs to be replaced due to environmental issues, and an alternative cooling method found that has minimum impact on the environment. For true sustainable cooling of the tool it is necessary to account for all energy used in the cooling process, including the energy involved in producing the coolant. Previous research has established that efficient cooling of the tool interface improves the tool life and cutting action. The objective of this research is to determine the most appropriate sustainable cooling method that can also reduce the rate of wear at the tool interface.

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.

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.

Triaxial X-Ray Diffraction Method and its Application to Monitor Residual Stress in Surface Layers after High-Feed Milling

NASA Astrophysics Data System (ADS)

Zaušková, Lucia; Czán, Andrej; Šajgalík, Michal; Pobijak, Jozef; Mikloš, Matej

2017-10-01

High-feed milling is a milling method characteristic with shallow depth of cut and high feed rate to maximize the amount of removed metal from a part, generating residual stresses in the surface and subsurface layers of the machined parts. The residual stress has a large influence on the functional properties of the components. The article is focused on the application of triaxial x-ray diffraction method to monitor residual stresses after high feed milling. Significance of triaxial measuring method is the capability of measuring in different angles so it is possible to acquire stress tensor containing normal and shear stress components.

An Ultra-Precise Method for the Nano Thin-Film Removal

NASA Astrophysics Data System (ADS)

Pa, P. S.

In this research an electrode-set is used to investigate via an ultra-precise method for the removal of Indium Tin Oxide (ITO) thin-film microstructure from defective display panels to conquer the low yield rate in display panel production as to from imperfect Indium Tin Oxide layer deposition is well known. This process, which involves the removal of ITO layer substructure by means of an electrochemical removal (ECMR), is of major interest to the optoelectronics semiconductor industry. In this electro machining process a high current flow and high feed rate of the display (color filter) achieves complete and efficient removal of the ITO layer. The ITO thin-film can be removed completely by a proper combination of feed rate and electric power. A small gap between the diameter cathode virtual rotation circle and the diameter virtual rotation circle also corresponds to a higher removal rate. A small anode edge radius with a small cathode edge radius effectively improves dregs discharge and is an advantage when associated with a high workpiece feed rate. This precision method for the recycling of defective display screen color filters is presented as an effective tool for use in the screen manufacturing process. The defective Indium Tin Oxide thin-film can be removed easily and cleanly in a short time. The complete removal of the ITO layer makes it possible to put these panels back into the production line for reuse with a considerable reduction of both waste and production cost.

Gastrointestinal Spatiotemporal mRNA Expression of Ghrelin vs Growth Hormone Receptor and New Growth Yield Machine Learning Model Based on Perturbation Theory.

PubMed

Ran, Tao; Liu, Yong; Li, Hengzhi; Tang, Shaoxun; He, Zhixiong; Munteanu, Cristian R; González-Díaz, Humberto; Tan, Zhiliang; Zhou, Chuanshe

2016-07-27

The management of ruminant growth yield has economic importance. The current work presents a study of the spatiotemporal dynamic expression of Ghrelin and GHR at mRNA levels throughout the gastrointestinal tract (GIT) of kid goats under housing and grazing systems. The experiments show that the feeding system and age affected the expression of either Ghrelin or GHR with different mechanisms. Furthermore, the experimental data are used to build new Machine Learning models based on the Perturbation Theory, which can predict the effects of perturbations of Ghrelin and GHR mRNA expression on the growth yield. The models consider eight longitudinal GIT segments (rumen, abomasum, duodenum, jejunum, ileum, cecum, colon and rectum), seven time points (0, 7, 14, 28, 42, 56 and 70 d) and two feeding systems (Supplemental and Grazing feeding) as perturbations from the expected values of the growth yield. The best regression model was obtained using Random Forest, with the coefficient of determination R(2) of 0.781 for the test subset. The current results indicate that the non-linear regression model can accurately predict the growth yield and the key nodes during gastrointestinal development, which is helpful to optimize the feeding management strategies in ruminant production system.

Gastrointestinal Spatiotemporal mRNA Expression of Ghrelin vs Growth Hormone Receptor and New Growth Yield Machine Learning Model Based on Perturbation Theory

PubMed Central

Ran, Tao; Liu, Yong; Li, Hengzhi; Tang, Shaoxun; He, Zhixiong; Munteanu, Cristian R.; González-Díaz, Humberto; Tan, Zhiliang; Zhou, Chuanshe

2016-01-01

The management of ruminant growth yield has economic importance. The current work presents a study of the spatiotemporal dynamic expression of Ghrelin and GHR at mRNA levels throughout the gastrointestinal tract (GIT) of kid goats under housing and grazing systems. The experiments show that the feeding system and age affected the expression of either Ghrelin or GHR with different mechanisms. Furthermore, the experimental data are used to build new Machine Learning models based on the Perturbation Theory, which can predict the effects of perturbations of Ghrelin and GHR mRNA expression on the growth yield. The models consider eight longitudinal GIT segments (rumen, abomasum, duodenum, jejunum, ileum, cecum, colon and rectum), seven time points (0, 7, 14, 28, 42, 56 and 70 d) and two feeding systems (Supplemental and Grazing feeding) as perturbations from the expected values of the growth yield. The best regression model was obtained using Random Forest, with the coefficient of determination R2 of 0.781 for the test subset. The current results indicate that the non-linear regression model can accurately predict the growth yield and the key nodes during gastrointestinal development, which is helpful to optimize the feeding management strategies in ruminant production system. PMID:27460882

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

Curry, Bennett

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

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.

Universal Tool Grinder Operator Instructor's Guide. Part of Single-Tool Skills Program Machine Industries Occupations.

ERIC Educational Resources Information Center

New York State Education Dept., Albany. Div. of Curriculum Development.

The document is an instructor's guide for a course on universal tool grinder operation. The course is designed to train people in making complicated machine setups and precision in the grinding operations and, although intended primarily for adult learners, it can be adapted for high school use. The guide is divided into three parts: (1) the…

Material removal characteristics of orthogonal velocity polishing tool for efficient fabrication of CVD SiC mirror surfaces

NASA Astrophysics Data System (ADS)

Seo, Hyunju; Han, Jeong-Yeol; Kim, Sug-Whan; Seong, Sehyun; Yoon, Siyoung; Lee, Kyungmook; Lee, Haengbok

2015-09-01

Today, CVD SiC mirrors are readily available in the market. However, it is well known to the community that the key surface fabrication processes and, in particular, the material removal characteristics of the CVD SiC mirror surface varies sensitively depending on the shop floor polishing and figuring variables. We investigated the material removal characteristics of CVD SiC mirror surfaces using a new and patented polishing tool called orthogonal velocity tool (OVT) that employs two orthogonal velocity fields generated simultaneously during polishing and figuring machine runs. We built an in-house OVT machine and its operating principle allows for generation of pseudo Gaussian shapes of material removal from the target surface. The shapes are very similar to the tool influence functions (TIFs) of other polishing machine such as IRP series polishing machines from Zeeko. Using two CVD SiC mirrors of 150 mm in diameter and flat surface, we ran trial material removal experiments over the machine run parameter ranges from 12.901 to 25.867 psi in pressure, 0.086 m/sec to 0.147 m/sec in tool linear velocity, and 5 to 15 sec in dwell time. An in-house developed data analysis program was used to obtain a number of Gaussian shaped TIFs and the resulting material removal coefficient varies from 3.35 to 9.46 um/psi hour m/sec with the mean value to 5.90 ± 1.26(standard deviation). We report the technical details of the new OVT machine, of the data analysis program, of the experiments and the results together with the implications to the future development of the OVT machine and process for large CVD SiC mirror surfaces.

Swept Mechanism of Micro-Milling Tool Geometry Effect on Machined Oxygen Free High Conductivity Copper (OFHC) Surface Roughness

PubMed Central

Shi, Zhenyu; Liu, Zhanqiang; Li, Yuchao; Qiao, Yang

2017-01-01

Cutting tool geometry should be very much considered in micro-cutting because it has a significant effect on the topography and accuracy of the machined surface, particularly considering the uncut chip thickness is comparable to the cutting edge radius. The objective of this paper was to clarify the influence of the mechanism of the cutting tool geometry on the surface topography in the micro-milling process. Four different cutting tools including two two-fluted end milling tools with different helix angles of 15° and 30° cutting tools, as well as two three-fluted end milling tools with different helix angles of 15° and 30° were investigated by combining theoretical modeling analysis with experimental research. The tool geometry was mathematically modeled through coordinate translation and transformation to make all three cutting edges at the cutting tool tip into the same coordinate system. Swept mechanisms, minimum uncut chip thickness, and cutting tool run-out were considered on modeling surface roughness parameters (the height of surface roughness Rz and average surface roughness Ra) based on the established mathematical model. A set of cutting experiments was carried out using four different shaped cutting tools. It was found that the sweeping volume of the cutting tool increases with the decrease of both the cutting tool helix angle and the flute number. Great coarse machined surface roughness and more non-uniform surface topography are generated when the sweeping volume increases. The outcome of this research should bring about new methodologies for micro-end milling tool design and manufacturing. The machined surface roughness can be improved by appropriately selecting the tool geometrical parameters. PMID:28772479

Transformer and Meter Tester

NASA Technical Reports Server (NTRS)

Stoms, R. M.

1984-01-01

Numerically-controlled 5-axis machine tool uses transformer and meter to determine and indicate whether tool is in home position, but lacks built-in test mode to check them. Tester makes possible test, and repair of components at machine rather then replace them when operation seems suspect.

Robotic edge machining using elastic abrasive tool

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Apprentice Machine Theory Outline.

ERIC Educational Resources Information Center

Connecticut State Dept. of Education, Hartford. Div. of Vocational-Technical Schools.

This volume contains outlines for 16 courses in machine theory that are designed for machine tool apprentices. Addressed in the individual course outlines are the following topics: basic concepts; lathes; milling machines; drills, saws, and shapers; heat treatment and metallurgy; grinders; quality control; hydraulics and pneumatics;…

Energy Survey of Machine Tools: Separating Power Information of the Main Transmission System During Machining Process

NASA Astrophysics Data System (ADS)

Liu, Shuang; Liu, Fei; Hu, Shaohua; Yin, Zhenbiao

The major power information of the main transmission system in machine tools (MTSMT) during machining process includes effective output power (i.e. cutting power), input power and power loss from the mechanical transmission system, and the main motor power loss. These information are easy to obtain in the lab but difficult to evaluate in a manufacturing process. To solve this problem, a separation method is proposed here to extract the MTSMT power information during machining process. In this method, the energy flow and the mathematical models of major power information of MTSMT during the machining process are set up first. Based on the mathematical models and the basic data tables obtained from experiments, the above mentioned power information during machining process can be separated just by measuring the real time total input power of the spindle motor. The operation program of this method is also given.

Vending machine assessment methodology. A systematic review.

PubMed

Matthews, Melissa A; Horacek, Tanya M

2015-07-01

The nutritional quality of food and beverage products sold in vending machines has been implicated as a contributing factor to the development of an obesogenic food environment. How comprehensive, reliable, and valid are the current assessment tools for vending machines to support or refute these claims? A systematic review was conducted to summarize, compare, and evaluate the current methodologies and available tools for vending machine assessment. A total of 24 relevant research studies published between 1981 and 2013 met inclusion criteria for this review. The methodological variables reviewed in this study include assessment tool type, study location, machine accessibility, product availability, healthfulness criteria, portion size, price, product promotion, and quality of scientific practice. There were wide variations in the depth of the assessment methodologies and product healthfulness criteria utilized among the reviewed studies. Of the reviewed studies, 39% evaluated machine accessibility, 91% evaluated product availability, 96% established healthfulness criteria, 70% evaluated portion size, 48% evaluated price, 52% evaluated product promotion, and 22% evaluated the quality of scientific practice. Of all reviewed articles, 87% reached conclusions that provided insight into the healthfulness of vended products and/or vending environment. Product healthfulness criteria and complexity for snack and beverage products was also found to be variable between the reviewed studies. These findings make it difficult to compare results between studies. A universal, valid, and reliable vending machine assessment tool that is comprehensive yet user-friendly is recommended. Copyright © 2015 Elsevier Ltd. All rights reserved.

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.

Metric Use in the Tool Industry. A Status Report and a Test of Assessment Methodology.

DTIC Science & Technology

1982-04-20

Weights and Measures) CIM - Computer-Integrated Manufacturing CNC - Computer Numerical Control DOD - Department of Defense DODISS - DOD Index of...numerically-controlled ( CNC ) machines that have an inch-millimeter selection switch and a corresponding dual readout scale. S -4- The use of both metric...satisfactorily met the demands of both domestic and foreign customers for metric machine tools by providing either metric- capable machines or NC and CNC

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.

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.

Machinability of Al 6061 Deposited with Cold Spray Additive Manufacturing

NASA Astrophysics Data System (ADS)

Aldwell, Barry; Kelly, Elaine; Wall, Ronan; Amaldi, Andrea; O'Donnell, Garret E.; Lupoi, Rocco

2017-10-01

Additive manufacturing techniques such as cold spray are translating from research laboratories into more mainstream high-end production systems. Similar to many additive processes, finishing still depends on removal processes. This research presents the results from investigations into aspects of the machinability of aluminum 6061 tubes manufactured with cold spray. Through the analysis of cutting forces and observations on chip formation and surface morphology, the effect of cutting speed, feed rate, and heat treatment was quantified, for both cold-sprayed and bulk aluminum 6061. High-speed video of chip formation shows changes in chip form for varying material and heat treatment, which is supported by the force data and quantitative imaging of the machined surface. The results shown in this paper demonstrate that parameters involved in cold spray directly impact on machinability and therefore have implications for machining parameters and strategy.

Chip formation and surface integrity in high-speed machining of hardened steel

NASA Astrophysics Data System (ADS)

Kishawy, Hossam Eldeen A.

Increasing demands for high production rates as well as cost reduction have emphasized the potential for the industrial application of hard turning technology during the past few years. Machining instead of grinding hardened steel components reduces the machining sequence, the machining time, and the specific cutting energy. Hard turning Is characterized by the generation of high temperatures, the formation of saw toothed chips, and the high ratio of thrust to tangential cutting force components. Although a large volume of literature exists on hard turning, the change in machined surface physical properties represents a major challenge. Thus, a better understanding of the cutting mechanism in hard turning is still required. In particular, the chip formation process and the surface integrity of the machined surface are important issues which require further research. In this thesis, a mechanistic model for saw toothed chip formation is presented. This model is based on the concept of crack initiation on the free surface of the workpiece. The model presented explains the mechanism of chip formation. In addition, experimental investigation is conducted in order to study the chip morphology. The effect of process parameters, including edge preparation and tool wear on the chip morphology, is studied using Scanning Electron Microscopy (SEM). The dynamics of chip formation are also investigated. The surface integrity of the machined parts is also investigated. This investigation focusses on residual stresses as well as surface and sub-surface deformation. A three dimensional thermo-elasto-plastic finite element model is developed to predict the machining residual stresses. The effect of flank wear is introduced during the analysis. Although residual stresses have complicated origins and are introduced by many factors, in this model only the thermal and mechanical factors are considered. The finite element analysis demonstrates the significant effect of the heat generated during cutting on the residual stresses. The machined specimens are also examined using x-ray diffraction technique to clarify the effect of different speeds, feeds and depths of cut as well as different edge preparations on the residual stress distribution beneath the machined surface. A reasonable agreement between the predicted and measured residual stress is obtained. The results obtained demonstrate the possibility of eliminating the existence of high tensile residual stresses in the workpiece surface by selecting the proper cutting conditions. The machined surfaces are examined using SEM to study the effect of different process parameters and edge preparations on the quality of the machined surface. The phenomenon of material side flow is investigated to clarify the mechanism of this phenomenon. The effect of process parameters and edge preparations on sub-surface deformation is also investigated.

Dietary Adherence Monitoring Tool for Free-living, Controlled Feeding Studies

USDA-ARS?s Scientific Manuscript database

Objective: To devise a dietary adherence monitoring tool for use in controlled human feeding trials involving free-living study participants. Methods: A scoring tool was devised to measure and track dietary adherence for an 8-wk randomized trial evaluating the effects of two different dietary patter...

Optimisation of wire-cut EDM process parameter by Grey-based response surface methodology

NASA Astrophysics Data System (ADS)

Kumar, Amit; Soota, Tarun; Kumar, Jitendra

2018-03-01

Wire electric discharge machining (WEDM) is one of the advanced machining processes. Response surface methodology coupled with Grey relation analysis method has been proposed and used to optimise the machining parameters of WEDM. A face centred cubic design is used for conducting experiments on high speed steel (HSS) M2 grade workpiece material. The regression model of significant factors such as pulse-on time, pulse-off time, peak current, and wire feed is considered for optimising the responses variables material removal rate (MRR), surface roughness and Kerf width. The optimal condition of the machining parameter was obtained using the Grey relation grade. ANOVA is applied to determine significance of the input parameters for optimising the Grey relation grade.

Positional reference system for ultraprecision machining

DOEpatents

Arnold, Jones B.; Burleson, Robert R.; Pardue, Robert M.

1982-01-01

A stable positional reference system for use in improving the cutting tool-to-part contour position in numerical controlled-multiaxis metal turning machines is provided. The reference system employs a plurality of interferometers referenced to orthogonally disposed metering bars which are substantially isolated from machine strain induced position errors for monitoring the part and tool positions relative to the metering bars. A microprocessor-based control system is employed in conjunction with the plurality of position interferometers and part contour description data inputs to calculate error components for each axis of movement and output them to corresponding axis drives with appropriate scaling and error compensation. Real-time position control, operating in combination with the reference system, makes possible the positioning of the cutting points of a tool along a part locus with a substantially greater degree of accuracy than has been attained previously in the art by referencing and then monitoring only the tool motion relative to a reference position located on the machine base.

Positional reference system for ultraprecision machining

DOEpatents

Arnold, J.B.; Burleson, R.R.; Pardue, R.M.

1980-09-12

A stable positional reference system for use in improving the cutting tool-to-part contour position in numerical controlled-multiaxis metal turning machines is provided. The reference system employs a plurality of interferometers referenced to orthogonally disposed metering bars which are substantially isolated from machine strain induced position errors for monitoring the part and tool positions relative to the metering bars. A microprocessor-based control system is employed in conjunction with the plurality of positions interferometers and part contour description data input to calculate error components for each axis of movement and output them to corresponding axis driven with appropriate scaling and error compensation. Real-time position control, operating in combination with the reference system, makes possible the positioning of the cutting points of a tool along a part locus with a substantially greater degree of accuracy than has been attained previously in the art by referencing and then monitoring only the tool motion relative to a reference position located on the machine base.

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.

4. Credit JPL. Original 4" x 5" black and white ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

4. Credit JPL. Original 4" x 5" black and white negative housed in the JPL Archives, Pasadena, California. This interior view displays the machine shop in the Administration/Shops Building (the compass angle of the view is undetermined). Looking clockwise from the lower left, the machine tools in view are a power hacksaw, a heat-treatment oven (with white gloves on top), a large hydraulic press with a tool grinder at its immediate right; along the wall in the back of the view are various unidentified machine tool attachments and a vertical milling machine. In the background, a machinist is operating a radial drilling machine, to the right of which is a small drill press. To the lower right, another machinist is operating a Pratt & Whitney engine lathe; behind the operator stand a workbench and vertical bandsaw (JPL negative no. 384-10939, 29 July 1975). - Jet Propulsion Laboratory Edwards Facility, Administration & Shops Building, Edwards Air Force Base, Boron, Kern County, CA

Modelling of teeth of a gear transmission for modern manufacturing technologies

NASA Astrophysics Data System (ADS)

Monica, Z.; Banaś, W.; Ćwikla, G.; Topolska, S.

2017-08-01

The technological process of manufacturing of gear wheels is influenced by many factors. It is designated depending on the type of material from which the gear is to be produced, its heat treatment parameters, the required accuracy, the geometrical form and the modifications of the tooth. Therefor the parameters selection process is not easy and moreover it is unambiguous. Another important stage of the technological process is the selection of appropriate tools to properly machine teeth in the operations of both roughing and finishing. In the presented work the focus is put first of all on modern production methods of gears using technologically advanced instruments in comparison with conventional tools. Conventional processing tools such as gear hobbing cutters or Fellows gear-shaper cutters are used from the beginning of the machines for the production of gear wheels. With the development of technology and the creation of CNC machines designated for machining of gears wheel it was also developed the manufacturing technology as well as the design knowledge concerning the technological tools. Leading manufacturers of cutting tools extended the range of tools designated for machining of gears on the so-called hobbing cutters with inserted cemented carbide tips. The same have be introduced to Fellows gear-shaper cutters. The results of tests show that is advantaged to use hobbing cutters with inserted cemented carbide tips for milling gear wheels with a high number of teeth, where the time gains are very high, in relation to the use of conventional milling cutters.

Feed rate measuring method and system

DOEpatents

Novak, J.L.; Wiczer, J.J.

1995-12-05

A system and method are provided for establishing the feed rate of a workpiece along a feed path with respect to a machine device. First and second sensors each having first and second sensing electrodes which are electrically isolated from the workpiece are positioned above, and in proximity to the desired surfaces of the workpiece along a feed path. An electric field is developed between the first and second sensing electrodes of each sensor and capacitance signals are developed which are indicative of the contour of the workpiece. First and second image signals representative of the contour of the workpiece along the feed path are developed by an image processor. The time delay between corresponding portions of the first and second image signals are then used to determine the feed rate based upon the separation of the first and second sensors and the amount of time between corresponding portions of the first and second image signals. 18 figs.

Feed rate measuring method and system

DOEpatents

Novak, James L.; Wiczer, James J.

1995-01-01

A system and method are provided for establishing the feed rate of a workpiece along a feed path with respect to a machine device. First and second sensors each having first and second sensing electrodes which are electrically isolated from the workpiece are positioned above, and in proximity to the desired surfaces of the workpiece along a feed path. An electric field is developed between the first and second sensing electrodes of each sensor and capacitance signals are developed which are indicative of the contour of the workpiece. First and second image signals representative of the contour of the workpiece along the feed path are developed by an image processor. The time delay between corresponding portions of the first and second image signals are then used to determine the feed rate based upon the separation of the first and second sensors and the amount of time between corresponding portions of the first and second image signals.

Improvement of automatic fish feeder machine design

NASA Astrophysics Data System (ADS)

Chui Wei, How; Salleh, S. M.; Ezree, Abdullah Mohd; Zaman, I.; Hatta, M. H.; Zain, B. A. Md; Mahzan, S.; Rahman, M. N. A.; Mahmud, W. A. W.

2017-10-01

Nation Plan of action for management of fishing is target to achieve an efficient, equitable and transparent management of fishing capacity in marine capture fisheries by 2018. However, several factors influence the fishery production and efficiency of marine system such as automatic fish feeder machine could be taken in consideration. Two latest fish feeder machines have been chosen as the reference for this study. Based on the observation, it has found that the both machine was made with heavy structure, low water and temperature resistance materials. This research’s objective is to develop the automatic feeder machine to increase the efficiency of fish feeding. The experiment has conducted to testing the new design of machine. The new machine with maximum storage of 5 kg and functioning with two DC motors. This machine able to distribute 500 grams of pellets within 90 seconds and longest distance of 4.7 meter. The higher speed could reduce time needed and increase the distance as well. The minimum speed range for both motor is 110 and 120 with same full speed range of 255.

Technical Report on Occupations in Numerically Controlled Metal-Cutting Machining.

ERIC Educational Resources Information Center

Manpower Administration (DOL), Washington, DC. U.S. Employment Service.

At the present time, only 5 percent of the short-run metal-cutting machining in the United States is done by numerically controlled machined tools, but within the next decade it is expected to increase by 50 percent. Numerically controlled machines use taped data which is changed into instructions and directs the machine to do certain steps…

Sine-Bar Attachment For Machine Tools

NASA Technical Reports Server (NTRS)

Mann, Franklin D.

1988-01-01

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

Analysis and classification of the tools for assessing the risks associated with industrial machines.

PubMed

Paques, Joseph-Jean; Gauthier, François; Perez, Alejandro

2007-01-01

To assess and plan future risk-analysis research projects, 275 documents describing methods and tools for assessing the risks associated with industrial machines or with other sectors such as the military, and the nuclear and aeronautics industries, etc., were collected. These documents were in the format of published books or papers, standards, technical guides and company procedures collected throughout industry. From the collected documents, 112 documents were selected for analysis; 108 methods applied or potentially applicable for assessing the risks associated with industrial machines were analyzed and classified. This paper presents the main quantitative results of the analysis of the methods and tools.

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.

Investigation of approximate models of experimental temperature characteristics of machines

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

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.

Multisensor systems today and tomorrow: Machine control, diagnosis and thermal compensation

NASA Astrophysics Data System (ADS)

Nunzio, D'Addea

2000-05-01

Multisensor techniques that deal with control of tribology test rig and with diagnosis and thermal error compensation of machine tools are the starting point for some consideration about the use of these techniques as in fuzzy and neural net systems. The author comes to conclusion that anticipatory systems and multisensor techniques will have in the next future a great improvement and a great development mainly in the thermal error compensation of machine tools.

The Python Spectral Analysis Tool (PySAT) for Powerful, Flexible, and Easy Preprocessing and Machine Learning with Point Spectral Data

NASA Astrophysics Data System (ADS)

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

2018-04-01

The PySAT point spectra tool provides a flexible graphical interface, enabling scientists to apply a wide variety of preprocessing and machine learning methods to point spectral data, with an emphasis on multivariate regression.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Machining of Fibre Reinforced Plastic Composite Materials.

PubMed

Caggiano, Alessandra

2018-03-18

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

Machining of Fibre Reinforced Plastic Composite Materials

PubMed Central

2018-01-01

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

Combined Grinding and Drying of Biomass in One Operation Phase I

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

Sokhansanj, S

2008-06-26

First American Scientific Corporation (FASC) has developed a unique and innovative grinder/dryer called KDS Micronex. The KS (Kinetic Disintegration System) combines two operations of grinding and drying into a single operation which reduces dependence on external heat input. The machine captures the heat of comminution and combines it will centrifugal forces to expedite moisture extraction from wet biomass. Because it uses mechanical forces rather than providing direct heat to perform the drying operation, it is a simpler machine and uses less energy than conventional grinding and drying operations which occur as two separate steps. The entire compact unit can bemore » transported on a flatbed trailer to the site where biomass is available. Hence, the KDS Micronex is a technology that enables inexpensive pretreatment of waste materials and biomass. A well prepared biomass can be used as feed, fuel or fertilizer instead of being discarded. Electricity and chemical feedstock produced from such biomass would displace the use of fossil fuels and no net greenhouse gas emissions would result from such bio-based operations. Organic fertilizers resulting from the KS Micronex grinding/drying process will be pathogen-free unlike raw animal manures. The feasibility tests on KS during Phase I showed that a prototype machine can be developed, field tested and the technology demonstrated for commercial applications. The present KDS machine can remove up to 400 kg/h of water from a wet feed material. Since biomass processors demand a finished product that is only 10% moist and most raw materials like corn stover, bagasse, layer manure, cow dung, and waste wood have moisture contents of the order of 50%, this water removal rate translates to a production rate of roughly half a ton per hour. this is too small for most processors who are unwilling to acquire multiple machines because of the added complexity to the feed and product removal systems. The economics suffer due to small production rates, because the labor costs are a much larger fraction of the production cost. The goal for further research and development work is to scale up the KDS technology incorporating findings from Phase I into a machine that has superior performance characteristics.« less

Detecting weak position fluctuations from encoder signal using singular spectrum analysis.

PubMed

Xu, Xiaoqiang; Zhao, Ming; Lin, Jing

2017-11-01

Mechanical fault or defect will cause some weak fluctuations to the position signal. Detection of such fluctuations via encoders can help determine the health condition and performance of the machine, and offer a promising alternative to the vibration-based monitoring scheme. However, besides the interested fluctuations, encoder signal also contains a large trend and some measurement noise. In applications, the trend is normally several orders larger than the concerned fluctuations in magnitude, which makes it difficult to detect the weak fluctuations without signal distortion. In addition, the fluctuations can be complicated and amplitude modulated under non-stationary working condition. To overcome this issue, singular spectrum analysis (SSA) is proposed for detecting weak position fluctuations from encoder signal in this paper. It enables complicated encode signal to be reduced into several interpretable components including a trend, a set of periodic fluctuations and noise. A numerical simulation is given to demonstrate the performance of the method, it shows that SSA outperforms empirical mode decomposition (EMD) in terms of capability and accuracy. Moreover, linear encoder signals from a CNC machine tool are analyzed to determine the magnitudes and sources of fluctuations during feed motion. The proposed method is proven to be feasible and reliable for machinery condition monitoring. Copyright © 2017 ISA. Published by Elsevier Ltd. All rights reserved.

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.