Method for producing ultrafine-grained materials using repetitive corrugation and straightening

DOEpatents

Zhu, Yuntian T.; Lowe, Terry C.; Jiang, Honggang; Huang, Jianyu

2001-01-01

A method of refining the grain structure and improving the hardness and strength properties of a metal or metal alloy workpiece is disclosed. The workpiece is subjected to forces that corrugate and then straighten the workpiece. These steps are repeated until an ultrafine-grained product having improved hardness and strength is produced.

Figure and caption for LDRD annual report

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

Suratwala, T.

2017-10-16

Material removal rate of various optical material workpieces polished using various colloidal slurries as a function of partial charge difference. Partial charge difference is a parameter calculated from a new chemical model proposed to link the condensation reaction rate with polishing material removal rate. This chemical model can serve as a global platform to predict & design polishing processes for a wide variety of workpiece materials and slurry compositions.

Importance of polarity change in the electrical discharge machining

NASA Astrophysics Data System (ADS)

Schulze, H.-P.

2017-10-01

The polarity change in the electrical discharge machining is still a problem and is often performed completely unmotivated or randomly. The polarity must be designated primarily, i.e. the anodic part must be clearly assigned to the tool or the workpiece. Normally, the polarity of the workpiece electrode is named. In paper, will be shown which determine fundamental causes the structural behavior of the cathode and anode, and when it makes sense to change the polarity. The polarity change is primarily dependent on the materials that are used as cathode and anode. This distinction must be made if there are pure metals or complex materials. Secondary of the polarity change is also affected by the process energy source (PES) and the supply line. The polarity change is mostly influenced by the fact that the removal is to be maximized on the workpiece while the tool is minimal removal (wear) occur. A second factor that makes a polarity change needed is the use of electrical discharge in combination with other machining methods, such as electrochemical machining (ECM).

Research on the Stress and Material Flow with Single Particle—Simulations and Experiments

NASA Astrophysics Data System (ADS)

Zhang, Tao; Jiang, Feng; Yan, Lan; Xu, Xipeng

2017-04-01

The scratching process of particle is a complex material removal process involving cutting, plowing, and rubbing. In this study, scratch experiments under different loads are performed on a multifunctional tester for material surface. Natural diamond and Fe-Cr-Ni stainless steel are chosen as indenter and workpiece material, respectively. The cutting depth and side flow height of scratch are measured using a white light interferometer. The finite element model is developed, and the numerical simulation of scratching is conducted using AdvantEdgeTM. The simulated forces and side flow height under different cutting depths correspond well with experimental results, validating the accuracy of the scratching simulation. The mises stress distribution of the particle is presented, with the maximum stress occurring inside the particle rather than on the surface. The pressure distribution of the particle is also given, and results show that the maximum pressure occurs on the contact surface of particle and workpiece. The material flow contour is presented, and material flow direction and velocity magnitude are analyzed.

Tribological investigations of the applicability of surface functionalization for dry extrusion processes

NASA Astrophysics Data System (ADS)

Teller, Marco; Prünte, Stephan; Ross, Ingo; Temmler, André; Schneider, Jochen M.; Hirt, Gerhard

2017-10-01

Cold extrusion processes are characterized by large relative contact stresses combined with a severe surface enlargement of the workpiece. Under these process conditions a high risk for galling of workpiece material to the tool steel occurs especially in processing of aluminum and aluminum alloys. In order to reduce adhesive wear lubricants for separation of workpiece and tool surfaces are used. As a consequence additional process steps (e.g. preparation and cleaning of workpieces) are necessary. Thus, the realization of a dry forming process is aspired from an environmental and economic perspective. In this paper a surface functionalization with self-assembled-monolayers (SAM) of the tool steels AISI D2 (DIN 1.2379) and AISI H11 (DIN 1.2343) is evaluated by a process-oriented tribological test. The tribological experiment is able to resemble and scale the process conditions of cold extrusion related to relative contact stress and surface enlargement for the forming of pure aluminum (Al99.5). The effect of reduced relative contact stress, surface enlargement and relative velocity on adhesive wear and tool lifetime is evaluated. Similar process conditions are achievable by different die designs with decreased extrusion ratios and adjusted die angles. The effect of surface functionalization critically depends on the substrate material. The different microstructure and the resulting differences in surface chemistry of the two tested tool steels appear to affect the performance of the tool surface functionalization with SAM.

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.

Effect of Electrical Discharge Machining on Stress Concentration in Titanium Alloy Holes

PubMed Central

Hsu, Wei-Hsuan; Chien, Wan-Ting

2016-01-01

Titanium alloys have several advantages, such as a high strength-to-weight ratio. However, the machinability of titanium alloys is not as good as its mechanical properties. Many machining processes have been used to fabricate titanium alloys. Among these machining processes, electrical discharge machining (EDM) has the advantage of processing efficiency. EDM is based on thermoelectric energy between a workpiece and an electrode. A pulse discharge occurs in a small gap between the workpiece and electrode. Then, the material from the workpiece is removed through melting and vaporization. However, defects such as cracks and notches are often detected at the boundary of holes fabricated using EDM and the irregular profile of EDM holes reduces product quality. In this study, an innovative method was proposed to estimate the effect of EDM parameters on the surface quality of the holes. The method combining the finite element method and image processing can rapidly evaluate the stress concentration factor of a workpiece. The stress concentration factor was assumed as an index of EDM process performance for estimating the surface quality of EDM holes. In EDM manufacturing processes, Ti-6Al-4V was used as an experimental material and, as process parameters, pulse current and pulse on-time were taken into account. The results showed that finite element simulations can effectively analyze stress concentration in EDM holes. Using high energy during EDM leads to poor hole quality, and the stress concentration factor of a workpiece is correlated to hole quality. The maximum stress concentration factor for an EDM hole was more than four times that for the same diameter of the undamaged hole. PMID:28774078

Simulation of Magnetic Field Assisted Finishing (MFAF) Process Utilizing Smart MR Polishing Tool

NASA Astrophysics Data System (ADS)

Barman, Anwesa; Das, Manas

2017-02-01

Magnetic field assisted finishing process is an advanced finishing process. This process is capable of producing nanometer level surface finish. In this process magnetic field is applied to control the finishing forces using magnetorheological polishing medium. In the current study, permanent magnet is used to provide the required magnetic field in the finishing zone. The working gap between the workpiece and the magnet is filled with MR fluid which is used as the polishing brush to remove surface undulations from the top surface of the workpiece. In this paper, the distribution of magnetic flux density on the workpiece surface and behaviour of MR polishing medium during finishing are analyzed using commercial finite element packages (Ansys Maxwell® and Comsol®). The role of magnetic force in the indentation of abrasive particles on the workpiece surface is studied. A two-dimensional simulation study of the steady, laminar, and incompressible MR fluid flow behaviour during finishing process is carried out. The material removal and surface roughness modelling of the finishing process are also presented. The indentation force by a single active abrasive particle on the workpiece surface is modelled during simulation. The velocity profile of MR fluid with and without application of magnetic field is plotted. It shows non-Newtonian property without application of magnetic field. After that the total material displacement due to one abrasive particle is plotted. The simulated roughness profile is in a good agreement with the experimental results. The conducted study will help in understanding the fluid behavior and the mechanism of finishing during finishing process. Also, the modelling and simulation of the process will help in achieving better finishing performance.

Effect of Electrical Discharge Machining on Stress Concentration in Titanium Alloy Holes.

PubMed

Hsu, Wei-Hsuan; Chien, Wan-Ting

2016-11-24

Titanium alloys have several advantages, such as a high strength-to-weight ratio. However, the machinability of titanium alloys is not as good as its mechanical properties. Many machining processes have been used to fabricate titanium alloys. Among these machining processes, electrical discharge machining (EDM) has the advantage of processing efficiency. EDM is based on thermoelectric energy between a workpiece and an electrode. A pulse discharge occurs in a small gap between the workpiece and electrode. Then, the material from the workpiece is removed through melting and vaporization. However, defects such as cracks and notches are often detected at the boundary of holes fabricated using EDM and the irregular profile of EDM holes reduces product quality. In this study, an innovative method was proposed to estimate the effect of EDM parameters on the surface quality of the holes. The method combining the finite element method and image processing can rapidly evaluate the stress concentration factor of a workpiece. The stress concentration factor was assumed as an index of EDM process performance for estimating the surface quality of EDM holes. In EDM manufacturing processes, Ti-6Al-4V was used as an experimental material and, as process parameters, pulse current and pulse on-time were taken into account. The results showed that finite element simulations can effectively analyze stress concentration in EDM holes. Using high energy during EDM leads to poor hole quality, and the stress concentration factor of a workpiece is correlated to hole quality. The maximum stress concentration factor for an EDM hole was more than four times that for the same diameter of the undamaged hole.

Computer Controlled Optical Surfacing With Orbital Tool Motion

NASA Astrophysics Data System (ADS)

Jones, Robert A.

1985-10-01

Asymmetric aspheric optical surfaces are very difficult to fabricate using classical techniques and laps the same size as the workpiece. Opticians can produce such surfaces by grinding and polishing, using small laps with orbital tool motion. However, hand correction is a time consuming process unsuitable for large optical elements. Itek has developed Computer Controlled Optical Surfacing (CCOS) for fabricating such aspheric optics. Automated equipment moves a nonrotating orbiting tool slowly over the workpiece surface. The process corrects low frequency surface errors by figuring. The velocity of the tool assembly over the workpiece surface is purposely varied. Since the amount of material removal is proportional to the polishing or grinding time, accurate control over material removal is achieved. The removal of middle and high frequency surface errors is accomplished by pad smoothing. For a soft pad material, the pad will compress to fit the workpiece surface producing greater pressure and more removal at the surface high areas. A harder pad will ride on only the high regions resulting in removal only for those locations.

Cavity formation and surface modeling of laser milling process under a thin-flowing water layer

NASA Astrophysics Data System (ADS)

Tangwarodomnukun, Viboon

2016-11-01

Laser milling process normally involves a number of laser scans over a workpiece to selectively remove the material and then to form cavities with shape and dimensions required. However, this process adversely causes a heat accumulation in work material, which can in turn damage the laser-milled area and vicinity in terms of recast deposition and change of material properties. Laser milling process performing in a thin-flowing water layer is a promising method that can overcome such damage. With the use of this technique, water can flush away the cut debris and at the same time cool the workpiece during the ablation. To understand the potential of this technique for milling application, the effects of process parameters on cavity dimensions and surface roughness were experimentally examined in this study. Titanium sheet was used as a workpiece to be milled by a nanosecond pulse laser under different water flow velocities. A smooth and uniform cut feature can be obtained when the metal was ablated under the high laser pulse frequency and high water flow velocity. Furthermore, a surface model based on the energy balance was developed in this study to predict the cavity profile and surface roughness. By comparing to the experiments, the predicted profiles had a good agreement with the measured ones.

Hydroforming device and method

DOEpatents

Guza, David E.

2007-09-11

An apparatus (10, 110) and method to form a workpiece (32, 132) into a useful product (28, 128) using a pressurized fluid (14), also termed as "hydroforming". The workpiece may be a tube or may be one or a plurality of sheets of a material. The apparatus has a chamber (12) adapted to contain a quantity of a fluid, a hydroforming means positioned within the chamber, and means for substantially immersing the workpiece in the fluid before, during and after the hydroforming operation. Dies (16, 18) enclose the workpiece and provide a cavity of desired shape against which the workpiece is expanded by the pressurized fluid. The chamber may be open or closed to the atmosphere during operation and the fluid temperature and/or level may be controlled.

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.

The improvement of laser induced damage resistance of optical workpiece surface by hydrodynamic effect polishing

NASA Astrophysics Data System (ADS)

Peng, Wenqiang; Guan, Chaoliang; Li, Shengyi; Wang, Zhuo

2016-10-01

Surface and subsurface damage in optical element will greatly decrease the laser induced damage threshold (LIDT) in the intense laser optical system. Processing damage on the workpiece surface can be inevitably caused when the material is removed in brittle or plastic mode. As a non-contact polishing technology, hydrodynamic effect polishing (HEP) shows very good performance on generating an ultra-smooth surface without damage. The material is removed by chemisorption between nanoparticle and workpiece surface in the elastic mode in HEP. The subsurface damage and surface scratches can be effectively removed after the polishing process. Meanwhile ultra-smooth surface with atomic level surface roughness can be achieved. To investigate the improvement of LIDT of optical workpiece, polishing experiment was conducted on a magnetorheological finishing (MRF) silica glass sample. AFM measurement results show that all the MRF directional plastic marks have been removed clearly and the root-mean-square (rms) surface roughness has decreased from 0.673nm to 0.177nm after HEP process. Laser induced damage experiment was conducted with laser pulse of 1064nm wavelength and 10ns time width. Compared with the original state, the LEDT of the silica glass sample polished by HEP has increased from 29.78J/cm2 to 45.47J/cm2. It demonstrates that LIDT of optical element treated by HEP can be greatly improved for ultra low surface roughness and nearly defect-free surface/subsurface.

Acoustic sensor for real-time control for the inductive heating process

DOEpatents

Kelley, John Bruce; Lu, Wei-Yang; Zutavern, Fred J.

2003-09-30

Disclosed is a system and method for providing closed-loop control of the heating of a workpiece by an induction heating machine, including generating an acoustic wave in the workpiece with a pulsed laser; optically measuring displacements of the surface of the workpiece in response to the acoustic wave; calculating a sub-surface material property by analyzing the measured surface displacements; creating an error signal by comparing an attribute of the calculated sub-surface material properties with a desired attribute; and reducing the error signal below an acceptable limit by adjusting, in real-time, as often as necessary, the operation of the inductive heating machine.

Elucidating Grinding Mechanism by Theoretical and Experimental Investigations

PubMed Central

Kubo, Akihiko; Chowdhury, M. A. K.

2018-01-01

Grinding is one of the essential manufacturing processes for producing brittle or hard materials-based precision parts (e.g., optical lenses). In grinding, a grinding wheel removes the desired amount of material by passing the same area on the workpiece surface multiple times. How the topography of a workpiece surface evolves with these passes is thus an important research issue, which has not yet been addressed elaborately. The present paper tackles this issue from both the theoretical and the experimental points of view. In particular, this paper presents the results of experimental and theoretical investigations on the multi-pass surface grinding operations where the workpiece surface is made of glass and the grinding wheel consists of cBN abrasive grains. Both investigations confirm that a great deal of stochasticity is involved in the grinding mechanism, and the complexity of the workpiece surface gradually increases along with the number of passes. PMID:29425160

Elucidating Grinding Mechanism by Theoretical and Experimental Investigations.

PubMed

Ullah, Amm Sharif; Caggiano, Alessandra; Kubo, Akihiko; Chowdhury, M A K

2018-02-09

Grinding is one of the essential manufacturing processes for producing brittle or hard materials-based precision parts (e.g., optical lenses). In grinding, a grinding wheel removes the desired amount of material by passing the same area on the workpiece surface multiple times. How the topography of a workpiece surface evolves with these passes is thus an important research issue, which has not yet been addressed elaborately. The present paper tackles this issue from both the theoretical and the experimental points of view. In particular, this paper presents the results of experimental and theoretical investigations on the multi-pass surface grinding operations where the workpiece surface is made of glass and the grinding wheel consists of cBN abrasive grains. Both investigations confirm that a great deal of stochasticity is involved in the grinding mechanism, and the complexity of the workpiece surface gradually increases along with the number of passes.

Mathematical Modeling of Thermofrictional Milling Process Using ANSYS WB Software

NASA Astrophysics Data System (ADS)

Sherov, K. T.; Sikhimbayev, M. R.; Sherov, A. K.; Donenbayev, B. S.; Rakishev, A. K.; Mazdubai, A. B.; Musayev, M. M.; Abeuova, A. M.

2017-06-01

This article presents ANSYS WB-based mathematical modelling of the thermofrictional milling process, which allowed studying the dynamics of thermal and physical processes occurring during the processing. The technique used also allows determination of the optimal cutting conditions of thermofrictional milling for processing various materials, in particular steel 40CN2MA, 30CGSA, 45, 3sp. In our study, from among a number of existing models of cutting fracture, we chose the criterion first proposed by prof. V. L. Kolmogorov. In order to increase the calculations performance, a mathematical model was proposed, that used only two objects: a parallelepiped-shaped workpiece and a cutting insert in the form of a pentagonal prism. In addition, the work takes into account the friction coefficient between a cutting insert and a workpiece taken equal to 0.4 mm. To determine the temperature in the subcontact layer of the workpiece, we introduced the coordinates of nine characteristic points with the same interval in the local coordinate system. As a result, the temperature values were obtained for different materials at the studied points during the cutter speed change. The research results showed the possibility of controlling thermal processes during processing by choosing the optimum cutting modes.

Method for maintaining a cutting blade centered in a kerf

DOEpatents

Blaedel, Kenneth L.; Davis, Pete J.; Landram, Charles S.

2002-01-01

A saw having a self-pumped hydrodynamic blade guide or bearing for retaining the saw blade in a centered position in the saw kerf (width of cut made by the saw). The hydrodynamic blade guide or bearing utilizes pockets or grooves incorporated into the sides of the blade. The saw kerf in the workpiece provides the guide or bearing stator surface. Both sides of the blade entrain cutting fluid as the blade enters the kerf in the workpiece, and the trapped fluid provides pressure between the blade and the workpiece as an inverse function of the gap between the blade surface and the workpiece surface. If the blade wanders from the center of the kerf, then one gap will increase and one gap will decrease and the consequent pressure difference between the two sides of the blade will cause the blade to re-center itself in the kerf. Saws using the hydrodynamic blade guide or bearing have particular application in slicing slabs from boules of single crystal materials, for example, as well as for cutting other difficult to saw materials such as ceramics, glass, and brittle composite materials.

Hydrodynamic blade guide

DOEpatents

Blaedel, Kenneth L.; Davis, Pete J.; Landram, Charles S.

2000-01-01

A saw having a self-pumped hydrodynamic blade guide or bearing for retaining the saw blade in a centered position in the saw kerf (width of cut made by the saw). The hydrodynamic blade guide or bearing utilizes pockets or grooves incorporated into the sides of the blade. The saw kerf in the workpiece provides the guide or bearing stator surface. Both sides of the blade entrain cutting fluid as the blade enters the kerf in the workpiece, and the trapped fluid provides pressure between the blade and the workpiece as an inverse function of the gap between the blade surface and the workpiece surface. If the blade wanders from the center of the kerf, then one gap will increase and one gap will decrease and the consequent pressure difference between the two sides of the blade will cause the blade to re-center itself in the kerf. Saws using the hydrodynamic blade guide or bearing have particular application in slicing slabs from boules of single crystal materials, for example, as well as for cutting other difficult to saw materials such as ceramics, glass, and brittle composite materials.

Comparison of subsurface damages on mono-crystalline silicon between traditional nanoscale machining and laser-assisted nanoscale machining via molecular dynamics simulation

NASA Astrophysics Data System (ADS)

Dai, Houfu; Li, Shaobo; Chen, Genyu

2018-01-01

Molecular dynamics is employed to compare nanoscale traditional machining (TM) with laser-assisted machining (LAM). LAM is that the workpiece is locally heated by an intense laser beam prior to material removal. We have a comprehensive comparison between LAM and TM in terms of atomic trajectories, phase transformation, radial distribution function, chips, temperature distribution, number of atoms in different temperature, grinding temperature, grinding force, friction coefficient and atomic potential energy. It can be found that there is a decrease of atoms with five and six nearest neighbors, and LAM generates more chips than that in the TM. It indicates that LAM reduces the subsurface damage of workpiece, gets a better-qualified ground surface and improves the material removal rate. Moreover, laser energy makes the materials fully softened before being removed, the number of atoms with temperature above 500 K is increased, and the average temperature of workpiece higher and faster to reach the equilibrium in LAM. It means that LAM has an absolute advantage in machining materials and greatly reduces the material resistance. Not only the tangential force (Fx) and the normal force (Fy) but also friction coefficients become smaller as laser heating reduces the strength and hardness of the material in LAM. These results show that LAM is a promising technique since it can get a better-qualified workpiece surface with larger material removal rates, less grinding force and lower friction coefficient.

3D surface coordinate inspection of formed sheet material parts using optical measurement systems and virtual distortion compensation

NASA Astrophysics Data System (ADS)

Weckenmann, Albert A.; Gall, P.; Gabbia, A.

2005-02-01

Modern forming technology allows the production of highly sophisticated free form sheet material components, affording great flexibility to the design and manufacturing processes across a wide range of industries. This increased design and manufacturing potential places an ever growing demand on the accompanying inspection metrology. As a consequence of their surface shape, these parts underlie a reversible geometrical deformation caused by variations of the material and the manufacturing process, as well as by gravity. This distortion is removed during the assembly process, usually performed in automated robotic processes. For this reason, the part's tolerated parameters have to be inspected in a defined state, simulating the assembly process' boundary conditions. Thus, the inspection process chain consists of six steps: picking the workpiece up, manual fixation of the workpiece, tactile measurement of the surface's coordinates using a defined measurement strategy, manual removal of the fixation and removal of the workpiece from the inspection area. These steps are both laborious and time consuming (for example, the inspection of a car door can take up to a working day to complete). Using optical measuring systems and virtual distortion compensation, this process chain can be dramatically shortened. Optical measuring systems provide as a measurement result a point cloud representing a sample of all nearest surfaces in the measuring range containing the measurand. From this data, a surface model of the measurand can be determined, independent of its position in the measuring range. For thin sheet material parts an approximating finite element model can be deduced from such a surface model. By means of pattern recognition, assembly relevant features of the measurand can be identified and located on this model. Together with the boundary conditions given by the assembly process, the shape of the surface in its assembled state can be calculated using the finite elements method. In application these methods culminate in a shortened inspection process chain (which can now also be automated): picking the workpiece up, placing it in the measuring range, optical measurement, virtual distortion compensation and removal of the workpiece from the inspection area. This work discusses the methodology of our approach in detail and also provides and analyses experimental results. The underlying research was greatfully funded by the German Research Foundation (DFG).

Experimental and Numerical Investigations in Shallow Cut Grinding by Workpiece Integrated Infrared Thermopile Array.

PubMed

Reimers, Marcel; Lang, Walter; Dumstorff, Gerrit

2017-09-30

The purpose of our study is to investigate the heat distribution and the occurring temperatures during grinding. Therefore, we did both experimental and numerical investigations. In the first part, we present the integration of an infrared thermopile array in a steel workpiece. Experiments are done by acquiring data from the thermopile array during grinding of a groove in a workpiece made of steel. In the second part, we present numerical investigations in the grinding process to further understand the thermal characteristic during grinding. Finally, we conclude our work. Increasing the feed speed leads to two things: higher heat flux densities in the workpiece and higher temperature gradients in the material.

Experimental and Numerical Investigations in Shallow Cut Grinding by Workpiece Integrated Infrared Thermopile Array

PubMed Central

Reimers, Marcel; Lang, Walter; Dumstorff, Gerrit

2017-01-01

The purpose of our study is to investigate the heat distribution and the occurring temperatures during grinding. Therefore, we did both experimental and numerical investigations. In the first part, we present the integration of an infrared thermopile array in a steel workpiece. Experiments are done by acquiring data from the thermopile array during grinding of a groove in a workpiece made of steel. In the second part, we present numerical investigations in the grinding process to further understand the thermal characteristic during grinding. Finally, we conclude our work. Increasing the feed speed leads to two things: higher heat flux densities in the workpiece and higher temperature gradients in the material. PMID:28973978

Accurate Micro-Tool Manufacturing by Iterative Pulsed-Laser Ablation

NASA Astrophysics Data System (ADS)

Warhanek, Maximilian; Mayr, Josef; Dörig, Christian; Wegener, Konrad

2017-12-01

Iterative processing solutions, including multiple cycles of material removal and measurement, are capable of achieving higher geometric accuracy by compensating for most deviations manifesting directly on the workpiece. Remaining error sources are the measurement uncertainty and the repeatability of the material-removal process including clamping errors. Due to the lack of processing forces, process fluids and wear, pulsed-laser ablation has proven high repeatability and can be realized directly on a measuring machine. This work takes advantage of this possibility by implementing an iterative, laser-based correction process for profile deviations registered directly on an optical measurement machine. This way efficient iterative processing is enabled, which is precise, applicable for all tool materials including diamond and eliminates clamping errors. The concept is proven by a prototypical implementation on an industrial tool measurement machine and a nanosecond fibre laser. A number of measurements are performed on both the machine and the processed workpieces. Results show production deviations within 2 μm diameter tolerance.

AN EXPERIMENTAL STUDY OF CUTTING FLUID EFFECTS IN DRILLING. (R825370C057)

EPA Science Inventory

Experiments were designed and conducted on aluminum alloys and gray cast iron to determine the function of cutting fluid in drilling. The variables examined included speed, feed, hole depth, tool and workpiece material, cutting fluid condition, workpiece temperatures and drill...

Additive manufacturing of tools for lapping glass

NASA Astrophysics Data System (ADS)

Williams, Wesley B.

2013-09-01

Additive manufacturing technologies have the ability to directly produce parts with complex geometries without the need for secondary processes, tooling or fixtures. This ability was used to produce concave lapping tools with a VFlash 3D printer from 3D Systems. The lapping tools were first designed in Creo Parametric with a defined constant radius and radial groove pattern. The models were converted to stereolithography files which the VFlash used in building the parts, layer by layer, from a UV curable resin. The tools were rotated at 60 rpm and used with 120 grit and 220 grit silicon carbide lapping paste to lap 0.750" diameter fused silica workpieces. The samples developed a matte appearance on the lapped surface that started as a ring at the edge of the workpiece and expanded to the center. This indicated that as material was removed, the workpiece radius was beginning to match the tool radius. The workpieces were then cleaned and lapped on a second tool (with equivalent geometry) using a 3000 grit corundum aluminum oxide lapping paste, until a near specular surface was achieved. By using lapping tools that have been additively manufactured, fused silica workpieces can be lapped to approach a specified convex geometry. This approach may enable more rapid lapping of near net shape workpieces that minimize the material removal required by subsequent polishing. This research may also enable development of new lapping tool geometry and groove patterns for improved loose abrasive finishing.

A comparison of neural network architectures for the prediction of MRR in EDM

NASA Astrophysics Data System (ADS)

Jena, A. R.; Das, Raja

2017-11-01

The aim of the research work is to predict the material removal rate of a work-piece in electrical discharge machining (EDM). Here, an effort has been made to predict the material removal rate through back-propagation neural network (BPN) and radial basis function neural network (RBFN) for a work-piece of AISI D2 steel. The input parameters for the architecture are discharge-current (Ip), pulse-duration (Ton), and duty-cycle (τ) taken for consideration to obtained the output for material removal rate of the work-piece. In the architecture, it has been observed that radial basis function neural network is comparatively faster than back-propagation neural network but logically back-propagation neural network results more real value. Therefore BPN may consider as a better process in this architecture for consistent prediction to save time and money for conducting experiments.

Method and apparatus for precision laser micromachining

DOEpatents

Chang, Jim; Warner, Bruce E.; Dragon, Ernest P.

2000-05-02

A method and apparatus for micromachining and microdrilling which results in a machined part of superior surface quality is provided. The system uses a near diffraction limited, high repetition rate, short pulse length, visible wavelength laser. The laser is combined with a high speed precision tilting mirror and suitable beam shaping optics, thus allowing a large amount of energy to be accurately positioned and scanned on the workpiece. As a result of this system, complicated, high resolution machining patterns can be achieved. A cover plate may be temporarily attached to the workpiece. Then as the workpiece material is vaporized during the machining process, the vapors condense on the cover plate rather than the surface of the workpiece. In order to eliminate cutting rate variations as the cutting direction is varied, a randomly polarized laser beam is utilized. A rotating half-wave plate is used to achieve the random polarization. In order to correctly locate the focus at the desired location within the workpiece, the position of the focus is first determined by monitoring the speckle size while varying the distance between the workpiece and the focussing optics. When the speckle size reaches a maximum, the focus is located at the first surface of the workpiece. After the location of the focus has been determined, it is repositioned to the desired location within the workpiece, thus optimizing the quality of the machined area.

Apparatus and method for atmospheric pressure reactive atom plasma processing for shaping of damage free surfaces

DOEpatents

Carr,; Jeffrey, W [Livermore, CA

2009-03-31

Fabrication apparatus and methods are disclosed for shaping and finishing difficult materials with no subsurface damage. The apparatus and methods use an atmospheric pressure mixed gas plasma discharge as a sub-aperture polisher of, for example, fused silica and single crystal silicon, silicon carbide and other materials. In one example, workpiece material is removed at the atomic level through reaction with fluorine atoms. In this example, these reactive species are produced by a noble gas plasma from trace constituent fluorocarbons or other fluorine containing gases added to the host argon matrix. The products of the reaction are gas phase compounds that flow from the surface of the workpiece, exposing fresh material to the etchant without condensation and redeposition on the newly created surface. The discharge provides a stable and predictable distribution of reactive species permitting the generation of a predetermined surface by translating the plasma across the workpiece along a calculated path.

CHIP MORPHOLOGY AND HOLE SURFACE TEXTURE IN THE DRILLING OF CAST ALUMINUM ALLOYS. (R825370C057)

EPA Science Inventory

The effects of cutting fluid and other process variables on chip morphology when drilling cast aluminium alloys are investigated. The effects of workpiece material, speed, feed, hole depth, cutting-fluid presence and percentage oil concentration, workpiece temperature, drill t...

Electro-thermal modelling of anode and cathode in micro-EDM

NASA Astrophysics Data System (ADS)

Yeo, S. H.; Kurnia, W.; Tan, P. C.

2007-04-01

Micro-electrical discharge machining is an evolution of conventional EDM used for fabricating three-dimensional complex micro-components and microstructure with high precision capabilities. However, due to the stochastic nature of the process, it has not been fully understood. This paper proposes an analytical model based on electro-thermal theory to estimate the geometrical dimensions of micro-crater. The model incorporates voltage, current and pulse-on-time during material removal to predict the temperature distribution on the workpiece as a result of single discharges in micro-EDM. It is assumed that the entire superheated area is ejected from the workpiece surface while only a small fraction of the molten area is expelled. For verification purposes, single discharge experiments using RC pulse generator are performed with pure tungsten as the electrode and AISI 4140 alloy steel as the workpiece. For the pulse-on-time range up to 1000 ns, the experimental and theoretical results are found to be in close agreement with average volume approximation errors of 2.7% and 6.6% for the anode and cathode, respectively.

Ceramic-glass-metal seal by microwave heating

DOEpatents

Meek, Thomas T.; Blake, Rodger D.

1985-01-01

A method for producing a ceramic-glass-metal seal by microwaving mixes a slurry of glass sealing material and coupling agent and applies same to ceramic and metal workpieces. The slurry and workpieces are then insulated and microwaved at a power, time and frequency sufficient to cause a liquid phase reaction in the slurry. The reaction of the glass sealing material forms a chemically different seal than that which would be formed by conventional heating because it is formed by diffusion rather than by wetting of the reactants.

Ceramic-glass-metal seal by microwave heating

DOEpatents

Meek, T.T.; Blake, R.D.

1983-10-04

A method for producing a ceramic-glass-metal seal by microwaving, mixes a slurry of glass sealing material and coupling agent and applies same to ceramic and metal workpieces. The slurry and workpieces are then insulated and microwaved at a power, time and frequency sufficient to cause a liquid-phase reaction in the slurry. The reaction of the glass sealing material forms a chemically different seal than that which would be formed by conventional heating because it is formed by diffusion rather than by wetting of the reactants.

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.

Investigation of the influence of process parameters on adhesive wear under hot stamping conditions

NASA Astrophysics Data System (ADS)

Schwingenschlögl, P.; Weldi, M.; Merklein, M.

2017-09-01

Current challenges like increasing safety standards and reducing fuel consumption motivate lightweight construction in modern car bodies. Besides using lightweight workpiece materials like aluminum, hot stamping has been established as a key technology for producing safety relevant components. Producing hot stamped parts out of ultra-high strength steels offers the possibility to improve the crash performance. At the same time the weight of car structure is reduced by using thinner sheet thicknesses. In order to avoid oxide scale formation and ensure corrosion protection, AlSi coatings are commonly deposited on the sheet surfaces used for direct hot stamping. This workpiece coating has a critical impact on the tribological conditions within the forming process and, as a consequence, influences the quality of hot stamped parts as well as tool wear. AlSi coatings have been identified as major reason for adhesive wear, which represents the main wear mechanism in hot stamping. Within this study, the influence of the process parameters on adhesive wear are investigated in dependency of workpiece and tool temperatures, drawing velocities and contact pressures. The tribological behavior is analyzed based on strip drawing experiments under direct hot stamping conditions. The experiments are performed with AlSi coated 22MnB5 in contact with the hot working tool steel 1.2367. For analyzing the amount of adhesion on the friction jaws, the surfaces are characterized by optical measurements. The experiments indicate that higher workpiece temperatures cause severe adhesive wear on the tool surface, while an increase of drawing velocity or contact pressure led to reduced adhesion. The measured friction coefficients decreased with rising amount of adhesion and remained at a constant level after a certain adhesive layer was built up on the tool surface.

Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

NASA Astrophysics Data System (ADS)

Grujicic, M.; Arakere, G.; Pandurangan, B.; Ochterbeck, J. M.; Yen, C.-F.; Cheeseman, B. A.; Reynolds, A. P.; Sutton, M. A.

2012-09-01

Workpiece material flow and stirring/mixing during the friction stir welding (FSW) process are investigated computationally. Within the numerical model of the FSW process, the FSW tool is treated as a Lagrangian component while the workpiece material is treated as an Eulerian component. The employed coupled Eulerian/Lagrangian computational analysis of the welding process was of a two-way thermo-mechanical character (i.e., frictional-sliding/plastic-work dissipation is taken to act as a heat source in the thermal-energy balance equation) while temperature is allowed to affect mechanical aspects of the model through temperature-dependent material properties. The workpiece material (AA5059, solid-solution strengthened and strain-hardened aluminum alloy) is represented using a modified version of the classical Johnson-Cook model (within which the strain-hardening term is augmented to take into account for the effect of dynamic recrystallization) while the FSW tool material (AISI H13 tool steel) is modeled as an isotropic linear-elastic material. Within the analysis, the effects of some of the FSW key process parameters are investigated (e.g., weld pitch, tool tilt-angle, and the tool pin-size). The results pertaining to the material flow during FSW are compared with their experimental counterparts. It is found that, for the most part, experimentally observed material-flow characteristics are reproduced within the current FSW-process model.

Ceramic-glass-ceramic seal by microwave heating

DOEpatents

Meek, T.T.; Blake, R.D.

1983-10-04

A method for producing a ceramic-glass-ceramic seal by microwaving, mixes a slurry of glass sealing material and coupling agent and applies same to ceramic workpieces. The slurry and workpieces are placed together, insulated and then microwaved at a power, time and frequency sufficient to cause a liquid phase reaction in the slurry. The reaction of the glass sealing material forms a chemically different seal than that which would be formed by conventional heating because it is formed by a diffusion rather than by wetting of the reactants.

Ceramic-glass-ceramic seal by microwave heating

DOEpatents

Meek, Thomas T.; Blake, Rodger D.

1985-01-01

A method for producing a ceramic-glass-ceramic seal by microwaving, mixes a slurry of glass sealing material and coupling agent and applies same to ceramic workpieces. The slurry and workpieces are placed together, insulated and then microwaved at a power, time and frequency sufficient to cause a liquid phase reaction in the slurry. The reaction of the glass sealing material forms a chemically different seal than that which would be formed by conventional heating because it is formed by a diffusion rather than by wetting of the reactants.

A novel approach of magnetorheological abrasive fluid finishing with swirling-assisted inlet flow

NASA Astrophysics Data System (ADS)

Kheradmand, Saeid; Esmailian, Mojtaba; Fatahy, A.

Abrasive flow machining has been the pioneer of new finishing processes. Rotating workpiece and imposing a magnetic field using magnetorheological working medium are some assisting manipulations to improve surface finishing, because they can increase the forces on the workpiece surface. Similarly, swirling the inlet flow using stationary swirler vanes, as a novel idea, may also increase forces on the surface, and then raise the material removal, with a lower expense and energy consumption compared with the case of workpiece rotation. Thus, in this paper, surface roughness improvement is studied in a pipe with rotating inlet flow of a magnetorheological finishing medium under imposing a magnetic field. The results are compared with the case of rotating workpiece, using 3D numerical simulation. The governing hydrodynamic parameters are investigated in both cases to monitor the flow variations. It is shown that surface roughness is improved by rotating inlet flow. However, it is found that finishing in the entrance length of swirling-assisted inlet flow can be so economical for short length workpieces, compared with the case of rotating workpiece, with very near Ra values. By comparison of the numerical results and published experimental data, current study also shows the ability of the numerical simulation, as an inexpensive and efficient tool, to predict the surface roughness changes in finishing processes.

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.

Influence of the direction of selective laser sintering on machinability of parts from 316L steel

NASA Astrophysics Data System (ADS)

Alexeev, V. P.; Balyakin, A. V.; Khaimovich, A. I.

2017-02-01

This work presents the results of research of the impact of layer-by-layer growing of workpieces made of 316L steel on their machinability. The results of determination of residual stresses and measurement of hardness of the workpieces grown have been demonstrated. A series of experimental studies has been performed in order to determine the cutting force which occurs in the process of machining. The microstructure of the workpieces grown has been examined. It has been shown that the workpieces machined using Selective Laser Melting technology have the microstructure which is a totality of ‘microwelded seams’, which have a significant influence on the behavior of deformation processes in case of machining. The studies have shown that in case of lateral milling of the horizontally grown workpiece, the codirectional microwelded borders prevent any significant deformation of the misalignment which increases the cutting force by up to 10% as compared with milling of the vertically grown workpiece.

Ultrasonic stir welding process and apparatus

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2009-01-01

An ultrasonic stir welding device provides a method and apparatus for elevating the temperature of a work piece utilizing at least one ultrasonic heater. Instead of relying on a rotating shoulder to provide heat to a workpiece an ultrasonic heater is utilized to provide ultrasonic energy to the workpiece. A rotating pin driven by a motor assembly performs the weld on the workpiece. A handheld version can be constructed as well as a fixedly mounted embodiment.

Hard particle effect on surface generation in nano-cutting

NASA Astrophysics Data System (ADS)

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-12-01

The influence of the hard particle on the surface generation, plastic deformation and processing forces in nano-cutting of aluminum is investigated by means of molecular dynamics simulations. In this investigation, a hard particle which is simplified as a diamond ball is embedded under the free surface of workpiece with different depths. The influence of the position of the hard ball on the surface generation and other material removal mechanism, such as the movement of the ball under the action of cutting tool edge, is revealed. The results show that when the hard particle is removed, only a small shallow pit is left on the machined surface. Otherwise, it is pressed down to the subsurface of the workpiece left larger and deeper pit on the generated surface. Besides that, the hard particle in the workpiece would increase the processing force when the cutting tool edge or the plastic carriers interact with the hard particle. It is helpful to optimize the cutting parameters and material properties for obtaining better surface quality in nano-cutting of composites or other materials with micro/nanoscale hard particles in it.

Grinding model and material removal mechanism of medical nanometer zirconia ceramics.

PubMed

Zhang, Dongkun; Li, Changhe; Jia, Dongzhou; Wang, Sheng; Li, Runze; Qi, Xiaoxiao

2014-01-01

Many patents have been devoted to developing medical nanometer zirconia ceramic grinding techniques that can significantly improve both workpiece surface integrity and grinding quality. Among these patents is a process for preparing ceramic dental implants with a surface for improving osseo-integration by sand abrasive finishing under a jet pressure of 1.5 bar to 8.0 bar and with a grain size of 30 µm to 250 µm. Compared with other materials, nano-zirconia ceramics exhibit unmatched biomedical performance and excellent mechanical properties as medical bone tissue and dentures. The removal mechanism of nano-zirconia materials includes brittle fracture and plastic removal. Brittle fracture involves crack formation, extension, peeling, and chipping to completely remove debris. Plastic removal is similar to chip formation in metal grinding, including rubbing, ploughing, and the formation of grinding debris. The materials are removed in shearing and chipping. During brittle fracture, the grinding-led transverse and radial extension of cracks further generate local peeling of blocks of the material. In material peeling and removal, the mechanical strength and surface quality of the workpiece are also greatly reduced because of crack extension. When grinding occurs in the plastic region, plastic removal is performed, and surface grinding does not generate grinding fissures and surface fracture, producing clinically satisfactory grinding quality. With certain grinding conditions, medical nanometer zirconia ceramics can be removed through plastic flow in ductile regime. In this study, we analyzed the critical conditions for the transfer of brittle and plastic removal in nano-zirconia ceramic grinding as well as the high-quality surface grinding of medical nanometer zirconia ceramics by ELID grinding.

High-Powered, Ultrasonically Assisted Thermal Stir Welding

NASA Technical Reports Server (NTRS)

Ding, Robert

2013-01-01

This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (˜13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (˜2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (˜13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.

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

PubMed

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

2013-01-01

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

Experimental exploration of the hydrodynamic effect polishing machinability for different types of material

NASA Astrophysics Data System (ADS)

Peng, W. Q.; Li, Y.; Wang, Z.; Li, S. Y.

2018-01-01

Hydrodynamic effect polishing (HEP), in which the material removal relies on the chemisorption between nanoparticles and the workpiece surface in elastic mode, can realize automatic level smooth surface without surface/subsurface damage. The machinability of different types of optical material (such as monocrystalline silicon and crystalline quartz, amorphous silicate glass, Zerodur and so on) were investigated experimentally. The workpiece surfaces before and after being polished by HEP was observed by atomic force microscopy. The experimental results show the surface roughness of monocrystalline silicon and quartz, amorphous silicate glass have decreased from Rms 0.737nm to Rms 0.175nm, Rms 0.490nm to Rms 0.187nm, Rms 0.469nm to Rms 0.157nm respectively, and meanwhile all the defects and bumpy structures have been removed clearly. However the surface roughness has increased from Rms 0.213nm to Rms 0.321nm with the obvious increment of micro unevenness. By comparison, we can conclude that excellent performance is shown when HEP is applied on the optical material structure with a single monocrystalline or amorphous component. However the ultrasmooth surface cannot be obtained when HEP was applied on the combinational materials such as Zerodur glass. The micro unevenness increases gradually along with polishing process due to the different material removal of the monocrystalline and amorphous component.

Ultrasonically assisted turning of aviation materials: simulations and experimental study.

PubMed

Babitsky, V I; Mitrofanov, A V; Silberschmidt, V V

2004-04-01

Ultrasonically assisted turning of modern aviation materials is conducted with ultrasonic vibration (frequency f approximately 20 kHz, amplitude a approximately 15 microm) superimposed on the cutting tool movement. An autoresonant control system is used to maintain the stable nonlinear resonant mode of vibration throughout the cutting process. Experimental comparison of roughness and roundness for workpieces machined conventionally and with the superimposed ultrasonic vibration, results of high-speed filming of the turning process and nanoindentation analyses of the microstructure of the machined material are presented. The suggested finite-element model provides numerical comparison between conventional and ultrasonic turning of Inconel 718 in terms of stress/strain state, cutting forces and contact conditions at the workpiece/tool interface.

Trajectory Calculator for Finite-Radius Cutter on a Lathe

NASA Technical Reports Server (NTRS)

Savchenkov, Anatoliy; Strekalov, Dmitry; Yu, Nan

2009-01-01

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

Calculation of electromagnetic force in electromagnetic forming process of metal sheet

NASA Astrophysics Data System (ADS)

Xu, Da; Liu, Xuesong; Fang, Kun; Fang, Hongyuan

2010-06-01

Electromagnetic forming (EMF) is a forming process that relies on the inductive electromagnetic force to deform metallic workpiece at high speed. Calculation of the electromagnetic force is essential to understand the EMF process. However, accurate calculation requires complex numerical solution, in which the coupling between the electromagnetic process and the deformation of workpiece needs be considered. In this paper, an appropriate formula has been developed to calculate the electromagnetic force in metal work-piece in the sheet EMF process. The effects of the geometric size of coil, the material properties, and the parameters of discharge circuit on electromagnetic force are taken into consideration. Through the formula, the electromagnetic force at different time and in different positions of the workpiece can be predicted. The calculated electromagnetic force and magnetic field are in good agreement with the numerical and experimental results. The accurate prediction of the electromagnetic force provides an insight into the physical process of the EMF and a powerful tool to design optimum EMF systems.

Mitigated-force carriage for high magnetic field environments

DOEpatents

Ludtka, Gerard M; Ludtka, Gail M; Wilgen, John B; Murphy, Bart L

2014-05-20

A carriage for high magnetic field environments includes a first work-piece holding means for holding a first work-piece, the first work-piece holding means being disposed in an operable relationship with a work-piece processing magnet having a magnetic field strength of at least 1 Tesla. The first work-piece holding means is further disposed in operable connection with a second work-piece holding means for holding a second work-piece so that, as the first work-piece is inserted into the magnetic field, the second work-piece is simultaneously withdrawn from the magnetic field, so that an attractive magnetic force imparted on the first work-piece offsets a resistive magnetic force imparted on the second work-piece.

Influencing Factors and Workpiece's Microstructure in Laser-Assisted Milling of Titanium

NASA Astrophysics Data System (ADS)

Wiedenmann, R.; Liebl, S.; Zaeh, M. F.

Today's lightweight components have to withstand increasing mechanical and thermal loads. Therefore, advanced materials substitute conventional materials like steel or aluminum alloys. Using these high-performance materials the associated costs become prohibitively high. This paper presents the newest fundamental investigations on the hybrid process 'laser-assisted milling' which is an innovative technique to process such materials. The focus is on the validation of a numerical database for a CAD/CAM process control unit which is calculated by using simulation. Prior to that, the influencing factors on a laser-assisted milling process are systematically investigated using Design of Experiments (DoE) to identify the main influencing parameters coming from the laser and the milling operation.

Kinematical and mechanical aspects of wafer slicing

NASA Technical Reports Server (NTRS)

Werner, P. G.

1982-01-01

Some recently achieved results concerning the technological fundamentals of slurry sawing are presented. The specific material removal process and the related kinematic and geometric contact conditions between workpiece and saw blade are described. The result of a functional description of the slurry sawing process is presented, expressing the main process criteria, such as infeed per stroke, specific removal rate, specific tool wear, and vertical stroke intensity, in terms of the dominating process parameters, such as stroke length, width of workpiece, stroke frequency, specific cutting force and slurry specification.

Fixture For Drilling And Tapping A Curved Workpiece

NASA Technical Reports Server (NTRS)

Espinosa, P. S.; Lockyer, R. T.

1992-01-01

Simple fixture guides drilling and tapping of holes in prescribed locations and orientations on workpiece having curved surface. Tool conceived for use in reworking complexly curved helicopter blades made of composite materials. Fixture is block of rigid foam with epoxy filler, custom-fitted to surface contour, containing bushings and sleeves at drilling and tapping sites. Bushings changed, so taps and drills of various sizes accommodated. In use, fixture secured to surface by hold-down bolts extending through sleeves and into threads in substrate.

Research of thread rolling on difficult-to-cut material workpieces

NASA Astrophysics Data System (ADS)

Popov, A. Yu; Bugay, I. A.; Nazarov, P. V.; Evdokimova, O. P.; Popov, P. E.; Vasilyev, E. V.

2018-01-01

In medicine production Ti-6Al-4V Grade 5 alloys are used. One of the most important tasks is to increase the strength of the products and decrease in value. The possibility to roll special thread on Ti-6Al-4V Grade 5 alloy workpiece on 2-roller thread rolling machine has been studied. This is wrought alloy, treatment of which in cold condition causes difficulties due to low plasticity. To obtain Ti-6Al-4V Grade 5 alloy product with thread by rolling is rather difficult. This is due to large axial workpiece displacements resulting from large alloy resistance to cold plastic deformation. The provision of adequate kinematics requires experimental researches and the selection of modes - speed of rolling and pressure on the movable roller. The purpose of the work is to determine the optimal modes for rolling thread on titanium alloy workpiece. It has been stated that, after rolling, the product strength has increased up to 30%. As a result of the work, the unit has been made and recommendations to choose the optimal rolling process modes have been offered.

Magnetorheological finishing: a perfect solution to nanofinishing requirements

NASA Astrophysics Data System (ADS)

Sidpara, Ajay

2014-09-01

Finishing of optics for different applications is the most important as well as difficult step to meet the specification of optics. Conventional grinding or other polishing processes are not able to reduce surface roughness beyond a certain limit due to high forces acting on the workpiece, embedded abrasive particles, limited control over process, etc. Magnetorheological finishing (MRF) process provides a new, efficient, and innovative way to finish optical materials as well many metals to their desired level of accuracy. This paper provides an overview of MRF process for different applications, important process parameters, requirement of magnetorheological fluid with respect to workpiece material, and some areas that need to be explored for extending the application of MRF process.

Method and apparatus for automatically tracking a workpiece surface. [Patents

DOEpatents

Not Available

1981-02-03

Laser cutting concepts and apparatus have been developed for cutting the shroud of the core fuel subassemblies. However, much care must be taken in the accuracy of the cutting since the fuel rods within the shroud often become warped and are forced into direct contact with the shroud in random regions. Thus, in order to cut the nuclear fuel rod shroud accurately so as not to puncture the cladding of the fuel rods, and to insure optimal cutting efficiency and performance, the focal point of beam need be maintained accurately at the workpiece surface. It becomes necessary to detect deviations in the level of the workpiece surface accurately in connection with the cutting process. Therefore, a method and apparatus for tracking the surface of a workpiece being cut by a laser beam coming from a focus head assembly is disclosed which includes two collimated laser beams directed onto the work-piece surface at spaced points by beam directing optics in generally parallel planes of incidence. A shift in spacing between the two points is detected by means of a video camera system and processed by a computer to yield a workpiece surface displacement signal which is input to a motor which raises or lowers the beam focus head accordingly.

Design of Friction Stir Welding Tool for Avoiding Root Flaws

PubMed Central

Ji, Shude; Xing, Jingwei; Yue, Yumei; Ma, Yinan; Zhang, Liguo; Gao, Shuangsheng

2013-01-01

In order to improve material flow behavior during friction stir welding and avoid root flaws of weld, a tool with a half-screw pin and a tool with a tapered-flute pin are suggested. The effect of flute geometry in tool pins on material flow velocity is investigated by the software ANSYS FLUENT. Numerical simulation results show that high material flow velocity appears near the rotational tool and material flow velocity rapidly decreases with the increase of distance away from the axis of the tool. Maximum material flow velocity by the tool with the tapered-flute pin appears at the beginning position of flute and the velocity decreases with the increase of flow length in flute. From the view of increasing the flow velocity of material near the bottom of the workpiece or in the middle of workpiece, the tool with the half-screw pin and the tool with the tapered-flute pin are both better than the conventional tool. PMID:28788426

Design of Friction Stir Welding Tool for Avoiding Root Flaws.

PubMed

Ji, Shude; Xing, Jingwei; Yue, Yumei; Ma, Yinan; Zhang, Liguo; Gao, Shuangsheng

2013-12-12

In order to improve material flow behavior during friction stir welding and avoid root flaws of weld, a tool with a half-screw pin and a tool with a tapered-flute pin are suggested. The effect of flute geometry in tool pins on material flow velocity is investigated by the software ANSYS FLUENT. Numerical simulation results show that high material flow velocity appears near the rotational tool and material flow velocity rapidly decreases with the increase of distance away from the axis of the tool. Maximum material flow velocity by the tool with the tapered-flute pin appears at the beginning position of flute and the velocity decreases with the increase of flow length in flute. From the view of increasing the flow velocity of material near the bottom of the workpiece or in the middle of workpiece, the tool with the half-screw pin and the tool with the tapered-flute pin are both better than the conventional tool.

Dynamic features of bubble induced by a nanosecond pulse laser in still and flowing water

NASA Astrophysics Data System (ADS)

Charee, Wisan; Tangwarodomnukun, Viboon

2018-03-01

Underwater laser ablation techniques have been developed and employed to synthesis nanoparticles, to texture workpiece surface and to assist the material removal in laser machining process. However, the understanding of laser-material-water interactions, bubble formation and effects of water flow on ablation performance has still been very limited. This paper thus aims at exploring the formation and collapse of bubbles during the laser ablation of silicon in water. The effects of water flow rate on bubble formation and its consequences to the laser disturbance and cut features obtained in silicon were observed by using a high speed camera. A nanosecond pulse laser emitting the laser pulse energy of 0.2-0.5 mJ was employed in the experiment. The results showed that the bubble size was found to increase with the laser pulse energy. The use of high water flow rate can importantly facilitate the ejection of ablated particles from the workpiece surface, hence resulting in less deposition to the work surface and minimizing any disturbance to the laser beam during the ablation in water. Furthermore, a clean micro-groove in silicon wafer can successfully be produced when the process was performed in the high water flow rate condition. The findings of this study could provide an essential guideline for process selection, control and improvement in the laser micro-/submicro-fabrication using the underwater technique.

Thin film deposition by electric and magnetic crossed-field diode sputtering

DOEpatents

Welch, Kimo M.

1977-01-01

Applying a thin film coating to the surface of a workpiece, in particular, applying a coating of titanium nitride to a klystron window by means of a crossed-field diode sputtering array. The array is comprised of a cohesive group of numerous small hollow electrically conducting cylinders and is mounted so that the open ends of the cylinders on one side of the group are adjacent a titanium cathode plate. The workpiece is mounted so as to face the open ends of the other side of the group. A magnetic field is applied to the array so as to be coaxial with the cylinders and a potential is applied across the cylinders and the cathode plate, the cylinders as an anode being positive with respect to the cathode plate. The cylinders, the cathode plate and the workpiece are situated in an atmosphere of nitrogen which becomes ionized such as by field emission because of the electric field between the cylinders and cathode plate, thereby establishing an anode-cathode discharge that results in sputtering of the titanium plate. The sputtered titanium coats the workpiece and chemically combines with the nitrogen to form a titanium nitride coating on the workpiece. Gas pressure, gas mixtures, cathode material composition, voltages applied to the cathode and anode, the magnetic field, cathode, anode and workpiece spacing, and the aspect ratio (ratio of length to inner diameter) of the anode cylinders, all may be controlled to provide consistent optimum thin film coatings of various compositions and thicknesses. Another facet of the disclosure is the coating of microwave components per se with titanium nitride to reduce multipactoring under operating conditions of the components.

Titanium nitride thin films for minimizing multipactoring

DOEpatents

Welch, Kimo M.

1979-01-01

Applying a thin film coating to the surface of a workpiece, in particular, applying a coating of titanium nitride to a klystron window by means of a crossed-field diode sputtering array. The array is comprised of a cohesive group of numerous small hollow electrically conducting cylinders and is mounted so that the open ends of the cylinders on one side of the group are adjacent a titanium cathode plate. The workpiece is mounted so as to face the open ends of the other side of the group. A magnetic field is applied to the array so as to be coaxial with the cylinders and a potential is applied across the cylinders and the cathode plate, the cylinders as an anode being positive with respect to the cathode plate. The cylinders, the cathode plate and the workpiece are situated in an atmosphere of nitrogen which becomes ionized such as by field emission because of the electric field between the cylinders and cathode plate, thereby establishing an anode-cathode discharge that results in sputtering of the titanium plate. The sputtered titanium coats the workpiece and chemically combines with the nitrogen to form a titanium nitride coating on the workpiece. Gas pressure, gas mixtures, cathode material composition, voltages applied to the cathode and anode, the magnetic field, cathode, anode and workpiece spacing, and the aspect ratio (ratio of length to inner diameter) of the anode cylinders, all may be controlled to provide consistent optimum thin film coatings of various compositions and thicknesses. Another facet of the disclosure is the coating of microwave components per se with titanium nitride to reduce multipactoring under operating conditions of the components.

Thin film deposition by electric and magnetic crossed-field diode sputtering

DOEpatents

Welch, Kimo M.

1980-01-01

Applying a thin film coating to the surface of a workpiece, in particular, applying a coating of titanium nitride to a klystron window by means of a crossed-field diode sputtering array. The array is comprised of a cohesive group of numerous small hollow electrically conducting cylinders and is mounted so that the open ends of the cylinders on one side of the group are adjacent a titanium cathode plate. The workpiece is mounted so as to face the open ends of the other side of the group. A magnetic field is applied to the array so as to be coaxial with the cylinders and a potential is applied across the cylinders and the cathode plate, the cylinders as an anode being positive with respect to the cathode plate. The cylinders, the cathode plate and the workpiece are situated in an atmosphere of nitrogen which becomes ionized such as by field emission because of the electric field between the cylinders and cathode plate, thereby establishing an anode-cathode discharge that results in sputtering of the titanium plate. The sputtered titanium coats the workpiece and chemically combines with the nitrogen to form a titanium nitride coating on the workpiece. Gas pressure, gas mixtures, cathode material composition, voltages applied to the cathode and anode, the magnetic field, cathode, anode and workpiece spacing, and the aspect ratio (ratio of length to inner diameter) of the anode cylinders, all may be controlled to provide consistent optimum thin film coatings of various compositions and thicknesses. Another facet of the disclosure is the coating of microwave components per se with titanium nitride to reduce multipactoring under operating conditions of the components.

Material Gradients in Oxygen System Components Improve Safety

NASA Technical Reports Server (NTRS)

Forsyth, Bradley S.

2011-01-01

Oxygen system components fabricated by Laser Engineered Net Shaping (TradeMark) (LENS(TradeMark)) could result in improved safety and performance. LENS(TradeMark) is a near-net shape manufacturing process fusing powdered materials injected into a laser beam. Parts can be fabricated with a variety of elemental metals, alloys, and nonmetallic materials without the use of a mold. The LENS(TradeMark) process allows the injected materials to be varied throughout a single workpiece. Hence, surfaces exposed to oxygen could be constructed of an oxygen-compatible material while the remainder of the part could be one chosen for strength or reduced weight. Unlike conventional coating applications, a compositional gradient would exist between the two materials, so no abrupt material boundary exists. Without an interface between dissimilar materials, there is less tendency for chipping or cracking associated with thermal-expansion mismatches.

System and method for 2D workpiece alignment

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

Weaver, William T.; Carlson, Charles T.; Smith, Scott A.

2015-07-14

A carrier capable of holding one or more workpieces is disclosed. The carrier includes movable projections located along the sides of each cell in the carrier. This carrier, in conjunction with a separate alignment apparatus, aligns each workpiece within its respective cell against several alignment pins, using a multiple step alignment process to guarantee proper positioning of the workpiece in the cell. First, the workpieces are moved toward one side of the cell. Once the workpieces have been aligned against this side, the workpieces are then moved toward an adjacent orthogonal side such that the workpieces are aligned to twomore » sides of the cell. Once aligned, the workpiece is held in place by the projections located along each side of each cell. In addition, the alignment pins are also used to align the associated mask, thereby guaranteeing that the mask is properly aligned to the workpiece.« less

Method of forming magnesium alloy sheets

DOEpatents

Mualidharan, Govindarajan; Muth, Thomas R.; Harper, David C.

2015-12-22

A machine for asymmetric rolling of a work-piece includes pair of rollers disposed in an arrangement to apply opposing, asymmetric rolling forces to roll a work-piece therebetween, wherein a surface of the work-piece is rolled faster than an opposite surface of the work-piece; and an exit constraint die rigidly disposed adjacent an exit side of the pair of rollers so that, as the work-piece exits the pair of rollers, the work-piece contacts the exit constraint die to constrain curling of the work-piece.

Forces acting between polishing tool and workpiece surface in magnetorheological finishing

NASA Astrophysics Data System (ADS)

Schinhaerl, Markus; Vogt, Christian; Geiss, Andreas; Stamp, Richard; Sperber, Peter; Smith, Lyndon; Smith, Gordon; Rascher, Rolf

2008-08-01

Magnetorheological finishing is a computer-controlled polishing technique that is used mainly in the field of high-quality optical lens production. The process is based on the use of a magnetorheological polishing fluid that is able, in a reversible manner, to change its viscosity from a liquid state to a solid state under the control of a magnetic field. This outstanding characteristic facilitates rapid control (in milliseconds) of the yield stress, and thus the pressure applied to the workpiece surface to be polished. A three-axis dynamometer was used to measure the forces acting between the magnetorheological fluid and the workpiece surface during determination of the material removal characteristic of the polishing tool (influence function). The results of a testing series using a QED Q22-X MRF polishing machine with a 50 mm wheel assembly show that the normal forces range from about 2 to 20 N. Knowledge of the forces is essential, especially when thin workpieces are to be polished and distortion becomes significant. This paper discusses, and gives examples of, the variation in the parameters experienced during a programme of experiments, and provides examples of the value of this work.

Tool life and surface integrity aspects when drilling nickel alloy

NASA Astrophysics Data System (ADS)

Kannan, S.; Pervaiz, S.; Vincent, S.; Karthikeyan, R.

2018-04-01

Nickel based super alloys manufactured through powder metallurgy (PM) route are required to increase the operational efficiency of gas turbine engines. They are material of choice for high pressure components due to their superior high temperature strength, excellent corrosion, oxidation and creep resistance. This unique combination of mechanical and thermal properties makes them even more difficult-to-machine. In this paper, the hole making process using coated carbide inserts by drilling and plunge milling for a nickel-based powder metallurgy super alloy has been investigated. Tool life and process capability studies were conducted using optimized process parameters using high pressure coolants. The experimental trials were directed towards an assessment of the tendency for surface malformations and detrimental residual stress profiles. Residual stresses in both the radial and circumferential directions have been evaluated as a function of depth from the machined surface using the target strain gauge / center hole drilling method. Circumferential stresses near workpiece surface and at depth of 512 µm in the starting material was primarily circumferential compression which was measured to be average of –404 MPa. However, the radial stresses near workpiece surface was tensile and transformed to be compressive in nature at depth of 512 µm in the starting material (average: -87 Mpa). The magnitude and the depth below the machined surface in both radial and circumferential directions were primarily tensile in nature which increased with hole number due to a rise of temperature at the tool–workpiece interface with increasing tool wear. These profiles are of critical importance for the selection of cutting strategies to ensure avoidance/minimization of tensile residual stresses that can be detrimental to the fatigue performance of the components. These results clearly show a tendency for the circumferential stresses to be more tensile than the radial stresses. Overall the results indicate that the effect of drilling and milling parameters is most marked in terms of surface quality in the circumferential direction. Material removal rates and tool flank wear must be maintained within the control limits to maintain hole integrity.

A Comparison between the Properties of Solid Cylinders and Tube Products in Multi-Pass Hot Radial Forging Using Finite Element Method

NASA Astrophysics Data System (ADS)

Abedian, A.; Poursina, M.; Golestanian, H.

2007-05-01

Radial forging is an open die forging process used for reducing the diameter of shafts, tubes, stepped shafts and axels, and creating internal profiles for tubes such as rifling of gun barrels. In this work, a comprehensive study of multi-pass hot radial forging of short hollow and solid products are presented using 2-D axisymmetric finite element simulation. The workpiece is modeled as an elastic-viscoplastic material. A mixture of Coulomb law and constant limit shear is used to model the die-workpiece and mandrel-workpiece contacts. Thermal effects are also taken in to account. Three-pass radial forging of solid cylinders and tube products are considered. Temperature, stress, strain and metal flow distribution are obtained in each pass through thermo-mechanical simulation. The numerical results are compared with available experimental data and are in good agreement with them.

Counterrotating-Shoulder Mechanism for Friction Stir Welding

NASA Technical Reports Server (NTRS)

Nunes, Arthur C., Jr.

2007-01-01

A counterrotating-shoulder mechanism has been proposed as an alternative to the mechanism and fixtures used in conventional friction stir welding. The mechanism would internally react most or all of the forces and torques exerted on the workpiece, making it unnecessary to react the forces and torques through massive external fixtures. In conventional friction stir welding, a rotating pin tool is inserted into, and moved along, a weld seam. As the pin tool moves, it stirs together material from the opposite sides of the seam to form the weld. A large axial plunge force must be exerted upon the workpiece through and by the pin tool and a shoulder attached above the pin tool in order to maintain the pressure necessary for the process. The workpiece is secured on top of an anvil, which supports the workpiece against the axial plunge force and against the torque exerted by the pin tool and shoulder. The anvil and associated fixtures must be made heavy (and, therefore, are expensive) to keep the workpiece stationary. In addition, workpiece geometries must be limited to those that can be accommodated by the fixtures. The predecessor of the proposed counterrotating-shoulder mechanism is a second-generation, self-reacting tool, resembling a bobbin, that makes it possible to dispense with the heavy anvil. This tool consists essentially of a rotating pin tool with opposing shoulders. Although the opposing shoulders maintain the necessary pressure without need to externally apply or react a large plunge force, the torque exerted on the workpiece remains unreacted in the absence of a substantial external fixture. Depending on the RPM and the thickness of the workpiece, the torque can be large. The proposed mechanism (see figure) would include a spindle attached to a pin tool with a lower shoulder. The spindle would be coupled via splines to the upper one of three bevel gears in a differential drive. The middle bevel gear would be the power-input gear and would be coupled to the upper and lower bevel gears. The lower bevel gear would be attached to the upper shoulder and would slide and rotate freely over the spindle. The spindle would be fastened by its threaded upper end to an external submechanism that would exert axial tension on the spindle to load the workpiece in compression between the shoulders. By reducing or eliminating (relative to the use of a self reacting tool) the torque that must be reacted externally, the use of the proposed tool would reduce the tendency toward distortion or slippage of the workpiece. To begin a weld, the spindle would be inserted through a hole in the workpiece or run-on tab at the beginning of the seam and fastened to the loading submechanism. Rotation and axial loading would be increased gradually from zero and, after a time to be determined by trial and error, translation along the weld seam would be increased gradually from zero to a steady weld speed. The weld would be ended by running the mechanism off the workpiece or, if the lower shoulder were detachable, by detaching the lower shoulder from the spindle and pulling the pin tool out.

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.

Experiments for practical education in process parameter optimization for selective laser sintering to increase workpiece quality

NASA Astrophysics Data System (ADS)

Reutterer, Bernd; Traxler, Lukas; Bayer, Natascha; Drauschke, Andreas

2016-04-01

Selective Laser Sintering (SLS) is considered as one of the most important additive manufacturing processes due to component stability and its broad range of usable materials. However the influence of the different process parameters on mechanical workpiece properties is still poorly studied, leading to the fact that further optimization is necessary to increase workpiece quality. In order to investigate the impact of various process parameters, laboratory experiments are implemented to improve the understanding of the SLS limitations and advantages on an educational level. Experiments are based on two different workstations, used to teach students the fundamentals of SLS. First of all a 50 W CO2 laser workstation is used to investigate the interaction of the laser beam with the used material in accordance with varied process parameters to analyze a single-layered test piece. Second of all the FORMIGA P110 laser sintering system from EOS is used to print different 3D test pieces in dependence on various process parameters. Finally quality attributes are tested including warpage, dimension accuracy or tensile strength. For dimension measurements and evaluation of the surface structure a telecentric lens in combination with a camera is used. A tensile test machine allows testing of the tensile strength and the interpreting of stress-strain curves. The developed laboratory experiments are suitable to teach students the influence of processing parameters. In this context they will be able to optimize the input parameters depending on the component which has to be manufactured and to increase the overall quality of the final workpiece.

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

NASA Astrophysics Data System (ADS)

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

1994-02-01

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

Robotic Water Blast Cleaner

NASA Technical Reports Server (NTRS)

Sharpe, M. H.; Roberts, M. L.; Hill, W. E.; Jackson, C. H.

1983-01-01

Water blasting system under development removes hard, dense, extraneous material from surfaces. High pressure pump forces water at supersonic speed through nozzle manipulated by robot. Impact of water blasts away unwanted material from workpiece rotated on air bearing turntable. Designed for removing thermal-protection material, system is adaptable to such industrial processes as cleaning iron or steel castings.

Mitigated-force carriage for high magnetic field environments

DOEpatents

Ludtka, Gerard M.; Ludtka, Gail M.; Wilgen, John B.; Murphy, Bart L.

2015-05-19

A carriage for high magnetic field environments includes a plurality of work-piece separators disposed in an operable relationship with a work-piece processing magnet having a magnetic field strength of at least 1 Tesla for supporting and separating a plurality of work-pieces by a preselected, essentially equal spacing, so that, as a first work-piece is inserted into the magnetic field, a second work-piece is simultaneously withdrawn from the magnetic field, so that an attractive magnetic force imparted on the first work-piece offsets a resistive magnetic force imparted on the second work-piece.

Apparatus for checking dimensions of workpieces

DOEpatents

Possati, Mario; Golinelli, Guido

1992-01-01

An apparatus for checking features of workpieces with rotational symmetry defining a geometrical axis, which includes a base, rest devices fixed to the base for supporting the workpiece with the geometrical axis horizontally arranged, and a support structure coupled to the base for rotation about a horizontal axis. A counterweight and sensor are coupled to the support structure and movable with the support structure from a rest position, allowing loading of the workpiece to be checked onto the rest devices to a working position where the sensor is brought into cooperation with the workpiece. The axis of rotation of the support structure is arranged below the axis of the workpiece, in correspondence to a vertical geometrical plane passing through the workpiece geometric axis when the workpiece is positioned on the rest devices.

Thin film deposition by electric and magnetic crossed-field diode sputtering. [Patent application

DOEpatents

Welch, K.M.

1975-04-04

Applying a coating of titanium nitride to a klystron window by means of a cross-field diode sputtering array is described. The array is comprised of a cohesive group of numerous small hollow electrically conducting cylinders and is mounted so that the open ends of the cylinders on one side of the group are adjacent to a titanium cathode plate. The workpiece is mounted so as to face the open ends of the other side of the group. A magnetic field is applied to the array so as to be coaxial with the cylinders and a potential is applied across the cylinders and the cathode plate, the cylinders as an anode being positive with respect to the cathode plate. The cylinders, the cathode plate, and the workpiece are situated in an atmosphere of nitrogen which becomes ionized such as by field emission because of the electric field between the cylinders and cathode plate, thereby establishing an anode-cathode discharge that results in sputtering of the titanium plate. The sputtered titanium coats the workpiece and chemically combines with the nitrogen to form a titanium nitride coating on the workpiece. Gas pressure, gas mixtures, cathode material composition, voltages applied to the cathode and anode, the magnetic field, cathode, anode and workpiece spacing, and the aspect ratio (ratio of length to inner diameter) of the anode cylinders, all may be controlled to provide consistent optimum thin film coatings of various compositions and thickness. Another facet of the disclosure is the coating of microwave components per se with titanium nitride to reduce multifactoring under operating conditions of the components.

Auto-adjustable pin tool for friction stir welding

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor); Oelgoetz, Peter A. (Inventor)

1999-01-01

An auto-adjusting pin tool for friction stir welding is presented wherein the pin tool automatically adjusts for welding materials of varying thicknesses, and the pin can be incrementally withdrawn from the workpieces thus eliminating any crater or keyhole in the weld. The inventive apparatus is comprised of a welding head housing a motor connected to a controller instrument package and an arbor supported by bearings. The arbor forms an interior cylinder and is encircled by a stationary slip ring though which are ported hydraulic passageways into the interior cylinder of the arbor such that a piston housed therein may be moved axially. Coupled to the piston is a pin tool which is treaded on its lower end and which is moveably seated in, and extending through, a shoulder housing having concave lower face. When welding, the rotating treaded end of the pin enters and stirs the workpieces while the lower face of the shoulder housing compacts the workpieces. As the welding head traverses the shoulder housing the controller senses any rising pressure on the lower face of the shoulder housing and withdraws the arbor to keep the pressure constant. At the same time, the piston moves towards the workpieces thus extending the pin further from the shoulder. This keeps the pin at a proper depth in the workpieces regardless of their thicknesses. As the weld terminates this same operation can be used to incrementally withdraw the pin during the final part of the traverse, thus eliminating any keyhole or crater that would otherwise be created.

Convergent Polishing: A Simple, Rapid, Full Aperture Polishing Process of High Quality Optical Flats & Spheres

PubMed Central

Suratwala, Tayyab; Steele, Rusty; Feit, Michael; Dylla-Spears, Rebecca; Desjardin, Richard; Mason, Dan; Wong, Lana; Geraghty, Paul; Miller, Phil; Shen, Nan

2014-01-01

Convergent Polishing is a novel polishing system and method for finishing flat and spherical glass optics in which a workpiece, independent of its initial shape (i.e., surface figure), will converge to final surface figure with excellent surface quality under a fixed, unchanging set of polishing parameters in a single polishing iteration. In contrast, conventional full aperture polishing methods require multiple, often long, iterative cycles involving polishing, metrology and process changes to achieve the desired surface figure. The Convergent Polishing process is based on the concept of workpiece-lap height mismatch resulting in pressure differential that decreases with removal and results in the workpiece converging to the shape of the lap. The successful implementation of the Convergent Polishing process is a result of the combination of a number of technologies to remove all sources of non-uniform spatial material removal (except for workpiece-lap mismatch) for surface figure convergence and to reduce the number of rogue particles in the system for low scratch densities and low roughness. The Convergent Polishing process has been demonstrated for the fabrication of both flats and spheres of various shapes, sizes, and aspect ratios on various glass materials. The practical impact is that high quality optical components can be fabricated more rapidly, more repeatedly, with less metrology, and with less labor, resulting in lower unit costs. In this study, the Convergent Polishing protocol is specifically described for fabricating 26.5 cm square fused silica flats from a fine ground surface to a polished ~λ/2 surface figure after polishing 4 hr per surface on a 81 cm diameter polisher. PMID:25489745

Laser material processing system

DOEpatents

Dantus, Marcos

2015-04-28

A laser material processing system and method are provided. A further aspect of the present invention employs a laser for micromachining. In another aspect of the present invention, the system uses a hollow waveguide. In another aspect of the present invention, a laser beam pulse is given broad bandwidth for workpiece modification.

An analytical method for prediction of stability lobes diagram of milling of large-size thin-walled workpiece

NASA Astrophysics Data System (ADS)

Yao, Jiming; Lin, Bin; Guo, Yu

2017-01-01

Different from common thin-walled workpiece, in the process of milling of large-size thin-walled workpiece chatter in the axial direction along the spindle is also likely to happen because of the low stiffness of the workpiece in this direction. An analytical method for prediction of stability lobes of milling of large-size thin-walled workpiece is presented in this paper. In the method, not only frequency response function of the tool point but also frequency response function of the workpiece is considered.

Methods for the Precise Locating and Forming of Arrays of Curved Features into a Workpiece

DOEpatents

Gill, David Dennis; Keeler, Gordon A.; Serkland, Darwin K.; Mukherjee, Sayan D.

2008-10-14

Methods for manufacturing high precision arrays of curved features (e.g. lenses) in the surface of a workpiece are described utilizing orthogonal sets of inter-fitting locating grooves to mate a workpiece to a workpiece holder mounted to the spindle face of a rotating machine tool. The matching inter-fitting groove sets in the workpiece and the chuck allow precisely and non-kinematically indexing the workpiece to locations defined in two orthogonal directions perpendicular to the turning axis of the machine tool. At each location on the workpiece a curved feature can then be on-center machined to create arrays of curved features on the workpiece. The averaging effect of the corresponding sets of inter-fitting grooves provide for precise repeatability in determining, the relative locations of the centers of each of the curved features in an array of curved features.

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.

Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Jain, Rahul; Pal, Surjya Kanta; Singh, Shiv Brat

2017-02-01

Friction Stir Welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Finite Element Method (FEM) is an important tool to predict state variables of the process but numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present work, a three dimensional coupled thermo-mechanical method based on Lagrangian implicit method is proposed to study the thermal history, strain distribution and thermo-mechanical process in butt welding of Aluminum alloy 2024 using DEFORM-3D software. Workpiece is defined as rigid-visco plastic material and sticking condition between tool and work piece is defined. Adaptive re-meshing is used to tackle high mesh distortion. Effect of tool rotational and welding speed on plastic strain is studied and insight is given on asymmetric nature of FSW process. Temperature distribution on the workpiece and tool is predicted and maximum temperature is found in workpiece top surface.

Numerical and experimental study on multi-pass laser bending of AH36 steel strips

NASA Astrophysics Data System (ADS)

Fetene, Besufekad N.; Kumar, Vikash; Dixit, Uday S.; Echempati, Raghu

2018-02-01

Laser bending is a process of bending of plates, small sized sheets, strips and tubes, in which a moving or stationary laser beam heats the workpiece to achieve the desired curvature due to thermal stresses. Researchers studied the effects of different process parameters related to the laser source, material and workpiece geometry on laser bending of metal sheets. The studies are focused on large sized sheets. The workpiece geometry parameters like sheet thickness, length and width also affect the bend angle considerably. In this work, the effects of width and thickness on multi-pass laser bending of AH36 steel strips were studied experimentally and numerically. Finite element model using ABAQUS® was developed to investigate the size effect on the prediction of the bend angle. Microhardness and flexure tests showed an increase in the flexural strength as well as microhardness in the scanned zone. The microstructures of the bent strips also supported the physical observations.

Ductile mode grinding of reaction-bonded silicon carbide mirrors.

PubMed

Dong, Zhichao; Cheng, Haobo

2017-09-10

The demand for reaction-bonded silicon carbide (RB-SiC) mirrors has escalated recently with the rapid development of space optical remote sensors used in astronomy or Earth observation. However, RB-SiC is difficult to machine due to its high hardness. This study intends to perform ductile mode grinding to RB-SiC, which produces superior surface integrity and fewer subsurface damages, thus minimizing the workload of subsequent lapping and polishing. For this purpose, a modified theoretical model for grain depth of cut of grinding wheels is presented, which correlates various processing parameters and the material characteristics (i.e., elastic module) of a wheel's bonding matrix and workpiece. Ductile mode grinding can be achieved as the grain depth of cut of wheels decreases to be less than the critical cut depth of workpieces. The theoretical model gives a roadmap to optimize the grinding parameters for ductile mode grinding of RB-SiC and other ultra-hard brittle materials. Its feasibility was validated by experiments. With the optimized grinding parameters for RB-SiC, the ductile mode grinding produced highly specular surfaces (with roughness of ∼2.2-2.8  nm Ra), which means the material removal mechanism of RB-SiC is dominated by plastic deformation rather than brittle fracture. Contrast experiments were also conducted on fused silica, using the same grinding parameters; this produced only very rough surfaces, which further validated the feasibility of the proposed model.

Testing of an actively damped boring bar featuring structurally integrated PZT stack actuators

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

Redmond, J.; Barney, P.

This paper summarizes the results of cutting tests performed using an actively damped boring bar to minimize chatter in metal cutting. A commercially available 2 inch diameter boring bar was modified to incorporate PZT stack actuators for controlling tool bending vibrations encountered during metal removal. The extensional motion of the actuators induce bending moments in the host structure through a two-point preloaded mounting scheme. Cutting tests performed at various speeds and depths of cuts on a hardened steel workpiece illustrate the bar`s effectiveness toward eliminating chatter vibrations and improving workpiece surface finish.

Use of dual coolant displacing media for in-process optical measurement of form profiles

NASA Astrophysics Data System (ADS)

Gao, Y.; Xie, F.

2018-07-01

In-process measurement supports feedback control to reduce workpiece surface form error. Without it, the workpiece surface must be measured offline causing significant errors in workpiece positioning and reduced productivity. To offer better performance, a new in-process optical measurement method based on the use of dual coolant displacing media is proposed and studied, which uses an air and liquid phase together to resist coolant and to achieve in-process measurement. In the proposed new design, coolant is used to replace the previously used clean water to avoid coolant dilution. Compared with the previous methods, the distance between the applicator and the workpiece surface can be relaxed to 1 mm. The result is 4 times larger than before, thus permitting measurement of curved surfaces. The use of air is up to 1.5 times less than the best method previously available. For a sample workpiece with curved surfaces, the relative error of profile measurement under coolant conditions can be as small as 0.1% compared with the one under no coolant conditions. Problems in comparing measured 3D surfaces are discussed. A comparative study between a Bruker Npflex optical profiler and the developed new in-process optical profiler was conducted. For a surface area of 5.5 mm  ×  5.5 mm, the average measurement error under coolant conditions is only 0.693 µm. In addition, the error due to the new method is only 0.10 µm when compared between coolant and no coolant conditions. The effect of a thin liquid film on workpiece surface is discussed. The experimental results show that the new method can successfully solve the coolant dilution problem and is able to accurately measure the workpiece surface whilst fully submerged in the opaque coolant. The proposed new method is advantageous and should be very useful for in-process optical form profile measurement in precision machining.

Process for the formation of wear- and scuff-resistant carbon coatings

DOEpatents

Malaczynski, Gerard W.; Qiu, Xiaohong; Mantese, Joseph V.; Elmoursi, Alaa A.; Hamdi, Aboud H.; Wood, Blake P.; Walter, Kevin C.; Nastasi, Michael A.

1995-01-01

A process for forming an adherent diamond-like carbon coating on a workpiece of suitable material such as an aluminum alloy is disclosed. The workpiece is successively immersed in different plasma atmospheres and subjected to short duration, high voltage, negative electrical potential pulses or constant negative electrical potentials or the like so as to clean the surface of oxygen atoms, implant carbon atoms into the surface of the alloy to form carbide compounds while codepositing a carbonaceous layer on the surface, bombard and remove the carbonaceous layer, and to thereafter deposit a generally amorphous hydrogen-containing carbon layer on the surface of the article.

Modifications in the AA5083 Johnson-Cook Material Model for Use in Friction Stir Welding Computational Analyses

DTIC Science & Technology

2011-12-30

which reduces the need for expensive post-weld machining; and (g) low environmental impact . However, some disadvantages of the FSW process have also...next set to that of AISI- H13 , a hot-worked tool steel, frequently used as the FSW-tool material (Ref 16). The work-piece material is assumed to be

Characteristics and performance of the variable polarity plasma arc welding process used in the Space Shuttle external tank

NASA Technical Reports Server (NTRS)

Hung, R. J.; Lee, C. C.; Liu, J. W.

1990-01-01

Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. Flow profiles and power distribution of argon plasma gas as a working fluid to produce plasma arc jet in the VPPA welding process was analyzed. Major loss of heat transfer for flow through the nozzle is convective heat transfer; for the plasma jet flow between the outlet of the nozzle and workpiece is radiative heat transfer; and for the flow through the keyhole of the workpiece is convective heat transfer. The majority of the power absorbed by the keyhole of the workpiece is used for melting the solid metal workpiece into a molten metallic puddle. The crown and root widths and the crown and root heights can be predicted. An algorithm for promoting automatic control of flow parameters and the dimensions of the final product of the welding specification to be used for the VPPA Welding System operated at MSFC are provided.

Non-contact capacitance based image sensing method and system

DOEpatents

Novak, James L.; Wiczer, James J.

1995-01-01

A system and a method is provided for imaging desired surfaces of a workpiece. A sensor having first and second sensing electrodes which are electrically isolated from the workpiece is positioned above and in proximity to the desired surfaces of the workpiece. An electric field is developed between the first and second sensing electrodes of the sensor in response to input signals being applied thereto and capacitance signals are developed which are indicative of any disturbances in the electric field as a result of the workpiece. An image signal of the workpiece may be developed by processing the capacitance signals. The image signals may provide necessary control information to a machining device for machining the desired surfaces of the workpiece in processes such as deburring or chamfering. Also, the method and system may be used to image dimensions of weld pools on a workpiece and surfaces of glass vials. The sensor may include first and second preview sensors used to determine the feed rate of a workpiece with respect to the machining device.

Non-contact capacitance based image sensing method and system

DOEpatents

Novak, James L.; Wiczer, James J.

1994-01-01

A system and a method for imaging desired surfaces of a workpiece. A sensor having first and second sensing electrodes which are electrically isolated from the workpiece is positioned above and in proximity to the desired surfaces of the workpiece. An electric field is developed between the first and second sensing electrodes of the sensor in response to input signals being applied thereto and capacitance signals are developed which are indicative of any disturbances in the electric field as a result of the workpiece. An image signal of the workpiece may be developed by processing the capacitance signals. The image signals may provide necessary control information to a machining device for machining the desired surfaces of the workpiece in processes such as deburring or chamfering. Also, the method and system may be used to image dimensions of weld pools on a workpiece and surfaces of glass vials. The sensor may include first and second preview sensors used to determine the feed rate of a workpiece with respect to the machining device.

Performing in-feed type centerless grinding process on a surface grinder

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

Xu, W.; Wu, Y.; Sato, T.

2011-01-17

In our previous study, a new centerless grinding method using surface grinder was proposed. In this method, centerless grinding operations are performed by installing a compact centerless grinding unit, consisting mainly of an ultrasonic elliptic-vibration shoe, a blade and their respective holders, on the worktable of a surface grinder. During grinding, the cylindrical workpiece is held on the ultrasonic shoe and the blade, and its rotational motion is controlled by the elliptic motion of the shoe end-face. An actual unit had been produced and its performance in tangential-feed type centerless grinding using a surface grinder had been confirmed in themore » previous workd. In this paper, the performance of the grinding unit in in-feed centerless grinding operation was confirmed, and the effects of the main process parameter, i.e., eccentric angle, on the workpiece roundness was investigated experimentally. The obtained results showed that: (1) the centerless grinding unit performed well in in-feed type centerless grinding; (2) the eccentric angle affects roundness significantly, and its optimal angle is 6 deg.; (3) the workpiece roundness can be further improved by varying the eccentric angle during grinding, and the final roundness reached 0.65 {mu}m after grinding as the eccentric angle varied from 9 deg. to 6 deg. and to 3 deg.« less

Performing in-feed type centerless grinding process on a surface grinder

NASA Astrophysics Data System (ADS)

Xu, W.; Wu, Y.; Sato, T.; Lin, W.

2011-01-01

In our previous study, a new centerless grinding method using surface grinder was proposed. In this method, centerless grinding operations are performed by installing a compact centerless grinding unit, consisting mainly of an ultrasonic elliptic-vibration shoe, a blade and their respective holders, on the worktable of a surface grinder. During grinding, the cylindrical workpiece is held on the ultrasonic shoe and the blade, and its rotational motion is controlled by the elliptic motion of the shoe end-face. An actual unit had been produced and its performance in tangential-feed type centerless grinding using a surface grinder had been confirmed in the previous workd. In this paper, the performance of the grinding unit in in-feed centerless grinding operation was confirmed, and the effects of the main process parameter, i.e., eccentric angle, on the workpiece roundness was investigated experimentally. The obtained results showed that: (1) the centerless grinding unit performed well in in-feed type centerless grinding; (2) the eccentric angle affects roundness significantly, and its optimal angle is 6°; (3) the workpiece roundness can be further improved by varying the eccentric angle during grinding, and the final roundness reached 0.65 μm after grinding as the eccentric angle varied from 9° to 6° and to 3°.

Self-aligning lathe chuck jaws

DOEpatents

Peterson, William R.

1982-01-01

A lathe chuck jaw for a lathe chuck having a radially moving actuator which radially moves the jaw in to and out from the workpiece. A jaw base part is rigidly connected to the actuator. A jaw shoe part is rotatably attached to the base part. The shoe part has a workpiece-comforming surface which can hold the workpiece. The rotatable attachment of the shoe part allows it to match the general orientation of the workpiece, including a nonlongitudinal orientation due to a workpiece's imperfect shape.

Self-aligning lathe chuck jaws

DOEpatents

Not Available

1980-08-26

A lathe chuck jaw for a lathe chuck having a radially moving actuator which radially moves the jaw into and out from the workpiece is described. A jaw base part is rigidly connected to the actuator. A jaw shoe part is rotatably attached to the base part. The shoe part has a workpiece-conforming surface which can hold the workpiece. The rotatable attachment of the shoe part allows it to match the general orientation of the workpiece, including a nonlongitudinal orientation due to a workpiece's imperfect shape.

Study of the influence of the cutting temperature on the magnitude of the contact forces in the machining fixtures

NASA Astrophysics Data System (ADS)

Cioată, V. G.; Kiss, I.; Alexa, V.; Raţiu, S. A.; Racov, M.

2018-01-01

In the machining process, the workpieces are installed in machining fixtures in order to establish a strictly determined position with the cutting tool or its trajectory. During the cutting process, the weight of the workpiece, the forces and moments of inertia, cutting forces and moments, clamping forces, the heat released during the cutting process determine the contact forces between the locators and the workpiece. The magnitude of these forces is important because too large value can destroy the surface of the workpiece, and a too small value can cause the workpiece to slip on the locators or even the loss of the contact with the workpiece. Both situations must be avoided. The paper presents a study, realized with CAE software, regarding the influence of the cutting temperature on the magnitude of the contact forces in a machining fixture for the milling a rectangular workpiece.

Investigations into the mechanism of material removal and surface modification at atomic scale on stainless steel using molecular dynamics simulation

NASA Astrophysics Data System (ADS)

Ranjan, Prabhat; Balasubramaniam, R.; Jain, V. K.

2018-06-01

A molecular dynamics simulation (MDS) has been carried out to investigate the material removal phenomenon of chemo-mechanical magnetorheological finishing (CMMRF) process. To understand the role of chemical assisted mechanical abrasion in CMMRF process, material removal phenomenon is subdivided into three different stages. In the first stage, new atomic bonds viz. Fe-O-Si is created on the surface of the workpiece (stainless steel). The second stage deals with the rupture of parent bonds like Fe-Fe on the workpiece. In the final stage, removal of material from the surface in the form of dislodged debris (cluster of atoms) takes place. Effects of process parameters like abrasive particles, depth of penetration and initial surface condition on finishing force, potential energy (towards secondary phenomenon such as chemical instability of the finished surface) and material removal at atomic scale have been investigated. It was observed that the type of abrasive particle is one of the important parameters to produce atomically smooth surface. Experiments were also conducted as per the MDS to generate defect-free and sub-nanometre-level finished surface (Ra value better than 0.2 nm). The experimental results reasonably agree well with the simulation results.

Non-contact capacitance based image sensing method and system

DOEpatents

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

1994-01-25

A system and a method for imaging desired surfaces of a workpiece is described. A sensor having first and second sensing electrodes which are electrically isolated from the workpiece is positioned above and in proximity to the desired surfaces of the workpiece. An electric field is developed between the first and second sensing electrodes of the sensor in response to input signals being applied thereto and capacitance signals are developed which are indicative of any disturbances in the electric field as a result of the workpiece. An image signal of the workpiece may be developed by processing the capacitance signals. The image signals may provide necessary control information to a machining device for machining the desired surfaces of the workpiece in processes such as deburring or chamfering. Also, the method and system may be used to image dimensions of weld pools on a workpiece and surfaces of glass vials. The sensor may include first and second preview sensors used to determine the feed rate of a workpiece with respect to the machining device. 18 figures.

Non-contact capacitance based image sensing method and system

DOEpatents

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

1995-01-03

A system and a method is provided for imaging desired surfaces of a workpiece. A sensor having first and second sensing electrodes which are electrically isolated from the workpiece is positioned above and in proximity to the desired surfaces of the workpiece. An electric field is developed between the first and second sensing electrodes of the sensor in response to input signals being applied thereto and capacitance signals are developed which are indicative of any disturbances in the electric field as a result of the workpiece. An image signal of the workpiece may be developed by processing the capacitance signals. The image signals may provide necessary control information to a machining device for machining the desired surfaces of the workpiece in processes such as deburring or chamfering. Also, the method and system may be used to image dimensions of weld pools on a workpiece and surfaces of glass vials. The sensor may include first and second preview sensors used to determine the feed rate of a workpiece with respect to the machining device. 18 figures.

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.

The variable polarity plasma arc welding process: Characteristics and performance

NASA Technical Reports Server (NTRS)

Hung, R. J.; Zhu, G. J.

1991-01-01

Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. The power distribution was analyzed for an argon plasma gas flow constituting the fluid in the VPPA Welding Process. The major heat loss at the torch nozzle is convective heat transfer; in the space between the outlet of the nozzle and the workpiece; radiative heat transfer; and in the keyhole in the workpiece, convective heat transfer. The power absorbed at the workpiece produces the molten puddle that solidifies into the weld bead. Crown and root widths, and crown and root heights of the weld bead are predicted. The basis is provided for an algorithm for automatic control of VPPA welding machine parameters to obtain desired weld bead dimensions.

Experimental Research and Method for Calculation of 'Upsetting-with-Buckling' Load at the Impression-Free (Dieless) Preforming of Workpiece

NASA Astrophysics Data System (ADS)

Kukhar, Volodymir; Artiukh, Victor; Prysiazhnyi, Andrii; Pustovgar, Andrey

2018-03-01

This paper presents the results of experimental studies of load characteristic changes during the upsetting of high billets with the upsetting ratio (height to diameter ratio) from 3.0 to 6.0, which is followed by buckling. Such pass is an effective way of preforming the workpiece for production of forgings with a bended axis or dual forming, and belongs to impression-free (dieless) operation of bulk forming. Based on the experimental data analysis, an engineering method for calculation of workpiece pre-forming load as a maximum buckling force has been developed. The analysis of the obtained data confirmed the possibility of performing of this pre-forming operation on the main forging equipment, since the load of shaping by buckling does not exceed the load of the dieforging.

Production of Transitional Diffused Layers by Electrospark Coating

NASA Astrophysics Data System (ADS)

Smolentsev, Vladislav P.; Boldyrev, Alexander I.; Smolentsev, Evgeniy V.; Boldyrev, Alexander A.; Mozgalin, Vladislav L.

2018-03-01

The article presents a new method for production of diffused transitional layers with nano- and microthickness by local removal of nanofilms on aluminum alloys. This allows procuring of high-quality coatings on fusible alloys (for example, on aluminum ones) by materials, the melting point of which is 2-3 times higher than that of the basis (for example, of cast iron). This permits imparting new useful properties to workpieces made from light alloys with decent values for electrochemical working. The authors show that application of coatings provides minimum heating of workpieces. This enables the regulation in temperature condition of operating environment and permits efficiency improving during the process of electrochemical working by means of higher density current supply.

Magnetic particle inspection

NASA Technical Reports Server (NTRS)

Sastri, Sankar

1990-01-01

The purpose of this experiment is to familiarize the student with magnetic particle inspection and relate it to classification of various defects. Magnetic particle inspection is a method of detecting the presence of cracks, laps, tears, inclusions, and similar discontinuities in ferromagnetic materials such as iron and steel. This method will most clearly show defects that are perpendicular to the magnetic field. The Magnaglo method uses a liquid which is sprayed on the workpiece to be inspected, and the part is magnetized at the same time. The workpiece is then viewed under a black light, and the presence of discontinuity is shown by the formation of a bright indication formed by the magnetic particles over the discontinuity. The equipment and experimental procedures are described.

Cutting assembly

DOEpatents

Racki, Daniel J.; Swenson, Clark E.; Bencloski, William A.; Wineman, Arthur L.

1984-01-01

A cutting apparatus includes a support table mounted for movement toward and away from a workpiece and carrying a mirror which directs a cutting laser beam onto the workpiece. A carrier is rotatably and pivotally mounted on the support table between the mirror and workpiece and supports a conduit discharging gas toward the point of impingement of the laser beam on the workpiece. Means are provided for rotating the carrier relative to the support table to place the gas discharging conduit in the proper positions for cuts made in different directions on the workpiece.

Apparatus and method for forming a workpiece surface into a non-rotationally symmetric shape

DOEpatents

Dow, Thomas A.; Garrard, Kenneth P.; Moorefield, II, George M.; Taylor, Lauren W.

1995-11-21

A turning machine includes a controller for generating both aspherical and non-symmetrical shape components defining the predetermined shape, and a controller for controlling a spindle and a positionable cutting blade to thereby form a predetermined non-rotationally symmetric shape in a workpiece surface. The apparatus includes a rotatable spindle for rotatably mounting the workpiece about an axis, a spindle encoder for sensing an angular position of the rotating workpiece, the cutting blade, and radial and transverse positioners for relatively positioning the cutting blade and workpiece along respective radial and transverse directions. The controller cooperates with a fast transverse positioner for positioning the cutting blade in predetermined varying transverse positions during a revolution of the workpiece.

Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

DTIC Science & Technology

2011-01-01

tool material (AISI H13 tool steel ) is modeled as an isotropic linear-elastic material. Within the analysis, the effects of some of the FSW key process...threads/m; (b) tool 598 material = AISI H13 tool steel ; (c) workpiece material = 599 AA5059; (d) tool rotation speed = 500 rpm; (e) tool travel 600 speed...the strain-hardening term is augmented to take into account for the effect of dynamic recrystallization) while the FSW tool material (AISI H13

Defect detection and classification of galvanized stamping parts based on fully convolution neural network

NASA Astrophysics Data System (ADS)

Xiao, Zhitao; Leng, Yanyi; Geng, Lei; Xi, Jiangtao

2018-04-01

In this paper, a new convolution neural network method is proposed for the inspection and classification of galvanized stamping parts. Firstly, all workpieces are divided into normal and defective by image processing, and then the defective workpieces extracted from the region of interest (ROI) area are input to the trained fully convolutional networks (FCN). The network utilizes an end-to-end and pixel-to-pixel training convolution network that is currently the most advanced technology in semantic segmentation, predicts result of each pixel. Secondly, we mark the different pixel values of the workpiece, defect and background for the training image, and use the pixel value and the number of pixels to realize the recognition of the defects of the output picture. Finally, the defect area's threshold depended on the needs of the project is set to achieve the specific classification of the workpiece. The experiment results show that the proposed method can successfully achieve defect detection and classification of galvanized stamping parts under ordinary camera and illumination conditions, and its accuracy can reach 99.6%. Moreover, it overcomes the problem of complex image preprocessing and difficult feature extraction and performs better adaptability.

Backscattering spectrometry device for identifying unknown elements present in a workpiece

DOEpatents

Doyle, Barney L.; Knapp, James A.

1991-01-01

A backscattering spectrometry method and device for identifying and quantifying impurities in a workpiece during processing and manufacturing of that workpiece. While the workpiece is implanted with an ion beam, that same ion beam backscatters resulting from collisions with known atoms and with impurities within the workpiece. Those ions backscatter along a predetermined scattering angle and are filtered using a self-supporting filter to stop the ions with a lower energy because they collided with the known atoms of the workpiece of a smaller mass. Those ions which pass through the filter have a greater energy resulting from impact with impurities having a greater mass than the known atoms of the workpiece. A detector counts the number and measures the energy of the ions which pass through the filter. From the energy determination and knowledge of the scattering angle, a mass calculation determines the identity, and from the number and solid angle of the scattering angle, a relative concentration of the impurity is obtained.

Analytical and Experimental Investigation of Process Loads on Incremental Severe Plastic Deformation

NASA Astrophysics Data System (ADS)

Okan Görtan, Mehmet

2017-05-01

From the processing point of view, friction is a major problem in the severe plastic deformation (SPD) using equal channel angular pressing (ECAP) process. Incremental ECAP can be used in order to optimize frictional effects during SPD. A new incremental ECAP has been proposed recently. This new process called as equal channel angular swaging (ECAS) combines the conventional ECAP and the incremental bulk metal forming method rotary swaging. ECAS tool system consists of two dies with an angled channel that contains two shear zones. During ECAS process, two forming tool halves, which are concentrically arranged around the workpiece, perform high frequency radial movements with short strokes, while samples are pushed through these. The oscillation direction nearly coincides with the shearing direction in the workpiece. The most important advantages in comparison to conventional ECAP are a significant reduction in the forces in material feeding direction plus the potential to be extended to continuous processing. In the current study, the mechanics of the ECAS process is investigated using slip line field approach. An analytical model is developed to predict process loads. The proposed model is validated using experiments and FE simulations.

Influence of the arc plasma parameters on the weld pool profile in TIG welding

NASA Astrophysics Data System (ADS)

Toropchin, A.; Frolov, V.; Pipa, A. V.; Kozakov, R.; Uhrlandt, D.

2014-11-01

Magneto-hydrodynamic simulations of the arc and fluid simulations of the weld pool can be beneficial in the analysis and further development of arc welding processes and welding machines. However, the appropriate coupling of arc and weld pool simulations needs further improvement. The tungsten inert gas (TIG) welding process is investigated by simulations including the weld pool. Experiments with optical diagnostics are used for the validation. A coupled computational model of the arc and the weld pool is developed using the software ANSYS CFX. The weld pool model considers the forces acting on the motion of the melt inside and on the surface of the pool, such as Marangoni, drag, electromagnetic forces and buoyancy. The experimental work includes analysis of cross-sections of the workpieces, highspeed video images and spectroscopic measurements. Experiments and calculations have been performed for various currents, distances between electrode and workpiece and nozzle diameters. The studies show the significant impact of material properties like surface tension dependence on temperature as well as of the arc structure on the weld pool behaviour and finally the weld seam depth. The experimental weld pool profiles and plasma temperatures are in good agreement with computational results.

Method and apparatus for spatially uniform electropolishing and electrolytic etching

DOEpatents

Mayer, Steven T.; Contolini, Robert J.; Bernhardt, Anthony F.

1992-01-01

In an electropolishing or electrolytic etching apparatus the anode is separated from the cathode to prevent bubble transport to the anode and to produce a uniform current distribution at the anode by means of a solid nonconducting anode-cathode barrier. The anode extends into the top of the barrier and the cathode is outside the barrier. A virtual cathode hole formed in the bottom of the barrier below the level of the cathode permits current flow while preventing bubble transport. The anode is rotatable and oriented horizontally facing down. An extended anode is formed by mounting the workpiece in a holder which extends the electropolishing or etching area beyond the edge of the workpiece to reduce edge effects at the workpiece. A reference electrode controls cell voltage. Endpoint detection and current shut-off stop polishing. Spatially uniform polishing or etching can be rapidly performed.

Method and apparatus for spatially uniform electropolishing and electrolytic etching

DOEpatents

Mayer, S.T.; Contolini, R.J.; Bernhardt, A.F.

1992-03-17

In an electropolishing or electrolytic etching apparatus the anode is separated from the cathode to prevent bubble transport to the anode and to produce a uniform current distribution at the anode by means of a solid nonconducting anode-cathode barrier. The anode extends into the top of the barrier and the cathode is outside the barrier. A virtual cathode hole formed in the bottom of the barrier below the level of the cathode permits current flow while preventing bubble transport. The anode is rotatable and oriented horizontally facing down. An extended anode is formed by mounting the workpiece in a holder which extends the electropolishing or etching area beyond the edge of the workpiece to reduce edge effects at the workpiece. A reference electrode controls cell voltage. Endpoint detection and current shut-off stop polishing. Spatially uniform polishing or etching can be rapidly performed. 6 figs.

Application of Deep Cryogenic Treatment to Uncoated Tungsten Carbide Inserts in the Turning of AISI 304 Stainless Steel

NASA Astrophysics Data System (ADS)

Özbek, Nursel Altan; Çİçek, Adem; Gülesİn, Mahmut; Özbek, Onur

2016-12-01

This study investigated the effects of deep cryogenic treatment (DCT) on the wear performance of uncoated tungsten carbide inserts. AISI 304 austenitic stainless steel, widely used in industry, was selected as the workpiece material. Cutting experiments showed that the amount of wear significantly increased with increasing cutting speed. In addition, it was found that DCT contributed to the wear resistance of the turning inserts. The treated turning inserts were less worn by 48 and 38 pct in terms of crater wear and notch wear, respectively, whereas they exhibited up to 18 pct superior wear performance in terms of flank wear. This was attributed to the precipitation of new and finer η-carbides and their homogeneous distribution in the microstructure of the tungsten carbide material after deep cryogenic treatment. Analyses via image processing, hardness measurements, and SEM observations confirmed these findings.

Computational Modeling of Microstructural-Evolution in AISI 1005 Steel During Gas Metal Arc Butt Welding

NASA Astrophysics Data System (ADS)

Grujicic, M.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Arakere, A.; Yen, C.-F.; Cheeseman, B. A.

2013-05-01

A fully coupled (two-way), transient, thermal-mechanical finite-element procedure is developed to model conventional gas metal arc welding (GMAW) butt-joining process. Two-way thermal-mechanical coupling is achieved by making the mechanical material model of the workpiece and the weld temperature-dependent and by allowing the potential work of plastic deformation resulting from large thermal gradients to be dissipated in the form of heat. To account for the heat losses from the weld into the surroundings, heat transfer effects associated with natural convection and radiation to the environment and thermal-heat conduction to the adjacent workpiece material are considered. The procedure is next combined with the basic physical-metallurgy concepts and principles and applied to a prototypical (plain) low-carbon steel (AISI 1005) to predict the distribution of various crystalline phases within the as-welded material microstructure in different fusion zone and heat-affected zone locations, under given GMAW-process parameters. The results obtained are compared with available open-literature experimental data to provide validation/verification for the proposed GMAW modeling effort.

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.

Dwell time algorithm based on the optimization theory for magnetorheological finishing

NASA Astrophysics Data System (ADS)

Zhang, Yunfei; Wang, Yang; Wang, Yajun; He, Jianguo; Ji, Fang; Huang, Wen

2010-10-01

Magnetorheological finishing (MRF) is an advanced polishing technique capable of rapidly converging to the required surface figure. This process can deterministically control the amount of the material removed by varying a time to dwell at each particular position on the workpiece surface. The dwell time algorithm is one of the most important key techniques of the MRF. A dwell time algorithm based on the1 matrix equation and optimization theory was presented in this paper. The conventional mathematical model of the dwell time was transferred to a matrix equation containing initial surface error, removal function and dwell time function. The dwell time to be calculated was just the solution to the large, sparse matrix equation. A new mathematical model of the dwell time based on the optimization theory was established, which aims to minimize the 2-norm or ∞-norm of the residual surface error. The solution meets almost all the requirements of precise computer numerical control (CNC) without any need for extra data processing, because this optimization model has taken some polishing condition as the constraints. Practical approaches to finding a minimal least-squares solution and a minimal maximum solution are also discussed in this paper. Simulations have shown that the proposed algorithm is numerically robust and reliable. With this algorithm an experiment has been performed on the MRF machine developed by ourselves. After 4.7 minutes' polishing, the figure error of a flat workpiece with a 50 mm diameter is improved by PV from 0.191λ(λ = 632.8 nm) to 0.087λ and RMS 0.041λ to 0.010λ. This algorithm can be constructed to polish workpieces of all shapes including flats, spheres, aspheres, and prisms, and it is capable of improving the polishing figures dramatically.

Multi-stage FE simulation of hot ring rolling

NASA Astrophysics Data System (ADS)

Wang, C.; Geijselaers, H. J. M.; van den Boogaard, A. H.

2013-05-01

As a unique and important member of the metal forming family, ring rolling provides a cost effective process route to manufacture seamless rings. Applications of ring rolling cover a wide range of products in aerospace, automotive and civil engineering industries [1]. Above the recrystallization temperature of the material, hot ring rolling begins with the upsetting of the billet cut from raw stock. Next a punch pierces the hot upset billet to form a hole through the billet. This billet, referred to as preform, is then rolled by the ring rolling mill. For an accurate simulation of hot ring rolling, it is crucial to include the deformations, stresses and strains from the upsetting and piercing process as initial conditions for the rolling stage. In this work, multi-stage FE simulations of hot ring rolling process were performed by mapping the local deformation state of the workpiece from one step to the next one. The simulations of upsetting and piercing stages were carried out by 2D axisymmetric models using adaptive remeshing and element erosion. The workpiece for the ring rolling stage was subsequently obtained after performing a 2D to 3D mapping. The commercial FE package LS-DYNA was used for the study and user defined subroutines were implemented to complete the control algorithm. The simulation results were analyzed and also compared with those from the single-stage FE model of hot ring rolling.

3D simulation of friction stir welding based on movable cellular automaton method

NASA Astrophysics Data System (ADS)

Eremina, Galina M.

2017-12-01

The paper is devoted to a 3D computer simulation of the peculiarities of material flow taking place in friction stir welding (FSW). The simulation was performed by the movable cellular automaton (MCA) method, which is a representative of particle methods in mechanics. Commonly, the flow of material in FSW is simulated based on computational fluid mechanics, assuming the material as continuum and ignoring its structure. The MCA method considers a material as an ensemble of bonded particles. The rupture of interparticle bonds and the formation of new bonds enable simulations of crack nucleation and healing as well as mas mixing and microwelding. The simulation results showed that using pins of simple shape (cylinder, cone, and pyramid) without a shoulder results in small displacements of plasticized material in workpiece thickness directions. Nevertheless, the optimal ratio of longitudinal velocity to rotational speed makes it possible to transport the welded material around the pin several times and to produce a joint of good quality.

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.

Effect of Carbon in the Dielectric Fluid and Workpieces on the Characteristics of Recast Layers Machined by Electrical Discharge Machining

NASA Astrophysics Data System (ADS)

Muttamara, Apiwat; Kanchanomai, Chaosuan

2016-06-01

Electrical discharge machining (EDM) is a popular non-traditional machining technique that is usually performed in kerosene. Carbon from the kerosene is mixed into the recast layer during EDM, increasing its hardness. EDM can be performed in deionized water, which causes decarburization. We studied the effects of carbon in the dielectric fluid and workpiece on the characteristics of recast layers. Experiments were conducted using gray cast iron and mild steel workpieces in deionized water or kerosene under identical operating conditions. Scanning electron microscopy revealed that the recast layer formed on gray iron was rougher than that produced on mild steel. Moreover, the dispersion of graphite flakes in the gray iron seemed to cause subsurface cracks, even when EDM was performed in deionized water. Dendritic structures and iron carbides were found in the recast layer of gray iron treated in deionized water. Kerosene caused more microcracks to form and increased surface roughness compared with deionized water. The microcrack length per unit area of mild steel treated in deionized water was greater than that treated in kerosene, but the cracks formed in kerosene were wider. The effect of the diffusion of carbon during cooling on the characteristics of the recast layer was discussed.

Use of miniature magnetic sensors for real-time control of the induction heating process

DOEpatents

Bentley, Anthony E.; Kelley, John Bruce; Zutavern, Fred J.

2002-01-01

A method of monitoring the process of induction heating a workpiece. A miniature magnetic sensor located near the outer surface of the workpiece measures changes in the surface magnetic field caused by changes in the magnetic properties of the workpiece as it heats up during induction heating (or cools down during quenching). A passive miniature magnetic sensor detects a distinct magnetic spike that appears when the saturation field, B.sub.sat, of the workpiece has been exceeded. This distinct magnetic spike disappears when the workpiece's surface temperature exceeds its Curie temperature, due to the sudden decrease in its magnetic permeability. Alternatively, an active magnetic sensor can also be used to measure changes in the resonance response of the monitor coil when the excitation coil is linearly swept over 0-10 MHz, due to changes in the magnetic permeability and electrical resistivity of the workpiece as its temperature increases (or decreases).

Thermal Stir Welder

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2012-01-01

A welding apparatus is provided for forming a weld joint between first and second elements of a workpiece. The apparatus heats the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding mixer, to remove any dendritic-type weld microstructures introduced into the interface material during heating.

Reusable captive blind fastener

NASA Technical Reports Server (NTRS)

Peterson, S. A. (Inventor)

1981-01-01

A one piece reusable fastener capable of joining materials together from one side (blind backside) comprises a screw driven pin ending in a wedge-shaped expander cone. The cone cooperates within a slotted collar end which has a number of tangs on a cylindrical body. The fastener is set by inserting it through aligned holes in the workpieces to be joined. Turning the pin in one direction draws the cone into the collar, deforming the tangs radially outward to mate with tapered back-tapered hold in the workpiece, thus fastening the two pieces together. Reversing the direction of the pin withdraws the cone from the collar, and allows the tangs to resume their contracted configuration without withdrawing the fastener from the insertion hole. The fastener is capable of joining materials together from only one side with substantial strength in tension and shear over many resue attachment cycles, with no special operations on the main assembly parts other than the tapering of the back end of the insertion hole.

Apparatus and method for deterministic control of surface figure during full aperture polishing

DOEpatents

Suratwala, Tayyab Ishaq; Feit, Michael Dennis; Steele, William Augustus

2013-11-19

A polishing system configured to polish a lap includes a lap configured to contact a workpiece for polishing the workpiece; and a septum configured to contact the lap. The septum has an aperture formed therein. The radius of the aperture and radius the workpiece are substantially the same. The aperture and the workpiece have centers disposed at substantially the same radial distance from a center of the lap. The aperture is disposed along a first radial direction from the center of the lap, and the workpiece is disposed along a second radial direction from the center of the lap. The first and second radial directions may be opposite directions.

Establishment of a Cutting Fluid Control System (Phase 1)

DTIC Science & Technology

1981-01-01

that prevent or reduce welding of contacting areas and minimize both material transfer and generation of metallic debris within the contact zone...not on ceramic abrasives. Welding between ceramics and workpiece materials is, however, less of a problem than metal-metal contact phenomena in...fluid film (hatched area) - no wear and low friction. Mating surfaces contacting at asperities with local plastic deformation and welding - wear with

Microwave interferometer controls cutting depth of plastics

NASA Technical Reports Server (NTRS)

Heisman, R. M.; Iceland, W. F.

1969-01-01

Microwave interferometer system controls the cutting of plastic materials to a prescribed depth. The interferometer is mounted on a carriage with a spindle and cutting tool. A cross slide, mounted on the carriage, allows the interferometer and cutter to move toward or away from the plastic workpiece.

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.

Apparatus and method for deterministic control of surface figure during full aperture pad polishing

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

Suratwala, Tayyab Ishaq; Feit, Michael Douglas; Steele, William Augustus

A polishing system configured to polish a lap includes a lap configured to contact a workpiece for polishing the workpiece; and a septum configured to contact the lap. The septum has an aperture formed therein. The radius of the aperture and radius the workpiece are substantially the same. The aperture and the workpiece have centers disposed at substantially the same radial distance from a center of the lap. The aperture is disposed along a first radial direction from the center of the lap, and the workpiece is disposed along a second radial direction from the center of the lap. Themore » first and second radial directions may be opposite directions.« less

Air-Bearing Table for Machine Shops

NASA Technical Reports Server (NTRS)

Ambrisco, D.

1986-01-01

Frequent workpiece repositioning made easier. Air-bearing table facilitates movement of heavy workpiece during machining or between repeated operations at different positions. Table assembly consists of workpiece supporting fixture riding on air bearing. Table especially useful for inertia welding, in which ease of mobility is important.

Processor and method for developing a set of admissible fixture designs for a workpiece

DOEpatents

Brost, R.C.; Goldberg, K.Y.; Wallack, A.S.; Canny, J.

1996-08-13

A fixture process and method is provided for developing a complete set of all admissible fixture designs for a workpiece which prevents the workpiece from translating or rotating. The fixture processor generates the set of all admissible designs based on geometric access constraints and expected applied forces on the workpiece. For instance, the fixture processor may generate a set of admissible fixture designs for first, second and third locators placed in an array of holes on a fixture plate and a translating clamp attached to the fixture plate for contacting the workpiece. In another instance, a fixture vice is used in which first, second, third and fourth locators are used and first and second fixture jaws are tightened to secure the workpiece. The fixture process also ranks the set of admissible fixture designs according to a predetermined quality metric so that the optimal fixture design for the desired purpose may be identified from the set of all admissible fixture designs. 27 figs.

Processor and method for developing a set of admissible fixture designs for a workpiece

DOEpatents

Brost, Randolph C.; Goldberg, Kenneth Y.; Wallack, Aaron S.; Canny, John

1996-01-01

A fixture process and method is provided for developing a complete set of all admissible fixture designs for a workpiece which prevents the workpiece from translating or rotating. The fixture processor generates the set of all admissible designs based on geometric access constraints and expected applied forces on the workpiece. For instance, the fixture processor may generate a set of admissible fixture designs for first, second and third locators placed in an array of holes on a fixture plate and a translating clamp attached to the fixture plate for contacting the workpiece. In another instance, a fixture vice is used in which first, second, third and fourth locators are used and first and second fixture jaws are tightened to secure the workpiece. The fixture process also ranks the set of admissible fixture designs according to a predetermined quality metric so that the optimal fixture design for the desired purpose may be identified from the set of all admissible fixture designs.

Evolution of stacking fault tetrahedral and work hardening effect in copper single crystals

NASA Astrophysics Data System (ADS)

Liu, Hai Tao; Zhu, Xiu Fu; Sun, Ya Zhou; Xie, Wen Kun

2017-11-01

Stacking fault tetrahedral (SFT), generated in machining of copper single crystal as one type of subsurface defects, has significant influence on the performance of workpiece. In this study, molecular dynamics (MD) simulation is used to investigate the evolution of stacking fault tetrahedral in nano-cutting of copper single crystal. The result shows that SFT is nucleated at the intersection of differently oriented stacking fault (SF) planes and SFT evolves from the preform only containing incomplete surfaces into a solid defect. The evolution of SFT contains several stress fluctuations until the complete formation. Nano-indentation simulation is then employed on the machined workpiece from nano-cutting, through which the interaction between SFT and later-formed dislocations in subsurface is studied. In the meanwhile, force-depth curves obtained from nano-indentation on pristine and machined workpieces are compared to analyze the mechanical properties. By simulation of nano-cutting and nano-indentation, it is verified that SFT is a reason of the work hardening effect.

Sinuous flow in metals

PubMed Central

Yeung, Ho; Viswanathan, Koushik; Compton, Walter Dale; Chandrasekar, Srinivasan

2015-01-01

Annealed metals are surprisingly difficult to cut, involving high forces and an unusually thick “chip.” This anomaly has long been explained, based on ex situ observations, using a model of smooth plastic flow with uniform shear to describe material removal by chip formation. Here we show that this phenomenon is actually the result of a fundamentally different collective deformation mode—sinuous flow. Using in situ imaging, we find that chip formation occurs via large-amplitude folding, triggered by surface undulations of a characteristic size. The resulting fold patterns resemble those observed in geophysics and complex fluids. Our observations establish sinuous flow as another mesoscopic deformation mode, alongside mechanisms such as kinking and shear banding. Additionally, by suppressing the triggering surface undulations, sinuous flow can be eliminated, resulting in a drastic reduction of cutting forces. We demonstrate this suppression quite simply by the application of common marking ink on the free surface of the workpiece material before the cutting. Alternatively, prehardening a thin surface layer of the workpiece material shows similar results. Besides obvious implications to industrial machining and surface generation processes, our results also help unify a number of disparate observations in the cutting of metals, including the so-called Rehbinder effect. PMID:26216980

Sinuous flow in metals.

PubMed

Yeung, Ho; Viswanathan, Koushik; Compton, Walter Dale; Chandrasekar, Srinivasan

2015-08-11

Annealed metals are surprisingly difficult to cut, involving high forces and an unusually thick "chip." This anomaly has long been explained, based on ex situ observations, using a model of smooth plastic flow with uniform shear to describe material removal by chip formation. Here we show that this phenomenon is actually the result of a fundamentally different collective deformation mode--sinuous flow. Using in situ imaging, we find that chip formation occurs via large-amplitude folding, triggered by surface undulations of a characteristic size. The resulting fold patterns resemble those observed in geophysics and complex fluids. Our observations establish sinuous flow as another mesoscopic deformation mode, alongside mechanisms such as kinking and shear banding. Additionally, by suppressing the triggering surface undulations, sinuous flow can be eliminated, resulting in a drastic reduction of cutting forces. We demonstrate this suppression quite simply by the application of common marking ink on the free surface of the workpiece material before the cutting. Alternatively, prehardening a thin surface layer of the workpiece material shows similar results. Besides obvious implications to industrial machining and surface generation processes, our results also help unify a number of disparate observations in the cutting of metals, including the so-called Rehbinder effect.

Mechanical properties of silicon in subsurface damage layer from nano-grinding studied by atomistic simulation

NASA Astrophysics Data System (ADS)

Zhang, Zhiwei; Chen, Pei; Qin, Fei; An, Tong; Yu, Huiping

2018-05-01

Ultra-thin silicon wafer is highly demanded by semi-conductor industry. During wafer thinning process, the grinding technology will inevitably induce damage to the surface and subsurface of silicon wafer. To understand the mechanism of subsurface damage (SSD) layer formation and mechanical properties of SSD layer, atomistic simulation is the effective tool to perform the study, since the SSD layer is in the scale of nanometer and hardly to be separated from underneath undamaged silicon. This paper is devoted to understand the formation of SSD layer, and the difference between mechanical properties of damaged silicon in SSD layer and ideal silicon. With the atomistic model, the nano-grinding process could be performed between a silicon workpiece and diamond tool under different grinding speed. To reach a thinnest SSD layer, nano-grinding speed will be optimized in the range of 50-400 m/s. Mechanical properties of six damaged silicon workpieces with different depths of cut will be studied. The SSD layer from each workpiece will be isolated, and a quasi-static tensile test is simulated to perform on the isolated SSD layer. The obtained stress-strain curve is an illustration of overall mechanical properties of SSD layer. By comparing the stress-strain curves of damaged silicon and ideal silicon, a degradation of Young's modulus, ultimate tensile strength (UTS), and strain at fracture is observed.

CONTROL FOR ROLLING MILL

DOEpatents

Shuck, A.B.; Shaw, W.C.

1961-06-20

A plutonium-rolling apparatus is patented that has two sets of feed rolls, shaping rolls between the feed rolls, and grippers beyond the feed rolls, which ready a workpiece for a new pass through the shaping rolls by angularly shifting the workpiece about its axis or transversely moving it on a line parallel to the axes of the shaping rolls. Actuation of each gripper for gripping or releasing the workpiece is produced by the relative positions assumed by the feed rolls adjacent to the gripper as the workpiece enters or leaves the feed rolls.

Method For Characterizing Residual Stress In Metals

DOEpatents

Jacobson, Loren A.; Michel, David J.; Wyatt, Jeffrey R.

2002-12-03

A method is provided for measuring the residual stress in metals. The method includes the steps of drilling one or more holes in a metal workpiece to a preselected depth and mounting one or more acoustic sensors on the metal workpiece and connecting the sensors to an electronic detecting and recording device. A liquid metal capable of penetrating into the metal workpiece placed at the bottom of the hole or holes. A recording is made over a period of time (typically within about two hours) of the magnitude and number of noise events which occur as the liquid metal penetrates into the metal workpiece. The magnitude and number of noise events are then correlated to the internal stress in the region of the workpiece at the bottom of the hole.

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

PubMed

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

2018-06-14

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

Plastic deformation history in infeed rotary swaging process

NASA Astrophysics Data System (ADS)

Liu, Yang; Herrmann, Marius; Schenck, Christian; Kuhfuss, Bernd

2017-10-01

In bulk forming processes, the net shape of a final product is achieved by plastic deformation as the material flows from the initial shape to the final shape of the workpiece. The material flow during the process is an important issue for its relationship with forging force, heat generation, microstructure transformation and energy consumption. Hence, the final properties of the product are directly influenced. Former researches showed that the material flow in the rotary swaging process is affected by different processing parameters like die angle, feeding velocity and friction condition. Thus, a profound knowledge of detailed material flow during the process is essential for a better understanding of the process. By using FEM, the material flow was investigated by the history of the plastic strain (PEEQ) development. In this study a 2D-axisymmetric model was built by using ABAQUS explicit. Both aluminum alloy (3.3206) and steel (1.0308) are studied with different feeding velocities and coefficients of friction. To achieve the development of PEEQ in different areas, the workpiece was divided into radial layers. The PEEQ history of each layer was tracked during the quasi-static forming process. Based on that, the plastic strain rate (PSR) was calculated and examined in a single stroke of the process. In that way, the material flow in different layers is presented and the material flow on the surface differs from that in the center, just the first 1/4 radial area from the surface is sensitive to different friction conditions.

Fabrication of Single Crystal MgO Capsules

NASA Technical Reports Server (NTRS)

Danielson, Lisa

2012-01-01

A method has been developed for machining MgO crystal blocks into forms for containing metallic and silicate liquids at temperatures up to 2,400 C, and pressures up to at least 320 kilobars. Possible custom shapes include tubes, rods, insulators, capsules, and guides. Key differences in this innovative method include drilling along the crystallographic zone axes, use of a vibration minimizing material to secure the workpiece, and constant flushing of material swarf with a cooling medium/lubricant (water). A single crystal MgO block is cut into a section .5 mm thick, 1 cm on a side, using a low-speed saw with a 0.004 blade. The cut is made parallel to the direction of cleavage. The block may be cut to any thickness to achieve the desired length of the piece. To minimize drilling vibrations, the MgO block is mounted on a piece of adhesive putty in a vise. The putty wad cradles the bottom half of the entire block. Diamond coring tools are used to drill the MgO to the desired custom shape, with water used to wet and wash the surface of swarf. Compressed air may also be used to remove swarf during breaks in drilling. The MgO workpiece must be kept cool at all times with water. After all the swarf is rinsed off, the piece is left to dry overnight. If the workpiece is still attached to the base of the MgO block after drilling, it may be cut off by using a diamond cutoff wheel on a rotary hand tool or by using a low-speed saw.

Thermal stir welding process

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2012-01-01

A welding method is provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

Thermal stir welding apparatus

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2011-01-01

A welding method and apparatus are provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

Mesoscopic Model — Advanced Simulation of Microforming Processes

NASA Astrophysics Data System (ADS)

Geißdörfer, Stefan; Engel, Ulf; Geiger, Manfred

2007-04-01

Continued miniaturization in many fields of forming technology implies the need for a better understanding of the effects occurring while scaling down from conventional macroscopic scale to microscale. At microscale, the material can no longer be regarded as a homogeneous continuum because of the presence of only a few grains in the deformation zone. This leads to a change in the material behaviour resulting among others in a large scatter of forming results. A correlation between the integral flow stress of the workpiece and the scatter of the process factors on the one hand and the mean grain size and its standard deviation on the other hand has been observed in experiments. The conventional FE-simulation of scaled down processes is not able to consider the size-effects observed such as the actual reduction of the flow stress, the increasing scatter of the process factors and a local material flow being different to that obtained in the case of macroparts. For that reason, a new simulation model has been developed taking into account all the size-effects. The present paper deals with the theoretical background of the new mesoscopic model, its characteristics like synthetic grain structure generation and the calculation of micro material properties — based on conventional material properties. The verification of the simulation model is done by carrying out various experiments with different mean grain sizes and grain structures but the same geometrical dimensions of the workpiece.

Heat sink effects in variable polarity plasma arc welding

NASA Technical Reports Server (NTRS)

Abdelmessih, Amanie N.

1991-01-01

The Space Shuttle External Tank is fabricated by the variable polarity plasma arc (VPPA) welding process. In VPPA welding, a noble gas, usually argon, is directed through an arc to emerge from the torch as a hot plasma jet. This jet is surrounded by a shielding gas, usually helium, to protect the weld from contamination with air. The high velocity, hot plasma jet completely penetrates the workpiece (resembling a line heat source) when operated in the 'keyhole' mode. The metal melts on touching the side of the jet, as the torch travels in the perpendicular direction to the direction of the jet, and melted metal moves around the plasma jet in the keyhole forming a puddle which solidifies behind the jet. Heat sink effects are observed when there are irregularities in the workpiece configuration, especially, if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, i.e., in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of this research is to study the effect of irregularities in workpiece configuration and fixture differences (heat sink effects) on the weld bead geometry with the ultimate objective to compensate for the heat sink effects and achieve a perfect weld. Experiments were performed on different workpiece geometries and compared to approximate models.

3D space positioning and image feature extraction for workpiece

NASA Astrophysics Data System (ADS)

Ye, Bing; Hu, Yi

2008-03-01

An optical system of 3D parameters measurement for specific area of a workpiece has been presented and discussed in this paper. A number of the CCD image sensors are employed to construct the 3D coordinate system for the measured area. The CCD image sensor of the monitoring target is used to lock the measured workpiece when it enters the field of view. The other sensors, which are placed symmetrically beam scanners, measure the appearance of the workpiece and the characteristic parameters. The paper established target image segmentation and the image feature extraction algorithm to lock the target, based on the geometric similarity of objective characteristics, rapid locking the goal can be realized. When line laser beam scan the tested workpiece, a number of images are extracted equal time interval and the overlapping images are processed to complete image reconstruction, and achieve the 3D image information. From the 3D coordinate reconstruction model, the 3D characteristic parameters of the tested workpiece are gained. The experimental results are provided in the paper.

Computation of the Distribution of the Fiber-Matrix Interface Cracks in the Edge Trimming of CFRP

NASA Astrophysics Data System (ADS)

Wang, Fu-ji; Zhang, Bo-yu; Ma, Jian-wei; Bi, Guang-jian; Hu, Hai-bo

2018-04-01

Edge trimming is commonly used to bring the CFRP components to right dimension and shape in aerospace industries. However, various forms of undesirable machining damage occur frequently which will significantly decrease the material performance of CFRP. The damage is difficult to predict and control due to the complicated changing laws, causing unsatisfactory machining quality of CFRP components. Since the most of damage has the same essence: the fiber-matrix interface cracks, this study aims to calculate the distribution of them in edge trimming of CFRP, thereby to obtain the effects of the machining parameters, which could be helpful to guide the optimal selection of the machining parameters in engineering. Through the orthogonal cutting experiments, the quantitative relation between the fiber-matrix interface crack depth and the fiber cutting angle, cutting depth as well as cutting speed is established. According to the analysis on material removal process on any location of the workpiece in edge trimming, the instantaneous cutting parameters are calculated, and the formation process of the fiber-matrix interface crack is revealed. Finally, the computational method for the fiber-matrix interface cracks in edge trimming of CFRP is proposed. Upon the computational results, it is found that the fiber orientations of CFRP workpieces is the most significant factor on the fiber-matrix interface cracks, which can not only change the depth of them from micrometers to millimeters, but control the distribution image of them. Other machining parameters, only influence the fiber-matrix interface cracks depth but have little effect on the distribution image.

Elevated temperature forming method and preheater apparatus

DOEpatents

Krajewski, Paul E; Hammar, Richard Harry; Singh, Jugraj; Cedar, Dennis; Friedman, Peter A; Luo, Yingbing

2013-06-11

An elevated temperature forming system in which a sheet metal workpiece is provided in a first stage position of a multi-stage pre-heater, is heated to a first stage temperature lower than a desired pre-heat temperature, is moved to a final stage position where it is heated to a desired final stage temperature, is transferred to a forming press, and is formed by the forming press. The preheater includes upper and lower platens that transfer heat into workpieces disposed between the platens. A shim spaces the upper platen from the lower platen by a distance greater than a thickness of the workpieces to be heated by the platens and less than a distance at which the upper platen would require an undesirably high input of energy to effectively heat the workpiece without being pressed into contact with the workpiece.

Laser weld jig. [Patent application

DOEpatents

Van Blarigan, P.; Haupt, D.L.

1980-12-05

A system is provided for welding a workpiece along a predetermined weld line that may be of irregular shape, which includes the step of forming a lip on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members. Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reusable jig forming the lip, and with the jig constructed to detachably hold parts to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

Development of an active boring bar for increased chatter immunity

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

Redmond, J.; Barney, P.; Smith, D.

The development and initial evaluation of a prototype boring bar featuring active vibration control for increased chatter immunity is described. The significance of active damping both normal and tangential to the workpiece surface is evaluated, indicating the need for two axis control to ensure adequate performance over expected variations in tool mounting procedures. The prototype tool features a commercially available boring bar modified to accommodate four PZT stack actuators for two axis bending control. Measured closed-loop dynamics are combined with a computer model of the boring process to simulate increased metal removal rate and improved workpiece surface finish through activemore » control.« less

Evaluation of Contact Heat Transfer Coefficient and Phase Transformation during Hot Stamping of a Hat-Type Part

PubMed Central

Kim, Heung-Kyu; Lee, Seong Hyeon; Choi, Hyunjoo

2015-01-01

Using an inverse analysis technique, the heat transfer coefficient on the die-workpiece contact surface of a hot stamping process was evaluated as a power law function of contact pressure. This evaluation was to determine whether the heat transfer coefficient on the contact surface could be used for finite element analysis of the entire hot stamping process. By comparing results of the finite element analysis and experimental measurements of the phase transformation, an evaluation was performed to determine whether the obtained heat transfer coefficient function could provide reasonable finite element prediction for workpiece properties affected by the hot stamping process. PMID:28788046

Gas Metal Arc Welding Process Modeling and Prediction of Weld Microstructure in MIL A46100 Armor-Grade Martensitic Steel

NASA Astrophysics Data System (ADS)

Grujicic, M.; Arakere, A.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.; Montgomery, J. S.

2013-06-01

A conventional gas metal arc welding (GMAW) butt-joining process has been modeled using a two-way fully coupled, transient, thermal-mechanical finite-element procedure. To achieve two-way thermal-mechanical coupling, the work of plastic deformation resulting from potentially high thermal stresses is allowed to be dissipated in the form of heat, and the mechanical material model of the workpiece and the weld is made temperature dependent. Heat losses from the deposited filler-metal are accounted for by considering conduction to the adjoining workpieces as well as natural convection and radiation to the surroundings. The newly constructed GMAW process model is then applied, in conjunction with the basic material physical-metallurgy, to a prototypical high-hardness armor martensitic steel (MIL A46100). The main outcome of this procedure is the prediction of the spatial distribution of various crystalline phases within the weld and the heat-affected zone regions, as a function of the GMAW process parameters. The newly developed GMAW process model is validated by comparing its predictions with available open-literature experimental and computational data.

Heat input and accumulation for ultrashort pulse processing with high average power

NASA Astrophysics Data System (ADS)

Finger, Johannes; Bornschlegel, Benedikt; Reininghaus, Martin; Dohrn, Andreas; Nießen, Markus; Gillner, Arnold; Poprawe, Reinhart

2018-05-01

Materials processing using ultrashort pulsed laser radiation with pulse durations <10 ps is known to enable very precise processing with negligible thermal load. However, even for the application of picosecond and femtosecond laser radiation, not the full amount of the absorbed energy is converted into ablation products and a distinct fraction of the absorbed energy remains as residual heat in the processed workpiece. For low average power and power densities, this heat is usually not relevant for the processing results and dissipates into the workpiece. In contrast, when higher average powers and repetition rates are applied to increase the throughput and upscale ultrashort pulse processing, this heat input becomes relevant and significantly affects the achieved processing results. In this paper, we outline the relevance of heat input for ultrashort pulse processing, starting with the heat input of a single ultrashort laser pulse. Heat accumulation during ultrashort pulse processing with high repetition rate is discussed as well as heat accumulation for materials processing using pulse bursts. In addition, the relevance of heat accumulation with multiple scanning passes and processing with multiple laser spots is shown.

Method of forming through substrate vias (TSVs) and singulating and releasing die having the TSVs from a mechanical support substrate

DOEpatents

Okandan, Murat; Nielson, Gregory N

2014-12-09

Accessing a workpiece object in semiconductor processing is disclosed. The workpiece object includes a mechanical support substrate, a release layer over the mechanical support substrate, and an integrated circuit substrate coupled over the release layer. The integrated circuit substrate includes a device layer having semiconductor devices. The method also includes etching through-substrate via (TSV) openings through the integrated circuit substrate that have buried ends at or within the release layer including using the release layer as an etch stop. TSVs are formed by introducing one or more conductive materials into the TSV openings. A die singulation trench is etched at least substantially through the integrated circuit substrate around a perimeter of an integrated circuit die. The integrated circuit die is at least substantially released from the mechanical support substrate.

Electromagnetic acoustic transducer

DOEpatents

Alers, George A.; Burns, Jr., Leigh R.; MacLauchlan, Daniel T.

1988-01-01

A noncontact ultrasonic transducer for studying the acoustic properties of a metal workpiece includes a generally planar magnetizing coil positioned above the surface of the workpiece, and a generally planar eddy current coil between the magnetizing coil and the workpiece. When a large current is passed through the magnetizing coil, a large magnetic field is applied to the near-surface regions of the workpiece. The eddy current coil can then be operated as a transmitter by passing an alternating current therethrough to excite ultrasonic waves in the surface of the workpiece, or operated as a passive receiver to sense ultrasonic waves in the surface by measuring the output signal. The geometries of the two coils can be varied widely to be effective for different types of ultrasonic waves. The coils are preferably packaged in a housing which does not interfere with their operation, but protects them from a variety of adverse environmental conditions.

Closed loop control of the induction heating process using miniature magnetic sensors

DOEpatents

Bentley, Anthony E.; Kelley, John Bruce; Zutavern, Fred J.

2003-05-20

A method and system for providing real-time, closed-loop control of the induction hardening process. A miniature magnetic sensor located near the outer surface of the workpiece measures changes in the surface magnetic field caused by changes in the magnetic properties of the workpiece as it heats up during induction heating (or cools down during quenching). A passive miniature magnetic sensor detects a distinct magnetic spike that appears when the saturation field, B.sub.sat, of the workpiece has been exceeded. This distinct magnetic spike disappears when the workpiece's surface temperature exceeds its Curie temperature, due to the sudden decrease in its magnetic permeability. Alternatively, an active magnetic sensor can measure changes in the resonance response of the monitor coil when the excitation coil is linearly swept over 0-10 MHz, due to changes in the magnetic permeability and electrical resistivity of the workpiece as its temperature increases (or decreases).

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.

Laser weld jig

DOEpatents

Van Blarigan, Peter; Haupt, David L.

1982-01-01

A system is provided for welding a workpiece (10, FIG. 1) along a predetermined weld line (12) that may be of irregular shape, which includes the step of forming a lip (32) on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members (34, 36). Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space (17) at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reuseable jig (24) forming the lip, and with the jig constructed to detachably hold parts (22, 20) to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

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.

Laser cutting system

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

Dougherty, Thomas J

A workpiece cutting apparatus includes a laser source, a first suction system, and a first finger configured to guide a workpiece as it moves past the laser source. The first finger includes a first end provided adjacent a point where a laser from the laser source cuts the workpiece, and the first end of the first finger includes an aperture in fluid communication with the first suction system.

Method for joining metal by solid-state bonding

DOEpatents

Burkhart, L. Elkin; Fultz, Chester R.; Maulden, Kerry A.

1979-01-01

The present development is directed to a method for joining metal at relatively low temperatures by solid-state bonding. Planar surfaces of the metal workpieces are placed in a parallel abutting relationship with one another. A load is applied to at least one of the workpieces for forcing the workpieces together while one of the workpieces is relatively slowly oscillated in a rotary motion over a distance of about 1.degree.. After a preselected number of oscillations, the rotary motion is terminated and the bond between the abutting surfaces is effected. An additional load may be applied to facilitate the bond after terminating the rotary motion.

Method of precisely modifying predetermined surface layers of a workpiece by cluster ion impact therewith

DOEpatents

Friedman, L.; Beuhler, R.J.; Matthew, M.W.; Ledbetter, M.

1984-06-25

A method of precisely modifying a selected area of a workpiece by producing a beam of charged cluster ions that is narrowly mass selected to a predetermined mean size of cluster ions within a range of 25 to 10/sup 6/ atoms per cluster ion, and accelerated in a beam to a critical velocity. The accelerated beam is used to impact a selected area of an outer surface of the workpiece at a preselected rate of impacts of cluster ions/cm/sup 2//sec in order to effect a precise modification in that selected area of the workpiece.

Method of precisely modifying predetermined surface layers of a workpiece by cluster ion impact therewith

DOEpatents

Friedman, Lewis; Buehler, Robert J.; Matthew, Michael W.; Ledbetter, Myron

1985-01-01

A method of precisely modifying a selected area of a workpiece by producing a beam of charged cluster ions that is narrowly mass selected to a predetermined mean size of cluster ions within a range of 25 to 10.sup.6 atoms per cluster ion, and accelerated in a beam to a critical velocity. The accelerated beam is used to impact a selected area of an outer surface of the workpiece at a preselected rate of impacts of cluster ions/cm.sup.2 /sec. in order to effect a precise modification in that selected area of the workpiece.

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.

Microstructure Evolution during Friction Stir Welding of Mill-Annealed Ti-6Al-4V (Preprint)

DTIC Science & Technology

2011-05-01

welding . One of the primary concerns regarding FSW of higher temperature materials like titanium is the welding tool. High temperature materials... welds as compared to aluminum alloys. This is related to the low thermal conductivity of titanium alloys which is typically lower than that of the...of the tools and workpieces in aluminum and titanium friction stir welds . Aluminum has a greater conductivity and thermal diffusivity than the tool

Application of Yb:YAG short pulse laser system

DOEpatents

Erbert, Gaylen V.; Biswal, Subrat; Bartolick, Joseph M.; Stuart, Brent C.; Crane, John K.; Telford, Steve; Perry, Michael D.

2004-07-06

A diode pumped, high power (at least 20W), short pulse (up to 2 ps), chirped pulse amplified laser using Yb:YAG as the gain material is employed for material processing. Yb:YAG is used as the gain medium for both a regenerative amplifier and a high power 4-pass amplifier. A single common reflective grating optical device is used to both stretch pulses for amplification purposes and to recompress amplified pulses before being directed to a workpiece.

Pre-resistance-welding resistance check

DOEpatents

Destefan, Dennis E.; Stompro, David A.

1991-01-01

A preweld resistance check for resistance welding machines uses an open circuited measurement to determine the welding machine resistance, a closed circuit measurement to determine the parallel resistance of a workpiece set and the machine, and a calculation to determine the resistance of the workpiece set. Any variation in workpiece set or machine resistance is an indication that the weld may be different from a control weld.

Method and system for treating an interior surface of a workpiece using a charged particle beam

DOEpatents

Swenson, David Richard

2007-05-23

A method and system of treating an interior surface on an internal cavity of a workpiece using a charged particle beam. A beam deflector surface of a beam deflector is placed within the internal cavity of the workpiece and is used to redirect the charged particle beam toward the interior surface to treat the interior surface.

Semiconductor etching by hyperthermal neutral beams

NASA Technical Reports Server (NTRS)

Minton, Timothy K. (Inventor); Giapis, Konstantinos P. (Inventor)

1999-01-01

An at-least dual chamber apparatus and method in which high flux beams of fast moving neutral reactive species are created, collimated and used to etch semiconductor or metal materials from the surface of a workpiece. Beams including halogen atoms are preferably used to achieve anisotropic etching with good selectivity at satisfactory etch rates. Surface damage and undercutting are minimized.

A Multi-Component Automated Laser-Origami System for Cyber-Manufacturing

NASA Astrophysics Data System (ADS)

Ko, Woo-Hyun; Srinivasa, Arun; Kumar, P. R.

2017-12-01

Cyber-manufacturing systems can be enhanced by an integrated network architecture that is easily configurable, reliable, and scalable. We consider a cyber-physical system for use in an origami-type laser-based custom manufacturing machine employing folding and cutting of sheet material to manufacture 3D objects. We have developed such a system for use in a laser-based autonomous custom manufacturing machine equipped with real-time sensing and control. The basic elements in the architecture are built around the laser processing machine. They include a sensing system to estimate the state of the workpiece, a control system determining control inputs for a laser system based on the estimated data and user’s job requests, a robotic arm manipulating the workpiece in the work space, and middleware, named Etherware, supporting the communication among the systems. We demonstrate automated 3D laser cutting and bending to fabricate a 3D product as an experimental result.

Evaluation of handle design characteristics in a maximum screwdriving torque task.

PubMed

Kong, Y-K; Lowe, B D; Lee, S-J; Krieg, E F

2007-09-01

The purpose of this study was to evaluate the effects of screwdriver handle shape, surface material and workpiece orientation on torque performance, finger force distribution and muscle activity in a maximum screwdriving torque task. Twelve male subjects performed maximum screw-tightening exertions using screwdriver handles with three longitudinal shapes (circular, hexagonal and triangular), four lateral shapes (cylindrical, double frustum, cone and reversed double frustum) and two surfaces (rubber and plastic). The average finger force contributions to the total hand force were 28.1%, 39.3%, 26.5% and 6.2%, in order from index to little fingers; the average phalangeal segment force contributions were 47.3%, 14.0%, 20.5% and 18.1% for distal, middle, proximal and metacarpal phalanges, respectively. The plastic surface handles were associated with 15% less torque output (4.86 Nm) than the rubber coated handles (5.73 Nm). In general, the vertical workpiece orientation was associated with higher torque output (5.9 Nm) than the horizontal orientation (4.69 Nm). Analysis of handle shapes indicates that screwdrivers designed with a circular or hexagonal cross-sectional shape result in greater torque outputs (5.49 Nm, 5.57 Nm), with less total finger force (95 N, 105 N). In terms of lateral shape, reversed double frustum handles were associated with less torque output (5.23 Nm) than the double frustum (5.44 Nm) and cone (5.37 Nm) handles. Screwdriver handles designed with combinations of circular or hexagonal cross-sectional shapes with double frustum and cone lateral shapes were optimal in this study.

Processor and method for developing a set of admissible fixture designs for a workpiece

DOEpatents

Brost, Randolph C.; Goldberg, Kenneth Y.; Canny, John; Wallack, Aaron S.

1999-01-01

Methods and apparatus are provided for developing a complete set of all admissible Type I and Type II fixture designs for a workpiece. The fixture processor generates the set of all admissible designs based on geometric access constraints and expected applied forces on the workpiece. For instance, the fixture processor may generate a set of admissible fixture designs for first, second and third locators placed in an array of holes on a fixture plate and a translating clamp attached to the fixture plate for contacting the workpiece. In another instance, a fixture vise is used in which first, second, third and fourth locators are used and first and second fixture jaws are tightened to secure the workpiece. The fixture process also ranks the set of admissible fixture designs according to a predetermined quality metric so that the optimal fixture design for the desired purpose may be identified from the set of all admissible fixture designs.

Processor and method for developing a set of admissible fixture designs for a workpiece

DOEpatents

Brost, R.C.; Goldberg, K.Y.; Canny, J.; Wallack, A.S.

1999-01-05

Methods and apparatus are provided for developing a complete set of all admissible Type 1 and Type 2 fixture designs for a workpiece. The fixture processor generates the set of all admissible designs based on geometric access constraints and expected applied forces on the workpiece. For instance, the fixture processor may generate a set of admissible fixture designs for first, second and third locators placed in an array of holes on a fixture plate and a translating clamp attached to the fixture plate for contacting the workpiece. In another instance, a fixture vise is used in which first, second, third and fourth locators are used and first and second fixture jaws are tightened to secure the workpiece. The fixture process also ranks the set of admissible fixture designs according to a predetermined quality metric so that the optimal fixture design for the desired purpose may be identified from the set of all admissible fixture designs. 44 figs.

Abnormal Condition Monitoring of Workpieces Based on RFID for Wisdom Manufacturing Workshops.

PubMed

Zhang, Cunji; Yao, Xifan; Zhang, Jianming

2015-12-03

Radio Frequency Identification (RFID) technology has been widely used in many fields. However, previous studies have mainly focused on product life cycle tracking, and there are few studies on real-time status monitoring of workpieces in manufacturing workshops. In this paper, a wisdom manufacturing model is introduced, a sensing-aware environment for a wisdom manufacturing workshop is constructed, and RFID event models are defined. A synthetic data cleaning method is applied to clean the raw RFID data. The Complex Event Processing (CEP) technology is adopted to monitor abnormal conditions of workpieces in real time. The RFID data cleaning method and data mining technology are examined by simulation and physical experiments. The results show that the synthetic data cleaning method preprocesses data well. The CEP based on the Rifidi(®) Edge Server technology completed abnormal condition monitoring of workpieces in real time. This paper reveals the importance of RFID spatial and temporal data analysis in real-time status monitoring of workpieces in wisdom manufacturing workshops.

Control and monitoring method and system for electromagnetic forming process

DOEpatents

Kunerth, Dennis C.; Lassahn, Gordon D.

1990-01-01

A process, system, and improvement for a process for electromagnetic forming of a workpiece in which characteristics of the workpiece such as its geometry, electrical conductivity, quality, and magnetic permeability can be determined by monitoring the current and voltage in the workcoil. In an electromagnet forming process in which a power supply provides current to a workcoil and the electromagnetic field produced by the workcoil acts to form the workpiece, the dynamic interaction of the electromagnetic fields produced by the workcoil with the geometry, electrical conductivity, and magnetic permeability of the workpiece, provides information pertinent to the physical condition of the workpiece that is available for determination of quality and process control. This information can be obtained by deriving in real time the first several time derivatives of the current and voltage in the workcoil. In addition, the process can be extended by injecting test signals into the workcoil during the electromagnetic forming and monitoring the response to the test signals in the workcoil.

Abnormal Condition Monitoring of Workpieces Based on RFID for Wisdom Manufacturing Workshops

PubMed Central

Zhang, Cunji; Yao, Xifan; Zhang, Jianming

2015-01-01

Radio Frequency Identification (RFID) technology has been widely used in many fields. However, previous studies have mainly focused on product life cycle tracking, and there are few studies on real-time status monitoring of workpieces in manufacturing workshops. In this paper, a wisdom manufacturing model is introduced, a sensing-aware environment for a wisdom manufacturing workshop is constructed, and RFID event models are defined. A synthetic data cleaning method is applied to clean the raw RFID data. The Complex Event Processing (CEP) technology is adopted to monitor abnormal conditions of workpieces in real time. The RFID data cleaning method and data mining technology are examined by simulation and physical experiments. The results show that the synthetic data cleaning method preprocesses data well. The CEP based on the Rifidi® Edge Server technology completed abnormal condition monitoring of workpieces in real time. This paper reveals the importance of RFID spatial and temporal data analysis in real-time status monitoring of workpieces in wisdom manufacturing workshops. PMID:26633418

Tool For Friction Stir Tack Welding of Aluminum Alloys

NASA Technical Reports Server (NTRS)

Bjorkman, Gerald W.; Dingler, Johnny W.; Loftus, Zachary

2003-01-01

A small friction-stir-welding tool has been developed for use in tack welding of aluminum-alloy workpieces. It is necessary to tack-weld the workpieces in order to hold them together during friction stir welding because (1) in operation, a full-size friction-stir-welding tool exerts a large force that tends to separate the workpieces and (2) clamping the workpieces is not sufficient to resist this force. It is possible to tack the pieces together by gas tungsten arc welding, but the process can be awkward and time-consuming and can cause sufficient damage to necessitate rework. Friction stir tack welding does not entail these disadvantages. In addition, friction stir tack welding can be accomplished by use of the same automated equipment (except for the welding tool) used in subsequent full friction stir welding. The tool for friction stir tack welding resembles the tool for full friction stir welding, but has a narrower shoulder and a shorter pin. The shorter pin generates a smaller workpiece-separating force so that clamping suffices to keep the workpieces together. This tool produces a continuous or intermittent partial-penetration tack weld. The tack weld is subsequently consumed by action of the larger tool used in full friction stir welding tool.

System for Controlling the Stirring Pin of a Friction Stir Welding Apparatus

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor); Romine, Peter L. (Inventor); Oelgoetz, Peter A. (Inventor)

2002-01-01

A control is provided for a friction stir welding apparatus comprising a pin tool which includes a shoulder and a rotating pin extending outwardly from the shoulder of the pin tool and which, in use, is plunged into a workpiece formed contacting workpiece members to stir weld the members together. The control system controls the penetration of the pin tool into the workpiece members which are mounted on a support anvil. The control system includes a pin length controller for controlling pin length relative to the shoulder and for producing a corresponding pin length signal. A pin force sensor senses the force being exerted on the pin during welding and produces a corresponding actual pin force signal. A probe controller controls a probe extending outwardly from the pin, senses a parameter related to the distance between the probe and the supporting anvil and produces a corresponding probe signal. A workpiece standoff sensor senses the standoff distance between the workpiece and the standoff sensor and produces a corresponding standoff signal. A control unit receives the various signals, together with a weld schedule, and, based on these signals and the weld schedule, controls the pin length controller so as to control pin penetration into the workpiece.

Gimballed Shoulders for Friction Stir Welding

NASA Technical Reports Server (NTRS)

Carter, Robert; Lawless, Kirby

2008-01-01

In a proposed improvement of tooling for friction stir welding, gimballed shoulders would supplant shoulders that, heretofore, have been fixedly aligned with pins. The proposal is especially relevant to self-reacting friction stir welding. Some definitions of terms, recapitulated from related prior NASA Tech Briefs articles, are prerequisite to a meaningful description of the proposed improvement. In friction stir welding, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a pin that rotates with the shoulder and protrudes from the shoulder into the depth of the workpiece. In conventional friction stir welding, the main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional friction stir welding is augmented with an auto-adjustable pin-tool (APT) capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or forcecontrol system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding as practiced heretofore, there are two shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. Both shoulders rotate with the pin and remain aligned coaxially with the pin. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft into the friction-stir-welding machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. This concludes the prerequisite definitions of terms.

Influence of vibrational treatment on thermomechanical response of material under conditions identical to friction stir welding

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

Konovalenko, Ivan S., E-mail: ivkon@ispms.tsc.ru; Konovalenko, Igor S., E-mail: igkon@ispms.tsc.ru; Kolubaev, Evgeniy A., E-mail: eak@ispms.tsc.ru

2015-10-27

A molecular dynamics model was constructed to describe material loading on the atomic scale by the mode identical to friction stir welding. It was shown that additional vibration applied to the tool during the loading mode provides specified intensity values and continuous thermomechanical action during welding. An increase in additional vibration intensity causes an increase both in the force acting on the workpiece from the rotating tool and in temperature within the welded area.

Rugged Preheaters For Vacuum Plasma Spraying

NASA Technical Reports Server (NTRS)

Woodford, William H.; Mckechnie, Timothy N.; Sander, Lewis D.; Power, Christopher A.; Sander, Heather L.; Nguyen, Dalton D.

1994-01-01

Electric preheater units built to ensure large workpieces to be coated with metals by vacuum plasma spraying heated uniformly to requisite high temperatures by time plasma torch arrives. Units similar to electrical-resistance ribbon heaters in toasters and in some small portable electric "space" heaters. Nichrome resistance-heating ribbons wrapped around ceramic insulating spools on rings and on plates. Round workpiece placed in middle of ring preheater. Plate preheaters stacked as needed near workpiece.

Portable cutting apparatus

DOEpatents

Gilmore, Richard F.

1986-01-01

A remotely operable, portable cutting apparatus detachably secured to the workpiece by laterally spaced clamp assemblies engageable with the workpiece on opposite sides of the intended line of cut. A reciprocal cutter head is mounted between the clamp assemblies and is provided with a traveling abrasive cutting wire adapted to sever the workpiece normal to the longitudinal axis thereof. Dust and debris are withdrawn from the cutting area by a vacuum force through a nozzle mounted on the cutting head.

Portable cutting apparatus

DOEpatents

Gilmore, R.F.

1984-07-17

A remotely operable, portable cutting apparatus detachably secured to the workpiece by laterally spaced clamp assemblies engagable with the workpiece on opposite sides of the intended line of cut. A reciprocal cutter head is mounted between the clamp assemblies and is provided with a traveling abrasive cutting wire adapted to sever the workpiece normal to the longitudinal axis thereof. Dust and debris are withdrawn from the cutting area by a vacuum force through a nozzle mounted on the cutting head.

Portable cutting apparatus

DOEpatents

Gilmore, Richard F.

1986-04-01

A remotely operable, portable cutting apparatus detachably secured to the workpiece by laterally spaced clamp assemblies engageable with the workpiece on opposite sides of the intended line of cut. A reciprocal cutter head is mounted between the clamp assemblies and is provided with a traveling abrasive cutting wire adapted to sever the workpiece normal to the longitudinal axis thereof. Dust and debris are withdrawn from the cutting area by a vacuum force through a nozzle mounted on the cutting head.

Computational Analysis and Experimental Validation of the Friction-Stir Welding Behavior of Ti-6Al-4V

DTIC Science & Technology

2011-01-01

tempera- ture and high-strength workpiece materials like tita - nium. Specifically, it was shown that due to high attendant temperatures these tools...relative amounts of the two phases and are typically classified as a-type, aþb-type, and b-type alloys. Among tita - nium alloys, aþb-type are of

Apparatus and method for microwave processing of materials using field-perturbing tool

DOEpatents

Tucker, Denise A.; Fathi, Zakaryae; Lauf, Robert J.

2001-01-01

A variable frequency microwave heating apparatus designed to allow modulation of the frequency of the microwaves introduced into a multi-mode microwave cavity for heating or other selected applications. A field-perturbing tool is disposed within the cavity to perturb the microwave power distribution in order to apply a desired level of microwave power to the workpiece.

Design of a high pulse repitition frequency carbon dioxide laser for processing high damage threshold materials

NASA Astrophysics Data System (ADS)

Chatwin, Christopher R.; McDonald, Donald W.; Scott, Brian F.

1989-07-01

The absence of an applications led design philosophy has compromised both the development of laser source technology and its effective implementation into manufacturing technology in particular. For example, CO2 lasers are still incapable of processing classes of refractory and non-ferrous metals. Whilst the scope of this paper is restricted to high power CO2 lasers; the design methodology reported herein is applicable to source technology in general, which when exploited, will effect an expansion of applications. The CO2 laser operational envelope should not only be expanded to incorporate high damage threshold materials but also offer a greater degree of controllability. By a combination of modelling and experimentation the requisite beam characteristics, at the workpiece, were determined then utilised to design the Laser Manufacturing System. The design of sub-system elements was achieved by a combination of experimentation and simulation which benefited from a comprehensive set of software tools. By linking these tools the physical processes in the laser - electron processes in the plasma, the history of photons in the resonator, etc. - can be related, in a detailed model, to the heating mechanisms in the workpiece.

Monoatomic layer removal mechanism in chemical mechanical polishing process: A molecular dynamics study

NASA Astrophysics Data System (ADS)

Si, Lina; Guo, Dan; Luo, Jianbin; Lu, Xinchun

2010-03-01

Molecular dynamics simulations of nanoscratching processes were used to study the atomic-scale removal mechanism of single crystalline silicon in chemical mechanical polishing (CMP) process and particular attention was paid to the effect of scratching depth. The simulation results under a scratching depth of 1 nm showed that a thick layer of silicon material was removed by chip formation and an amorphous layer was formed on the silicon surface after nanoscratching. By contrast, the simulation results with a depth of 0.1 nm indicated that just one monoatomic layer of workpiece was removed and a well ordered crystalline surface was obtained, which is quite consistent with previous CMP experimental results. Therefore, monoatomic layer removal mechanism was presented, by which it is considered that during CMP process the material was removed by one monoatomic layer after another, and the mechanism could provide a reasonable understanding on how the high precision surface was obtained. Also, the effects of the silica particle size and scratching velocity on the removal mechanism were investigated; the wear regimes and interatomic forces between silica particle and workpiece were studied to account for the different removal mechanisms with indentation depths of 0.1 and 1 nm.

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

NASA Astrophysics Data System (ADS)

Lu, Kaibo; Lian, Zisheng; Gu, Fengshou; Liu, Hunju

2018-02-01

Machining long slender workpieces still presents a technical challenge on the shop floor due to their low stiffness and damping. Regenerative chatter is a major hindrance in machining processes, reducing the geometric accuracies and dynamic stability of the cutting system. This study has been motivated by the fact that chatter occurrence is generally in relation to the cutting position in straight turning of slender workpieces, which has seldom been investigated comprehensively in literature. In the present paper, a predictive chatter model of turning a tailstock supported slender workpiece considering the cutting position change during machining is explored. Based on linear stability analysis and stiffness distribution at different cutting positions along the workpiece, the effect of the cutting tool movement along the length of the workpiece on chatter stability is studied. As a result, an entire stability chart for a single cutting pass is constructed. Through this stability chart the critical cutting condition and the chatter onset location along the workpiece in a turning operation can be estimated. The difference between the predicted tool locations and the experimental results was within 9% at high speed cutting. Also, on the basis of the predictive model the dynamic behavior during chatter that when chatter arises at some cutting location it will continue for a period of time until another specified location is arrived at, can be inferred. The experimental observation is in good agreement with the theoretical inference. In chatter detection respect, besides the delay strategy and overlap processing technique, a relative threshold algorithm is proposed to detect chatter by comparing the spectrum and variance of the acquired acceleration signals with the reference saved during stable cutting. The chatter monitoring method has shown reliability for various machining conditions.

Implementation and verification of a four-probe motion error measurement system for a large-scale roll lathe used in hybrid manufacturing

NASA Astrophysics Data System (ADS)

Chen, Yuan-Liu; Niu, Zengyuan; Matsuura, Daiki; Lee, Jung Chul; Shimizu, Yuki; Gao, Wei; Oh, Jeong Seok; Park, Chun Hong

2017-10-01

In this paper, a four-probe measurement system is implemented and verified for the carriage slide motion error measurement of a large-scale roll lathe used in hybrid manufacturing where a laser machining probe and a diamond cutting tool are placed on two sides of a roll workpiece for manufacturing. The motion error of the carriage slide of the roll lathe is composed of two straightness motion error components and two parallelism motion error components in the vertical and horizontal planes. Four displacement measurement probes, which are mounted on the carriage slide with respect to four opposing sides of the roll workpiece, are employed for the measurement. Firstly, based on the reversal technique, the four probes are moved by the carriage slide to scan the roll workpiece before and after a 180-degree rotation of the roll workpiece. Taking into consideration the fact that the machining accuracy of the lathe is influenced by not only the carriage slide motion error but also the gravity deformation of the large-scale roll workpiece due to its heavy weight, the vertical motion error is thus characterized relating to the deformed axis of the roll workpiece. The horizontal straightness motion error can also be synchronously obtained based on the reversal technique. In addition, based on an error separation algorithm, the vertical and horizontal parallelism motion error components are identified by scanning the rotating roll workpiece at the start and the end positions of the carriage slide, respectively. The feasibility and reliability of the proposed motion error measurement system are demonstrated by the experimental results and the measurement uncertainty analysis.

Sheet metal stamping die design for warm forming

DOEpatents

Ghosh, Amit K.

2003-04-22

In metal stamping dies, by taking advantage of improved material flow by selectively warming the die, flat sections of the die can contribute to the flow of material throughout the workpiece. Local surface heating can be accomplished by placing a heating block in the die. Distribution of heating at the flat lower train central regions outside of the bend region allows a softer flow at a lower stress to enable material flow into the thinner, higher strain areas at the bend/s. The heating block is inserted into the die and is powered by a power supply.

Automated Laser Cutting In Three Dimensions

NASA Technical Reports Server (NTRS)

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

1995-01-01

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

Pre-loading of components during laser peenforming

DOEpatents

Hackel, Lloyd A [Livermore, CA; Halpin, John M [Tracy, CA; Harris, Fritz B [Rocklin, CA

2003-12-30

A method and apparatus are provided for forming shapes and contours in metal sections by prestressing a workpiece and generating laser induced compressive stress on the surface of the metal workpiece. The step of prestressing the workpiece is carried out with a jig. The laser process can generate deep compressive stresses to shape even thick components without inducing unwanted tensile stress at the metal surface. The precision of the laser-induced stress enables exact prediction and subsequent contouring of parts.

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.

Optimization of Control Points Number at Coordinate Measurements based on the Monte-Carlo Method

NASA Astrophysics Data System (ADS)

Korolev, A. A.; Kochetkov, A. V.; Zakharov, O. V.

2018-01-01

Improving the quality of products causes an increase in the requirements for the accuracy of the dimensions and shape of the surfaces of the workpieces. This, in turn, raises the requirements for accuracy and productivity of measuring of the workpieces. The use of coordinate measuring machines is currently the most effective measuring tool for solving similar problems. The article proposes a method for optimizing the number of control points using Monte Carlo simulation. Based on the measurement of a small sample from batches of workpieces, statistical modeling is performed, which allows one to obtain interval estimates of the measurement error. This approach is demonstrated by examples of applications for flatness, cylindricity and sphericity. Four options of uniform and uneven arrangement of control points are considered and their comparison is given. It is revealed that when the number of control points decreases, the arithmetic mean decreases, the standard deviation of the measurement error increases and the probability of the measurement α-error increases. In general, it has been established that it is possible to repeatedly reduce the number of control points while maintaining the required measurement accuracy.

Design and analysis of drum lathe for manufacturing large-scale optical microstructured surface and load characteristics of aerostatic spindle

NASA Astrophysics Data System (ADS)

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

2014-08-01

In this paper, a four-axis ultra-precision lathe for machining large-scale drum mould with microstructured surface is presented. Firstly, because of the large dimension and weight of drum workpiece, as well as high requirement of machining accuracy, the design guidelines and component parts of this drum lathe is introduced in detail, including control system, moving and driving components, position feedback system and so on. Additionally, the weight of drum workpiece would result in the structural deformation of this lathe, therefore, this paper analyses the effect of structural deformation on machining accuracy by means of ANSYS. The position change is approximately 16.9nm in the X-direction(sensitive direction) which could be negligible. Finally, in order to study the impact of bearing parameters on the load characteristics of aerostatic journal bearing, one of the famous computational fluid dynamics(CFD) software, FLUENT, is adopted, and a series of simulations are carried out. The result shows that the aerostatic spindle has superior performance of carrying capacity and stiffness, it is possible for this lathe to bear the weight of drum workpiece up to 1000kg since there are two aerostatic spindles in the headstock and tailstock.

Numerical investigations on the lateral angular co-extrusion of aluminium and steel

NASA Astrophysics Data System (ADS)

Behrens, B.-A.; Klose, C.; Chugreev, A.; Thürer, S. E.; Uhe, J.

2018-05-01

In order to save weight and costs, different materials can be combined within one component. In the novel process chain being developed within the Collaborative Research Centre (CRC) 1153, joined semi-finished workpieces are used to produce hybrid solid components with locally adapted properties. Different materials are joined in an initial step before the forming process takes place. Hereby, the quality of the joining zone is improved by means of the thermo-mechanical treatment during the forming and machining processes. The lateral angular co-extrusion (LACE) approach is used to produce semi-finished workpieces because it allows for the production of coaxial semi-finished products consisting of aluminium and steel. In the further process chain, these semi-finished products are processed into hybrid bearing bushings with locally adapted properties by die forging. In the scope of this work, numerical investigations of the co-extrusion of aluminium-steel compounds were carried out using finite element (FE) simulation in order to examine the influence of the process parameters on the co-extrusion process. For this purpose, the relevant material properties of the aluminium alloy EN AW-6082 were determined experimentally and subsequently implemented in the numerical model. The obtained numerical model was used to study the impact of different ram speeds, press ratios and billet temperatures on the resulting extrusion forces and the material flow. The numerical results have been validated using force-time curves obtained from experimental extrusion tests carried out on a 2.5 MN laboratory extrusion press.

Automated edge finishing using an active XY table

DOEpatents

Loucks, Clifford S.; Starr, Gregory P.

1993-01-01

The disclosure is directed to an apparatus and method for automated edge finishing using hybrid position/force control of an XY table. The disclosure is particularly directed to learning the trajectory of the edge of a workpiece by "guarded moves". Machining is done by controllably moving the XY table, with the workpiece mounted thereon, along the learned trajectory with feedback from a force sensor. Other similar workpieces can be mounted, without a fixture on the XY table, located and the learned trajectory adjusted

Rotary slot dog

DOEpatents

Cutburth, Ronald W.; Smauley, David A.

1987-01-01

A clamp or dog is disclosed which preferably comprises a slotted stepped cylindrical body which is inserted into a hole in a workpiece and then fastened to a base or fixture using a screw which is inserted through the slot. The stepped configuration provides an annular clamping surface which securely clamps the workpiece against the base or fixture. The slotted cylindrical configuration permits adjustment of the workpiece and retaining clamp in any direction, i.e., over 360.degree., relative to the mounting position of the screw in the base or fixture.

RANGE INCREASER FOR PNEUMATIC GAUGES

DOEpatents

Fowler, A.H.; Seaborn, G.B. Jr.

1960-09-27

An improved pneumatic gage is offered in which the linear range has been increased without excessive air consumption. This has been accomplished by providing an expansible antechamber connected to the nozzle of the gage so that the position of the nozzle with respect to the workpiece is varied automatically by variation in pressure within the antechamber. This arrangement ensures that the nozzle-to-workpiece clearance is maintained within certain limits, thus obtaining a linear relation of air flow to nozzle-to-workpiece clearance over a wider range.

Blue 450nm high power semiconductor continuous wave laser bars exceeding rollover output power of 80W

NASA Astrophysics Data System (ADS)

König, H.; Lell, A.; Stojetz, B.; Ali, M.; Eichler, C.; Peter, M.; Löffler, A.; Strauss, U.; Baumann, M.; Balck, A.; Malchus, J.; Krause, V.

2018-02-01

Industrial material processing like cutting or welding of metals is rather energy efficient using direct diode or diode pumped solid state lasers. However, many applications cannot be addressed by established infrared laser technology due to fundamental material properties of the workpiece: For example materials like copper or gold have too low absorption in the near infrared wavelength range to be processed efficiently by use of existing high power laser systems. The huge interest to enable high power kW systems with more suitable wavelengths in the blue spectral range triggered the German funded research project 'BLAULAS': Therein the feasibility and capability of CW operating high power laser bars based on the GaN material system was investigated by Osram and Laserline. High performance bars were enabled by defeating fundamental challenges like material quality as well as the chip processes, both of which differ significantly from well-known IR laser bars. The research samples were assembled on actively cooled heat sinks with hard solder technology. For the first time an output power of 98W per bar at 60A drive current was achieved. Conversion efficiency as high as 46% at 50W output power was demonstrated.

Biomachining: metal etching via microorganisms.

PubMed

Díaz-Tena, Estíbaliz; Barona, Astrid; Gallastegui, Gorka; Rodríguez, Adrián; López de Lacalle, L Norberto; Elías, Ana

2017-05-01

The use of microorganisms to remove metal from a workpiece is known as biological machining or biomachining, and it has gained in both importance and scientific relevance over the past decade. Conversely to mechanical methods, the use of readily available microorganisms is low-energy consuming, and no thermal damage is caused during biomachining. The performance of this sustainable process is assessed by the material removal rate, and certain parameters have to be controlled for manufacturing the machined part with the desired surface finish. Although the variety of microorganisms is scarce, cell concentration or density plays an important role in the process. There is a need to control the temperature to maintain microorganism activity at its optimum, and a suitable shaking rate provides an efficient contact between the workpiece and the biological medium. The system's tolerance to the sharp changes in pH is quite limited, and in many cases, an acid medium has to be maintained for effective performance. This process is highly dependent on the type of metal being removed. Consequently, the operating parameters need to be determined on a case-by-case basis. The biomachining time is another variable with a direct impact on the removal rate. This biological technique can be used for machining simple and complex shapes, such as series of linear, circular, and square micropatterns on different metal surfaces. The optimal biomachining process should be fast enough to ensure high production, a smooth and homogenous surface finish and, in sum, a high-quality piece. As a result of the high global demand for micro-components, biomachining provides an effective and sustainable alternative. However, its industrial-scale implementation is still pending.

Tool for Two Types of Friction Stir Welding

NASA Technical Reports Server (NTRS)

Carter, Robert

2006-01-01

A tool that would be useable in both conventional and self-reacting friction stir welding (FSW) has been proposed. The tool would embody both a prior tooling concept for self-reacting FSW and an auto-adjustable pin-tool (APT) capability developed previously as an augmentation for conventional FSW. Some definitions of terms are prerequisite to a meaningful description of the proposed tool. In conventional FSW, depicted in Figure 1, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a rotating pin that protrudes from the shoulder into the depth of the workpiece. The main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional FSW is augmented with an APT capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or force-control system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding (SR-FSW), there are two rotating shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft, back into the FSW machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. A tool for SRFSW embodying this concept was reported in "Mechanism for Self-Reacted Friction Stir Welding" (MFS-31914), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 53. In its outward appearance, the proposed tool (see Figure 2) would fit the above description of an SR-FSW tool. In this case, the FSW machine would have an APT capability and the pin would be modified to accept a bottom shoulder. The APT capability could be used to vary the distance between the front and back shoulders in real time to accommodate process and workpiece-thickness variations. The tool could readily be converted to a conventional FSW tool, with or without APT capability, by simply replacing the modified pin with a conventional FSW pin.

A new multiple air beam approach for in-process form error optical measurement

NASA Astrophysics Data System (ADS)

Gao, Y.; Li, R.

2018-07-01

In-process measurement can provide feedback for the control of workpiece precision in terms of size, roughness and, in particular, mid-spatial frequency form error. Optical measurement methods are of the non-contact type and possess high precision, as required for in-process form error measurement. In precision machining, coolant is commonly used to reduce heat generation and thermal deformation on the workpiece surface. However, the use of coolant will induce an opaque coolant barrier if optical measurement methods are used. In this paper, a new multiple air beam approach is proposed. The new approach permits the displacement of coolant from any direction and with a large thickness, i.e. with a large amount of coolant. The model, the working principle, and the key features of the new approach are presented. Based on the proposed new approach, a new in-process form error optical measurement system is developed. The coolant removal capability and the performance of this new multiple air beam approach are assessed. The experimental results show that the workpiece surface y(x, z) can be measured successfully with standard deviation up to 0.3011 µm even under a large amount of coolant, such that the coolant thickness is 15 mm. This means a relative uncertainty of 2σ up to 4.35% and the workpiece surface is deeply immersed in the opaque coolant. The results also show that, in terms of coolant removal capability, air supply and air velocity, the proposed new approach improves by, respectively, 3.3, 1.3 and 5.3 times on the previous single air beam approach. The results demonstrate the significant improvements brought by the new multiple air beam method together with the developed measurement system.

Optimization of Maghemite (γ-Fe2O3) Nano-Powder Mixed micro-EDM of CoCrMo with Multiple Responses Using Gray Relational Analysis (GRA)

NASA Astrophysics Data System (ADS)

Mejid Elsiti, Nagwa; Noordin, M. Y.; Idris, Ani; Saed Majeed, Faraj

2017-10-01

This paper presents an optimization of process parameters of Micro-Electrical Discharge Machining (EDM) process with (γ-Fe2O3) nano-powder mixed dielectric using multi-response optimization Grey Relational Analysis (GRA) method instead of single response optimization. These parameters were optimized based on 2-Level factorial design combined with Grey Relational Analysis. The machining parameters such as peak current, gap voltage, and pulse on time were chosen for experimentation. The performance characteristics chosen for this study are material removal rate (MRR), tool wear rate (TWR), Taper and Overcut. Experiments were conducted using electrolyte copper as the tool and CoCrMo as the workpiece. Experimental results have been improved through this approach.

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

NASA Astrophysics Data System (ADS)

Pitts, James Daniel

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

Study on residual stresses in ultrasonic torsional vibration assisted micro-milling

NASA Astrophysics Data System (ADS)

Lu, Zesheng; Hu, Haijun; Sun, Yazhou; Sun, Qing

2010-10-01

It is well known that machining induced residual stresses can seriously affect the dimensional accuracy, corrosion and wear resistance, etc., and further influence the longevity and reliability of Micro-Optical Components (MOC). In Ultrasonic Torsional Vibration Assisted Micro-milling (UTVAM), cutting parameters, vibration parameters, mill cutter parameters, the status of wear length of tool flank are the main factors which affect residual stresses. A 2D model of UTVAM was established with FE analysis software ABAQUS. Johnson-Cook's flow stress model and shear failure principle are used as the workpiece material model and failure principle, while friction between tool and workpiece uses modified Coulomb's law whose sliding friction area is combined with sticking friction. By means of FEA, the influence rules of cutting parameters, vibration parameters, mill cutter parameters, the status of wear length of tool flank on residual stresses are obtained, which provides a basis for choosing optimal process parameters and improving the longevity and reliability of MOC.

Diagnostics of flexible workpiece using acoustic emission, acceleration and eddy current sensors in milling operation

NASA Astrophysics Data System (ADS)

Filippov, A. V.; Tarasov, S. Yu.; Filippova, E. O.; Chazov, P. A.; Shamarin, N. N.; Podgornykh, O. A.

2016-11-01

Monitoring of the edge clamped workpiece deflection during milling has been carried our using acoustic emission, accelerometer and eddy current sensors. Such a monitoring is necessary in precision machining of vital parts used in air-space engineering where a majority of them made by milling. The applicability of the AE, accelerometers and eddy current sensors has been discussed together with the analysis of measurement errors. The appropriate sensor installation diagram has been proposed for measuring the workpiece elastic deflection exerted by the cutting force.

Hypervelocity cutting machine and method

DOEpatents

Powell, J.R.; Reich, M.

1996-11-12

A method and machine are provided for cutting a workpiece such as concrete. A gun barrel is provided for repetitively loading projectiles therein and is supplied with a pressurized propellant from a storage tank. A thermal storage tank is disposed between the propellant storage tank and the gun barrel for repetitively receiving and heating propellant charges which are released in the gun barrel for repetitively firing projectiles therefrom toward the workpiece. In a preferred embodiment, hypervelocity of the projectiles is obtained for cutting the concrete workpiece by fracturing thereof. 10 figs.

Apparatus and method for electroforming high aspect ratio micro-parts

DOEpatents

Hachman, John T [Stockton, CA; Losey, Matthew W [Rancho Cucamonga, CA; McLean, Dorrance E [Manteca, CA

2009-11-27

A fixture is disclosed to more easily affix a workpiece in the proper orientation and spacing with sealed electrical interconnection within an electrochemical plating bath. The workpiece can be any planar metallic or non-metallic substrate such as a silicon wafer commonly used in LIGA or microsystem fabrication. The fixture described allows the workpiece to be submerged deep within an electrolytic cell, facing upwards, and allows easy transfer from one cell to another. The edges, backside, and electrical connections are sealed and protected from the electrolyte.

Hybrid friction stir welding for dissimilar materials through electro-plastic effect

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

Liu, Xun; Lan, Shuhuai; Ni, Jun

A hybrid Friction Stir Welding approach and device for dissimilar materials joining employing Electro-Plastic Effect. The approach and device include an introduction of high density, short period current pulses into traditional friction stir welding process, which therefore can generate a localized softened zone in the workpiece during plastic stirring without significant additional temperature increase. This material softened zone is created by high density current pulses based on Electro-Plastic Effect and will move along with the friction stir welding tool. Smaller downward force, larger processing window and better joint quality for dissimilar materials are expected to be achieved through this hybridmore » welding technique.« less

Portable Roller Staking Tool

NASA Technical Reports Server (NTRS)

Bird, R. G.; Berson, L. A.

1983-01-01

Staking tool compact and portable. Tool combines clamping and staking operations in single unit. Tool clamps workpiece (a bearing or bushing), alines it, and stakes on of flat faces. Used for most roller staking operations which acess both faces of workpiece.

Effects of high power ultrasonic vibration on temperature distribution of workpiece in dry creep feed up grinding.

PubMed

Paknejad, Masih; Abdullah, Amir; Azarhoushang, Bahman

2017-11-01

Temperature history and distribution of steel workpiece (X20Cr13) was measured by a high tech infrared camera under ultrasonic assisted dry creep feed up grinding. For this purpose, a special experimental setup was designed and fabricated to vibrate only workpiece along two directions by a high power ultrasonic transducer. In this study, ultrasonic effects with respect to grinding parameters including depth of cut (a e ), feed speed (v w ), and cutting speed (v s ) has been investigated. The results indicate that the ultrasonic vibration has considerable effect on reduction of temperature, depth of thermal damage of workpiece and width of temperature contours. Maximum temperature reduction of 25.91% was reported at condition of v s =15m/s, v w =500mm/min, a e =0.4mm in the presence of ultrasonic vibration. Copyright © 2017 Elsevier B.V. All rights reserved.

Burnishing of rotatory parts to improve surface quality

NASA Astrophysics Data System (ADS)

Celaya, A.; López de Lacalle, L. N.; Albizuri, J.; Alberdi, R.

2009-11-01

In this paper, the use of rolling burnishing process to improve the final quality of railway and automotive workpieces is studied. The results are focused on the improvement of the manufacturing processes of rotary workpieces used in railway and automotion industry, attending to generic target of achieving `maximum surface quality with minimal process time'. Burnishing is a finishing operation in which plastic deformation of surface irregularities occurs by applying pressure through a very hard element, a roller or a ceramic ball. This process gives additional advantages to the workpiece such as good surface roughness, increased hardness and high compressive residual stresses. The effect of the initial turning conditions on the final burnishing operation has also been studied. The results show that feeds used in the initial rough turning have little influence in the surface finish of the burnished workpieces. So, the process times of the combined turning and burnishing processes can be reduced, optimizing the shaft's machining process.

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.

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

Webb, Aaron P.; Carlson, Charles T.; Weaver, William T.

A mask alignment system for providing precise and repeatable alignment between ion implantation masks and workpieces. The system includes a mask frame having a plurality of ion implantation masks loosely connected thereto. The mask frame is provided with a plurality of frame alignment cavities, and each mask is provided with a plurality of mask alignment cavities. The system further includes a platen for holding workpieces. The platen may be provided with a plurality of mask alignment pins and frame alignment pins configured to engage the mask alignment cavities and frame alignment cavities, respectively. The mask frame can be lowered ontomore » the platen, with the frame alignment cavities moving into registration with the frame alignment pins to provide rough alignment between the masks and workpieces. The mask alignment cavities are then moved into registration with the mask alignment pins, thereby shifting each individual mask into precise alignment with a respective workpiece.« less

Influence of Nanostructuration on the Sound Velocity in Aluminum Al_99.50

NASA Astrophysics Data System (ADS)

Cazac, A. M.; Alexandru, A.; Baciu, C.; Sandu, A. V.; Bejinariu, C.

2018-06-01

The paper proposes is a multidisciplinary study on the influence of nanostructured material obtained by cyclic closed die forging process, in this case the aluminum with a purity of 99.50% (Al_99.50), on the sound velocity. The study of nanomaterials is a branch of material science on the basis of which nanotechnology can be approached. Severe plastic deformation (SPD) is a generic term describing a group of metal and alloy processing techniques involving very high stresses without including significant changes in the overall dimensions of the model or workpiece. The sample is of a regular quadrangular prism shape with the side square of a = 10 mm and the height of h = 16 mm, so with a dimensional factor h / a = 1.6. For each sample, a number of 7 determinations were performed to establish a mean value for the sound velocity. As a result of the microstructure analysis, it is observed that at the deformation cycle 4 the grains have an average size between 250 and 500 nm.

Induction hardening: Differences to a conventional heat treatment process and optimization of its parameters

NASA Astrophysics Data System (ADS)

Vieweg, A.; Ressel, G.; Prevedel, P.; Raninger, P.; Panzenböck, M.; Marsoner, S.; Ebner, R.

2016-03-01

The possibility of obtaining similar mechanical properties with faster heating processes than the conventional ones has been of interest for several years. In the present study, investigations were performed in terms of the influences of such fast heat-treatments on the microstructure and mechanical properties of the material. This investigation compares an inductive with a conventional furnace heat treating process of a 50CrMo4 steel, however only the austenitizing treatment was changed and subsequent quenching and tempering was done in the same way. To this end experiments with a middle frequency generator, using different heating rates and austenitizing temperatures, were conducted and followed by oil quenching of the workpieces. The resulting structures were characterized regarding their microstructures and mechanical properties in order to gather a better understanding of the differences between the inductive and the conventional heat treating process. As a main result it was found, that the fast austenitized samples exhibited worse ductility than the conventional treated material.

Vacuum Deposition From A Welding Torch

NASA Technical Reports Server (NTRS)

Poorman, R. M.

1993-01-01

Process derived from arc welding produces films of high quality. Modified gas/tungsten-arc welding process developed for use in outer space. Welding apparatus in process includes hollow tungsten electrode through which inert gas flows so arc struck between electrode and workpiece in vacuum of space. Offers advantages of fast deposition, possibility of applying directional impetus to flow of materials, very low pressure at surface being coated, and inert environment.

Process optimization for ultrasonic vibration assisted polishing of micro-structured surfaces on super hard material

NASA Astrophysics Data System (ADS)

Sun, Zhiyuan; Guo, Bing; Rao, Zhimin; Zhao, Qingliang

2014-08-01

In consideration of the excellent property of SiC, the ground micro-structured surface quality is hard to meet the requirement - consequently the ultrasonic vibration assisted polishing (UVAP) of micro-structures of molds is proposed in this paper. Through the orthogonal experiment, the parameters of UVAP of micro-structures were optimized. The experimental results show that, abrasive polishing process, the effect of the workpiece feed rate on the surface roughness (Ra), groove tip radius (R) and material removal rate (MRR) of micro-structures is significant. While, the UVAP, the most significant effect factor for Ra, R and MRR is the ultrasonic amplitude of the ultrasonic vibration. In addition, within the scope of the polishing process parameters selected by preliminary experiments, ultrasonic amplitude of 2.5μm, polishing force of 0.5N, workpiece feed rate of 5 mm·min-1, polishing wheel rotational speed of 50rpm, polishing time of 35min, abrasive size of 100nm and the polishing liquid concentration of 15% is the best technology of UVAP of micro-structures. Under the optimal parameters, the ground traces on the micro-structured surface were removed efficiently and the integrity of the edges of the micro-structure after grinding was maintained efficiently.

A study of process parameters on workpiece anisotropy in the laser engineered net shaping (LENSTM) process

NASA Astrophysics Data System (ADS)

Chandra, Shubham; Rao, Balkrishna C.

2017-06-01

The process of laser engineered net shaping (LENSTM) is an additive manufacturing technique that employs the coaxial flow of metallic powders with a high-power laser to form a melt pool and the subsequent deposition of the specimen on a substrate. Although research done over the past decade on the LENSTM processing of alloys of steel, titanium, nickel and other metallic materials typically reports superior mechanical properties in as-deposited specimens, when compared to the bulk material, there is anisotropy in the mechanical properties of the melt deposit. The current study involves the development of a numerical model of the LENSTM process, using the principles of computational fluid dynamics (CFD), and the subsequent prediction of the volume fraction of equiaxed grains to predict process parameters required for the deposition of workpieces with isotropy in their properties. The numerical simulation is carried out on ANSYS-Fluent, whose data on thermal gradient are used to determine the volume fraction of the equiaxed grains present in the deposited specimen. This study has been validated against earlier efforts on the experimental studies of LENSTM for alloys of nickel. Besides being applicable to the wider family of metals and alloys, the results of this study will also facilitate effective process design to improve both product quality and productivity.

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

NASA Astrophysics Data System (ADS)

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

2016-02-01

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

Thermal modeling of grinding for process optimization and durability improvements

NASA Astrophysics Data System (ADS)

Hanna, Ihab M.

Both thermal and mechanical aspects of the grinding process are investigated in detail in an effort to predict grinding induced residual stresses. An existing thermal model is used as a foundation for computing heat partitions and temperatures in surface grinding. By numerically processing data from IR temperature measurements of the grinding zone; characterizations are made of the grinding zone heat flux. It is concluded that the typical heat flux profile in the grinding zone is triangular in shape, supporting this often used assumption found in the literature. Further analyses of the computed heat flux profiles has revealed that actual grinding zone contact lengths exceed geometric contact lengths by an average of 57% for the cases considered. By integrating the resulting heat flux profiles; workpiece energy partitions are computed for several cases of dry conventional grinding of hardened steel. The average workpiece energy partition for the cases considered was 37%. In an effort to more accurately predict grinding zone temperatures and heat fluxes, refinements are made to the existing thermal model. These include consideration of contact length extensions due to local elastic deformations, variations of the assumed contact area ratio as a function of grinding process parameters, consideration of coolant latent heat of vaporization and its effect on heat transfer beyond the coolant boiling point, and incorporation of coolant-workpiece convective heat flux effects outside the grinding zone. The result of the model refinements accounting for contact length extensions and process-dependant contact area ratios is excellent agreement with IR temperature measurements over a wide range of grinding conditions. By accounting for latent heat of vaporization effects, grinding zone temperature profiles are shown to be capable of reproducing measured profiles found in the literature for cases on the verge of thermal surge conditions. Computed peak grinding zone temperatures for the aggressive grinding examples given are 30--50% lower than those computed using the existing thermal model formulation. By accounting for convective heat transfer effects outside the grinding zone, it is shown that while surface temperatures in the wake of the grinding zone may be significantly affected under highly convective conditions, computed residual stresses are less sensitive to such conditions. Numerical models are used to evaluate both thermally and mechanically induced stress fields in an elastic workpiece, while finite element modeling is used to evaluate residual stresses for workpieces with elastic-plastic material properties. Modeling of mechanical interactions at the local grit-workpiece length scale is used to create the often measured effect of compressive surface residual stress followed by a subsurface tensile peak. The model is shown to be capable of reproducing trends found in the literature of surface residual stresses which are compressive for low temperature grinding conditions, with surface stresses increasing linearly and becoming tensile with increasing temperatures. Further modifications to the finite element model are made to allow for transiently varying inputs for more complicated grinding processes of industrial components such as automotive cam lobes.

Optimization of Gas Metal Arc Welding (GMAW) Process for Maximum Ballistic Limit in MIL A46100 Steel Welded All-Metal Armor

NASA Astrophysics Data System (ADS)

Grujicic, M.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.

2015-01-01

Our recently developed multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process has been upgraded with respect to its predictive capabilities regarding the process optimization for the attainment of maximum ballistic limit within the weld. The original model consists of six modules, each dedicated to handling a specific aspect of the GMAW process, i.e., (a) electro-dynamics of the welding gun; (b) radiation-/convection-controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler metal consumable electrode to the weld; (c) prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; (d) the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; (e) spatial distribution of the as-welded material mechanical properties; and (f) spatial distribution of the material ballistic limit. In the present work, the model is upgraded through the introduction of the seventh module in recognition of the fact that identification of the optimum GMAW process parameters relative to the attainment of the maximum ballistic limit within the weld region entails the use of advanced optimization and statistical sensitivity analysis methods and tools. The upgraded GMAW process model is next applied to the case of butt welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler metal electrodes made of the same material. The predictions of the upgraded GMAW process model pertaining to the spatial distribution of the material microstructure and ballistic limit-controlling mechanical properties within the MIL A46100 butt weld are found to be consistent with general expectations and prior observations.

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718.

PubMed

Wang, Bing; Liu, Zhanqiang; Hou, Xin; Zhao, Jinfu

2018-03-21

The paper aims to investigate the influences of material constitutive and fracture parameters in addition to cutting speed on chip formation during high-speed cutting of Inconel 718. Finite element analyses for chip formation are conducted with Johnson-Cook constitutive and fracture models. Meanwhile, experiments of high-speed orthogonal cutting are performed to verify the simulation results with cutting speeds ranging from 50 m/min to 7000 m/min. The research indicates that the chip morphology transforms from serrated to fragmented at the cutting speed of 7000 m/min due to embrittlement of the workpiece material under ultra-high cutting speeds. The parameter of shear localization sensitivity is put forward to describe the influences of material mechanical properties on serrated chip formation. The results demonstrate that the effects of initial yield stress and thermal softening coefficient on chip shear localization are much more remarkable than the other constitutive parameters. For the material fracture parameters, the effects of initial fracture strain and exponential factor of stress state on chip shear localization are more much prominent. This paper provides guidance for controlling chip formation through the adjustment of material mechanical properties and the selection of appropriate cutting parameters.

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718

PubMed Central

Hou, Xin; Zhao, Jinfu

2018-01-01

The paper aims to investigate the influences of material constitutive and fracture parameters in addition to cutting speed on chip formation during high-speed cutting of Inconel 718. Finite element analyses for chip formation are conducted with Johnson–Cook constitutive and fracture models. Meanwhile, experiments of high-speed orthogonal cutting are performed to verify the simulation results with cutting speeds ranging from 50 m/min to 7000 m/min. The research indicates that the chip morphology transforms from serrated to fragmented at the cutting speed of 7000 m/min due to embrittlement of the workpiece material under ultra-high cutting speeds. The parameter of shear localization sensitivity is put forward to describe the influences of material mechanical properties on serrated chip formation. The results demonstrate that the effects of initial yield stress and thermal softening coefficient on chip shear localization are much more remarkable than the other constitutive parameters. For the material fracture parameters, the effects of initial fracture strain and exponential factor of stress state on chip shear localization are more much prominent. This paper provides guidance for controlling chip formation through the adjustment of material mechanical properties and the selection of appropriate cutting parameters. PMID:29561770

Metal-Matrix/Hollow-Ceramic-Sphere Composites

NASA Technical Reports Server (NTRS)

Baker, Dean M.

2011-01-01

A family of metal/ceramic composite materials has been developed that are relatively inexpensive, lightweight alternatives to structural materials that are typified by beryllium, aluminum, and graphite/epoxy composites. These metal/ceramic composites were originally intended to replace beryllium (which is toxic and expensive) as a structural material for lightweight mirrors for aerospace applications. These materials also have potential utility in automotive and many other terrestrial applications in which there are requirements for lightweight materials that have high strengths and other tailorable properties as described below. The ceramic component of a material in this family consists of hollow ceramic spheres that have been formulated to be lightweight (0.5 g/cm3) and have high crush strength [40.80 ksi (.276.552 MPa)]. The hollow spheres are coated with a metal to enhance a specific performance . such as shielding against radiation (cosmic rays or x rays) or against electromagnetic interference at radio and lower frequencies, or a material to reduce the coefficient of thermal expansion (CTE) of the final composite material, and/or materials to mitigate any mismatch between the spheres and the matrix metal. Because of the high crush strength of the spheres, the initial composite workpiece can be forged or extruded into a high-strength part. The total time taken in processing from the raw ingredients to a finished part is typically 10 to 14 days depending on machining required.

Soldering tool heats workpieces and applies solder in one operation

NASA Technical Reports Server (NTRS)

Gudkese, V. W.

1966-01-01

Fountain-pen type soldering iron heats workpieces and applies solder to joints in densely packed electronics assemblies. The basic soldering tool is used with different-sized orifice tips, eliminating the need for an assortment of conventional soldering guns.

Hypervelocity cutting machine and method

DOEpatents

Powell, James R.; Reich, Morris

1996-11-12

A method and machine 14 are provided for cutting a workpiece 12 such as concrete. A gun barrel 16 is provided for repetitively loading projectiles 22 therein and is supplied with a pressurized propellant from a storage tank 28. A thermal storage tank 32,32A is disposed between the propellant storage tank 28 and the gun barrel 16 for repetitively receiving and heating propellant charges which are released in the gun barrel 16 for repetitively firing projectiles 22 therefrom toward the workpiece 12. In a preferred embodiment, hypervelocity of the projectiles 22 is obtained for cutting the concrete workpiece 12 by fracturing thereof.

Laser cutting with chemical reaction assist

DOEpatents

Gettemy, Donald J.

1992-01-01

A method for cutting with a laser beam where an oxygen-hydrocarbon reaction is used to provide auxiliary energy to a metal workpiece to supplement the energy supplied by the laser. Oxygen is supplied to the laser focus point on the workpiece by a nozzle through which the laser beam also passes. A liquid hydrocarbon is supplied by coating the workpiece along the cutting path with the hydrocarbon prior to laser irradiation or by spraying a stream of hydrocarbon through a nozzle aimed at a point on the cutting path which is just ahead of the focus point during irradiation.

Laser cutting with chemical reaction assist

DOEpatents

Gettemy, D.J.

1992-11-17

A method is described for cutting with a laser beam where an oxygen-hydrocarbon reaction is used to provide auxiliary energy to a metal workpiece to supplement the energy supplied by the laser. Oxygen is supplied to the laser focus point on the workpiece by a nozzle through which the laser beam also passes. A liquid hydrocarbon is supplied by coating the workpiece along the cutting path with the hydrocarbon prior to laser irradiation or by spraying a stream of hydrocarbon through a nozzle aimed at a point on the cutting path which is just ahead of the focus point during irradiation. 1 figure.

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.

A molecular dynamics investigation into the mechanisms of subsurface damage and material removal of monocrystalline copper subjected to nanoscale high speed grinding

NASA Astrophysics Data System (ADS)

Li, Jia; Fang, Qihong; Liu, Youwen; Zhang, Liangchi

2014-06-01

This paper investigates the mechanisms of subsurface damage and material removal of monocrystalline copper when it is under a nanoscale high speed grinding of a diamond tip. The analysis was carried out with the aid of three-dimensional molecular dynamics simulations. The key factors that would influence the deformation of the material were carefully explored by analyzing the chip, dislocation movement, and workpiece deformation, which include grinding speed, depth of cut, grid tip radius, crystal orientation and machining angle of copper. An analytical model was also established to predict the emission of partial dislocations during the nanoscale high speed grinding. The investigation showed that a higher grinding velocity, a larger tip radius or a larger depth of cut would result in a larger chipping volume and a greater temperature rise in the copper workpiece. A lower grinding velocity would produce more intrinsic stacking faults. It was also found that the transition of deformation mechanisms depends on the competition between the dislocations and deformation twinning. There is a critical machining angle, at which a higher velocity, a smaller tip radius, or a smaller depth of cut will reduce the subsurface damage and improve the smoothness of a ground surface. The established analytical model showed that the Shockley dislocation emission is most likely to occur with the crystal orientations of (0 0 1)[1 0 0] at 45° angle.

Heat Control via Torque Control in Friction Stir Welding

NASA Technical Reports Server (NTRS)

Venable, Richard; Colligan, Kevin; Knapp, Alan

2004-01-01

In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

Linear Friction Welding Process Model for Carpenter Custom 465 Precipitation-Hardened Martensitic Stainless Steel

DTIC Science & Technology

2014-04-11

Fig. 9(a) and (b). In addition, the temperature dependencies of the true and room-temperature-based mean values of the linear thermal expansion ...Variation of (a) thermal conductivity, (b) specific heat, (c) true linear thermal expansion coefficient, and (d) room-temperature-based mean thermal ...defined as follows: (a) alloy-grade and thermal -mechanical treatment of the workpiece materials to be joined, (b) frequency of reciprocating motion

USSR and Eastern Europe Scientific Abstracts, Materials Science and Metallurgy, Number 47

DTIC Science & Technology

1977-09-27

temperature intervals may vary and depends on the composition and previous heat treatment history of the alloy. Figures 2; references 13: 1 Russian, 12... HISTORY OF AMg6 ALLOY INTERMEDIATE WORKPIECES ON THE TIGHTNESS AND MECHANICAL PROPERTIES OF WELDS Kiev AVTOMATICHESKAYA SVARKA In Russian No 5(290), May...of Sciences Ukrainian SSR [Abstract] The effect of flux composition during argon-arc welding of titani - um with a nonconsumable electrode on melting

Factors Governing Surface Form Accuracy In Diamond Machined Components

NASA Astrophysics Data System (ADS)

Myler, J. K.; Page, D. A.

1988-10-01

Manufacturing methods for diamond machined optical surfaces, for application at infrared wavelengths, require that a new set of criteria must be recognised for the specification of surface form. Appropriate surface form parameters are discussed with particular reference to an XY cartesian geometry CNC machine. Methods for reducing surface form errors in diamond machining are discussed for certain areas such as tool wear, tool centring, and the fixturing of the workpiece. Examples of achievable surface form accuracy are presented. Traditionally, optical surfaces have been produced by use of random polishing techniques using polishing compounds and lapping tools. For lens manufacture, the simplest surface which could be created corresponded to a sphere. The sphere is a natural outcome of a random grinding and polishing process. The measurement of the surface form accuracy would most commonly be performed using a contact test gauge plate, polished to a sphere of known radius of curvature. QA would simply be achieved using a diffuse monochromatic source and looking for residual deviations between the polished surface and the test plate. The specifications governing the manufacture of surfaces using these techniques would call for the accuracy to which the generated surface should match the test plate as defined by a spherical deviations from the required curvature and a non spherical astigmatic error. Consequently, optical design software has tolerancing routines which specifically allow the designer to assess the influence of spherical error and astigmatic error on the optical performance. The creation of general aspheric surfaces is not so straightforward using conventional polishing techniques since the surface profile is non spherical and a good approximation to a power series. For infra red applications (X = 8-12p,m) numerically controlled single point diamond turning is an alternative manufacturing technology capable of creating aspheric profiles as well as simple spheres. It is important however to realise that a diamond turning process will possess a new set of criteria which limit the accuracy of the surface profile created corresponding to a completely new set of specifications. The most important factors are:- tool centring accuracy, surface waviness, conical form error, and other rotationally symmetric non spherical errors. The fixturing of the workpiece is very different from that of a conventional lap, since in many cases the diamond machine resembles a conventional lathe geometry where the workpiece rotates at a few thousand R.P.M. Substrates must be held rigidly for rotation at such speeds as compared with more delicate mounting methods for conventional laps. Consequently the workpiece may suffer from other forms of deformation which are non-rotationally symmetric due to mounting stresses (static deformation) and stresses induced at the speed of rotation (dynamic deformation). The magnitude of each of these contributions to overall form error will be a function of the type of machine, the material, substrate, and testing design. The following sections describe each of these effects in more detail based on experience obtained on a Pneumo Precision MSG325 XY CNC machine. Certain in-process measurement techniques have been devised to minimise and quantify each contribution.

Apparatus for electrolytically tapered or contoured cavities

NASA Technical Reports Server (NTRS)

Williams, L. A. (Inventor)

1967-01-01

An electrolytic machining apparatus for forming tapered or contoured cavities in an electrically conductive and electrochemically erodible piece is presented. It supports the workpiece and an electrode for movement relatively toward each other and has means for pumping an electrolyte between the workpiece and the electrode.

Charge neutralization apparatus for ion implantation system

DOEpatents

Leung, Ka-Ngo; Kunkel, Wulf B.; Williams, Malcom D.; McKenna, Charles M.

1992-01-01

Methods and apparatus for neutralization of a workpiece such as a semiconductor wafer in a system wherein a beam of positive ions is applied to the workpiece. The apparatus includes an electron source for generating an electron beam and a magnetic assembly for generating a magnetic field for guiding the electron beam to the workpiece. The electron beam path preferably includes a first section between the electron source and the ion beam and a second section which is coincident with the ion beam. The magnetic assembly generates an axial component of magnetic field along the electron beam path. The magnetic assembly also generates a transverse component of the magnetic field in an elbow region between the first and second sections of the electron beam path. The electron source preferably includes a large area lanthanum hexaboride cathode and an extraction grid positioned in close proximity to the cathode. The apparatus provides a high current, low energy electron beam for neutralizing charge buildup on the workpiece.

Active hold-down for heat treating

NASA Technical Reports Server (NTRS)

Collins, E. R., Jr. (Inventor)

1986-01-01

The object of the disclosure is to provide a vacuum hold-down for holding thin sheets to a support surface, which permits the thin sheet to change dimensions as it is held down. The hold-down includes numerous holes in the support surface, through which a vacuum is applied from a vacuum source. The holes are arranged in zones. The vacuum is repeatedly interrupted at only one or a few zones, while it continues to be applied to other zones, to allow the workpiece to creep along that interrupted zone. The vacuum to different zones is interrupted at different times, as by a slowly turning valve number, to allow each zone of the workpiece to creep. A positive pressure may be applied from a pressured air source to a zone when the vacuum is interrupted there, to help lift the corresponding workpiece zone off the surface to aid in creeping. The workpiece may undergo dimensional changes because of heating, cooling, drying, or other procedure.

Clinical measuring system for the form and position errors of circular workpieces using optical fiber sensors

NASA Astrophysics Data System (ADS)

Tan, Jiubin; Qiang, Xifu; Ding, Xuemei

1991-08-01

Optical sensors have two notable advantages in modern precision measurement. One is that they can be used in nondestructive measurement because the sensors need not touch the surfaces of workpieces in measuring. The other one is that they can strongly resist electromagnetic interferences, vibrations, and noises, so they are suitable to be used in machining sites. But the drift of light intensity and the changing of the reflection coefficient at different measuring positions of a workpiece may have great influence on measured results. To solve the problem, a spectroscopic differential characteristic compensating method is put forward. The method can be used effectively not only in compensating the measuring errors resulted from the drift of light intensity but also in eliminating the influence to measured results caused by the changing of the reflection coefficient. Also, the article analyzes the possibility of and the means of separating data errors of a clinical measuring system for form and position errors of circular workpieces.

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.

Thermal resilient multiple jaw braze fixture

DOEpatents

Ney, Robert; Perrone, Alex J.

1995-07-11

A braze fixture has side walls forming a cavity with an opening to receive a stack of parts to be brazed. Sidewalls of the housing have a plurality of bearing receiving openings into which bearing rods or jaws are inserted to align the stacked elements of the workpiece. The housing can also have view ports to allow a visual check of the alignment. Straps or wires around the fixture are selected to have thermal characteristics similar to the thermal characteristics of the workpiece undergoing brazing. The straps or wires make physical contact with the bearing rods thereby causing bearing rods to maintain the workpiece in proper alignment throughout the entire brazing cycle.

Precision aligned split V-block

DOEpatents

George, Irwin S.

1984-01-01

A precision aligned split V-block for holding a workpiece during a milling operation having an expandable frame for allowing various sized workpieces to be accommodated, is easily secured directly to the mill table and having key lugs in one base of the split V-block that assures constant alignment.

Model of the material removal function and an experimental study on a magnetorheological finishing process using a small ball-end permanent-magnet polishing head.

PubMed

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

2017-07-01

In order to achieve the deterministic finishing of optical components with concave surfaces of a curvature radius less than 10 mm, a novel magnetorheological finishing (MRF) process using a small ball-end permanent-magnet polishing head with a diameter of 4 mm is introduced. The characteristics of material removal in the proposed MRF process are studied. The model of the material removal function for the proposed MRF process is established based on the three-dimensional hydrodynamics analysis and Preston's equation. The shear stress on the workpiece surface is calculated by means of resolving the presented mathematical model using a numerical solution method. The analysis result reveals that the material removal in the proposed MRF process shows a positive dependence on shear stress. Experimental research is conducted to investigate the effect of processing parameters on the material removal rate and improve the surface accuracy of a typical rotational symmetrical optical component. The experimental results show that the surface accuracy of the finished component of K9 glass material has been improved to 0.14 μm (PV) from the initial 0.8 μm (PV), and the finished surface roughness Ra is 0.0024 μm. It indicates that the proposed MRF process can be used to achieve the deterministic removal of surface material and perform the nanofinishing of small curvature radius concave surfaces.

Residual heat generated during laser processing of CFRP with picosecond laser pulses

NASA Astrophysics Data System (ADS)

Freitag, Christian; Pauly, Leon; Förster, Daniel J.; Wiedenmann, Margit; Weber, Rudolf; Kononenko, Taras V.; Konov, Vitaly I.; Graf, Thomas

2018-05-01

One of the major reasons for the formation of a heat-affected zone during laser processing of carbon fiber-reinforced plastics (CFRP) with repetitive picosecond (ps) laser pulses is heat accumulation. A fraction of every laser pulse is left as what we termed residual heat in the material also after the completed ablation process and leads to a gradual temperature increase in the processed workpiece. If the time between two consecutive pulses is too short to allow for a sufficient cooling of the material in the interaction zone, the resulting temperature can finally exceed a critical temperature and lead to the formation of a heat-affected zone. This accumulation effect depends on the amount of energy per laser pulse that is left in the material as residual heat. Which fraction of the incident pulse energy is left as residual heat in the workpiece depends on the laser and process parameters, the material properties, and the geometry of the interaction zone, but the influence of the individual quantities at the present state of knowledge is not known precisely due to the lack of comprehensive theoretical models. With the present study, we, therefore, experimentally determined the amount of residual heat by means of calorimetry. We investigated the dependence of the residual heat on the fluence, the pulse overlap, and the depth of laser-generated grooves in CRFP. As expected, the residual heat was found to increase with increasing groove depth. This increase occurs due to an indirect heating of the kerf walls by the ablation plasma and the change in the absorbed laser fluence caused by the altered geometry of the generated structures.

Ion beam figuring of small optical components

NASA Astrophysics Data System (ADS)

Drueding, Thomas W.; Fawcett, Steven C.; Wilson, Scott R.; Bifano, Thomas G.

1995-12-01

Ion beam figuring provides a highly deterministic method for the final precision figuring of optical components with advantages over conventional methods. The process involves bombarding a component with a stable beam of accelerated particles that selectively removes material from the surface. Figure corrections are achieved by rastering the fixed-current beam across the workplace at appropriate, time-varying velocities. Unlike conventional methods, ion figuring is a noncontact technique and thus avoids such problems as edge rolloff effects, tool wear, and force loading of the workpiece. This work is directed toward the development of the precision ion machining system at NASA's Marshall Space Flight Center. This system is designed for processing small (approximately equals 10-cm diam) optical components. Initial experiments were successful in figuring 8-cm-diam fused silica and chemical-vapor-deposited SiC samples. The experiments, procedures, and results of figuring the sample workpieces to shallow spherical, parabolic (concave and convex), and non-axially-symmetric shapes are discussed. Several difficulties and limitations encountered with the current system are discussed. The use of a 1-cm aperture for making finer corrections on optical components is also reported.

Spatial structure of the arc in a pulsed GMAW process

NASA Astrophysics Data System (ADS)

Kozakov, R.; Gött, G.; Schöpp, H.; Uhrlandt, D.; Schnick, M.; Häßler, M.; Füssel, U.; Rose, S.

2013-06-01

A pulsed gas metal arc welding (GMAW) process of steel under argon shielding gas in the globular mode is investigated by measurements and simulation. The analysis is focussed on the spatial structure of the arc during the current pulse. Therefore, the radial profiles of the temperature, the metal vapour species and the electric conductivity are determined at different heights above the workpiece by optical emission spectroscopy (OES). It is shown that under the presence of metal vapour the temperature minimum occurs at the centre of the arc. This minimum is preserved at different axial positions up to 1 mm above the workpiece. In addition, estimations of the electric field in the arc from the measurements are given. All these results are compared with magneto-hydrodynamic simulations which include the evaporation of the wire material and the change of the plasma properties due to the metal vapour admixture in particular. The experimental method and the simulation model are validated by means of the satisfactory correspondence between the results. Possible reasons for the remaining deviations and improvements of the methods which should be aspired are discussed.

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

NASA Astrophysics Data System (ADS)

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

2011-01-01

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

Physics of Fusion Welding

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.

1986-01-01

Applicabilities and limitations of three techniques analyzed. NASA technical memorandum discusses physics of electron-beam, gas/ tungsten-arc, and laser-beam welding. From comparison of capabilities and limitations of each technique with regard to various welding conditions and materials, possible to develop criteria for selecting best welding technique in specific application. All three techniques classified as fusion welding; small volume of workpiece melted by intense heat source. Heat source moved along seam, leaving in wake solid metal that joins seam edges together.

Modified subaperture tool influence functions of a flat-pitch polisher with reverse-calculated material removal rate.

PubMed

Dong, Zhichao; Cheng, Haobo; Tam, Hon-Yuen

2014-04-10

Numerical simulation of subaperture tool influence functions (TIF) is widely known as a critical procedure in computer-controlled optical surfacing. However, it may lack practicability in engineering because the emulation TIF (e-TIF) has some discrepancy with the practical TIF (p-TIF), and the removal rate could not be predicted by simulations. Prior to the polishing of a formal workpiece, opticians have to conduct TIF spot experiments on another sample to confirm the p-TIF with a quantitative removal rate, which is difficult and time-consuming for sequential polishing runs with different tools. This work is dedicated to applying these e-TIFs into practical engineering by making improvements from two aspects: (1) modifies the pressure distribution model of a flat-pitch polisher by finite element analysis and least square fitting methods to make the removal shape of e-TIFs closer to p-TIFs (less than 5% relative deviation validated by experiments); (2) predicts the removal rate of e-TIFs by reverse calculating the material removal volume of a pre-polishing run to the formal workpiece (relative deviations of peak and volume removal rate were validated to be less than 5%). This can omit TIF spot experiments for the particular flat-pitch tool employed and promote the direct usage of e-TIFs in the optimization of a dwell time map, which can largely save on cost and increase fabrication efficiency.

Manufacturing information system

NASA Astrophysics Data System (ADS)

Allen, D. K.; Smith, P. R.; Smart, M. J.

1983-12-01

The size and cost of manufacturing equipment has made it extremely difficult to perform realistic modeling and simulation of the manufacturing process in university research laboratories. Likewise the size and cost factors, coupled with many uncontrolled variables of the production situation has even made it difficult to perform adequate manufacturing research in the industrial setting. Only the largest companies can afford manufacturing research laboratories; research results are often held proprietary and seldom find their way into the university classroom to aid in education and training of new manufacturing engineers. It is the purpose for this research to continue the development of miniature prototype equipment suitable for use in an integrated CAD/CAM Laboratory. The equipment being developed is capable of actually performing production operations (e.g. drilling, milling, turning, punching, etc.) on metallic and non-metallic workpieces. The integrated CAD/CAM Mini-Lab is integrating high resolution, computer graphics, parametric design, parametric N/C parts programmings, CNC machine control, automated storage and retrieval, with robotics materials handling. The availability of miniature CAD/CAM laboratory equipment will provide the basis for intensive laboratory research on manufacturing information systems.

A new approach to the form and position error measurement of the auto frame surface based on laser

NASA Astrophysics Data System (ADS)

Wang, Hua; Li, Wei

2013-03-01

Auto frame is a very large workpiece, with length up to 12 meters and width up to 2 meters, and it's very easy to know that it's inconvenient and not automatic to measure such a large workpiece by independent manual operation. In this paper we propose a new approach to reconstruct the 3D model of the large workpiece, especially the auto truck frame, based on multiple pulsed lasers, for the purpose of measuring the form and position errors. In a concerned area, it just needs one high-speed camera and two lasers. It is a fast, high-precision and economical approach.

Fixture for holding testing transducer

DOEpatents

Wagner, T.A.; Engel, H.P.

A fixture for mounting an ultrasonic transducer against the end of a threaded bolt or stud to test the same for flaws. A base means threadedly secured to the side of the bolt has a rotating ring thereon. A post rising up from the ring (parallel to the axis of the workpiece) pivotally mounts a variable length cross arm, on the inner end of which is mounted the transducer. A spring means acts between the cross arm and the base to apply the testing transducer against the workpiece at a constant pressure. The device maintains constant for successive tests the radial and circumferential positions of the testing transducer and its contact pressure against the end of the workpiece.

Fixture for holding testing transducer

DOEpatents

Wagner, Thomas A.; Engel, Herbert P.

1984-01-01

A fixture for mounting an ultrasonic transducer against the end of a threaded bolt or stud to test the same for flaws. A base means threadedly secured to the side of the bolt has a rotating ring thereon. A post rising up from the ring (parallel to the axis of the workpiece) pivotally mounts a variable length cross arm, on the inner end of which is mounted the transducer. A spring means acts between the cross arm and the base to apply the testing transducer against the workpiece at a constant pressure. The device maintains constant for successive tests the radial and circumferential positions of the testing transducer and its contact pressure against the end of the workpiece.

Thermal resilient multiple jaw braze fixture

DOEpatents

Ney, R.; Perrone, A.J.

1995-07-11

A braze fixture has side walls forming a cavity with an opening to receive a stack of parts to be brazed. Sidewalls of the housing have a plurality of bearing receiving openings into which bearing rods or jaws are inserted to align the stacked elements of the workpiece. The housing can also have view ports to allow a visual check of the alignment. Straps or wires around the fixture are selected to have thermal characteristics similar to the thermal characteristics of the workpiece undergoing brazing. The straps or wires make physical contact with the bearing rods thereby causing bearing rods to maintain the workpiece in proper alignment throughout the entire brazing cycle. 9 figs.

Turntable mechanism

NASA Technical Reports Server (NTRS)

Myers, William Neill (Inventor)

1993-01-01

In vacuum plasma spraying a turntable must be provided which not only makes it possible to rotate and tilt a heavy workpiece, but to operate at vacuum plasma temperatures to do so. In the vacuum plasma coating of large parts such as combustion chambers of rocket engines, the workpiece must not only be rotated, but it must be tilted. Hence, the turntable must be capable not only of supporting heavy parts, but of angulating such heavy workpieces. And this must be done without drive means failure due to extremely high temperatures under which the turntable mechanism is operated. A turntable mechanism is provided which is capable of operating under such conditions. For cooling the turntable drive mechanism, internal cooling means are included.

Alignment Fixtures For Vacuum-Plasma-Spray Gun

NASA Technical Reports Server (NTRS)

Woodford, William H.; Mckechnie, Timothy N.; Power, Christopher A.; Daniel, Ronald L., Jr.

1993-01-01

Fixtures for alignment of vacuum-plasma-spray guns built. Each fixture designed to fit specific gun and holds small, battery-powered laser on centerline of gun. Laser beam projects small red dot where centerline intersects surface of workpiece to be sprayed. After laser beam positioned on surface of workpiece, fixture removed from gun and spraying proceeds.

Laser peening with fiber optic delivery

DOEpatents

Friedman, Herbert W.; Ault, Earl R.; Scheibner, Karl F.

2004-11-16

A system for processing a workpiece using a laser. The laser produces at least one laser pulse. A laser processing unit is used to process the workpiece using the at least one laser pulse. A fiber optic cable is used for transmitting the at least one laser pulse from the laser to the laser processing unit.

Vibration Damping Analysis of Lightweight Structures in Machine Tools

PubMed Central

Aggogeri, Francesco; Borboni, Alberto; Merlo, Angelo; Pellegrini, Nicola; Ricatto, Raffaele

2017-01-01

The dynamic behaviour of a machine tool (MT) directly influences the machining performance. The adoption of lightweight structures may reduce the effects of undesired vibrations and increase the workpiece quality. This paper aims to present and compare a set of hybrid materials that may be excellent candidates to fabricate the MT moving parts. The selected materials have high dynamic characteristics and capacity to dampen mechanical vibrations. In this way, starting from the kinematic model of a milling machine, this study evaluates a number of prototypes made of Al foam sandwiches (AFS), Al corrugated sandwiches (ACS) and composite materials reinforced by carbon fibres (CFRP). These prototypes represented the Z-axis ram of a commercial milling machine. The static and dynamical properties have been analysed by using both finite element (FE) simulations and experimental tests. The obtained results show that the proposed structures may be a valid alternative to the conventional materials of MT moving parts, increasing machining performance. In particular, the AFS prototype highlighted a damping ratio that is 20 times greater than a conventional ram (e.g., steel). Its application is particularly suitable to minimize unwanted oscillations during high-speed finishing operations. The results also show that the CFRP structure guarantees high stiffness with a weight reduced by 48.5%, suggesting effective applications in roughing operations, saving MT energy consumption. The ACS structure has a good trade-off between stiffness and damping and may represent a further alternative, if correctly evaluated. PMID:28772653

Grinding tool for making hemispherical bores in hard materials

DOEpatents

Duran, E.L.

1985-04-03

A grinding tool for forming hemispherical bores in hard materials such as boron carbide. The tool comprises a hemicircular grinding bit, formed of a metal bond diamond matrix, which is mounted transversely on one end of a tubular tool shaft. The bit includes a spherically curved outer edge surface which is the active grinding surface of the tool. Two coolant fluid ports on opposite sides of the bit enable introduction of coolant fluid through the bore of the tool shaft so as to be emitted adjacent the opposite sides of the grinding bit, thereby providing optimum cooling of both the workpiece and the bit.

Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding

NASA Astrophysics Data System (ADS)

Grujicic, M.; Arakere, G.; Yalavarthy, H. V.; He, T.; Yen, C.-F.; Cheeseman, B. A.

2010-07-01

A concise yet a fairly comprehensive overview of the friction stir welding (FSW) process is provided. This is followed by a computational investigation in which FSW behavior of a prototypical solution-strengthened and strain-hardened aluminum alloy, AA5083-H131, is modeled using a fully coupled thermo-mechanical finite-element procedure developed in our prior study. Particular attention is given to proper modeling of the welding work-piece material behavior during the FSW process. Specifically, competition and interactions between plastic-deformation and dynamic-recrystallization processes are considered to properly account for the material-microstructure evolution in the weld nugget zone. The results showed that with proper modeling of the material behavior under high-temperature/severe-plastic-deformation conditions, significantly improved agreement can be attained between the computed and measured post-FSW residual-stress and material-strength distribution results.

Micro Fluidic Channel Machining on Fused Silica Glass Using Powder Blasting

PubMed Central

Jang, Ho-Su; Cho, Myeong-Woo; Park, Dong-Sam

2008-01-01

In this study, micro fluid channels are machined on fused silica glass via powder blasting, a mechanical etching process, and the machining characteristics of the channels are experimentally evaluated. In the process, material removal is performed by the collision of micro abrasives injected by highly compressed air on to the target surface. This approach can be characterized as an integration of brittle mode machining based on micro crack propagation. Fused silica glass, a high purity synthetic amorphous silicon dioxide, is selected as a workpiece material. It has a very low thermal expansion coefficient and excellent optical qualities and exceptional transmittance over a wide spectral range, especially in the ultraviolet range. The powder blasting process parameters affecting the machined results are injection pressure, abrasive particle size and density, stand-off distance, number of nozzle scanning, and shape/size of the required patterns. In this study, the influence of the number of nozzle scanning, abrasive particle size, and pattern size on the formation of micro channels is investigated. Machined shapes and surface roughness are measured using a 3-dimensional vision profiler and the results are discussed. PMID:27879730

Principles and applications of laser-induced liquid-phase jet-chemical etching

NASA Astrophysics Data System (ADS)

Stephen, Andreas; Metev, Simeon; Vollertsen, Frank

2003-11-01

In this treatment method laser radiation, which is guided from a coaxially expanding liquid jet-stream, locally initiates a thermochemical etching reaction on a metal surface, which leads to selective material removal at high resolution and quality of the treated surface as well as low thermal influence on the workpiece. Electrochemical investigations were performed under focused laser irradiation using a cw-Nd:YAG laser with a maximum power of 15 W and a simultaneous impact of the liquid jet-stream consisting of phosphoric acid with a maximum flow rate of 20 m/s. The time resolved measurements of the electrical potential difference against an electrochemical reference electrode were correlated with the specific processing parameters and corresponding etch rates to identify processing conditions for temporally stable and enhanced chemical etching reactions. Applications of laser-induced liquid-phase jet-chemical etching in the field of sensor technology, micromechanics and micrmoulding technology are presented. This includes the microstructuring of thin film systems, cutting of foils of shape memory alloys or the generation of structures with defined shape in bulk material.

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

A Review on Parametric Analysis of Magnetic Abrasive Machining Process

NASA Astrophysics Data System (ADS)

Khattri, Krishna; Choudhary, Gulshan; Bhuyan, B. K.; Selokar, Ashish

2018-03-01

The magnetic abrasive machining (MAM) process is a highly developed unconventional machining process. It is frequently used in manufacturing industries for nanometer range surface finishing of workpiece with the help of Magnetic abrasive particles (MAPs) and magnetic force applied in the machining zone. It is precise and faster than conventional methods and able to produce defect free finished components. This paper provides a comprehensive review on the recent advancement of MAM process carried out by different researcher till date. The effect of different input parameters such as rotational speed of electromagnet, voltage, magnetic flux density, abrasive particles size and working gap on the performances of Material Removal Rate (MRR) and surface roughness (Ra) have been discussed. On the basis of review, it is observed that the rotational speed of electromagnet, voltage and mesh size of abrasive particles have significant impact on MAM process.

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

PubMed

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

2018-01-11

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

Investigation of 1-Dimensional ultrasonic vibration compliance mechanism based on finite element analysis

NASA Astrophysics Data System (ADS)

Latif, A. Afiff; Ibrahim, M. Rasidi; Rahim, E. A.; Cheng, K.

2017-04-01

The conventional milling has many difficulties in the processing of hard and brittle material. Hence, ultrasonic vibration assisted milling (UVAM) was proposed to overcome this problem. The objective of this research is to study the behavior of compliance mechanism (CM) as the critical part affect the performance of the UVAM. The design of the CM was investigated and focuses on 1-Dimensional. Experimental result was obtained from a portable laser digital vibrometer. While the 1-Dimensional value such as safety factor, deformation of hinges and stress analysis are obtained from finite elements simulation. Finally, the findings help to find the best design judging from the most travelled distance of the piezoelectric actuators. In addition, this paper would provide a clear picture the behavior of the CM embedded in the UVAM, which can provide good data and to improve the machining on reducing tool wear, and lower cutting force on the workpiece surface roughness.

Ceramic Ti—B Composites Synthesized by Combustion Followed by High-Temperature Deformation

PubMed Central

Bazhin, Pavel M.; Stolin, Alexander M.; Konstantinov, Alexander S.; Kostitsyna, Elena V.; Ignatov, Andrey S.

2016-01-01

Long compact cylindrical rods, which consist of a titanium monoboride-based TiB—30 wt % Ti ceramic composite material, are synthesized during combustion of the initial components (titanium, boron) followed by high-temperature deformation. High-temperature deformation is found to affect the orientation of the hardening titanium monoboride phase in the sample volume and the phase composition of the sample. The combustion temperature is studied as a function of the relative density of the initial workpiece under the experimental conditions. PMID:28774147

Ceramic Ti-B Composites Synthesized by Combustion Followed by High-Temperature Deformation.

PubMed

Bazhin, Pavel M; Stolin, Alexander M; Konstantinov, Alexander S; Kostitsyna, Elena V; Ignatov, Andrey S

2016-12-20

Long compact cylindrical rods, which consist of a titanium monoboride-based TiB-30 wt % Ti ceramic composite material, are synthesized during combustion of the initial components (titanium, boron) followed by high-temperature deformation. High-temperature deformation is found to affect the orientation of the hardening titanium monoboride phase in the sample volume and the phase composition of the sample. The combustion temperature is studied as a function of the relative density of the initial workpiece under the experimental conditions.

The efficiency of backward magnetic-pulse processing

NASA Astrophysics Data System (ADS)

Kudasov, Yu. B.; Maslov, D. A.; Surdin, O. M.

2017-01-01

The dependence of the efficiency of magnetic-pulse processing of materials on the pulsed magnetic-field shape has been studied. It is shown that, by using a pulse train instead of a single pulse in the fast-rising component of a magnetic field applied during the backward forming process, it is possible to increase the specific mechanical impulse transferred to a workpiece and, thus, improve the efficiency of processing. Possible applications of the proposed method to removing dents from car chassis and aircraft parts are considered

Ablation layers to prevent pitting in laser peening

DOEpatents

Hackel, Lloyd A

2016-08-09

A hybrid ablation layer that comprises a separate under layer is applied to a material to prevent pitting resulting from laser peening. The underlayer adheres to the surface of the workpiece to be peened and does not have bubbles and voids that exceed an acceptable size. One or more overlayers are placed over and in contact with the underlayer. Any bubbles formed under the over layers are insulated from the surface to be peened. The process significantly reduces the incidence of pits on peened surfaces.

Plasma-Arc Torch For Welding Ducts In Place

NASA Technical Reports Server (NTRS)

Gangl, Kenneth J.; Bayless, Ernest; Looney, Alan

1991-01-01

Plasma-arc-welding torch redesigned, more suitable for applications in which moved in circular or other orbits about stationary cylindrical workpieces. Preserves elements of original design critical to performance and endurance, but modifies other elements to decrease overall size of torch. Electrode collet and collet nut installed and removed through hole in top; makes installation and removal easier.

Muffling Hammer Blows In A Workshop

NASA Technical Reports Server (NTRS)

Thiele, Alfred W.; Gilbert, Jeffrey L.; Gutow, David A.

1994-01-01

Sound-deadening bags placed on hammered workpieces. Useful in many workshop situations. Fabricated easily and inexpensively. Bags filled with particles of sand, metal shot, plastic, or glass, then sewn or molded shut. Tailored to fit special configurations of some workpieces. Devices used to deaden print rollers and to reduce vibrations in main-injector inlet manifold of rocket engine.

Spot-Welding Gun Is Easy To Use

NASA Technical Reports Server (NTRS)

Morgan, Gene E.; Nguyen, Francis H.

1991-01-01

Electrical-resistance spot-welding gun designed to produce more welds per unit time by decreasing technician's effort and fatigue. Vacuum cups on frame secure welding gun to workpiece while compressed air drives welding tip against workpiece to make spot resistance weld. When weld completed, vacuum in frame cups released so frame and gun moved to position of next spot weld.

Holding fixture for a hot stamping press

NASA Technical Reports Server (NTRS)

Harris, R. P. (Inventor)

1983-01-01

A hand held guide for manually positioning a work piece between the anvil rib and tool of a hot die stamping press is described. A groove completed by interchangeable cover plates attached at one end of the guide conforms to a cross sectional dimension common to similar workpieces and, with a force fit, retentively holds each of the workpieces.

Decontamination apparatus and method

DOEpatents

Oakley, David J.

1987-01-01

A blast head including a plurality of spray nozzles mounted in a chamber for receiving a workpiece. The several spray nozzles concurrently direct a plurality of streams of a pressurized gas and abrasive grit mixture toward a peripheral portion of the workpiece to remove particulates or debris therefrom. An exhaust outlet is formed in the chamber for discharging the particulates and spent grit.

Decontamination apparatus and method

DOEpatents

Oakley, David J.

1987-01-06

A blast head including a plurality of spray nozzles mounted in a chamber for receiving a workpiece. The several spray nozzles concurrently direct a plurality of streams of a pressurized gas and abrasive grit mixture toward a peripheral portion of the workpiece to remove particulates or debris therefrom. An exhaust outlet is formed in the chamber for discharging the particulates and spent grit.

Electrical potential difference during laser welding

NASA Astrophysics Data System (ADS)

Zohm, H.; Ambrosy, G.; Lackner, K.

2015-01-01

We present a new model for the generation of thermoelectric currents during laser welding, taking into account sheath effects at both contact points as well as the potential drop within the quasi-neutral plasma generated by the laser. We show that the model is in good agreement with experimentally measured electric potential difference between the hot and the cold parts of the welded workpiece. In particular, all three elements of the model are needed to correctly reproduce the sign of the measured voltage difference. The mechanism proposed relies on the temperature dependence of the electron flux from the plasma to the workpiece and hence does not need thermoemission from the workpiece surface to explain the experimentally observed sign and magnitude of the potential drop.

Influence of tool shape on lattice rearrangement under loading conditions reproducing friction stir welding

NASA Astrophysics Data System (ADS)

Konovalenko, Ivan S.; Konovalenko, Igor S.

2015-10-01

Metal behavior under loading conditions that reproduce friction stir welding was studied on the atomic scale. Calculations were conducted based on molecular dynamics simulation with potentials calculated within the embedded atom method. The loading of the interface between two crystallites, whose structure corresponded to aluminum alloy 2024, was simulated by the motion of a cone-shaped tool along the interface with constant angular and translational velocities. The motion of the rotating tool causes fracture of the workpiece crystal structure with subsequent mixing of surface atoms of the interfacing crystallites. It is shown that the resistance force acting on the moving tool from the workpiece and the process of structural defect formation in the workpiece depend on the tool shape.

Robot Hand Grips Cylinders Securely

NASA Technical Reports Server (NTRS)

Parma, George F.

1989-01-01

Jaws and linkage accommodate various sizes. Robot hand includes two pairs of parallel jaws that grasp rods, pipes, tubes, struts, and other long, heavy cylindrical objects. Hand features compact rotary drive and butterfly configuration simplifying approach and gripping maneuvers of robot. Parallelogram linkages maintain alignment of each jaw with other jaws. One bar of each linkage connected to one of two concentric, counterrotating shafts; rotation of shafts moves jaws in each pair toward or away from each other to grasp or release workpiece. Each jaw includes rigid gripping pad lined with rubber to give firm grip and to prevent damage to workpiece. Inner cylindrical surface (corner) of each jaw tapers off to flat sides. Enables jaw to grasp workpieces with diameters larger than or equal to twice the corner radius.

Mechanical and biological behavior of ultrafine-grained Ti alloy aneurysm clip processed using high-pressure torsion.

PubMed

Um, Ho Yong; Park, Byung Ho; Ahn, Dong-Hyun; Abd El Aal, Mohamed Ibrahim; Park, Jaechan; Kim, Hyoung Seop

2017-04-01

Severe plastic deformation (SPD) has recently been advanced as the main process for fabricating bulk ultrafine grained or nanocrystalline metallic materials, which present much higher strength and better bio-compatibility than coarse-grained counterparts. Medical devices, such as aneurysm clips and dental implants, require high mechanical and biological performance (e.g., stiffness, yield strength, fatigue resistance, and bio-compatibility). These requirements match well the characteristics of SPD-processed materials. Typical aneurysm clips are made of a commercial Ti-6Al-4V alloy, which has higher yield strength than Ti. In this work, Ti and Ti-6Al-4V workpieces were processed by high-pressure torsion (HPT) to enhance their mechanical properties. Tensile tests and hardness tests were performed to evaluate their mechanical properties, and their microstructure was investigated. The hardness and yield stress of the HPT-processed Ti are comparable to those of the initial Ti-6Al-4V due to significantly refined microstructure. Finite element analyses for evaluating the opening performance of a specific geometry of the YASARGIL aneurysm clip were carried out using mechanical properties of the initial and HPT-processed Ti and Ti-6Al-4V. These results indicate that SPD-processed Ti could be a good candidate to substitute for Ti-6Al-4V in aneurysm clips. Copyright © 2017 Elsevier Ltd. All rights reserved.

Improvement of Functional Properties by Sever Plastic Deformation on Parts of Titanium Biomaterials

NASA Astrophysics Data System (ADS)

Czán, Andrej; Babík, Ondrej; Daniš, Igor; Martikáň, Pavol; Czánová, Tatiana

2017-12-01

Main task of materials for invasive implantology is their biocompatibility with the tissue but also requirements for improving the functional properties of given materials are increasing constantly. One of problems of materials biocompatibility is the impossibility to improve of functional properties by change the percentage of the chemical elements and so it is necessary to find other innovative methods of improving of functional properties such as mechanical action in the form of high deformation process. This paper is focused on various methods of high deformation process such as Equal Channel Angular Pressing (ECAP) when rods with record strength properties were obtained.The actual studies of the deformation process properties as tri-axial compress stress acting on workpiece with high speed of deformation shows effects similar to results obtained using the other methods, but in lower levels of stress. Hydrostatic extrusion (HE) is applying for the purpose of refining the structure of the commercially pure titanium up to nano-scale. Experiments showed the ability to reduce the grain size below 100 nm. Due to the significant change in the performance of the titanium materials by severe plastic deformation is required to identify the processability of materials with respect to the identification of created surfaces and monitoring the surface integrity, where the experimental results show ability of SPD technologies application on biomaterials.

Analysis of the Material Removal Rate in Magnetic Abrasive Finishing of Thin Film Coated Pyrex Glass

NASA Astrophysics Data System (ADS)

Lee, Hee Hwan; Lee, Seoung Hwan

The material removal rate (MRR) during precision finishing/polishing is a key factor, which dictates the process performance. Moreover, the MRR or wear rate is closely related to the material/part reliability. For nanoscale patterning and/or planarization on nano-order thickness coatings, the prediction and in-process monitoring of the MRR is necessary, because the process is not characterizable due to size effects and material property/process condition variations as a result of the coating/substrate interactions. The purpose of this research was to develop a practical methodology for the prediction and in-process monitoring of MRR during nanoscale finishing of coated surfaces. Using a specially designed magnetic abrasive finishing (MAF) and acoustic emission (AE) monitoring setup, experiments were carried out on indium-zinc-oxide (IZO) coated Pyrex glasses. After a given polishing time interval, AFM indentation was conducted for each workpiece sample to measure the adhesion force variations of the coating layers (IZO), which are directly related to the MRR changes. The force variation and AE monitoring data were compared to the MRR calculated form the surface measurement (Nanoview) results. The experimental results demonstrate strong correlations between AFM indentation and MRR measurement data. In addition, the monitored AE signals show sensitivity of the material structure variations of the coating layer, as the polishing progresses.

A Biomechanical Assessment of Hand/Arm Force with Pneumatic Nail Gun Actuation Systems.

PubMed

Lowe, Brian D; Albers, James; Hudock, Stephen D

2014-09-01

A biomechanical model is presented, and combined with measurements of tip press force, to estimate total user hand force associated with two pneumatic nail gun trigger systems. The contact actuation trigger (CAT) can fire a nail when the user holds the trigger depressed first and then "bumps" the nail gun tip against the workpiece. With a full sequential actuation trigger (SAT) the user must press the tip against the workpiece prior to activating the trigger. The SAT is demonstrably safer in reducing traumatic injury risk, but increases the duration (and magnitude) of tip force exertion. Time integrated (cumulative) hand force was calculated for a single user from measurements of the tip contact force with the workpiece and transfer time between nails as inputs to a static model of the nail gun and workpiece in two nailing task orientations. The model shows the hand force dependence upon the orientation of the workpiece in addition to the trigger system. Based on standard time allowances from work measurement systems (i.e. Methods-Time Measurement - 1) it is proposed that efficient application of hand force with the SAT in maintaining tip contact can reduce force exertion attributable to the sequential actuation trigger to 2-8% (horizontal nailing) and 9-20% (vertical nailing) of the total hand/arm force. The present model is useful for considering differences in cumulative hand/arm force exposure between the SAT and CAT systems and may explain the appeal of the CAT trigger in reducing the user's perception of muscular effort.

A Biomechanical Assessment of Hand/Arm Force with Pneumatic Nail Gun Actuation Systems

PubMed Central

Lowe, Brian D.; Albers, James; Hudock, Stephen D.

2015-01-01

A biomechanical model is presented, and combined with measurements of tip press force, to estimate total user hand force associated with two pneumatic nail gun trigger systems. The contact actuation trigger (CAT) can fire a nail when the user holds the trigger depressed first and then “bumps” the nail gun tip against the workpiece. With a full sequential actuation trigger (SAT) the user must press the tip against the workpiece prior to activating the trigger. The SAT is demonstrably safer in reducing traumatic injury risk, but increases the duration (and magnitude) of tip force exertion. Time integrated (cumulative) hand force was calculated for a single user from measurements of the tip contact force with the workpiece and transfer time between nails as inputs to a static model of the nail gun and workpiece in two nailing task orientations. The model shows the hand force dependence upon the orientation of the workpiece in addition to the trigger system. Based on standard time allowances from work measurement systems (i.e. Methods-Time Measurement - 1) it is proposed that efficient application of hand force with the SAT in maintaining tip contact can reduce force exertion attributable to the sequential actuation trigger to 2–8% (horizontal nailing) and 9–20% (vertical nailing) of the total hand/arm force. The present model is useful for considering differences in cumulative hand/arm force exposure between the SAT and CAT systems and may explain the appeal of the CAT trigger in reducing the user’s perception of muscular effort. PMID:26321780

Investigation into nanoscratching mechanical response of AlCrCuFeNi high-entropy alloys using atomic simulations

NASA Astrophysics Data System (ADS)

Wang, Zining; Li, Jia; Fang, QiHong; Liu, Bin; Zhang, Liangchi

2017-09-01

The mechanical behaviors and deformation mechanisms of scratched AlCrCuFeNi high entropy alloys (HEAs) have been studied by molecular dynamics (MD) simulations, in terms of the scratching forces, atomic strain, atomic displacement, microstructural evolution and dislocation density. The results show that the larger tangential and normal forces and higher friction coefficient take place in AlCrCuFeNi HEA due to its outstanding strength and hardness, and high adhesion and fracture toughness over the pure metal materials. Moreover, the stacking fault energy (SFE) in HEA increases the probability to initiate dislocation and twinning, which is conducive to the formation of complex deformation modes. Compared to the single element metal workpieces, the segregation potency of solutes into twinning boundary (TB) is raised due to the decreasing segregation energy of TB, resulting in the stronger solute effects on improving twinning properties for HEA workpiece. The higher dislocation density and the more activated slipping planes lead to the outstanding plasticity of AlCrCuFeNi HEA. The solute atoms as barriers to hinder the motion of dislocation and the severe lattice distortion to suppress the free slipping of dislocation are significantly stronger obstacles to strengthen HEA. The excellent comprehensive scratching properties of the bulk AlCrCuFeNi HEAs are associated with the combined effects of multiple strengthening mechanisms, such as dislocation strengthening, deformation twinning strengthening as well as solute strengthening. This work provides a basis for further understanding and tailoring SFE in mechanical properties and deformation mechanism of HEAs, which maybe facilitate the design and preparation of new HEAs with high performance.

Rib forming tool for tubing

DOEpatents

Rowley, James P.; Lewandowski, Edward F.; Groh, Edward F.

1976-01-01

Three cylindrical rollers are rotatably mounted equidistant from the center of a hollow tool head on radii spaced 120.degree. apart. Each roller has a thin flange; the three flanges lie in a single plane to form an internal circumferential rib in a rotating tubular workpiece. The tool head has two complementary parts with two rollers in one part of the head and one roller in the other part; the two parts are joined by a hinge. A second hinge, located so the rollers are between the two hinges, connects one of the parts to a tool bar mounted in a lathe tool holder. The axes of rotation of both hinges and all three rollers are parallel. A hole exposing equal portions of the three roller flanges is located in the center of the tool head. The two hinges permit the tool head to be opened and rotated slightly downward, taking the roller flanges out of the path of the workpiece which is supported on both ends and rotated by the lathe. The parts of the tool head are then closed on the workpiece so that the flanges are applied to the workpiece and form the rib. The tool is then relocated for forming of the next rib.

Analysis of Flatness Deviations for Austenitic Stainless Steel Workpieces after Efficient Surface Machining

NASA Astrophysics Data System (ADS)

Nadolny, K.; Kapłonek, W.

2014-08-01

The following work is an analysis of flatness deviations of a workpiece made of X2CrNiMo17-12-2 austenitic stainless steel. The workpiece surface was shaped using efficient machining techniques (milling, grinding, and smoothing). After the machining was completed, all surfaces underwent stylus measurements in order to obtain surface flatness and roughness parameters. For this purpose the stylus profilometer Hommel-Tester T8000 by Hommelwerke with HommelMap software was used. The research results are presented in the form of 2D surface maps, 3D surface topographies with extracted single profiles, Abbott-Firestone curves, and graphical studies of the Sk parameters. The results of these experimental tests proved the possibility of a correlation between flatness and roughness parameters, as well as enabled an analysis of changes in these parameters from shaping and rough grinding to finished machining. The main novelty of this paper is comprehensive analysis of measurement results obtained during a three-step machining process of austenitic stainless steel. Simultaneous analysis of individual machining steps (milling, grinding, and smoothing) enabled a complementary assessment of the process of shaping the workpiece surface macro- and micro-geometry, giving special consideration to minimize the flatness deviations

Development of a Tri-Axial Cutting Force Sensor for the Milling Process

PubMed Central

Li, Yingxue; Zhao, Yulong; Fei, Jiyou; Zhao, You; Li, Xiuyuan; Gao, Yunxiang

2016-01-01

This paper presents a three-component fixed dynamometer based on a strain gauge, which reduces output errors produced by the cutting force imposed on different milling positions of the workpiece. A reformative structure of tri-layer cross beams is proposed, sensitive areas were selected, and corresponding measuring circuits were arranged to decrease the inaccuracy brought about by positional variation. To simulate the situation with a milling cutter moving on the workpiece and validate the function of reducing the output errors when the milling position changes, both static calibration and dynamic milling tests were implemented on different parts of the workpiece. Static experiment results indicate that with standard loads imposed, the maximal deviation between the measured forces and the standard inputs is 4.87%. The results of the dynamic milling test illustrate that with identical machining parameters, the differences in output variation between the developed sensor and standard dynamometer are no larger than 6.61%. Both static and dynamic experimental results demonstrate that the developed dynamometer is suitable for measuring milling force imposed on different positions of the workpiece, which shows potential applicability in machining a monitoring system. PMID:27007374

Effect of Width of Kerf on Machining Accuracy and Subsurface Layer After WEDM

NASA Astrophysics Data System (ADS)

Mouralova, K.; Kovar, J.; Klakurkova, L.; Prokes, T.

2018-02-01

Wire electrical discharge machining is an unconventional machining technology that applies physical principles to material removal. The material is removed by a series of recurring current discharges between the workpiece and the tool electrode, and a `kerf' is created between the wire and the material being machined. The width of the kerf is directly dependent not only on the diameter of the wire used, but also on the machine parameter settings and, in particular, on the set of mechanical and physical properties of the material being machined. To ensure precise machining, it is important to have the width of the kerf as small as possible. The present study deals with the evaluation of the width of the kerf for four different metallic materials (some of which were subsequently heat treated using several methods) with different machine parameter settings. The kerf is investigated on metallographic cross sections using light and electron microscopy.

Influence of tool shape on lattice rearrangement under loading conditions reproducing friction stir welding

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

Konovalenko, Ivan S., E-mail: ivkon@ispms.tsc.ru; Konovalenko, Igor S., E-mail: igkon@ispms.tsc.ru; National Research Tomsk Polytechnic University, Tomsk, 634050

2015-10-27

Metal behavior under loading conditions that reproduce friction stir welding was studied on the atomic scale. Calculations were conducted based on molecular dynamics simulation with potentials calculated within the embedded atom method. The loading of the interface between two crystallites, whose structure corresponded to aluminum alloy 2024, was simulated by the motion of a cone-shaped tool along the interface with constant angular and translational velocities. The motion of the rotating tool causes fracture of the workpiece crystal structure with subsequent mixing of surface atoms of the interfacing crystallites. It is shown that the resistance force acting on the moving toolmore » from the workpiece and the process of structural defect formation in the workpiece depend on the tool shape.« less

Technological capabilities of increasing surface quality of workpieces made of titanium alloy VT22 and stability of surface grinding

NASA Astrophysics Data System (ADS)

Soler, Ya I.; Salov, V. M.; Mai, D. S.

2018-03-01

Surface grinding of flat workpieces made of alloy VT22 was conducted by the periphery of a highly porous wheel (HPW) from cubic boron nitride CBN30 B107 100 OV K27 КF40 with three processing techniques (ij). They are 10 - cross-feed per stroke, HPW cutting into a workpiece changes alternately from up to down; 12 – cross-feed per double stroke during the up HPW cutting-in at the working stroke; 22 – cross-feed per double stroke during the down HPW cutting-in at the working stroke. With the involvement of artificial neural network models, it was revealed that to improve the quality of surfaces and stability of its formation, grinding should be conducted if ij = 12.

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Fabrication technology

NASA Astrophysics Data System (ADS)

1988-05-01

Many laboratory programs continue to need optical components of ever-increasing size and accuracy. Unfortunately, optical surfaces produced by the conventional sequence of grinding, lapping, and polishing can become prohibitively expensive. Research in the Fabrication Technology area focuses on methods of fabricating components with heretofore unrealized levels of precision. In FY87, researchers worked to determine the fundamental mechanical limits of material removal, experimented with unique material removal and deposition processes, developed servo systems for controlling the geometric position of ultraprecise machine tools, and advanced the ability to precisely measure contoured workpieces. Continued work in these areas will lead to more cost-effective processes to fabricate even higher quality optical components for advanced lasers and for visible, ultraviolet, and X-ray diagnostic systems.

Theoretical study on removal rate and surface roughness in grinding a RB-SiC mirror with a fixed abrasive.

PubMed

Wang, Xu; Zhang, Xuejun

2009-02-10

This paper is based on a microinteraction principle of fabricating a RB-SiC material with a fixed abrasive. The influence of the depth formed on a RB-SiC workpiece by a diamond abrasive on the material removal rate and the surface roughness of an optical component are quantitatively discussed. A mathematical model of the material removal rate and the simulation results of the surface roughness are achieved. In spite of some small difference between the experimental results and the theoretical anticipation, which is predictable, the actual removal rate matches the theoretical prediction very well. The fixed abrasive technology's characteristic of easy prediction is of great significance in the optical fabrication industry, so this brand-new fixed abrasive technology has wide application possibilities.

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.

Influence of electrical resistivity and machining parameters on electrical discharge machining performance of engineering ceramics.

PubMed

Ji, Renjie; Liu, Yonghong; Diao, Ruiqiang; Xu, Chenchen; Li, Xiaopeng; Cai, Baoping; Zhang, Yanzhen

2014-01-01

Engineering ceramics have been widely used in modern industry for their excellent physical and mechanical properties, and they are difficult to machine owing to their high hardness and brittleness. Electrical discharge machining (EDM) is the appropriate process for machining engineering ceramics provided they are electrically conducting. However, the electrical resistivity of the popular engineering ceramics is higher, and there has been no research on the relationship between the EDM parameters and the electrical resistivity of the engineering ceramics. This paper investigates the effects of the electrical resistivity and EDM parameters such as tool polarity, pulse interval, and electrode material, on the ZnO/Al2O3 ceramic's EDM performance, in terms of the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). The results show that the electrical resistivity and the EDM parameters have the great influence on the EDM performance. The ZnO/Al2O3 ceramic with the electrical resistivity up to 3410 Ω·cm can be effectively machined by EDM with the copper electrode, the negative tool polarity, and the shorter pulse interval. Under most machining conditions, the MRR increases, and the SR decreases with the decrease of electrical resistivity. Moreover, the tool polarity, and pulse interval affect the EWR, respectively, and the electrical resistivity and electrode material have a combined effect on the EWR. Furthermore, the EDM performance of ZnO/Al2O3 ceramic with the electrical resistivity higher than 687 Ω·cm is obviously different from that with the electrical resistivity lower than 687 Ω·cm, when the electrode material changes. The microstructure character analysis of the machined ZnO/Al2O3 ceramic surface shows that the ZnO/Al2O3 ceramic is removed by melting, evaporation and thermal spalling, and the material from the working fluid and the graphite electrode can transfer to the workpiece surface during electrical discharge machining ZnO/Al2O3 ceramic.

Wrinkle-Free Hydroforming of Wire Mesh

NASA Technical Reports Server (NTRS)

Fadness, J.

1986-01-01

Plastic films lubricate workpiece so it deforms smoothly. Thin layers of plastic below top die and above bottom die ensure wire screen slides as shaped by hydroforming. Plastic layers are 0.0043 in. (0.11 m) thick. Preformed to contours of dies and final workpiece. New method of hydroforming fine-wire-mesh heat-shield screens eliminates wrinkles and marks. Prevents screen from being damaged and pores from becoming blocked.

METHOD OF OBTAINING AN IMPROVED WELD IN INERT ARC WELDING

DOEpatents

Correy, T.B.

1962-12-11

A method is reported for inert arc welding. An a-c welding current is applied to the workpiece and welding electrode such that the positive portion of each cycle thereof, with the electrode positive, has only sufficient energy to clean the surface of the workpiece and the negative portion of each cycle thereof, with the electrode negative, contains the energy required to weld. (AEC)

Electric arc saw apparatus

DOEpatents

Deichelbohrer, Paul R [Richland, WA

1986-01-01

A portable, hand held electric arc saw has a small frame for supporting an electrically conducting rotary blade which serves as an electrode for generating an electric arc to erode a workpiece. Electric current is supplied to the blade by biased brushes and a slip ring which are mounted in the frame. A pair of freely movable endless belts in the form of crawler treads stretched between two pulleys are used to facilitate movement of the electric arc saw. The pulleys are formed of dielectric material to electrically insulate the crawler treads from the frame.

Computational simulation of laser heat processing of materials

NASA Astrophysics Data System (ADS)

Shankar, Vijaya; Gnanamuthu, Daniel

1987-04-01

A computational model simulating the laser heat treatment of AISI 4140 steel plates with a CW CO2 laser beam has been developed on the basis of the three-dimensional, time-dependent heat equation (subject to the appropriate boundary conditions). The solution method is based on Newton iteration applied to a triple-approximate factorized form of the equation. The method is implicit and time-accurate; the maintenance of time-accuracy in the numerical formulation is noted to be critical for the simulation of finite length workpieces with a finite laser beam dwell time.

Copper vapor laser precision processing

NASA Astrophysics Data System (ADS)

Nikonchuk, Michail O.

1991-05-01

Copper vapor laser (CVL) was designed on the basis master oscillator (MO) - spatial filter - amplifier (AMP) system which is placed in thermostable volume. Processing material is moved by means of CNC system GPM-AP-400 with +/- 5 micrometers accuracy. Several cutting parameters are considered which define the quality and productivity of vaporization cutting: efficiency, cutwidth, height of upper and lower burr, roughness, laser and heat affected zones. Estimates are made for some metals with thickness 0.02 - 0.3 mm and cutwidth 0.01 - 0.03 mm. The examples of workpieces produced by CVL are presented.

A Precise Visual Method for Narrow Butt Detection in Specular Reflection Workpiece Welding

PubMed Central

Zeng, Jinle; Chang, Baohua; Du, Dong; Hong, Yuxiang; Chang, Shuhe; Zou, Yirong

2016-01-01

During the complex path workpiece welding, it is important to keep the welding torch aligned with the groove center using a visual seam detection method, so that the deviation between the torch and the groove can be corrected automatically. However, when detecting the narrow butt of a specular reflection workpiece, the existing methods may fail because of the extremely small groove width and the poor imaging quality. This paper proposes a novel detection method to solve these issues. We design a uniform surface light source to get high signal-to-noise ratio images against the specular reflection effect, and a double-line laser light source is used to obtain the workpiece surface equation relative to the torch. Two light sources are switched on alternately and the camera is synchronized to capture images when each light is on; then the position and pose between the torch and the groove can be obtained nearly at the same time. Experimental results show that our method can detect the groove effectively and efficiently during the welding process. The image resolution is 12.5 μm and the processing time is less than 10 ms per frame. This indicates our method can be applied to real-time narrow butt detection during high-speed welding process. PMID:27649173

Effects of shielding gas composition on arc profile and molten pool dynamics in gas metal arc welding of steels

NASA Astrophysics Data System (ADS)

Wang, L. L.; Lu, F. G.; Wang, H. P.; Murphy, A. B.; Tang, X. H.

2014-11-01

In gas metal arc welding, gases of different compositions are used to produce an arc plasma, which heats and melts the workpiece. They also protect the workpiece from the influence of the air during the welding process. This paper models gas metal arc welding (GMAW) processes using an in-house simulation code. It investigates the effects of the gas composition on the temperature distribution in the arc and on the molten pool dynamics in gas metal arc welding of steels. Pure argon, pure CO2 and different mixtures of argon and CO2 are considered in the study. The model is validated by comparing the calculated weld profiles with physical weld measurements. The numerical calculations reveal that gas composition greatly affects the arc temperature profile, heat transfer to the workpiece, and consequently the weld dimension. As the CO2 content in the shielding gas increases, a more constricted arc plasma with higher energy density is generated as a result of the increased current density in the arc centre and increased Lorentz force. The calculation also shows that the heat transferred from the arc to the workpiece increases with increasing CO2 content, resulting in a wider and deeper weld pool and decreased reinforcement height.

A Precise Visual Method for Narrow Butt Detection in Specular Reflection Workpiece Welding.

PubMed

Zeng, Jinle; Chang, Baohua; Du, Dong; Hong, Yuxiang; Chang, Shuhe; Zou, Yirong

2016-09-13

During the complex path workpiece welding, it is important to keep the welding torch aligned with the groove center using a visual seam detection method, so that the deviation between the torch and the groove can be corrected automatically. However, when detecting the narrow butt of a specular reflection workpiece, the existing methods may fail because of the extremely small groove width and the poor imaging quality. This paper proposes a novel detection method to solve these issues. We design a uniform surface light source to get high signal-to-noise ratio images against the specular reflection effect, and a double-line laser light source is used to obtain the workpiece surface equation relative to the torch. Two light sources are switched on alternately and the camera is synchronized to capture images when each light is on; then the position and pose between the torch and the groove can be obtained nearly at the same time. Experimental results show that our method can detect the groove effectively and efficiently during the welding process. The image resolution is 12.5 μm and the processing time is less than 10 ms per frame. This indicates our method can be applied to real-time narrow butt detection during high-speed welding process.

Combined process "helical rolling-pressing" and its effect on the microstructure of ferrous and non-ferrous materials

NASA Astrophysics Data System (ADS)

Naizabekov, Abdrakhman; Lezhnev, Sergey; Arbuz, Alexandr; Panin, Evgeniy

2018-02-01

Ultrafine-grained materials are one of the most promising structural and functional materials. However, the known methods of obtaining them are not enough powerful and technologically advanced for profitable industrial applications. Development of the combined process "helical rolling-pressing" is an attempt to bring technology to produce ultrafine-grained materials to the industry. The combination of intense processing of the surface by helical rolling and the entire cross section of workpiece in equal channel angular matrix, with intense deformation by torsion between rolls and matrix will increase the degree of deformation per pass and allows to mutually compensate disadvantages of these methods in the case of their separate use. This paper describes the development of a laboratory stand and study of influence of combined process "helical rolling-pressing"on the microstructure of tool steel, technical copper and high alloy stainless high-temperature steel.

Relationship between influence function accuracy and polishing quality in magnetorheological finishing

NASA Astrophysics Data System (ADS)

Schinhaerl, Markus; Schneider, Florian; Rascher, Rolf; Vogt, Christian; Sperber, Peter

2010-10-01

Magnetorheological finishing is a typical commercial application of a computer-controlled polishing process in the manufacturing of precision optical surfaces. Precise knowledge of the material removal characteristic of the polishing tool (influence function) is essential for controlling the material removal on the workpiece surface by the dwell time method. Results from the testing series with magnetorheological finishing have shown that a deviation of only 5% between the actual material removal characteristic of the polishing tool and that represented by the influence function caused a considerable reduction in the polishing quality. The paper discusses reasons for inaccuracies in the influence function and the effects on the polishing quality. The generic results of this research serve for the development of improved polishing strategies, and may be used in alternative applications of computer-controlled polishing processes that quantify the material removal characteristic by influence functions.

The electrical discharge machining of ceramics

NASA Astrophysics Data System (ADS)

Trueman, Christopher Stuart

This study introduces the concept of developing a novel and rapid rough-machining methodology for spark eroding suitable ceramic compositions based on material removal by thermal shock induced spalling, as opposed to conventional melting mechanisms. The principal materials studied were TiB2 dispersion toughened SiC, and Syalon501 - a commercially available TiN toughened sialon ceramic specifically designed for spark erosion. A preliminary study was also carried out on a range of SiC:B4C composites. Machinability and material performance were assessed where appropriate using machining parameters, material removal rate tests, surface analysis, four-point flexure testing, and tool wear. The machining technologies which supported the different mechanisms of material removal were identified, and each mechanism investigated by analysis of captured debris and sectioning of the workpiece. The SiC:B4C composites were found to be spark erodible only with B4C levels above 50% (by mass), and material removal was found to be solely by melting mechanisms. A SiC:TiB2 composition with the addition of 26.5% TiB2 (by mass) was found to be more machinable than a composition with 10% TiB2 (by mass), achieving greater material removal rates owing to its higher electrical conductivity. An in-depth study of the latter (10%TiB2) SiC composition and Syalon501 revealed surprisingly robust materials. Under conventional sparking (no arcing), material was removed by combined dissociation, melting and evaporation. Syalon501 in particular behaved with a high degree of predictability, and neither material could be made to spall under conventional sparking. However, by imposing conditions which deliberately induced arcing, both compositions spalled large flakes of material (up to several hundred microns across) in the localised region of the arc-strike. Examination of captured debris and fracture facets of the spall interface revealed the existence of small "penny cracks", each characterised by the presence of a dispersed particle (of greater thermal expansion) at its centre acting as a stress- raising nucleation point under the intense thermal loading of arcing. Sub-surface cracks in the near horizontal and near-vertical planes were discovered in line with published models based on the application of a hot-spot to brittle material, and evidence of discrete crack propagation under the thermally punctuated pulses of successive sparking was identified. Similar sub-surface cracking was also confirmed in Syalon501 which had been subjected to arcing. Sectioning of the workpiece revealed shallow sub-surface cracks which followed the profile of the machined surface in the near-horizontal plane, and which often limited the extent of near-vertical cracking to the layer of material above the crack, thereby offering the potential for a reliable and fast "planning" technique in which material would be removed in shallow layers. This research has shown that the possibility exists for increased material removal rates and improved process efficiency under a spalling-based machining regime, in which layers of material are released by thermal-shock induced fracture caused by arcing. The viability of developing a new rough-machining technology for ceramics, in which material is "planed" away prior to fine surface finishing by conventional spark erosion has, therefore, been successfully demonstrated.

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.

Development of the Gliding Hole of the Dynamics Compression Plate

NASA Astrophysics Data System (ADS)

Salim, U. A.; Suyitno; Magetsari, R.; Mahardika, M.

2017-02-01

The gliding hole of the dynamics compression plate is designed to facilitate relative movement of pedicle screw during surgery application. The gliding hole shape is then geometrically complex. The gliding hole manufactured using machining processes used to employ ball-nose cutting tool. Then, production cost is expensive due to long production time. This study proposed to increase productivity of DCP products by introducing forming process (cold forming). The forming process used to involve any press tool devices. In the closed die forming press tool is designed with little allowance, then work-pieces is trapped in the mould after forming. Therefore, it is very important to determine hole geometry and dimensions of raw material in order to success on forming process. This study optimized the hole sizes with both geometry analytics and experiments. The success of the forming process was performed by increasing the holes size on the raw materials. The holes size need to be prepared is diameter of 5.5 mm with a length of 11.4 mm for the plate thickness 3 mm and diameter of 6 mm with a length of 12.5 mm for the plate thickness 4 mm.

Design of an ultraprecision computerized numerical control chemical mechanical polishing machine and its implementation

NASA Astrophysics Data System (ADS)

Zhang, Chupeng; Zhao, Huiying; Zhu, Xueliang; Zhao, Shijie; Jiang, Chunye

2018-01-01

The chemical mechanical polishing (CMP) is a key process during the machining route of plane optics. To improve the polishing efficiency and accuracy, a CMP model and machine tool were developed. Based on the Preston equation and the axial run-out error measurement results of the m circles on the tin plate, a CMP model that could simulate the material removal at any point on the workpiece was presented. An analysis of the model indicated that lower axial run-out error led to lower material removal but better polishing efficiency and accuracy. Based on this conclusion, the CMP machine was designed, and the ultraprecision gas hydrostatic guideway and rotary table as well as the Siemens 840Dsl numerical control system were incorporated in the CMP machine. To verify the design principles of machine, a series of detection and machining experiments were conducted. The LK-G5000 laser sensor was employed for detecting the straightness error of the gas hydrostatic guideway and the axial run-out error of the gas hydrostatic rotary table. A 300-mm-diameter optic was chosen for the surface profile machining experiments performed to determine the CMP efficiency and accuracy.

Electric arc saw apparatus

DOEpatents

Deichelbohrer, P.R.

1983-08-08

A portable, hand-held electric arc saw apparatus comprising a small frame for supporting an electrically conducting rotary blade which serves as an electrode for generating an electric arc between the blade and a workpiece of opposite polarity. Electrically conducting means are provided on said frame for transmitting current to said blade. A pair of freely movable endless belts in the form of crawler treads are employed to facilitate movement of the apparatus relative to the workpiece.

Lathe Attachment Finishes Inner Surface of Tubes

NASA Technical Reports Server (NTRS)

Lancki, A. J.

1982-01-01

Extremely smooth finishes are machined on inside surfaces of tubes by new attachment for a lathe. The relatively inexpensive accessory, called a "microhone," holds a honing stone against workpiece by rigid tangs instead of springs as in conventional honing tools. Inner rod permits adjustment of microhoning stone, while outer tube supports assembly. Outer tube is held between split blocks on lathe toolpost. Microhoning can be done with either microhone or workpiece moving and other member stationary.

Toolmarks made by lathe chuck jaws.

PubMed

Finkelstein, Nir; Aronson, Ayal; Tsach, Tsadok

2017-06-01

This paper presents a forensic method to evidentially tie a workpiece with a specific lathe. Examining using this method can prove or exclude a connection between the two. The importance of this method is mostly due to the growing trend among lawbreakers of manufacturing improvised firearm parts using machining processes. This method is based on comparing jaw impressions made by the chuck on a workpiece. Copyright © 2017 Elsevier B.V. All rights reserved.

Spatial feature tracking impedence sensor using multiple electric fields

DOEpatents

Novak, J.L.

1998-08-11

Linear and other features on a workpiece are tracked by measuring the fields generated between electrodes arrayed in pairs. One electrode in each pair operates as a transmitter and the other as a receiver, and both electrodes in a pair are arrayed on a carrier. By combining and subtracting fields between electrodes in one pair and between a transmitting electrode in one pair and a receiving electrode in another pair, information describing the location and orientation of the sensor relative to the workpiece in up to six degrees of freedom may be obtained. Typical applications will measure capacitance, but other impedance components may be measured as well. The sensor is designed to track a linear feature axis or a protrusion or pocket in a workpiece. Seams and ridges can be tracked by this non-contact sensor. The sensor output is useful for robotic applications. 10 figs.

Precision cleaning apparatus and method

DOEpatents

Schneider, T.W.; Frye, G.C.; Martin, S.J.

1998-01-13

A precision cleaning apparatus and method are disclosed. The precision cleaning apparatus includes a cleaning monitor further comprising an acoustic wave cleaning sensor such as a quartz crystal microbalance (QCM), a flexural plate wave (FPW) sensor, a shear horizontal acoustic plate mode (SH--APM) sensor, or a shear horizontal surface acoustic wave (SH--SAW) sensor; and measurement means connectable to the sensor for measuring in-situ one or more electrical response characteristics that vary in response to removal of one or more contaminants from the sensor and a workpiece located adjacent to the sensor during cleaning. Methods are disclosed for precision cleaning of one or more contaminants from a surface of the workpiece by means of the cleaning monitor that determines a state of cleanliness and any residual contamination that may be present after cleaning; and also for determining an effectiveness of a cleaning medium for removing one or more contaminants from a workpiece. 11 figs.

Lateral position detection and control for friction stir systems

DOEpatents

Fleming, Paul; Lammlein, David H.; Cook, George E.; Wilkes, Don Mitchell; Strauss, Alvin M.; Delapp, David R.; Hartman, Daniel A.

2012-06-05

An apparatus and computer program are disclosed for processing at least one workpiece using a rotary tool with rotating member for contacting and processing the workpiece. The methods include oscillating the rotary tool laterally with respect to a selected propagation path for the rotating member with respect to the workpiece to define an oscillation path for the rotating member. The methods further include obtaining force signals or parameters related to the force experienced by the rotary tool at least while the rotating member is disposed at the extremes of the oscillation. The force signals or parameters associated with the extremes can then be analyzed to determine a lateral position of the selected path with respect to a target path and a lateral offset value can be determined based on the lateral position. The lateral distance between the selected path and the target path can be decreased based on the lateral offset value.

Lateral position detection and control for friction stir systems

DOEpatents

Fleming, Paul [Boulder, CO; Lammlein, David H [Houston, TX; Cook, George E [Brentwood, TN; Wilkes, Don Mitchell [Nashville, TN; Strauss, Alvin M [Nashville, TN; Delapp, David R [Ashland City, TN; Hartman, Daniel A [Fairhope, AL

2011-11-08

Friction stir methods are disclosed for processing at least one workpiece using a rotary tool with rotating member for contacting and processing the workpiece. The methods include oscillating the rotary tool laterally with respect to a selected propagation path for the rotating member with respect to the workpiece to define an oscillation path for the rotating member. The methods further include obtaining force signals or parameters related to the force experienced by the rotary tool at least while the rotating member is disposed at the extremes of the oscillation. The force signals or parameters associated with the extremes can then be analyzed to determine a lateral position of the selected path with respect to a target path and a lateral offset value can be determined based on the lateral position. The lateral distance between the selected path and the target path can be decreased based on the lateral offset value.

Spatial feature tracking impedence sensor using multiple electric fields

DOEpatents

Novak, James L.

1998-01-01

Linear and other features on a workpiece are tracked by measuring the fields generated between electrodes arrayed in pairs. One electrode in each pair operates as a transmitter and the other as a receiver, and both electrodes in a pair are arrayed on a carrier. By combining and subtracting fields between electrodes in one pair and between a transmitting electrode in one pair and a receiving electrode in another pair, information describing the location and orientation of the sensor relative to the workpiece in up to six degrees of freedom may be obtained. Typical applications will measure capacitance, but other impedance components may be measured as well. The sensor is designed to track a linear feature axis or a protrusion or pocket in a workpiece. Seams and ridges can be tracked by this non-contact sensor. The sensor output is useful for robotic applications.

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

NASA Astrophysics Data System (ADS)

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

2009-11-01

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

Precision cleaning apparatus and method

DOEpatents

Schneider, Thomas W.; Frye, Gregory C.; Martin, Stephen J.

1998-01-01

A precision cleaning apparatus and method. The precision cleaning apparatus includes a cleaning monitor further comprising an acoustic wave cleaning sensor such as a quartz crystal microbalance (QCM), a flexural plate wave (FPW) sensor, a shear horizontal acoustic plate mode (SH--APM) sensor, or a shear horizontal surface acoustic wave (SH--SAW) sensor; and measurement means connectable to the sensor for measuring in-situ one or more electrical response characteristics that vary in response to removal of one or more contaminants from the sensor and a workpiece located adjacent to the sensor during cleaning. Methods are disclosed for precision cleaning of one or more contaminants from a surface of the workpiece by means of the cleaning monitor that determines a state of cleanliness and any residual contamination that may be present after cleaning; and also for determining an effectiveness of a cleaning medium for removing one or more contaminants from a workpiece.

Process of super-black shading material applied to the star sensor based on Ni-P alloys

NASA Astrophysics Data System (ADS)

Liu, Fengdeng; Xing, Fei; Wu, Yuelong; You, Zheng

2014-12-01

Super-black materials based on Nanotechnology have very important applications in many science fields. Super-black materials which have been reported currently, although have excellent light-trapping properties, most of them need the use of sophisticated equipment , the long-time synthesis , high temperature environment and release flammable, explosive and other dangerous gases. So many kinds of problems have hindered the application of such super-black material in practice. This project had nano super-black material developed with simple equipment and process, instead of complicated and dangerous process steps in high temperature and high pressure. On the basis of literature research, we successfully worked out a set of large-area Ni-P alloy plating method through a series of experiments exploring and analyze the experimental results. In the condition of the above Ni-P alloy, we took the solution, which anodized the Ni-P alloy immersed in the non-oxidizing acid, instead of conventional blackening process. It`s a big break for changing the situation in which oxidation, corrosion, vigorous evolution of hydrogen gas in the process are performed at the same location. As a result, not only the reaction process decreased sensitivity to time error, but also the position of the bubble layer no longer located in the surface of the workpiece which may impede observing the process of reaction. Consequently, the solution improved the controllability of the blackening process. In addition, we conducted the research of nano super-black material, exploring nano-super-black material in terms of space optical sensor.

Efficient production by laser materials processing integrated into metal cutting machines

NASA Astrophysics Data System (ADS)

Wiedmaier, M.; Meiners, E.; Dausinger, Friedrich; Huegel, Helmut

1994-09-01

Beam guidance of high power YAG-laser (cw, pulsed, Q-switched) with average powers up to 2000 W by flexible glass fibers facilitates the integration of the laser beam as an additional tool into metal cutting machines. Hence, technologies like laser cutting, joining, hardening, caving, structuring of surfaces and laser-marking can be applied directly inside machining centers in one setting, thereby reducing the flow of workpieces resulting in a lowering of costs and production time. Furthermore, materials with restricted machinability--especially hard materials like ceramics, hard metals or sintered alloys--can be shaped by laser-caving or laser assisted machining. Altogether, the flexibility of laser integrated machining centers is substantially increased or the efficiency of a production line is raised by time-savings or extended feasibilities with techniques like hardening, welding or caving.

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

Britten, J

WET-ETCH FIGURING (WEF) is an automated method of precisely figuring optical materials by the controlled application of aqueous etchant solution. This technology uses surface-tension-gradient-driven flow to confine and stabilize a wetted zone of an etchant solution or other aqueous processing fluid on the surface of an object. This wetted zone can be translated on the surface in a computer-controlled fashion for precise spatial control of the surface reactions occurring (e.g. chemical etching). WEF is particularly suitable for figuring very thin optical materials because it applies no thermal or mechanical stress to the material. Also, because the process is stress-free themore » workpiece can be monitored during figuring using interferometric metrology, and the measurements obtained can be used to control the figuring process in real-time--something that cannot be done with traditional figuring methods.« less

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.

A new magnetic compound fluid slurry and its performance in magnetic field-assisted polishing of oxygen-free copper

NASA Astrophysics Data System (ADS)

Wang, Youliang; Wu, Yongbo; Guo, Huiru; Fujimoto, Masakazu; Nomura, Mitsuyoshi; Shimada, Kunio

2015-05-01

In nano-precision surface finishing of engineering materials using MCF (magnetic compound fluid) slurry, the water-based MCF slurry is preferable from the viewpoint of the environmental issue and the running cost of cleaning workpiece and equipment. However, the uncoated-CIPs (carbonyl-iron-powders) within the conventional MCF slurry have low ability against aqueous corrosion, leading to the performance deterioration and working life shortening of the conventional MCF slurry. This study proposed a new MCF slurry containing ZrO2-coated CIPs instead of the uncoated CIPs. Its performance in the polishing of oxygen-free copper was compared experimentally with that of the conventional one. The results showed that the work-surface finish polished with the new slurry was in the same level as that with the conventional one when the slurry was used soon after prepared, i.e., the settling time was 0 min; however, as the settling time increased the uncoated-CIPs got rusty, leading to a deterioration in the slurry performance. By contrast, no rust was observed on ZrO2-coated CIPs even the settling time reached several days, indicating the employment of ZrO2-coated CIPs prolonged the working-life of the MCF slurry greatly.

Understanding the creation of & reducing surface microroughness during polishing & post-processing of glass optics

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

Suratwala, Tayyab

2016-09-22

In the follow study, we have developed a detailed understanding of the chemical and mechanical microscopic interactions that occur during polishing affecting the resulting surface microroughness of the workpiece. Through targeted experiments and modeling, the quantitative relationships of many important polishing parameters & characteristics affecting surface microroughness have been determined. These behaviors and phenomena have been described by a number of models including: (a) the Ensemble Hertzian Multi Gap (EHMG) model used to predict the removal rate and roughness at atomic force microscope (AFM) scale lengths as a function of various polishing parameters, (b) the Island Distribution Gap (IDG) modelmore » used to predict the roughness at larger scale lengths, (c) the Deraguin-Verwey-Landau-Overbeek (DLVO) 3-body electrostatic colloidal model used to predict the interaction of slurry particles at the interface and roughness behavior as a function of pH, and (d) a diffusion/chemical reaction rate model of the incorporation of impurities species into the polishing surface layer (called the Bielby layer). Based on this improved understanding, novel strategies to polish the workpiece have been developed simultaneously leading to both ultrasmooth surfaces and high material removal rates. Some of these strategies include: (a) use of narrow PSD slurries, (b) a novel diamond conditioning recipe of the lap to increase the active contact area between the workpiece and lap without destroying its surface figure, (c) proper control of pH for a given glass type to allow for a uniform distribution of slurry particles at the interface, and (d) increase in applied load just up to the transition between molecular to plastic removal regime for a single slurry particle. These techniques have been incorporated into a previously developed finishing process called Convergent Polishing leading to not just economical finishing process with improved surface figure control, but also simultaneously leading to low roughness surface with high removal rates.« less

Design of forging process variables under uncertainties

NASA Astrophysics Data System (ADS)

Repalle, Jalaja; Grandhi, Ramana V.

2005-02-01

Forging is a complex nonlinear process that is vulnerable to various manufacturing anomalies, such as variations in billet geometry, billet/die temperatures, material properties, and workpiece and forging equipment positional errors. A combination of these uncertainties could induce heavy manufacturing losses through premature die failure, final part geometric distortion, and reduced productivity. Identifying, quantifying, and controlling the uncertainties will reduce variability risk in a manufacturing environment, which will minimize the overall production cost. In this article, various uncertainties that affect the forging process are identified, and their cumulative effect on the forging tool life is evaluated. Because the forging process simulation is time-consuming, a response surface model is used to reduce computation time by establishing a relationship between the process performance and the critical process variables. A robust design methodology is developed by incorporating reliability-based optimization techniques to obtain sound forging components. A case study of an automotive-component forging-process design is presented to demonstrate the applicability of the method.

Applications of optical sensing for laser cutting and drilling.

PubMed

Fox, Mahlen D T; French, Paul; Peters, Chris; Hand, Duncan P; Jones, Julian D C

2002-08-20

Any reliable automated production system must include process control and monitoring techniques. Two laser processing techniques potentially lending themselves to automation are percussion drilling and cutting. For drilling we investigate the performance of a modification of a nonintrusive optical focus control system we previously developed for laser welding, which exploits the chromatic aberrations of the processing optics to determine focal error. We further developed this focus control system for closed-loop control of laser cutting. We show that an extension of the technique can detect deterioration in cut quality, and we describe practical trials carried out on different materials using both oxygen and nitrogen assist gas. We base our techniques on monitoring the light generated by the process, captured nonintrusively by the effector optics and processed remotely from the workpiece. We describe the relationship between the temporal and the chromatic modulation of the detected light and process quality and show how the information can be used as the basis of a process control system.

Computer Programs For Automated Welding System

NASA Technical Reports Server (NTRS)

Agapakis, John E.

1993-01-01

Computer programs developed for use in controlling automated welding system described in MFS-28578. Together with control computer, computer input and output devices and control sensors and actuators, provide flexible capability for planning and implementation of schemes for automated welding of specific workpieces. Developed according to macro- and task-level programming schemes, which increases productivity and consistency by reducing amount of "teaching" of system by technician. System provides for three-dimensional mathematical modeling of workpieces, work cells, robots, and positioners.

Penetration in GTA welding

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

Heiple, C.R.; Burgardt, P.

1990-01-01

The size and shape of the weld bead produced in GTA welding depends on the magnitude and distribution of the energy incident on the workpiece surfaces as well as the dissipation of that energy in the workpiece. The input energy is largely controllable through the welding parameters selected, however the dissipation of that energy in the workpiece is less subject to control. Changes in energy dissipation can produce large changes in weld shape or penetration. Heat transport away from the weld pool is almost entirely by conduction, but heat transport in the weld pool is more complicated. Heat conduction throughmore » the liquid is an important component, but heat transport by convection (mass transport) is often the dominant mechanism. Convective heat transport is directional and changes the weld pool shape from that produced by conduction alone. Surface tension gradients are often the dominant forces driving fluid flow in GTA weld pools. These gradients are sensitive functions of weld pool chemistry and the energy input distribution to the weld. Experimental and theoretical work conducted primarily in the past decade has greatly enhanced our understanding of weld pool fluid flow, the forces which drive it, and its effects on weld pool shape. This work is reviewed here. While less common, changes in energy dissipation through the unmelted portion of the workpiece can also affect fusion zone shape or penetration. These effects are also described. 41 refs., 9 figs.« less

Effects of tool handle dimension and workpiece orientation and size on wrist ulnar/radial torque strength, usability and discomfort in a wrench task.

PubMed

Dianat, Iman; Rahimi, Soleyman; Nedaei, Moein; Asghari Jafarabadi, Mohammad; Oskouei, Ali E

2017-03-01

The effects of tool handle dimension (three modified designs of wrenches with 30-50 mm diameter cylindrical handles and traditional design with rectangular cross-sectional (5 mm × 25 mm) handle), workpiece orientation (vertical/horizontal) and workpiece size (small/large) as well as user's hand size on wrist ulnar/radial (U/R) torque strength, usability and discomfort, and also the relationship between these variables were evaluated in a maximum torque task using wrenches. The highest and lowest levels of maximal wrist U/R torque strength were recorded for the 30 mm diameter handle and traditional wrench design, respectively. The prototype handle with 30 mm diameter, together with 40 mm diameter handle, was also better than other designs as they received higher usability ratings and caused less discomfort. The mean wrist torque strength exerted on a vertically oriented workpiece (in the sagittal plane) was 23.8% higher than that exerted on a horizontally oriented one (in the transverse plane). The user's hand size had no effect on torque exertions. The wrist torque strength and usability were negatively correlated with hand and finger discomfort ratings. The results are also discussed in terms of their implications for hand tool and workstation configuration in torque tasks involving wrenches. Copyright © 2016 Elsevier Ltd. All rights reserved.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

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

NASA Astrophysics Data System (ADS)

Jaeger, Valentin E.

1989-04-01

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

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

Coordinate metrology of a primary surface composite panel from the Large Millimeter Telescope

NASA Astrophysics Data System (ADS)

Gale, David M.; Lucero Álvarez, Maribel; Cabrera Cuevas, Lizeth; Leon-Huerta, Andrea; Arizmendi Reyes, Edgar; Icasio Hernández, Octavio; Castro Santos, David; Hernández Ríos, Emilio; Tecuapetla Sosa, Esteban; Tzile Torres, Carlos; Viliesid Alonso, Miguel

2016-07-01

The Large Millimeter Telescope (LMT) is a single-dish fully-steerable radio telescope presently operating with a 32.5 m parabolic primary reflector, in the process of extension to 50 m. The project is managed by the Instituto Nacional de Astrofísica, Óptica y Electrónica (INAOE) in México, and the University of Massachusetts Amherst, USA. A laminated surface panel from the LMT primary reflector has been subjected to a surface measurement assay at Mexico's National Metrology Center (CENAM). Data obtained using a coordinate measuring machine and laser tracker owned by CENAM is compared with measurements using an identical model laser tracker and the photogrammetry technique, the latter systems owned and operated by the LMT. All measurements were performed within the controlled metrology environment at CENAM. The measurement exercise is intended to prepare the groundwork for converting this spare surface panel into a calibrated work-piece. The establishment of a calibrated work-piece provides quality assurance for metrology through measurement traceability. It also simplifies the evaluation of measurement uncertainty for coordinate metrology procedures used by the LMT project during reflector surface qualification.

Design and Development of a Three-Component Force Sensor for Milling Process Monitoring

PubMed Central

Li, Yingxue; Zhao, Yulong; Fei, Jiyou; Qin, Yafei; Zhao, You; Cai, Anjiang; Gao, Song

2017-01-01

A strain-type three-component table dynamometer is presented in this paper, which reduces output errors produced by cutting forces imposed on the different milling positions of a workpiece. A sensor structure with eight parallel elastic beams is proposed, and sensitive regions and Wheastone measuring circuits are also designed in consideration of eliminating the influences of the eccentric forces. To evaluate the sensor decoupling performance, both of the static calibration and dynamic milling test were implemented in different positions of the workpiece. Static experiment results indicate that the maximal deviation between the measured forces and the standard inputs is 4.58%. Milling tests demonstrate that with same machining parameters, the differences of the measured forces between different milling positions derived by the developed sensor are no larger than 6.29%. In addition, the natural frequencies of the dynamometer are kept higher than 2585.5 Hz. All the measuring results show that as a strain-type dynamometer, the developed force sensor has an improved eccentric decoupling accuracy with natural frequencies not much decreased, which owns application potential in milling process monitoring. PMID:28441354

Enhancement of image contrast by fluorescence in microtechnology

NASA Astrophysics Data System (ADS)

Berndt, Michael; Tutsch, Rainer

2005-06-01

New developments in production technology increasingly focus on hybrid microsystems. Especially for systems with movable components, the process step of assembly is mandatory. In general, the accuracy of positioning of the parts has to be better than 1 μm. This makes specialized and automated production equipment necessary, which can lead to a conflict with the aim of flexibility of the range of products. Design for manufacturing is a well known remedy. Assembly aids are common practice today. These features of the workpieces bear no functionality for the end product but considerably ease certain process steps. By standardization of assembly aids generalized production equipment free from product-specific features could be developed. In our contribution, we demonstrate the photogrammetric determination of the positions of workpieces without reference to their exterior shape, using circular fiducial marks of 150 μm in diameter. The surface properties of the workpieces, however, still have an influence on image formation. As an example, the marks may be hidden by local specular reflections. A solution to this problem is to add an exclusive optical property to the fiducial marks to get an image with high contrast against the surface of the workpiece. In biology and medicine samples are stained with fluorescing dyes to enhance the contrast in optical microscopy. In fluorochromes, light of a characteristic wavelength is emitted after the absorption of light with a shorter wavelength. In our experiments we added a fluorochrome to a common photoresist and coated the surface of the workpiece with a thin layer thereof. Using photolithography as a patterning technique we generated fiducial marks with structures down to 25 μm. These marks can be identified by their characteristic emission wavelength under short-wavelength illumination. Only the fiducial marks remain visible in the images and processing these images is straightforward. The generation of fluorescing patterns by photolithography opens new possibilities for testing and process control in many fields of microtechnology.

Normal contour error measurement on-machine and compensation method for polishing complex surface by MRF

NASA Astrophysics Data System (ADS)

Chen, Hua; Chen, Jihong; Wang, Baorui; Zheng, Yongcheng

2016-10-01

The Magnetorheological finishing (MRF) process, based on the dwell time method with the constant normal spacing for flexible polishing, would bring out the normal contour error in the fine polishing complex surface such as aspheric surface. The normal contour error would change the ribbon's shape and removal characteristics of consistency for MRF. Based on continuously scanning the normal spacing between the workpiece and the finder by the laser range finder, the novel method was put forward to measure the normal contour errors while polishing complex surface on the machining track. The normal contour errors was measured dynamically, by which the workpiece's clamping precision, multi-axis machining NC program and the dynamic performance of the MRF machine were achieved for the verification and security check of the MRF process. The unit for measuring the normal contour errors of complex surface on-machine was designed. Based on the measurement unit's results as feedback to adjust the parameters of the feed forward control and the multi-axis machining, the optimized servo control method was presented to compensate the normal contour errors. The experiment for polishing 180mm × 180mm aspherical workpiece of fused silica by MRF was set up to validate the method. The results show that the normal contour error was controlled in less than 10um. And the PV value of the polished surface accuracy was improved from 0.95λ to 0.09λ under the conditions of the same process parameters. The technology in the paper has been being applied in the PKC600-Q1 MRF machine developed by the China Academe of Engineering Physics for engineering application since 2014. It is being used in the national huge optical engineering for processing the ultra-precision optical parts.

Controlling Arc Length in Plasma Welding

NASA Technical Reports Server (NTRS)

Iceland, W. F.

1986-01-01

Circuit maintains arc length on irregularly shaped workpieces. Length of plasma arc continuously adjusted by control circuit to maintain commanded value. After pilot arc is established, contactor closed and transfers arc to workpiece. Control circuit then half-wave rectifies ac arc voltage to produce dc control signal proportional to arc length. Circuit added to plasma arc welding machines with few wiring changes. Welds made with circuit cleaner and require less rework than welds made without it. Beads smooth and free of inclusions.

FUEL HANDLING MECHANISM

DOEpatents

Koch, L.J.; Hutter, E.

1960-02-01

A remotely operable handling device specifically adapted for the handling of vertically disposed fuel rods in a nuclear reactor was developed. The device consists essentially of an elongated tubular member having a gripping device at the lower end of the pivoted jaw type adapted to grip an enlarged head on the upper end of the workpiece. The device includes a sensing element which engages the enlarged head and is displaced to remotely indicate when the workpiece is in the proper position to be engaged by the jaws.

Beam/seam alignment control for electron beam welding

DOEpatents

Burkhardt, Jr., James H.; Henry, J. James; Davenport, Clyde M.

1980-01-01

This invention relates to a dynamic beam/seam alignment control system for electron beam welds utilizing video apparatus. The system includes automatic control of workpiece illumination, near infrared illumination of the workpiece to limit the range of illumination and camera sensitivity adjustment, curve fitting of seam position data to obtain an accurate measure of beam/seam alignment, and automatic beam detection and calculation of the threshold beam level from the peak beam level of the preceding video line to locate the beam or seam edges.

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining.

PubMed

Ramulu, M; Spaulding, Mathew

2016-09-01

An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application.

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

PubMed Central

Ramulu, M.; Spaulding, Mathew

2016-01-01

An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application. PMID:28773866

A Study of Chip Formation Feedrates of Various Steels in Low-Speed Milling Process

NASA Astrophysics Data System (ADS)

Prasetyo, L.; Tauviqirrahman, M.; Rusnaldy

2017-05-01

Milling is a process of metal removal by feeding the workpiece a rotating multitoothed cutter. The objective of the study was to investigate the chip characteristics (chip length, width, and thickness) during the milling process by varying the feedrates and the types of materials used based on an experimental approach. The chosen materials were AISI 1020, AISI 1045, AISI 1090, AISI D2, and AISI 4340 with a high-speed steel (HSS) as a cutter. In this work, the feedrates were varied of 5, 10, and 15 mm/minutes with the depth of cut of 0.5 mm and a low spindle speed of 70 rpm. The results show that, in general, increasing the feedrate will lead to the growth of chip length, width, and thickness for all types of materials used. Also, related to the chip shape, AISI 1020 produces the discontinuous chip which can be related to its hardness value.

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

NASA Astrophysics Data System (ADS)

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

2007-04-01

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

Estimation of the laser cutting operating cost by support vector regression methodology

NASA Astrophysics Data System (ADS)

Jović, Srđan; Radović, Aleksandar; Šarkoćević, Živče; Petković, Dalibor; Alizamir, Meysam

2016-09-01

Laser cutting is a popular manufacturing process utilized to cut various types of materials economically. The operating cost is affected by laser power, cutting speed, assist gas pressure, nozzle diameter and focus point position as well as the workpiece material. In this article, the process factors investigated were: laser power, cutting speed, air pressure and focal point position. The aim of this work is to relate the operating cost to the process parameters mentioned above. CO2 laser cutting of stainless steel of medical grade AISI316L has been investigated. The main goal was to analyze the operating cost through the laser power, cutting speed, air pressure, focal point position and material thickness. Since the laser operating cost is a complex, non-linear task, soft computing optimization algorithms can be used. Intelligent soft computing scheme support vector regression (SVR) was implemented. The performance of the proposed estimator was confirmed with the simulation results. The SVR results are then compared with artificial neural network and genetic programing. According to the results, a greater improvement in estimation accuracy can be achieved through the SVR compared to other soft computing methodologies. The new optimization methods benefit from the soft computing capabilities of global optimization and multiobjective optimization rather than choosing a starting point by trial and error and combining multiple criteria into a single criterion.

Optimization of Dimensional accuracy in plasma arc cutting process employing parametric modelling approach

NASA Astrophysics Data System (ADS)

Naik, Deepak kumar; Maity, K. P.

2018-03-01

Plasma arc cutting (PAC) is a high temperature thermal cutting process employed for the cutting of extensively high strength material which are difficult to cut through any other manufacturing process. This process involves high energized plasma arc to cut any conducting material with better dimensional accuracy in lesser time. This research work presents the effect of process parameter on to the dimensional accuracy of PAC process. The input process parameters were selected as arc voltage, standoff distance and cutting speed. A rectangular plate of 304L stainless steel of 10 mm thickness was taken for the experiment as a workpiece. Stainless steel is very extensively used material in manufacturing industries. Linear dimension were measured following Taguchi’s L16 orthogonal array design approach. Three levels were selected to conduct the experiment for each of the process parameter. In all experiments, clockwise cut direction was followed. The result obtained thorough measurement is further analyzed. Analysis of variance (ANOVA) and Analysis of means (ANOM) were performed to evaluate the effect of each process parameter. ANOVA analysis reveals the effect of input process parameter upon leaner dimension in X axis. The results of the work shows that the optimal setting of process parameter values for the leaner dimension on the X axis. The result of the investigations clearly show that the specific range of input process parameter achieved the improved machinability.

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

Rabin, B.H.

This paper reports on a ceramic joining technique that has been developed that utilizes an exothermic combustion reaction to simultaneously synthesize the joint interlayer material and to bond together the ceramic workpieces. The method has been used to join SiC ceramics using Ti-C-Ni powder mixtures that ignite below 1200{degrees} C to form a TiC-Ni joining material. Thin layers of the powder reactants were prepared by tape casting, and joining was accomplished by heating in a hot-press to ignite the combustion reaction. during this process, localized exothermic heating of the joint region resulted in chemical interaction at the interface between themore » TiC-Ni and the SiC ceramic that contributed to bonding. Room-temperature four-point bending strengths of joints produced by this method have exceeded 100 MPa.« less

Optimum Design of Forging Process Parameters and Preform Shape under Uncertainties

NASA Astrophysics Data System (ADS)

Repalle, Jalaja; Grandhi, Ramana V.

2004-06-01

Forging is a highly complex non-linear process that is vulnerable to various uncertainties, such as variations in billet geometry, die temperature, material properties, workpiece and forging equipment positional errors and process parameters. A combination of these uncertainties could induce heavy manufacturing losses through premature die failure, final part geometric distortion and production risk. Identifying the sources of uncertainties, quantifying and controlling them will reduce risk in the manufacturing environment, which will minimize the overall cost of production. In this paper, various uncertainties that affect forging tool life and preform design are identified, and their cumulative effect on the forging process is evaluated. Since the forging process simulation is computationally intensive, the response surface approach is used to reduce time by establishing a relationship between the system performance and the critical process design parameters. Variability in system performance due to randomness in the parameters is computed by applying Monte Carlo Simulations (MCS) on generated Response Surface Models (RSM). Finally, a Robust Methodology is developed to optimize forging process parameters and preform shape. The developed method is demonstrated by applying it to an axisymmetric H-cross section disk forging to improve the product quality and robustness.

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.

Autoresonant control of nonlinear mode in ultrasonic transducer for machining applications.

PubMed

Babitsky, V I; Astashev, V K; Kalashnikov, A N

2004-04-01

Experiments conducted in several countries have shown that the improvement of machining quality can be promoted through conversion of the cutting process into one involving controllable high-frequency vibration at the cutting zone. This is achieved through the generation and maintenance of ultrasonic vibration of the cutting tool to alter the fracture process of work-piece material cutting to one in which loading of the materials at the tool tip is incremental, repetitive and controlled. It was shown that excitation of the high-frequency vibro-impact mode of the tool-workpiece interaction is the most effective way of ultrasonic influence on the dynamic characteristics of machining. The exploitation of this nonlinear mode needs a new method of adaptive control for excitation and stabilisation of ultrasonic vibration known as autoresonance. An approach has been developed to design an autoresonant ultrasonic cutting unit as an oscillating system with an intelligent electronic feedback controlling self-excitation in the entire mechatronic system. The feedback produces the exciting force by means of transformation and amplification of the motion signal. This allows realisation for robust control of fine resonant tuning to bring the nonlinear high Q-factor systems into technological application. The autoresonant control provides the possibility of self-tuning and self-adaptation mechanisms for the system to keep the nonlinear resonant mode of oscillation under unpredictable variation of load, structure and parameters. This allows simple regulation of intensity of the process whilst keeping maximum efficiency at all times. An autoresonant system with supervisory computer control was developed, tested and used for the control of the piezoelectric transducer during ultrasonically assisted cutting. The system has been developed as combined analog-digital, where analog devices process the control signal, and parameters of the devices are controlled digitally by computer. The system was applied for advanced machining of aviation materials.

A Comprehensive Understanding of Machine and Material Behaviors During Inertia Friction Welding

NASA Astrophysics Data System (ADS)

Tung, Daniel J.

Inertia Friction Welding (IFW), a critical process to many industries, currently relies on trial-and-error experimentation to optimize process parameters. Although this Edisonian approach is very effective, the high time and dollar costs incurred during process development are the driving force for better design approaches. Thermal-stress finite element modeling has been increasingly used to aid in process development in the literature; however, several fundamental questions on machine and material behaviors remain unanswered. The work presented here aims produce an analytical foundation to significantly reduce the costly physical experimentation currently required to design the inertia welding of production parts. Particularly, the work is centered around the following two major areas. First, machine behavior during IFW, which critically determines deformation and heating, had not been well understood to date. In order to properly characterize the IFW machine behavior, a novel method based on torque measurements was invented to measure machine efficiency, i.e. the ratio of the initial kinetic energy of the flywheel to that contributing to workpiece heating and deformation. The measured efficiency was validated by both simple energy balance calculations and more sophisticated finite element modeling. For the first time, the efficiency dependence on both process parameters (flywheel size, initial rotational velocity, axial load, and surface roughness) and materials (1018 steel, Low Solvus High Refractory LSHR and Waspaloy) was quantified using the torque based measurement method. The effect of process parameters on machine efficiency was analyzed to establish simple-to-use yet powerful equations for selection and optimization of IFW process parameters for making welds; however, design criteria such as geometry and material optimization were not addressed. Second, there had been a lack of understanding of the bond formation during IFW. In the present research, an interrupted welding study was developed utilizing purposefully-designed dissimilar metal couples to investigate bond formation for this specific material combination. The inertia welding process was interrupted at various times as the flywheel velocity decreased. The fraction of areas with intermixed metals was quantified to reveal the bond formation during IFW. The results revealed a relationship between the upset and the fraction of bonded material, which, interestingly, was found to be consistent to that established for roll bonding literature. The relationship is critical to studying the bonding mechanism and surface interactions during IFW. Moreover, it is essential to accurately interpret the modeling results to determine the extent of bonding using the computed strains near the workpiece interface. With this method developed, similar data can now be collected for additional similar and dissimilar material combinations. In summary, in the quest to develop, validate, and execute a modeling framework to study the inertia friction weldability of different alloy systems, particularly Fe- and Ni-base alloys, many new discoveries have been made to enhance the body of knowledge surrounding IFW. The data and trends discussed in this dissertation constitute a physics-based framework to understand the machine and material behaviors during IFW. Such a physics-based framework is essential to significantly reduce the costly trial-and-error experimentation currently required to successfully and consistently perform the inertia welding of production parts.

Influence of Electrical Resistivity and Machining Parameters on Electrical Discharge Machining Performance of Engineering Ceramics

PubMed Central

Ji, Renjie; Liu, Yonghong; Diao, Ruiqiang; Xu, Chenchen; Li, Xiaopeng; Cai, Baoping; Zhang, Yanzhen

2014-01-01

Engineering ceramics have been widely used in modern industry for their excellent physical and mechanical properties, and they are difficult to machine owing to their high hardness and brittleness. Electrical discharge machining (EDM) is the appropriate process for machining engineering ceramics provided they are electrically conducting. However, the electrical resistivity of the popular engineering ceramics is higher, and there has been no research on the relationship between the EDM parameters and the electrical resistivity of the engineering ceramics. This paper investigates the effects of the electrical resistivity and EDM parameters such as tool polarity, pulse interval, and electrode material, on the ZnO/Al2O3 ceramic's EDM performance, in terms of the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). The results show that the electrical resistivity and the EDM parameters have the great influence on the EDM performance. The ZnO/Al2O3 ceramic with the electrical resistivity up to 3410 Ω·cm can be effectively machined by EDM with the copper electrode, the negative tool polarity, and the shorter pulse interval. Under most machining conditions, the MRR increases, and the SR decreases with the decrease of electrical resistivity. Moreover, the tool polarity, and pulse interval affect the EWR, respectively, and the electrical resistivity and electrode material have a combined effect on the EWR. Furthermore, the EDM performance of ZnO/Al2O3 ceramic with the electrical resistivity higher than 687 Ω·cm is obviously different from that with the electrical resistivity lower than 687 Ω·cm, when the electrode material changes. The microstructure character analysis of the machined ZnO/Al2O3 ceramic surface shows that the ZnO/Al2O3 ceramic is removed by melting, evaporation and thermal spalling, and the material from the working fluid and the graphite electrode can transfer to the workpiece surface during electrical discharge machining ZnO/Al2O3 ceramic. PMID:25364912

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.

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

Application of electrolytic in-process dressing for high-efficiency grinding of ceramic parts. Research activities 1995--96

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

Bandyopadhyay, B.P.

1997-02-01

The application of Electrolytic In-Process Dressing (ELID) for highly efficient and stable grinding of ceramic parts is discussed. This research was performed at the Institute of Physical and Chemical Research (RIKEN), Tokyo, Japan, June 1995 through August 1995. Experiments were conducted using a vertical machining center. The silicon nitride work material, of Japanese manufacture and supplied in the form of a rectangular block, was clamped to a vice which was firmly fixed on the base of a strain gage dynamometer. The dynamometer was clamped on the machining center table. Reciprocating grinding was performed with a flat-faced diamond grinding wheel. Themore » output from the dynamometer was recorded with a data acquisition system and the normal component of the force was monitored. Experiments were carried out under various cutting conditions, different ELID conditions, and various grinding wheel bonds types. Rough grinding wheels of grit sizes {number_sign}170 and {number_sign}140 were used in the experiments. Compared to conventional grinding, there was a significant reduction in grinding force with ELID grinding. Therefore, ELID grinding can be recommended for high material removal rate grinding, low rigidity machines, and low rigidity workpieces. Compared to normal grinding, a reduction in grinding ratio was observed when ELID grinding was performed. A negative aspect of the process, this reduced G-ratio derives from bond erosion and can be improved somewhat by adjustments in the ELID current. The results of this investigation are discussed in detail in this report.« less

Applying High-Speed Vision Sensing to an Industrial Robot for High-Performance Position Regulation under Uncertainties

PubMed Central

Huang, Shouren; Bergström, Niklas; Yamakawa, Yuji; Senoo, Taku; Ishikawa, Masatoshi

2016-01-01

It is traditionally difficult to implement fast and accurate position regulation on an industrial robot in the presence of uncertainties. The uncertain factors can be attributed either to the industrial robot itself (e.g., a mismatch of dynamics, mechanical defects such as backlash, etc.) or to the external environment (e.g., calibration errors, misalignment or perturbations of a workpiece, etc.). This paper proposes a systematic approach to implement high-performance position regulation under uncertainties on a general industrial robot (referred to as the main robot) with minimal or no manual teaching. The method is based on a coarse-to-fine strategy that involves configuring an add-on module for the main robot’s end effector. The add-on module consists of a 1000 Hz vision sensor and a high-speed actuator to compensate for accumulated uncertainties. The main robot only focuses on fast and coarse motion, with its trajectories automatically planned by image information from a static low-cost camera. Fast and accurate peg-and-hole alignment in one dimension was implemented as an application scenario by using a commercial parallel-link robot and an add-on compensation module with one degree of freedom (DoF). Experimental results yielded an almost 100% success rate for fast peg-in-hole manipulation (with regulation accuracy at about 0.1 mm) when the workpiece was randomly placed. PMID:27483274

Machine imparting complex rotary motion for lapping a spherical inner diameter

DOEpatents

Carroll, Thomas A.; Yetter, Harold H.

1986-01-01

An apparatus for imparting complex rotary motion is used to lap an inner spherical diameter surface of a workpiece. A lapping tool consists of a dome and rod mounted along the dome's vertical axis. The workpiece containing the lapping tool is held in a gimbal which uses power derived from a secondary takeoff means to impart rotary motion about a horizontal axis. The gimbal is rotated about a vertical axis by a take means while mounted at a radially outward position on a rotating arm.

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.

Decontamination apparatus and method. [Patent applications

DOEpatents

Oakley, D.J.

1983-12-16

This invention relates generally to the fabrication of fuel pin elements employed in nuclear reactors and, more particularly, to removing radioactive contamination disposed on the exterior of finally assembled fuel pins. A blast head includes a plurality of spray nozzles mounted in a chamber for receiving a workpiece. The several spray nozzles concurrently direct a plurality of streams of a pressurized gas and abrasive grit mixture toward a peripheral portion of the workpiece to remove particulates or debris therefrom. An exhaust outlet is formed in the chamber for discharging the particulates and spent grit.

Machine imparting complex rotary motion for lapping a spherical inner diameter

DOEpatents

Carroll, T.A.; Yetter, H.H.

1985-01-30

An apparatus for imparting complex rotary motion is used to lap an inner spherical diameter surface of a workpiece. A lapping tool consists of a dome and rod mounted along the dome's vertical axis. The workpiece containing the lapping tool is held in a gimbal which uses power derived from a secondary takeoff means to impart rotary motion about a horizontal axis. The gimbal is rotated about a vertical axis by a take means while mounted at a radially outward position on a rotating arm.

Thermal barrier coatings on gas turbine blades: Chemical vapor deposition (Review)

NASA Astrophysics Data System (ADS)

Igumenov, I. K.; Aksenov, A. N.

2017-12-01

Schemes are presented for experimental setups (reactors) developed at leading scientific centers connected with the development of technologies for the deposition of coatings using the CVD method: at the Technical University of Braunschweig (Germany), the French Aerospace Research Center, the Materials Research Institute (Tohoku University, Japan) and the National Laboratory Oak Ridge (USA). Conditions and modes for obtaining the coatings with high operational parameters are considered. It is established that the formed thermal barrier coatings do not fundamentally differ in their properties (columnar microstructure, thermocyclic resistance, thermal conductivity coefficient) from standard electron-beam condensates, but the highest growth rates and the perfection of the crystal structure are achieved in the case of plasma-chemical processes and in reactors with additional laser or induction heating of a workpiece. It is shown that CVD reactors can serve as a basis for the development of rational and more advanced technologies for coating gas turbine blades that are not inferior to standard electron-beam plants in terms of the quality of produced coatings and have a much simpler and cheaper structure. The possibility of developing a new technology based on CVD processes for the formation of thermal barrier coatings with high operational parameters is discussed, including a set of requirements for industrial reactors, high-performance sources of vapor precursors, and promising new materials.

Self-Advancing Step-Tap Drills

NASA Technical Reports Server (NTRS)

Pettit, Donald R.; Camarda, Charles J.; Penner, Ronald K.; Franklin, Larry D.

2007-01-01

Self-advancing tool bits that are hybrids of drills and stepped taps make it possible to form threaded holes wider than about 1/2 in. (about 13 mm) without applying any more axial force than is necessary for forming narrower pilot holes. These self-advancing stepped-tap drills were invented for use by space-suited astronauts performing repairs on reinforced carbon/carbon space-shuttle leading edges during space walks, in which the ability to apply axial drilling forces is severely limited. Self-advancing stepped-tap drills could also be used on Earth for making wide holes without applying large axial forces. A self-advancing stepped-tap drill (see figure) includes several sections having progressively larger diameters, typically in increments between 0.030 and 0.060 in. (between about 0.8 and about 1.5 mm). The tip section, which is the narrowest, is a pilot drill bit that typically has a diameter between 1/8 and 3/16 in. (between about 3.2 and about 4.8 mm). The length of the pilot-drill section is chosen, according to the thickness of the object to be drilled and tapped, so that the pilot hole is completed before engagement of the first tap section. Provided that the cutting-edge geometry of the drill bit is optimized for the material to be drilled, only a relatively small axial force [typically of the order of a few pounds (of the order of 10 newtons)] must be applied during drilling of the pilot hole. Once the first tap section engages the pilot hole, it is no longer necessary for the drill operator to apply axial force: the thread engagement between the tap and the workpiece provides the axial force to advance the tool bit. Like the pilot-drill section, each tap section must be long enough to complete its hole before engagement of the next, slightly wider tap section. The precise values of the increments in diameter, the thread pitch, the rake angle of the tap cutting edge, and other geometric parameters of the tap sections must be chosen, in consideration of the workpiece material and thickness, to prevent stripping of threads during the drilling/tapping operation. A stop-lip or shoulder at the shank end of the widest tap section prevents further passage of the tool bit through the hole.

Verifying the functional ability of microstructured surfaces by model-based testing

NASA Astrophysics Data System (ADS)

Hartmann, Wito; Weckenmann, Albert

2014-09-01

Micro- and nanotechnology enables the use of new product features such as improved light absorption, self-cleaning or protection, which are based, on the one hand, on the size of functional nanostructures and the other hand, on material-specific properties. With the need to reliably measure progressively smaller geometric features, coordinate and surface-measuring instruments have been refined and now allow high-resolution topography and structure measurements down to the sub-nanometre range. Nevertheless, in many cases it is not possible to make a clear statement about the functional ability of the workpiece or its topography because conventional concepts of dimensioning and tolerancing are solely geometry oriented and standardized surface parameters are not sufficient to consider interaction with non-geometric parameters, which are dominant for functions such as sliding, wetting, sealing and optical reflection. To verify the functional ability of microstructured surfaces, a method was developed based on a parameterized mathematical-physical model of the function. From this model, function-related properties can be identified and geometric parameters can be derived, which may be different for the manufacturing and verification processes. With this method it is possible to optimize the definition of the shape of the workpiece regarding the intended function by applying theoretical and experimental knowledge, as well as modelling and simulation. Advantages of this approach will be discussed and demonstrated by the example of a microstructured inking roll.

Friction Spinning—New Innovative Tool Systems For The Production of Complex Functionally Graded Workpieces

NASA Astrophysics Data System (ADS)

Homberg, Werner; Hornjak, Daniel

2011-05-01

Friction spinning is a new innovative and promising incremental forming technology implying high potential regarding the manufacturing of complex functionally graded workpieces and enhancing existing forming limits of conventional metal spinning processes. The friction spinning process is based on the integration of thermo-mechanical friction subprocesses in this incremental forming process. By choosing the appropriate process parameters, e.g. axial feed rate or relative motion, the contact conditions between tool and workpiece can be influenced in a defined way and, thus, a required temperature profile can be obtained. Friction spinning allows the extension of forming limits compared to conventional metal spinning in order to produce multifunctional components with locally varying properties and the manufacturing of e.g. complex hollow parts made of tubes, profiles, or sheet metals. In this way, it meets the demands regarding efficiency and the manufacturing of functionally graded lightweight components. There is e.g. the possibility of locally increasing the wall thickness in joining zones and, as a consequence, achieving higher quality of the joint at decreased expense. These products are not or only hardly producible by conventional processes so far. In order to benefit from the advantages and potentials of this new innovative process new tooling systems and concepts are indispensable which fulfill the special requirements of this thermo-mechanical process concerning thermal and tribological loads and which allow simultaneous and defined forming and friction operations. An important goal of the corresponding research work at the Chair of Forming and Machining Technology at the University of Paderborn is the development of tool systems that allow the manufacturing of such complex parts by simple uniaxial or sequential biaxial linear tool paths. In the paper, promising tool systems and geometries as well as results of theoretical and experimental research work (e.g. regarding the influence and interaction of process parameters on the workpiece quality) will be discussed. Furthermore, possibilities regarding the manufacturing of geometries (demonstrator workpieces) which are not or only hardly producible with conventional processes will be presented.

Superplastic forging nitride ceramics

DOEpatents

Panda, P.C.; Seydel, E.R.; Raj, R.

1988-03-22

A process is disclosed for preparing silicon nitride ceramic parts which are relatively flaw free and which need little or no machining, said process comprising the steps of: (a) preparing a starting powder by wet or dry mixing ingredients comprising by weight from about 70% to about 99% silicon nitride, from about 1% to about 30% of liquid phase forming additive and from 1% to about 7% free silicon; (b) cold pressing to obtain a preform of green density ranging from about 30% to about 75% of theoretical density; (c) sintering at atmospheric pressure in a nitrogen atmosphere at a temperature ranging from about 1,400 C to about 2,200 C to obtain a density which ranges from about 50% to about 100% of theoretical density and which is higher than said preform green density, and (d) press forging workpiece resulting from step (c) by isothermally uniaxially pressing said workpiece in an open die without initial contact between said workpiece and die wall perpendicular to the direction of pressing and so that pressed workpiece does not contact die wall perpendicular to the direction of pressing, to substantially final shape in a nitrogen atmosphere utilizing a temperature within the range of from about 1,400 C to essentially 1,750 C and strain rate within the range of about 10[sup [minus]7] to about 10[sup [minus]1] seconds[sup [minus]1], the temperature and strain rate being such that surface cracks do not occur, said pressing being carried out to obtain a shear deformation greater than 30% whereby superplastic forging is effected.

Space-dependent characterization of laser-induced plasma plume during fiber laser welding

NASA Astrophysics Data System (ADS)

Xiao, Xianfeng; Song, Lijun; Xiao, Wenjia; Liu, Xingbo

2016-12-01

The role of a plasma plume in high power fiber laser welding is of considerable interest due to its influence on the energy transfer mechanism. In this study, the space-dependent plasma characteristics including spectrum intensity, plasma temperature and electron density were investigated using optical emission spectroscopy technique. The plasma temperature was calculated using the Boltzmann plot of atomic iron lines, whereas the electron density was determined from the Stark broadening of the Fe I line at 381.584 nm. Quantitative analysis of plasma characteristics with respect to the laser radiation was performed. The results show that the plasma radiation increases as the laser power increases during the partial penetration mode, and then decreases sharply after the initiation of full penetration. Both the plasma temperature and electron density increase with the increase of laser power until they reach steady state values after full penetration. Moreover, the hottest core of the plasma shifts toward the surface of the workpiece as the penetration depth increases, whereas the electron density is more evenly distributed above the surface of the workpiece. The results also indicate that the absorption and scattering of nanoparticles in the plasma plume is the main mechanism for laser power attenuation.

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.

MRR and TWR evaluation on electrical discharge machining of Ti-6Al-4V using tungsten : copper composite electrode

NASA Astrophysics Data System (ADS)

Prasanna, J.; Rajamanickam, S.; Amith Kumar, O.; Karthick Raj, G.; Sathya Narayanan, P. V. V.

2017-05-01

In this paper Ti-6Al-4V used as workpiece material and it is keenly seen in variety of field including medical, chemical, marine, automotive, aerospace, aviation, electronic industries, nuclear reactor, consumer products etc., The conventional machining of Ti-6Al-4V is very difficult due to its distinctive properties. The Electrical Discharge Machining (EDM) is right choice of machining this material. The tungsten copper composite material is employed as tool material. The gap voltage, peak current, pulse on time and duty factor is considered as the machining parameter to analyze the machining characteristics Material Removal Rate (MRR) and Tool Wear Rate (TWR). The Taguchi method is provided to work for finding the significant parameter of EDM. It is found that for MRR significant parameters rated in the following order Gap Voltage, Pulse On-Time, Peak Current and Duty Factor. On the other hand for TWR significant parameters are listed in line of Gap Voltage, Duty Factor, Peak Current and Pulse On-Time.

Static tool influence function for fabrication simulation of hexagonal mirror segments for extremely large telescopes.

PubMed

Kim, Dae Wook; Kim, Sug-Whan

2005-02-07

We present a novel simulation technique that offers efficient mass fabrication strategies for 2m class hexagonal mirror segments of extremely large telescopes. As the first of two studies in series, we establish the theoretical basis of the tool influence function (TIF) for precessing tool polishing simulation for non-rotating workpieces. These theoretical TIFs were then used to confirm the reproducibility of the material removal foot-prints (measured TIFs) of the bulged precessing tooling reported elsewhere. This is followed by the reverse-computation technique that traces, employing the simplex search method, the real polishing pressure from the empirical TIF. The technical details, together with the results and implications described here, provide the theoretical tool for material removal essential to the successful polishing simulation which will be reported in the second study.

Analysis and design of friction stir welding tool

NASA Astrophysics Data System (ADS)

Jagadeesha, C. B.

2016-12-01

Since its inception no one has done analysis and design of FSW tool. Initial dimensions of FSW tool are decided by educated guess. Optimum stresses on tool pin have been determined at optimized parameters for bead on plate welding on AZ31B-O Mg alloy plate. Fatigue analysis showed that the chosen FSW tool for the welding experiment has not ∞ life and it has determined that the life of FSW tool is 2.66×105 cycles or revolutions. So one can conclude that any arbitrarily decided FSW tool generally has finite life and cannot be used for ∞ life. In general, one can determine the suitability of tool and its material to be used in FSW of the given workpiece materials in advance by this analysis in terms of fatigue life of the tool.

Biomachining - A new approach for micromachining of metals

NASA Astrophysics Data System (ADS)

Vigneshwaran, S. C. Sakthi; Ramakrishnan, R.; Arun Prakash, C.; Sashank, C.

2018-04-01

Machining is the process of removal of material from workpiece. Machining can be done by physical, chemical or biological methods. Though physical and chemical methods have been widely used in machining process, they have their own disadvantages such as development of heat affected zone and usage of hazardous chemicals. Biomachining is the machining process in which bacteria is used to remove material from the metal parts. Chemolithotrophic bacteria such as Acidothiobacillus ferroxidans has been used in biomachining of metals like copper, iron etc. These bacteria are used because of their property of catalyzing the oxidation of inorganic substances. Biomachining is a suitable process for micromachining of metals. This paper reviews the biomachining process and various mechanisms involved in biomachining. This paper also briefs about various parameters/factors to be considered in biomachining and also the effect of those parameters on metal removal rate.

Laser Processing of Carbon Fiber Reinforced Plastics - Release of Carbon Fiber Segments During Short-pulsed Laser Processing of CFRP

NASA Astrophysics Data System (ADS)

Walter, Juergen; Brodesser, Alexander; Hustedt, Michael; Bluemel, Sven; Jaeschke, Peter; Kaierle, Stefan

Cutting and ablation using short-pulsed laser radiation are promising technologies to produce or repair CFRP components with outstanding mechanical properties e.g. for automotive and aircraft industry. Using sophisticated laser processing strategies and avoiding excessive heating of the workpiece, a high processing quality can be achieved. However, the interaction of laser radiation and composite material causes a notable release of hazardous substances from the process zone, amongst others carbon fiber segments or fibrous particles. In this work, amounts and geometries of the released fiber segments are analyzed and discussed in terms of their hazardous potential. Moreover, it is investigated to what extent gaseous organic process emissions are adsorbed at the fiber segments, similar to an adsorption of volatile organic compounds at activated carbon, which is typically used as filter material.

Evaluation of Workpiece Temperature during Drilling of GLARE Fiber Metal Laminates Using Infrared Techniques: Effect of Cutting Parameters, Fiber Orientation and Spray Mist Application.

PubMed

Giasin, Khaled; Ayvar-Soberanis, Sabino

2016-07-28

The rise in cutting temperatures during the machining process can influence the final quality of the machined part. The impact of cutting temperatures is more critical when machining composite-metal stacks and fiber metal laminates due to the stacking nature of those hybrids which subjects the composite to heat from direct contact with metallic part of the stack and the evacuated hot chips. In this paper, the workpiece surface temperature of two grades of fiber metal laminates commercially know as GLARE is investigated. An experimental study was carried out using thermocouples and infrared thermography to determine the emissivity of the upper, lower and side surfaces of GLARE laminates. In addition, infrared thermography was used to determine the maximum temperature of the bottom surface of machined holes during drilling GLARE under dry and minimum quantity lubrication (MQL) cooling conditions under different cutting parameters. The results showed that during the machining process, the workpiece surface temperature increased with the increase in feed rate and fiber orientation influenced the developed temperature in the laminate.

High temperature pressurized high frequency testing rig and test method

DOEpatents

De La Cruz, Jose; Lacey, Paul

2003-04-15

An apparatus is described which permits the lubricity of fuel compositions at or near temperatures and pressures experienced by compression ignition fuel injector components during operation in a running engine. The apparatus consists of means to apply a measured force between two surfaces and oscillate them at high frequency while wetted with a sample of the fuel composition heated to an operator selected temperature. Provision is made to permit operation at or near the flash point of the fuel compositions. Additionally a method of using the subject apparatus to simulate ASTM Testing Method D6079 is disclosed, said method involving using the disclosed apparatus to contact the faces of prepared workpieces under a measured load, sealing the workface contact point into the disclosed apparatus while immersing said contact point between said workfaces in a lubricating media to be tested, pressurizing and heating the chamber and thereby the fluid and workfaces therewithin, using the disclosed apparatus to impart a differential linear motion between the workpieces at their contact point until a measurable scar is imparted to at least one workpiece workface, and then evaluating the workface scar.

Offline motion planning and simulation of two-robot welding coordination

NASA Astrophysics Data System (ADS)

Zhang, Tie; Ouyang, Fan

2012-03-01

This paper focuses on the two-robot welding coordination of complex curve seam which means one robot grasp the workpiece, the other hold the torch, the two robots work on the same workpiece simultaneously. This paper builds the dual-robot coordinate system at the beginning, and three point calibration method of two robots' relative base coordinate system is presented. After that, the non master/slave scheme is chosen for the motion planning, the non master/slave scheme sets the poses versus time function of the point u on the workpiece, and calculates the two robot end effecter trajectories through the constrained relationship matrix automatically. Moreover, downhand welding is employed which can guarantee the torch and the seam keep in good contact condition all the time during the welding. Finally, a Solidworks-Sim Mechanics simulation platform is established, and a simulation of curved steel pipe welding is conducted. The results of the simulation illustrate the welding process can meet the requirements of downhand welding, the joint displacement curves are smooth and continuous and no joint velocities are out of working scope.

Evaluation of Workpiece Temperature during Drilling of GLARE Fiber Metal Laminates Using Infrared Techniques: Effect of Cutting Parameters, Fiber Orientation and Spray Mist Application

PubMed Central

Giasin, Khaled; Ayvar-Soberanis, Sabino

2016-01-01

The rise in cutting temperatures during the machining process can influence the final quality of the machined part. The impact of cutting temperatures is more critical when machining composite-metal stacks and fiber metal laminates due to the stacking nature of those hybrids which subjects the composite to heat from direct contact with metallic part of the stack and the evacuated hot chips. In this paper, the workpiece surface temperature of two grades of fiber metal laminates commercially know as GLARE is investigated. An experimental study was carried out using thermocouples and infrared thermography to determine the emissivity of the upper, lower and side surfaces of GLARE laminates. In addition, infrared thermography was used to determine the maximum temperature of the bottom surface of machined holes during drilling GLARE under dry and minimum quantity lubrication (MQL) cooling conditions under different cutting parameters. The results showed that during the machining process, the workpiece surface temperature increased with the increase in feed rate and fiber orientation influenced the developed temperature in the laminate. PMID:28773757

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.

Torque-Limiting Manipulation Device

NASA Technical Reports Server (NTRS)

Moetteli, John B. (Inventor)

1999-01-01

A device for manipulating a workpiece in space includes a fixture, a stanchion assembly, a manipulation mechanism, an actuation mechanism, and a reaction mechanism. The fixture has an end onto which the workpiece affixes. The stanchion assembly has an upper and a lower end. The manipulation mechanism connects the fixture and the upper end of the stanchion assembly. The lower end of the stanchion assembly mounts, via probe and a socket, to a structure. The actuation mechanism operably connects to the manipulation mechanism, and moves the fixture in space. The reaction mechanism provides a point through which force inputs into the actuation mechanism may react.

Multi Objective Optimization of Multi Wall Carbon Nanotube Based Nanogrinding Wheel Using Grey Relational and Regression Analysis

NASA Astrophysics Data System (ADS)

Sethuramalingam, Prabhu; Vinayagam, Babu Kupusamy

2016-07-01

Carbon nanotube mixed grinding wheel is used in the grinding process to analyze the surface characteristics of AISI D2 tool steel material. Till now no work has been carried out using carbon nanotube based grinding wheel. Carbon nanotube based grinding wheel has excellent thermal conductivity and good mechanical properties which are used to improve the surface finish of the workpiece. In the present study, the multi response optimization of process parameters like surface roughness and metal removal rate of grinding process of single wall carbon nanotube (CNT) in mixed cutting fluids is undertaken using orthogonal array with grey relational analysis. Experiments are performed with designated grinding conditions obtained using the L9 orthogonal array. Based on the results of the grey relational analysis, a set of optimum grinding parameters is obtained. Using the analysis of variance approach the significant machining parameters are found. Empirical model for the prediction of output parameters has been developed using regression analysis and the results are compared empirically, for conditions of with and without CNT grinding wheel in grinding process.

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

Jiang, Xiujuan; Whalen, Scott A.; Darsell, Jens T.

Soft magnetic materials are often limited in scalability due to conventional processes that do not retain beneficial microstructures, and their associated physical properties, during densification. In this work, friction consolidation (FC) has been studied to fabricate Fe-Si soft magnetic materials from gas-atomized powder precursors. Fe-Si powder is consolidated using variable pressure and tool rotation speed in an effort to evaluate this unique densification approach for potential improvements in magnetic properties. FC, due to the high shear deformation involved, is shown to result in uniform gradual grain structure refinement across the consolidated workpiece from the center nearest the tool to themore » edge. Magnetic properties along different orientations indicate little, if any, textural orientation in the refined grain structure. The effect of annealing on the magnetic properties is evaluated and shown to decrease coercivity. FC processing was able to retain the magnetization of the original gas-atomized powders but further process optimization is needed to reach the optimal coercivity for the soft magnetic materials applications.« less

Gas and plasma dynamics of RF discharge jet of low pressure in a vacuum chamber with flat electrodes and inside tube, influence of RF discharge on the steel surface parameters

NASA Astrophysics Data System (ADS)

Khristoliubova, V. I.; Kashapov, N. F.; Shaekhov, M. F.

2016-06-01

Researches results of the characteristics of the RF discharge jet of low pressure and the discharge influence on the surface modification of high speed and structural steels are introduced in the article. Gas dynamics, power and energy parameters of the RF low pressure discharge flow in the discharge chamber and the electrode gap are studied in the presence of the materials. Plasma flow rate, discharge power, the concentration of electrons, the density of RF power, the ion current density, and the energy of the ions bombarding the surface materials are considered for the definition of basic properties crucial for the process of surface modification of materials as they were put in the plasma jet. The influence of the workpiece and effect of products complex configuration on the RF discharge jet of low pressure is defined. The correlation of the input parameters of the plasma unit on the characteristics of the discharge is established.

Influence of tools geometry and processing conditions on behavior of a difficult-to-work Al-Mg alloy during equal channel angular pressing

NASA Astrophysics Data System (ADS)

Comǎneci, Radu Ioachim; Nedelcu, Dumitru; Bujoreanu, Leandru Gheorghe

2017-10-01

Equal channel angular pressing (ECAP) is a well-established method for grain refinement in metallic materials by large shear plastic deformation, being the most promising and effective severe plastic deformation (SPD) technique. ECAP is a discontinuous process, so the billet removal implies a new development of the procedure: the new sample pushes out the previous sample. In resuming the process the head and the tail ends of the work piece which becomes strongly distorted and receiving different amount of strain have to be removed. Due to the path difference in material flow between upper and lower region of the outlet channel, a non-uniform strain and stress distribution across the width of the workpiece leaving the plastic deformation zone (PDZ) is achieved. A successful ECAP requires surpassing two obstacles: the necessary load level which directly affects tools and a favorable stress distribution so the material withstanding the accumulated strain of repeated deformation. Under back pressure (BP), materials have shown to be able to withstand more passes. As soon as the billet passes the PDZ along the bisector plane of the two channels, the compressive mean stress changes to tensile (leading to crack initiation), while in the presence of BP, a negative (compressive) stress is applied during the process. In this paper a comparative tridimensional finite element analysis (FEA) is performed to evaluate the behavior of a difficult-to-work Al-Mg alloy depending on tools geometry and process parameters. The results in terms of load level and strain distribution show the influence of the punch geometry and BP on the material behavior.

Surface quality of silicon wafer improved by hydrodynamic effect polishing

NASA Astrophysics Data System (ADS)

Peng, Wenqiang; Guan, Chaoliang; Li, Shengyi

2014-08-01

Differing from the traditional pad polishing, hydrodynamic effect polishing (HEP) is non-contact polishing with the wheel floated on the workpiece. A hydrodynamic lubricated film is established between the wheel and the workpiece when the wheel rotates at a certain speed in HEP. Nanoparticles mixed with deionized water are employed as the polishing slurry, and with action of the dynamic pressure, nanoparticles with high chemisorption due to the high specific surface area can easily reacted with the surface atoms forming a linkage with workpiece surface. The surface atoms are dragged away when nanoparticles are transported to separate by the flow shear stress. The development of grand scale integration put extremely high requirements on the surface quality on the silicon wafer with surface roughness at subnanometer and extremely low surface damage. In our experiment a silicon sample was processed by HEP, and the surface topography before and after polishing was observed by the atomic force microscopy. Experiment results show that plastic pits and bumpy structures on the initial surface have been removed away clearly with the removal depth of 140nm by HEP process. The processed surface roughness has been improved from 0.737nm RMS to 0.175nm RMS(10μm×10μm) and the section profile shows peaks of the process surface are almost at the same height. However, the machining ripples on the wheel surface will duplicate on the silicon surface under the action of the hydrodynamic effect. Fluid dynamic simulation demonstrated that the coarse surface on the wheel has greatly influence on the distribution of shear stress and dynamic pressure on the workpiece surface.

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.

Combination drilling and skiving tool

DOEpatents

Stone, William J.

1989-01-01

A combination drilling and skiving tool including a longitudinally extending hollow skiving sleeve slidably and concentrically mounted on a right-handed twist drill. Dogs or pawls provided on the internal periphery of the skiving sleeve engage with the helical grooves of the drill. During a clockwise rotation of the tool, the drill moves downwardly and the sleeve translates upwardly, so that the drill performs a drilling operation on a workpiece. On the other hand, the drill moves upwardly and the sleeve translates downwardly, when the tool is rotated in a counter-clockwise direction, and the sleeve performs a skiving operation. The drilling and skiving operations are separate, independent and exclusive of each other.

Use Of Lasers In Seam Welding Of Engine Parts For Cars

NASA Astrophysics Data System (ADS)

Luttke, A.

1986-11-01

The decision in favour of active research into laser technology was taken in our company in 1978. In the following years we started with the setting-up of a laser laboratory charged with the task of performing basic manufacturing technology experiments in order to examine the ap-plications of laser technology for cutting, welding, hardening, remelting and secondary alloys. The first laboratory-laser - a 2,5 kW fast axial flow CO2 laser - is connected with a CNC-controlled workpiece manipulation unit, which is designed in such a way that workpieces from the smallest component of a car gearbox up to crankcases for commercial vehicles can be manipulated at speeds considered theoretically feasible for laser machining. The use of the laser beam for cutting, hardening and welding tasks has been under investigation in our company, in this laboratory for some 6 years. Laser cutting is now no longer a question of development, but is instead standard practice and is already used in various sec-tions of our production division for pilot-series manufacturing and for small batches. Laser hardening has, in our opinion, great possibilities for tasks which, for distortion and accessibility reasons, cannot be satisfactorily performed using present-day processes, for instance induction hardening. However, a great deal of development work is still necessary before economically reasonable and quality-assured production installation can be undertaken. Laser-welding is now used in series-production in our company for two engine components. More details are given below.

The effect of additive geometry on the integration of secondary elements during Friction Stir Processing

NASA Astrophysics Data System (ADS)

Zens, A.; Gnedel, M.; Zaeh, M. F.; Haider, F.

2018-06-01

Friction Stir Processing (FSP) can be used to locally modify properties in materials such as aluminium. This may be used, for example, to produce a fine microstructure or to integrate secondary elements into the base material. The purpose of this work is to examine the effect of the properties of the metal additives on the resulting material distribution in the processed region. For this, commercially pure iron and copper were integrated into an EN AW-1050 aluminium base material using FSP. Iron in the form of powder, wire and foil as well as copper in powder form were assessed. The various additive forms represent materials with differing surface-to-volume ratios as well as varying dispersion characteristics in the processing zone. The processing parameters for each additive form remained constant; however, two- and four-pass FSP processes were conducted. The results of CT analysis proved especially insightful regarding the spatial distribution of the various additive form within the workpiece. As expected, the powder additive was most widely distributed within the welding zone. Micro-hardness mappings showed that the powder additive contributed to the hardness within the weld nugget in comparison to the processed material without secondary elements.

Study on Circular Complex viewed from Environmental Systems

NASA Astrophysics Data System (ADS)

Takeguchi, Tomoo; Adachi, Katsushige; Yoshikawa, Akira; Hiratsuka, Akira; Tsujino, Ryoji; Iguchi, Manabu

In machining processes, cutting fluids are generally used for cooling and lubricating workpieces at the point cutting. However, these fluids frequently include chlorine, sulfur, phosphorus, or other additives. The chemicals not only become a mist affecting the health of workers engaged in the processing but also make the workshop environment worse. In particular, the chlorine becomes one of the causes of global warming by treating waste oil under high temperature conditions. It is furthermore said that huge cost beyond the purchase cost of oil occurs and dioxins (carcinogen) usually exist in the waste oil. Therefore, an environmentally-friendly cooling-air cutting system is required from the standpoint of green manufacturing. This system has been noted as a technique to solve the issues against the environment mentioned above. In the cooling-air cutting processing, the amount of CO2 emission shows a low value compared with the dry cutting one which uses oil. It is therefore thought that the cooling-air cutting system is a very important processing technique as an environmental countermeasure. At present, in strictly economic and environmental situations, the compatibility of the betterment of production efficiency with the improvement of environment is a subject in the actual spot of a cut processing. This study deals with the test results of cooling-air drilling performance from the viewpoint of taking green manufacturing into account. The workpiece made of die steel SKDll was manufactured by the cooling-air drilling performance at a revolution of 840 rpm and a temperature of -20°C with a high-speed steel drill (SKH56). The results were compared with those for the dry cutting performance. The main results obtained in this study are as follows: 1) The tool life for cooling-air drilling performance was about 6 times as long as that for the dry cutting performance. 2) The chip temperature for cooling-air drilling was 220°C lower than that for the dry cutting performance.

Method and apparatus for use in making an object

NASA Technical Reports Server (NTRS)

Derkacs, Thomas (Inventor); Fetheroff, Charles W. (Inventor); Matay, Istvan M. (Inventor); Toth, Istvan J. (Inventor)

1982-01-01

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbine engine. The airfoil is held by a gripper assembly (86) while a spray gun (24) is effective to apply the covering over the airfoil. When a portion of the covering has been applied, a sensor (28) is utilized to detect the thickness of the covering. A control apparatus (32) compares the thickness of the covering of material which has been applied with the desired thickness and is subsequently effective to regulate the operation of the spray gun to adaptively apply a covering of a desired thickness with an accuracy of at least plus or minus 0.0015 inches (1.5 mils) despite unanticipated process variations.

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.

Control apparatus

NASA Technical Reports Server (NTRS)

Derkacs, Thomas (Inventor); Fetheroff, Charles W. (Inventor); Matay, Istvan M. (Inventor); Toth, Istvan J. (Inventor)

1982-01-01

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbine engine. The airfoil is held by a gripper assembly (86) while a spray gun (24) is effective to apply the covering over the airfoil. When a portion of the covering has been applied, a sensor (28) is utilized to detect the thickness of the covering. A control apparatus (32) compares the thickness of the covering of material which has been applied with the desired thickness and is subsequently effective to regulate the operation of the spray gun to adaptively apply a covering of a desired thickness with an accuracy of at least plus or minus 0.0015 inches (1.5 mils) despite unanticipated process variations.

Dynamic Tensile Properties of Iron and Steels for a Wide Range of Strain Rates and Strain

NASA Astrophysics Data System (ADS)

Kojima, Nobusato; Hayashi, Hiroyuki; Yamamoto, Terumi; Mimura, Koji; Tanimura, Shinji

The tensile stress-strain curves of iron and a variety of steels, covering a wide range of strength level, over a wide strain rate range on the order of 10-3 ~ 103 s-1, were obtained systematically by using the Sensing Block Type High Speed Material Testing System (SBTS, Saginomiya). Through intensive analysis of these results, the strain rate sensitivity of the flow stress for the large strain region, including the viscous term at high strain rates, the true fracture strength and the true fracture strain were cleared for the material group of the ferrous metals. These systematical data may be useful to develop a practical constitutive model for computer codes, including a fracture criterion for simulations of the dynamic behavior in crash worthiness studies and of work-pieces subjected to dynamic plastic working for a wide strain rate range.

Microstructural Evolution of Ti-6Al-4V during High Strain Rate Conditions of Metal Cutting

NASA Technical Reports Server (NTRS)

Dong, Lei; Schneider, Judy

2009-01-01

The microstructural evolution following metal cutting was investigated within the metal chips of Ti-6Al-4V. Metal cutting was used to impose a high strain rate on the order of approx.10(exp 5)/s within the primary shear zone as the metal was removed from the workpiece. The initial microstructure of the parent material (PM) was composed of a bi-modal microstructure with coarse prior grains and equiaxed primary located at the boundaries. After metal cutting, the microstructure of the metal chips showed coarsening of the equiaxed primary grains and lamellar. These metallographic findings suggest that the metal chips experienced high temperatures which remained below the transus temperature.

Microstructure Evolution in Cut Metal Chips of Ti-6Al-4V

NASA Technical Reports Server (NTRS)

Dong, L.; Schneider, J. A.

2008-01-01

The microstructural evolution following metal cutting was investigated within metal chips of Ti-6Al-4V. Metal cutting was used to impose a high strain rate on the order of approx.10(exp 5)/s within the primary shear zone as the metal was removed from the workpiece. The initial microstructure of the parent material (PM) was composed of a bi-modal microstructure with coarse prior beta grains and equiaxed primary alpha located at the boundaries. After metal cutting, the microstructure of the metal chips showed coarsening of the equiaxed primary alpha grains and beta lamellar. These metallographic findings suggest that the metal chips experienced high temperatures which remained below the beta transus temperature.

Management of laser welding based on analysis informative signals

NASA Astrophysics Data System (ADS)

Zvezdin, V. V.; Rakhimov, R. R.; Saubanov, Ruz R.; Israfilov, I. H.; Akhtiamov, R. F.

2017-09-01

Features of formation precision weld of metal were presented. It has been shown that the quality of the welding process depends not only on the energy characteristics of the laser processing facility, the temperature of the surface layer, but also on the accuracy of positioning laser focus relative to seam and the workpiece surface. So the laser focus positioning accuracy is an estimate of the quality of the welding process. This approach allows to build a system automated control of the laser technological complex with the stabilization of the setpoint accuracy of of positioning of the laser beam relative to the workpiece surface.

Parallelism measurement for base plate of standard artifact with multiple tactile approaches

NASA Astrophysics Data System (ADS)

Ye, Xiuling; Zhao, Yan; Wang, Yiwen; Wang, Zhong; Fu, Luhua; Liu, Changjie

2018-01-01

Nowadays, as workpieces become more precise and more specialized which results in more sophisticated structures and higher accuracy for the artifacts, higher requirements have been put forward for measuring accuracy and measuring methods. As an important method to obtain the size of workpieces, coordinate measuring machine (CMM) has been widely used in many industries. In order to achieve the calibration of a self-developed CMM, it is found that the parallelism of the base plate used for fixing the standard artifact is an important factor which affects the measurement accuracy in the process of studying self-made high-precision standard artifact. And aimed to measure the parallelism of the base plate, by using the existing high-precision CMM, gauge blocks, dial gauge and marble platform with the tactile approach, three methods for parallelism measurement of workpieces are employed, and comparisons are made within the measurement results. The results of experiments show that the final accuracy of all the three methods is able to reach micron level and meets the measurement requirements. Simultaneously, these three approaches are suitable for different measurement conditions which provide a basis for rapid and high-precision measurement under different equipment conditions.

Geometric improvement of electrochemical discharge micro-drilling using an ultrasonic-vibrated electrolyte

NASA Astrophysics Data System (ADS)

Han, Min-Seop; Min, Byung-Kwon; Lee, Sang Jo

2009-06-01

Electrochemical discharge machining (ECDM) is a spark-based micromachining method especially suitable for the fabrication of various microstructures on nonconductive materials, such as glass and some engineering ceramics. However, since the spark discharge frequency is drastically reduced as the machining depth increases ECDM microhole drilling has confronted difficulty in achieving uniform geometry for machined holes. One of the primary reasons for this is the difficulty of sustaining an adequate electrolyte flow in the narrow gap between the tool and the workpiece, which results in a widened taper at the hole entrance, as well as a significant reduction of the machining depth. In this paper, ultrasonic electrolyte vibration was used to enhance the machining depth of the ECDM drilling process by assuring an adequate electrolyte flow, thus helping to maintain consistent spark generation. Moreover, the stability of the gas film formation, as well as the surface quality of the hole entrance, was improved with the aid of a side-insulated electrode and a pulse-power generator. The side-insulated electrode prevented stray electrolysis and concentrated the spark discharge at the tool tip, while the pulse voltage reduced thermal damage to the workpiece surface by introducing a periodic pulse-off time. Microholes were fabricated in order to investigate the effects of ultrasonic assistance on the overcut and machining depth of the holes. The experimental results demonstrated that the possibility of consistent spark generation and the machinability of microholes were simultaneously enhanced.

Empirical Models for Quantification of Machining Damage in Composite Materials

NASA Astrophysics Data System (ADS)

Machado, Carla Maria Moreira

The tremendous growth which occurs at a global level of demand and use of composite materials brings with the need to develop new manufacturing tools and methodologies. One of the major uses of such materials, in particular plastics reinforced with carbon fibres, is their application in structural components for the aircraft industry with low weight and high stiffness. These components are produced in near-final form but the so-called secondary processes such as machining are often unavoidable. In this type of industry, drilling is the most frequent operation due to the need to obtain holes for riveting and fastening bolt assembly of structures. However, the problems arising from drilling, particularly the damage caused during the operation, may lead to rejection of components because it is an origin of lack of resistance. The delamination is the most important damage, as it causes a decrease of the mechanical properties of the components of an assembly and, irrefutably, a reduction of its reliability in use. It can also raise problems with regard to the tolerances of the assemblies. Moreover, the high speed machining is increasingly recognized to be a manufacturing technology that promotes productivity by reducing production times. However, the investigation whose focus is in high speed drilling is quite limited, and few studies on this subject have been found in the literature review. Thus, this thesis aims to investigate the effects of process variables in high speed drilling on the damage produced. The empirical models that relate the delamination damage, the thrust force and the torque with the process parameters were established using Response Surface Methodology. The process parameters considered as input factors were the spindle speed, the feed per tooth, the tool diameter and the workpiece thickness. A new method for fixing the workpiece was developed and tested. The results proved to be very promising since in the same cutting conditions and with this new methodology, it was observed a significant reduction of the delamination damage. Finally, it has been found that is possible to use high speed drilling, using conventional twist drills, to produce holes with good quality, minimizing the damage.

Fabrication development for ODS-superalloy, air-cooled turbine blades

NASA Technical Reports Server (NTRS)

Moracz, D. J.

1984-01-01

MA-600 is a gamma prime and oxide dispersion strengthened superalloy made by mechanical alloying. At the initiation of this program, MA-6000 was available as an experimental alloy only and did not go into production until late in the program. The objective of this program was to develop a thermal-mechanical-processing approach which would yield the necessary elongated grain structure and desirable mechanical properties after conventional press forging. Forging evaluations were performed to select optimum thermal-mechanical-processing conditions. These forging evaluations indicated that MA-6000 was extremely sensitive to die chilling. In order to conventionally hot forge the alloy, an adherent cladding, either the original extrusion can or a thick plating, was required to prevent cracking of the workpiece. Die design must reflect the requirement of cladding. MA-6000 was found to be sensitive to the forging temperature. The correct temperature required to obtain the proper grain structure after recrystallization was found to be between 1010-1065 C (1850-1950 F). The deformation level did not affect subsequent crystallization; however, sharp transition areas in tooling designs should be avoided in forming a blade shape because of the potential for grain structure discontinuities. Starting material to be used for forging should be processed so that it is capable of being zone annealed to a coarse elongated grain structure as bar stock. This conclusion means that standard processed bar materials can be used.

Dust Emission Induced By Friction Modifications At Tool Chip Interface In Dry Machining In MMCp

NASA Astrophysics Data System (ADS)

Kremer, Arnaud; El Mansori, Mohamed

2011-01-01

This paper investigates the relationship between dust emission and tribological conditions at the tool-chip interface when machining Metal Matrix composite reinforced with particles (MMCp) in dry mode. Machining generates aerosols that can easily be inhaled by workers. Aerosols may be composed of oil mist, tool material or alloying elements of workpiece material. Bar turning tests were conducted on a 2009 aluminum alloy reinforced with different level of Silicon Carbide particles (15, 25 and 35% of SiCp). Variety of PCD tools and nanostructured diamond coatings were used to analyze their performances on air pollution. A spectrometer was used to detect airborne aerosol particles in the size range between 0.3μm to 20 μm and to sort them in 15 size channels in real time. It was used to compare the effects of test parameters on dust emission. Observations of tool face and chip morphology reveal the importance of friction phenomena. It was demonstrated that level of friction modifies chip curvature and dust emission. The increase of level of reinforcement increase the chip segmentation and decrease the contact length and friction area. A "running in" phenomenon with important dust emission appeared with PCD tool due to the tool rake face flatness. In addition dust generation is more sensitive to edge integrity than power consumption.

Analysis about diamond tool wear in nano-metric cutting of single crystal silicon using molecular dynamics method

NASA Astrophysics Data System (ADS)

Wang, Zhiguo; Liang, Yingchun; Chen, Mingjun; Tong, Zhen; Chen, Jiaxuan

2010-10-01

Tool wear not only changes its geometry accuracy and integrity, but also decrease machining precision and surface integrity of workpiece that affect using performance and service life of workpiece in ultra-precision machining. Scholars made a lot of experimental researches and stimulant analyses, but there is a great difference on the wear mechanism, especially on the nano-scale wear mechanism. In this paper, the three-dimensional simulation model is built to simulate nano-metric cutting of a single crystal silicon with a non-rigid right-angle diamond tool with 0 rake angle and 0 clearance angle by the molecular dynamics (MD) simulation approach, which is used to investigate the diamond tool wear during the nano-metric cutting process. A Tersoff potential is employed for the interaction between carbon-carbon atoms, silicon-silicon atoms and carbon-silicon atoms. The tool gets the high alternating shear stress, the tool wear firstly presents at the cutting edge where intension is low. At the corner the tool is splitted along the {1 1 1} crystal plane, which forms the tipping. The wear at the flank face is the structure transformation of diamond that the diamond structure transforms into the sheet graphite structure. Owing to the tool wear the cutting force increases.

Surface quality and topographic inspection of variable compliance part after precise turning

NASA Astrophysics Data System (ADS)

Nieslony, P.; Krolczyk, G. M.; Wojciechowski, S.; Chudy, R.; Zak, K.; Maruda, R. W.

2018-03-01

The paper presents the problem of precise turning of the mould parts with variable compliance and demonstrates a topographic inspection of the machined surface quality. The study was conducted for the cutting tools made of cemented carbide with coatings, in a range of variable cutting parameters. The long shaft with special axial hole, made of hardened 55NiCrMoV6 steel was selected as a workpiece. The carried out study included the stiffness measurement of the machining system, as well as the investigation of cutting force components. In this context, the surface topography parameters were evaluated using the stylus profile meter and analysed. The research revealed that the surface topography, alongside the 3D functional parameters, and PSD influences the performance of the machined surface. The lowest surface roughness parameters values, equalled to Sa = 1 μm and Sz = 4.3 μm have been obtained during turning with cutting speed vc = 90 m/min. The stable turning of variable compliance part affects the surface texture formation with a unidirectional perpendicular, anisotropic structure. Nevertheless, in case of unstable turning, the characteristic chatter marks are observed, and process dynamics has greater contribution in formation of surface finish than turning kinematics and elastic plastic deformation of workpiece.

Remote repair appliance

DOEpatents

Heumann, Frederick K.; Wilkinson, Jay C.; Wooding, David R.

1997-01-01

A remote appliance for supporting a tool for performing work at a worksite on a substantially circular bore of a workpiece and for providing video signals of the worksite to a remote monitor comprising: a baseplate having an inner face and an outer face; a plurality of rollers, wherein each roller is rotatably and adjustably attached to the inner face of the baseplate and positioned to roll against the bore of the workpiece when the baseplate is positioned against the mouth of the bore such that the appliance may be rotated about the bore in a plane substantially parallel to the baseplate; a tool holding means for supporting the tool, the tool holding means being adjustably attached to the outer face of the baseplate such that the working end of the tool is positioned on the inner face side of the baseplate; a camera for providing video signals of the worksite to the remote monitor; and a camera holding means for supporting the camera on the inner face side of the baseplate, the camera holding means being adjustably attached to the outer face of the baseplate. In a preferred embodiment, roller guards are provided to protect the rollers from debris and a bore guard is provided to protect the bore from wear by the rollers and damage from debris.

Differential Laser Doppler based Non-Contact Sensor for Dimensional Inspection with Error Propagation Evaluation

PubMed Central

Mekid, Samir; Vacharanukul, Ketsaya

2006-01-01

To achieve dynamic error compensation in CNC machine tools, a non-contact laser probe capable of dimensional measurement of a workpiece while it is being machined has been developed and presented in this paper. The measurements are automatically fed back to the machine controller for intelligent error compensations. Based on a well resolved laser Doppler technique and real time data acquisition, the probe delivers a very promising dimensional accuracy at few microns over a range of 100 mm. The developed optical measuring apparatus employs a differential laser Doppler arrangement allowing acquisition of information from the workpiece surface. In addition, the measurements are traceable to standards of frequency allowing higher precision.

Machining fixture layout optimization using particle swarm optimization algorithm

NASA Astrophysics Data System (ADS)

Dou, Jianping; Wang, Xingsong; Wang, Lei

2011-05-01

Optimization of fixture layout (locator and clamp locations) is critical to reduce geometric error of the workpiece during machining process. In this paper, the application of particle swarm optimization (PSO) algorithm is presented to minimize the workpiece deformation in the machining region. A PSO based approach is developed to optimize fixture layout through integrating ANSYS parametric design language (APDL) of finite element analysis to compute the objective function for a given fixture layout. Particle library approach is used to decrease the total computation time. The computational experiment of 2D case shows that the numbers of function evaluations are decreased about 96%. Case study illustrates the effectiveness and efficiency of the PSO based optimization approach.

Effect of focusing flow on stationary spot machining properties in elastic emission machining

PubMed Central

2013-01-01

Ultraprecise optical elements are applied in advanced optical apparatus. Elastic emission machining (EEM) is one of the ultraprecision machining methods used to fabricate shapes with 0.1-nm accuracy. In this study, we proposed and experimentally tested the control of the shape of a stationary spot profile by introducing a focusing-flow state between the nozzle outlet and the workpiece surface in EEM. The simulation results indicate that the focusing-flow nozzle sharpens the distribution of the velocity on the workpiece surface. The results of machining experiments verified those of the simulation. The obtained stationary spot conditions will be useful for surface processing with a high spatial resolution. PMID:23680043

Linear array optical edge sensor

NASA Technical Reports Server (NTRS)

Bejczy, Antal K. (Inventor); Primus, Howard C. (Inventor)

1987-01-01

A series of independent parallel pairs of light emitting and detecting diodes for a linear pixel array, which is laterally positioned over an edge-like discontinuity in a workpiece to be scanned, is disclosed. These independent pairs of light emitters and detectors sense along intersecting pairs of separate optical axes. A discontinuity, such as an edge in the sensed workpiece, reflects a detectable difference in the amount of light from that discontinuity in comparison to the amount of light that is reflected on either side of the discontinuity. A sequentially sychronized clamping and sampling circuit detects that difference as an electrical signal which is recovered by circuitry that exhibits an improved signal-to-noise capability for the system.

Fundamental Study of Material Flow in Friction Stir Welds

NASA Technical Reports Server (NTRS)

Reynolds, Anthony P.

1999-01-01

The presented research project consists of two major parts. First, the material flow in solid-state, friction stir, butt-welds as been investigated using a marker insert technique. Changes in material flow due to welding parameter as well as tool geometry variations have been examined for different materials. The method provides a semi-quantitative, three-dimensional view of the material transport in the welded zone. Second, a FSW process model has been developed. The fully coupled model is based on fluid mechanics; the solid-state material transport during welding is treated as a laminar, viscous flow of a non-Newtonian fluid past a rotating circular cylinder. The heat necessary for the material softening is generated by deformation of the material. As a first step, a two-dimensional model, which contains only the pin of the FSW tool, has been created to test the suitability of the modeling approach and to perform parametric studies of the boundary conditions. The material flow visualization experiments agree very well with the predicted flow field. Accordingly, material within the pin diameter is transported only in the rotation direction around the pin. Due to the simplifying assumptions inherent in the 2-D model, other experimental data such as forces on the pin, torque, and weld energy cannot be directly used for validation. However, the 2-D model predicts the same trends as shown in the experiments. The model also predicts a deviation from the "normal" material flow at certain combinations of welding parameters, suggesting a possible mechanism for the occurrence of some typical FSW defects. The next step has been the development of a three-dimensional process model. The simplified FSW tool has been designed as a flat shoulder rotating on the top of the workpiece and a rotating, cylindrical pin, which extends throughout the total height of the flow domain. The thermal boundary conditions at the tool and at the contact area to the backing plate have been varied to fit experimental data such as temperature profiles, torque and tool forces. General aspects of the experimentally visualized material flow pattern are confirmed by the 3-D model.

Modelling of a mecanum wheel taking into account the geometry of road rollers

NASA Astrophysics Data System (ADS)

Hryniewicz, P.; Gwiazda, A.; Banaś, W.; Sękala, A.; Foit, K.

2017-08-01

During the process planning in a company one of the basic factors associated with the production costs is the operation time for particular technological jobs. The operation time consists of time units associated with the machining tasks of a workpiece as well as the time associated with loading and unloading and the transport operations of this workpiece between machining stands. Full automation of manufacturing in industry companies tends to a maximal reduction in machine downtimes, thereby the fixed costs simultaneously decreasing. The new construction of wheeled vehicles, using Mecanum wheels, reduces the transport time of materials and workpieces between machining stands. These vehicles have the ability to simultaneously move in two axes and thus more rapid positioning of the vehicle relative to the machining stand. The Mecanum wheel construction implies placing, around the wheel free rollers that are mounted at an angle 450, which allow the movement of the vehicle not only in its axis but also perpendicular thereto. The improper selection of the rollers can cause unwanted vertical movement of the vehicle, which may cause difficulty in positioning of the vehicle in relation to the machining stand and the need for stabilisation. Hence the proper design of the free rollers is essential in designing the whole Mecanum wheel construction. It allows avoiding the disadvantageous and unwanted vertical vibrations of a whole vehicle with these wheels. In the article the process of modelling the free rollers, in order to obtain the desired shape of unchanging, horizontal trajectory of the vehicle is presented. This shape depends on the desired diameter of the whole Mecanum wheel, together with the road rollers, and the width of the drive wheel. Another factor related with the curvature of the trajectory shape is the length of the road roller and its diameter decreases depending on the position with respect to its centre. The additional factor, limiting construction of the road rollers, is their bearings. Depending on the load, carried by the vehicle and the rotational speed of the drive wheel, the bearings themselves can greatly affect the diameter of the rollers and the whole Mecanum wheels. The solution of this problem is presented in the paper. It is illustrated with virtual models elaborated in advanced program of the CAE class.

Design of Feedforward Controller to Reduce Force Ripple for Linear Motor using Halbach Magnet Array with T Shape Magnet

NASA Astrophysics Data System (ADS)

Kim, Moojong; Kim, Jinyoung; Lee, Moon G.

Recently, in micro/nano fabrication equipments, linear motors are widely used as an actuator to position workpiece, machining tool and measurement head. To control them faster and more precise, the motor should have high actuating force and small force ripple. High actuating force enable us to more workpiece with high acceleration. Eventually, it may provide higher throughput. Force ripple gives detrimental effect on the precision and tracking performance of the equipments. In order to accomplish more precise motion, it is important to make lower the force ripple. Force ripple is categorized into cogging and mutual ripple. First is dependent on the shape of magnets and/or core. The second is not dependent on them but dependent on current commutation. In this work, coreless mover i.e. coil winding is applied to the linear motor to avoid the cogging ripple. Therefore, the mutual ripple is only considered to be minimized. Ideal Halbach magnet array has continuously varying magnetization. The THMA (Halbach magnet array with T shape magnets) is proposed to approximate the ideal one. The THMA can not produce ideal sinusoidal flux, therefore, the linear motor with THMA and sinusoidal commutation of current generates the mutual force ripple. In this paper, in order to compensate mutual force ripple by feedforward(FF) controller, we calculate the optimized commutation of input current. The ripple is lower than 1.17% of actuating force if the commutation current agree with the magnetic flux from THMA. The performance of feedforward(FF) controller is verified by experiment.

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.

An Alternative Frictional Boundary Condition for Computational Fluid Dynamics Simulation of Friction Stir Welding

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

Chen, Gaoqiang; Feng, Zhili; Zhu, Yucan

For better application of numerical simulation in optimization and design of friction stir welding (FSW), this paper presents a new frictional boundary condition at the tool/workpiece interface for computational fluid dynamics (CFD) modeling of FSW. The proposed boundary condition is based on an implementation of the Coulomb friction model. Using the new boundary condition, the CFD simulation yields non-uniform distribution of contact state over the tool/workpiece interface, as validated by the experimental weld macrostructure. It is found that interfacial sticking state is present over large area at the tool-workpiece interface, while significant interfacial sliding occurs at the shoulder periphery, themore » lower part of pin side, and the periphery of pin bottom. Due to the interfacial sticking, a rotating flow zone is found under the shoulder, in which fast circular motion occurs. The diameter of the rotating flow zone is smaller than the shoulder diameter, which is attributed to the presence of the interfacial sliding at the shoulder periphery. For the simulated welding condition, the heat generation due to friction and plastic deformation makes up 54.4 and 45.6% of the total heat generation rate, respectively. In conclusion, the simulated temperature field is validated by the good agreement to the experimental measurements.« less

An Alternative Frictional Boundary Condition for Computational Fluid Dynamics Simulation of Friction Stir Welding

DOE PAGES

Chen, Gaoqiang; Feng, Zhili; Zhu, Yucan; ...

2016-07-11

For better application of numerical simulation in optimization and design of friction stir welding (FSW), this paper presents a new frictional boundary condition at the tool/workpiece interface for computational fluid dynamics (CFD) modeling of FSW. The proposed boundary condition is based on an implementation of the Coulomb friction model. Using the new boundary condition, the CFD simulation yields non-uniform distribution of contact state over the tool/workpiece interface, as validated by the experimental weld macrostructure. It is found that interfacial sticking state is present over large area at the tool-workpiece interface, while significant interfacial sliding occurs at the shoulder periphery, themore » lower part of pin side, and the periphery of pin bottom. Due to the interfacial sticking, a rotating flow zone is found under the shoulder, in which fast circular motion occurs. The diameter of the rotating flow zone is smaller than the shoulder diameter, which is attributed to the presence of the interfacial sliding at the shoulder periphery. For the simulated welding condition, the heat generation due to friction and plastic deformation makes up 54.4 and 45.6% of the total heat generation rate, respectively. In conclusion, the simulated temperature field is validated by the good agreement to the experimental measurements.« less

Advances in Solid State Joining of High Temperature Alloys

NASA Technical Reports Server (NTRS)

Ding, R. Jeff; Schneider, Judy; Walker, Bryant

2011-01-01

Many of the metals used in the oil and gas industry are difficult to fusion weld including titanium and its alloys. Thus solid state joining processes, such as friction stir welding (FSWing) and a patented modification termed thermal stir welding (TSWing), are being pursued as alternatives to produce robust structures more amenable to high pressure applications. Unlike the FSWing process where the tool is used to heat the workpiece, TSWing utilizes an induction coil to preheat the material prior to stirring thus minimizing the burden on the weld tool and thereby extending its life. This study reports on the initial results of using a hybrid (H)-TSW process to join commercially pure, 1.3cm thick panels of titanium (CP Ti) Grade 2.

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.

Laser induced heating of coated carbon steel sheets: Consideration of melting and Marangoni flow

NASA Astrophysics Data System (ADS)

Shuja, S. Z.; Yilbas, B. S.

2013-04-01

Laser induced melting of coated carbon steel workpiece is simulated. The coating materials include tungsten carbide, alumina, and boron are incorporated in the simulations. The coating thickness is kept constant at 7.5 μm in the analysis. The enthalpy porosity method is used to account for the phase change in the irradiated region. The study is extended to include the influence of laser intensity transverse mode pattern (β) on the resulting melting characteristics. It is found that peak temperature predicted at the surface is higher for alumina and boron coatings than that of tungsten carbide coating. The influence of the laser intensity transverse mode pattern on the melting characteristics is considerable. Surface temperature predicted agrees with the thermocouple data.

Method for curing polymers using variable-frequency microwave heating

DOEpatents

Lauf, R.J.; Bible, D.W.; Paulauskas, F.L.

1998-02-24

A method for curing polymers incorporating a variable frequency microwave furnace system designed to allow modulation of the frequency of the microwaves introduced into a furnace cavity is disclosed. By varying the frequency of the microwave signal, non-uniformities within the cavity are minimized, thereby achieving a more uniform cure throughout the workpiece. A directional coupler is provided for detecting the direction of a signal and further directing the signal depending on the detected direction. A first power meter is provided for measuring the power delivered to the microwave furnace. A second power meter detects the magnitude of reflected power. The furnace cavity may be adapted to be used to cure materials defining a continuous sheet or which require compressive forces during curing. 15 figs.

Comparative Assessment of Cutting Inserts and Optimization during Hard Turning: Taguchi-Based Grey Relational Analysis

NASA Astrophysics Data System (ADS)

Venkata Subbaiah, K.; Raju, Ch.; Suresh, Ch.

2017-08-01

The present study aims to compare the conventional cutting inserts with wiper cutting inserts during the hard turning of AISI 4340 steel at different workpiece hardness. Type of insert, hardness, cutting speed, feed, and depth of cut are taken as process parameters. Taguchi’s L18 orthogonal array was used to conduct the experimental tests. Parametric analysis carried in order to know the influence of each process parameter on the three important Surface Roughness Characteristics (Ra, Rz, and Rt) and Material Removal Rate. Taguchi based Grey Relational Analysis (GRA) used to optimize the process parameters for individual response and multi-response outputs. Additionally, the analysis of variance (ANOVA) is also applied to identify the most significant factor.

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.

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

Mou, J.I.; King, C.

The focus of this study is to develop a sensor fused process modeling and control methodology to model, assess, and then enhance the performance of a hexapod machine for precision product realization. Deterministic modeling technique was used to derive models for machine performance assessment and enhancement. Sensor fusion methodology was adopted to identify the parameters of the derived models. Empirical models and computational algorithms were also derived and implemented to model, assess, and then enhance the machine performance. The developed sensor fusion algorithms can be implemented on a PC-based open architecture controller to receive information from various sensors, assess themore » status of the process, determine the proper action, and deliver the command to actuators for task execution. This will enhance a hexapod machine`s capability to produce workpieces within the imposed dimensional tolerances.« less

Heat Treatment of Friction-Stir-Welded 7050 Aluminum Plates

NASA Technical Reports Server (NTRS)

Petter, George E.; Figert, John D.; Rybicki, Daniel J.; Burns, Timothy

2006-01-01

A method of heat treatment has been developed to reverse some of the deleterious effects of friction stir welding of plates of aluminum alloy 7050. This alloy is considered unweldable by arc and high-energy-density beam fusion welding processes. The alloy can be friction stir welded, but as-welded workpieces exhibit low ductility, low tensile and yield strengths, and low resistance to stress corrosion cracking. Heat treatment according to the present method increases tensile and yield strengths, and minimizes or eliminates stress corrosion cracking. It also increases ductility. This method of heat treatment is a superior alternative to a specification-required heat treatment that caused the formation of large columnar grains, which are undesired. Workpieces subjected to the prior heat treatment exhibited elongations <2 percent, and standard three-point bend specimens shattered. The development of the present heat treatment method was guided partly by the principles that (1) by minimizing grain sizes and relieving deformation stresses, one can minimize or eliminate stress corrosion cracking and (2) the key to maximizing strength and eliminating residual stresses is to perform post-weld solution heating for as long a time as possible while incurring little or no development of large columnar grains in friction stir weld nuggets. It is necessary to perform some of the solution heat treatment (to soften the alloy and improve machine welding parameters) before welding. The following is an example of thickness- dependent pre- and post-weld heat treatments according to the present method: For plates 0.270 in. (approx.6.86 mm) thick milled from plates 4.5 in. (114.3 mm) thick, perform pre-weld solution heating at 890 F (477 C) for 1 hour, then cool in air. After friction stir welding, perform solution heating for 10 minutes, quench, hold at room temperature for 96 hours, then age at 250 F (121 C) for 5 hours followed by 325 F (163 C) for 27 hours.

Noise Source Identification and Dynamic Modeling of a Pneumatic Nailing Device =

NASA Astrophysics Data System (ADS)

Nili Ahmadabadi, Zahra

Exposure to hazardous noise levels emitted by pneumatic nailing devices contributes significantly to risk of hearing damage among the construction workers throughout the world. This health problem comes from the lack of appropriate technology such as low noise devices which in turn results from the lack of scientific knowledge about designing reduced noise devices. This study contributes to the design improvement of pneumatic nailing devices through identifying the noise sources and developing the simulation tool required to redesign the pneumatic nailing device. To identify the noise sources, the study uses a combination of two complementary experimental approaches. The first makes use of time-synchronized data analysis of several variables during the machine operation. This strategy allows identifying the physical processes and provides a detailed separation of the noise generation mechanisms in successive time sequences. However, since multiple noise sources radiate at the same time, this observation approach is not sufficient for noise source identification and ranking. Thus, it is completed by a selective wrapping and muffler procedure. This technique provides overall generated noise associated with each process, as well as ranking of the three major sources: (1) exhaust noise, (2) machine body vibrations, and (3) workpiece vibrations. A special investigation is conducted on this third one with two cases: a workpiece/worktable setup representative of the actual field usage of a nailing device and a workpiece/sandbox setup used in a standardized laboratory test. The study evaluates the efficiency of the workpiece/sandbox setup in reducing the workpiece radiation and obtains a typical workpiece contribution on an actual worksite. To provide a simulation tool, a dynamic model of the pneumatic nailing device needs to be developed. Dynamic modeling of the nailing device requires mathematical modeling of the physical processes involved in its operation. All of these processes can be described through already existing mathematical relations, except for the penetration resistance force (PRF) imposed on the nails when penetrating the wood. The PRF depends on various factors. This study follows two approaches in parallel to develop an empirical prediction law for the PRF: quasi-static and high-speed. The quasi-static approach provides a rapid and precise representation of the law at quasistatic penetration velocities. The law covers the entire displacement range, various nail geometries and sizes, and wood types. The high-speed approach aims to provide a law which covers a much wider range of penetration velocities. The approach is complicated since it requires a sophisticated test machine to conduct the nail driving tests at high penetration velocities. The study designs and fabricates an advanced test machine to later extend the prediction range of the PRF law. The last part of this study develops the dynamic model of a nail gun while integrating the quasi-static PRF law. The model includes dynamics of all the air chambers and the moving parts, and interactions and impacts/contacts between different parts. The study integrates a comprehensive experimental validation of the model. Future improvements in the dynamic model precision will be possible by using the extended version of the PRF law.

Characteristics for electrochemical machining with nanoscale voltage pulses.

PubMed

Lee, E S; Back, S Y; Lee, J T

2009-06-01

Electrochemical machining has traditionally been used in highly specialized fields, such as those of the aerospace and defense industries. It is now increasingly being applied in other industries, where parts with difficult-to-cut material, complex geometry and tribology, and devices of nanoscale and microscale are required. Electric characteristic plays a principal function role in and chemical characteristic plays an assistant function role in electrochemical machining. Therefore, essential parameters in electrochemical machining can be described current density, machining time, inter-electrode gap size, electrolyte, electrode shape etc. Electrochemical machining provides an economical and effective method for machining high strength, high tension and heat-resistant materials into complex shapes such as turbine blades of titanium and aluminum alloys. The application of nanoscale voltage pulses between a tool electrode and a workpiece in an electrochemical environment allows the three-dimensional machining of conducting materials with sub-micrometer precision. In this study, micro probe are developed by electrochemical etching and micro holes are manufactured using these micro probe as tool electrodes. Micro holes and microgroove can be accurately achieved by using nanoscale voltages pulses.

New numerical approach for the modelling of machining applied to aeronautical structural parts

NASA Astrophysics Data System (ADS)

Rambaud, Pierrick; Mocellin, Katia

2018-05-01

The manufacturing of aluminium alloy structural aerospace parts involves several steps: forming (rolling, forging …etc), heat treatments and machining. Before machining, the manufacturing processes have embedded residual stresses into the workpiece. The final geometry is obtained during this last step, when up to 90% of the raw material volume is removed by machining. During this operation, the mechanical equilibrium of the part is in constant evolution due to the redistribution of the initial stresses. This redistribution is the main cause for workpiece deflections during machining and for distortions - after unclamping. Both may lead to non-conformity of the part regarding the geometrical and dimensional specifications and therefore to rejection of the part or additional conforming steps. In order to improve the machining accuracy and the robustness of the process, the effect of the residual stresses has to be considered for the definition of the machining process plan and even in the geometrical definition of the part. In this paper, the authors present two new numerical approaches concerning the modelling of machining of aeronautical structural parts. The first deals with the use of an immersed volume framework to model the cutting step, improving the robustness and the quality of the resulting mesh compared to the previous version. The second is about the mechanical modelling of the machining problem. The authors thus show that in the framework of rolled aluminium parts the use of a linear elasticity model is functional in the finite element formulation and promising regarding the reduction of computation times.

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Experiments and observations regarding the mechanisms of glass removal in magnetorheological finishing.

PubMed

Shorey, A B; Jacobs, S D; Kordonski, W I; Gans, R F

2001-01-01

Recent advances in the study of the magnetorheological finishing (MRF) have allowed for the characterization of the dynamic yield stress of the magnetorheological (MR) fluid, as well as the nanohardness (H(nano)) of the carbonyl iron (CI) used in MRF. Knowledge of these properties has allowed for a more complete study of the mechanisms of material removal in MRF. Material removal experiments show that the nanohardness of CI is important in MRF with nonaqueous MR fluids with no nonmagnetic abrasives, but is relatively unimportant in aqueous MR fluids or when nonmagnetic abrasives are present. The hydrated layer created by the chemical effects of water is shown to change the way material is removed by hard CI as the MR fluid transitions from a nonaqueous MR fluid to an aqueous MR fluid. Drag force measurements and atomic force microscope scans demonstrate that, when added to a MR fluid, nonmagnetic abrasives (cerium oxide, aluminum oxide, and diamond) are driven toward the workpiece surface because of the gradient in the magnetic field and hence become responsible for material removal. Removal rates increase with the addition of these polishing abrasives. The relative increase depends on the amount and type of abrasive used.

An atomic-scale and high efficiency finishing method of zirconia ceramics by using magnetorheological finishing

NASA Astrophysics Data System (ADS)

Luo, Hu; Guo, Meijian; Yin, Shaohui; Chen, Fengjun; Huang, Shuai; Lu, Ange; Guo, Yuanfan

2018-06-01

Zirconia ceramics is a valuable crucial material for fabricating functional components applied in aerospace, biology, precision machinery, military industry and other fields. However, the properties of its high brittleness and high hardness could seriously reduce its finishing efficiency and surface quality by conventional processing technology. In this work, we present a high efficiency and high-quality finishing process by using magnetorheological finishing (MRF), which employs the permanent magnetic yoke with straight air gap as excitation unit. The sub-nanoscale surface roughness and damage free surface can be obtained after magnetorheological finishing. The XRD results and SEM morphologies confirmed that the mechanical shear removal with ductile modes are the dominant material removal mechanism for the magnetorheological finishing of zirconia ceramic. With the developed experimental apparatus, the effects of workpiece speed, trough speed and work gap on material removal rate and surface roughness were systematically investigated. Zirconia ceramics finished to ultra-smooth surface with surface roughness less than Ra 1 nm was repeatedly achieved during the parametric experiments. Additionally, the highest material removal rate exceeded 1 mg/min when using diamond as an abrasive particle. Magnetorheological finishing promises to be an adaptable and efficient method for zirconia ceramics finishing.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Computerized system for translating a torch head

NASA Technical Reports Server (NTRS)

Wall, W. A., Jr.; Ives, R. E.; Bruce, M. M., Jr.; Pryor, P. P., Jr.; Gard, L. H. (Inventor)

1978-01-01

The system provides a constant travel speed along a contoured workpiece. It has a driven skate characterized by an elongated bed, with a pair of independently pivoted trucks connected to the bed for support. The trucks are mounted on a contoured track of arbitrary configuration in a mutually spaced relation. An axially extensible torch head manipulator arm is mounted on the bed of the carriage and projects perpendicular from the midportion. The torch head is mounted at its distal end. A real-time computerized control drive subsystem is used to advance the skate along the track of a variable rate for maintaining a constant speed for the torch head tip, and to position the torch axis relative to a preset angle to the workpiece.

Heat flow in variable polarity plasma arc welds

NASA Technical Reports Server (NTRS)

Abdelmessih, Amanie N.

1992-01-01

The space shuttle external tank and the space station Freedom are fabricated by the variable polarity plasma arc (VPPA) welding. Heat sink effects (taper) are observed when there are irregularities in the work-piece configuration especially if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, and in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of the previous, present, and consecutive research studies is to investigate the effect of irregularities in the work-piece configuration and fixture differences on the weld bead geometry with the ultimate objective to compensate automatically for the heat sink effects and achieve a perfect weld.

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.

Curing Composite Materials Using Lower-Energy Electron Beams

NASA Technical Reports Server (NTRS)

Byrne, Catherine A.; Bykanov, Alexander

2004-01-01

In an improved method of fabricating composite-material structures by laying up prepreg tapes (tapes of fiber reinforcement impregnated by uncured matrix materials) and then curing them, one cures the layups by use of beams of electrons having kinetic energies in the range of 200 to 300 keV. In contrast, in a prior method, one used electron beams characterized by kinetic energies up to 20 MeV. The improved method was first suggested by an Italian group in 1993, but had not been demonstrated until recently. With respect to both the prior method and the present improved method, the impetus for the use of electron- beam curing is a desire to avoid the high costs of autoclaves large enough to effect thermal curing of large composite-material structures. Unfortunately, in the prior method, the advantages of electron-beam curing are offset by the need for special walls and ceilings on curing chambers to shield personnel from x rays generated by impacts of energetic electrons. These shields must be thick [typically 2 to 3 ft (about 0.6 to 0.9 m) if made of concrete] and are therefore expensive. They also make it difficult to bring large structures into and out of the curing chambers. Currently, all major companies that fabricate composite-material spacecraft and aircraft structures form their layups by use of automated tape placement (ATP) machines. In the present improved method, an electron-beam gun is attached to an ATP head and used to irradiate the tape as it is pressed onto the workpiece. The electron kinetic energy between 200 and 300 keV is sufficient for penetration of the ply being laid plus one or two of the plies underneath it. Provided that the electron-beam gun is properly positioned, it is possible to administer the required electron dose and, at the same time, to protect personnel with less shielding than is needed in the prior method. Adequate shielding can be provided by concrete walls 6 ft (approximately equal to 1.8 m) high and 16 in. (approximately equal to 41 cm) thick, without a ceiling. The success of the present method depends on the use of a cationic epoxy as the matrix material in the prepreg tape, heating the prepreg tape to a temperature of 50 C immediately prior to layup, and exposing the workpiece to an electron-beam dose of approximately 2 Mrad. Experiments have shown that structures fabricated by the present method have the same mechanical properties as those of nominally identical structures fabricated by the prior method with electron beams of 3 to 4 MeV.

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

PubMed

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

2017-02-20

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

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

PubMed Central

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

2017-01-01

Owing to high specific strength and designability, unidirectional carbon fiber reinforced polymer (UD-CFRP) has been utilized in numerous fields to replace conventional metal materials. Post machining processes are always required for UD-CFRP to achieve dimensional tolerance and assembly specifications. Due to inhomogeneity and anisotropy, UD-CFRP differs greatly from metal materials in machining and failure mechanism. To improve the efficiency and avoid machining-induced damage, this paper undertook to study the correlations between cutting parameters, fiber orientation angle, cutting forces, and cutting-induced damage for UD-CFRP laminate. Scanning acoustic microscopy (SAM) was employed and one-/two-dimensional damage factors were then created to quantitatively characterize the damage of the laminate workpieces. According to the 3D Hashin’s criteria a numerical model was further proposed in terms of the finite element method (FEM). A good agreement between simulation and experimental results was validated for the prediction and structural optimization of the UD-CFRP. PMID:28772565

Computerized tomography calibrator

NASA Technical Reports Server (NTRS)

Engel, Herbert P. (Inventor)

1991-01-01

A set of interchangeable pieces comprising a computerized tomography calibrator, and a method of use thereof, permits focusing of a computerized tomographic (CT) system. The interchangeable pieces include a plurality of nestable, generally planar mother rings, adapted for the receipt of planar inserts of predetermined sizes, and of predetermined material densities. The inserts further define openings therein for receipt of plural sub-inserts. All pieces are of known sizes and densities, permitting the assembling of different configurations of materials of known sizes and combinations of densities, for calibration (i.e., focusing) of a computerized tomographic system through variation of operating variables thereof. Rather than serving as a phanton, which is intended to be representative of a particular workpiece to be tested, the set of interchangeable pieces permits simple and easy standardized calibration of a CT system. The calibrator and its related method of use further includes use of air or of particular fluids for filling various openings, as part of a selected configuration of the set of pieces.

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

NASA Astrophysics Data System (ADS)

Samardžiová, Michaela

2016-09-01

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

Apparatus and method for microwave processing of materials

DOEpatents

Johnson, A.C.; Lauf, R.J.; Bible, D.W.; Markunas, R.J.

1996-05-28

Disclosed is a variable frequency microwave heating apparatus designed to allow modulation of the frequency of the microwaves introduced into a furnace cavity for testing or other selected applications. The variable frequency heating apparatus is used in the method of the present invention to monitor the resonant processing frequency within the furnace cavity depending upon the material, including the state thereof, from which the workpiece is fabricated. The variable frequency microwave heating apparatus includes a microwave signal generator and a high-power microwave amplifier or a microwave voltage-controlled oscillator. A power supply is provided for operation of the high-power microwave oscillator or microwave amplifier. A directional coupler is provided for detecting the direction and amplitude of signals incident upon and reflected from the microwave cavity. A first power meter is provided for measuring the power delivered to the microwave furnace. A second power meter detects the magnitude of reflected power. Reflected power is dissipated in the reflected power load. 10 figs.

Friction stir welding process to repair voids in aluminum alloys

NASA Technical Reports Server (NTRS)

Rosen, Charles D. (Inventor); Litwinski, Edward (Inventor); Valdez, Juan M. (Inventor)

1999-01-01

The present invention provides an in-process method to repair voids in an aluminum alloy, particularly a friction stir weld in an aluminum alloy. For repairing a circular void or an in-process exit hole in a weld, the method includes the steps of fabricating filler material of the same composition or compatible with the parent material into a plug form to be fitted into the void, positioning the plug in the void, and friction stir welding over and through the plug. For repairing a longitudinal void (30), the method includes machining the void area to provide a trough (34) that subsumes the void, fabricating filler metal into a strip form (36) to be fitted into the trough, positioning the strip in the trough, and rewelding the void area by traversing a friction stir welding tool longitudinally through the strip. The method is also applicable for repairing welds made by a fusing welding process or voids in aluminum alloy workpieces themselves.

Localised anodic oxidation of aluminium material using a continuous electrolyte jet

NASA Astrophysics Data System (ADS)

Kuhn, D.; Martin, A.; Eckart, C.; Sieber, M.; Morgenstern, R.; Hackert-Oschätzchen, M.; Lampke, T.; Schubert, A.

2017-03-01

Anodic oxidation of aluminium and its alloys is often used as protection against material wearout and corrosion. Therefore, anodic oxidation of aluminium is applied to produce functional oxide layers. The structure and properties of the oxide layers can be influenced by various factors. These factors include for example the properties of the substrate material, like alloy elements and heat treatment or process parameters, like operating temperature, electric parameters or the type of the used electrolyte. In order to avoid damage to the work-piece surface caused by covering materials in masking applications, to minimize the use of resources and to modify the surface in a targeted manner, the anodic oxidation has to be localised to partial areas. Within this study a proper alternative without preparing the substrate by a mask is investigated for generating locally limited anodic oxidation by using a continuous electrolyte jet. Therefore aluminium material EN AW 7075 is machined by applying a continuous electrolyte jet of oxalic acid. Experiments were carried out by varying process parameters like voltage or processing time. The realised oxide spots on the aluminium surface were investigated by optical microscopy, SEM and EDX line scanning. Furthermore, the dependencies of the oxide layer properties from the process parameters are shown.

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

Progress toward a performance based specification for diamond grinding wheels

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

Taylor, J.S.; Piscotty, M.S.; Blaedel, K.L.

1996-11-12

This work sought to improve the communication between users and makers of fine diamond grinding wheels. A promising avenue for this is to formulate a voluntary product standard that comprises performance indicators that bridge the gap between specific user requirements and the details of wheel formulations. We propose a set of performance specifiers of figures-of-merit, that might be assessed by straightforward and traceable testing methods, but do not compromise proprietary information of the wheel user of wheel maker. One such performance indicator might be wheel hardness. In addition we consider technologies that might be required to realize the benefits ofmore » optimized grinding wheels. A non-contact wheel-to- workpiece proximity sensor may provide a means of monitoring wheel wear and thus wheel position, for wheels that exhibit high wear rates in exchange for improved surface finish.« less

Work Hardening Behavior of 1020 Steel During Cold-Beating Simulation

NASA Astrophysics Data System (ADS)

CUI, Fengkui; LING, Yuanfei; XUE, Jinxue; LIU, Jia; LIU, Yuhui; LI, Yan

2017-03-01

The present research of cold-beating formation mainly focused on roller design and manufacture, kinematics, constitutive relation, metal flow law, thermo-mechanical coupling, surface micro-topography and microstructure evolution. However, the research on surface quality and performance of workpieces in the process of cold-beating is rare. Cold-beating simulation experiment of 1020 steel is conducted at room temperature and strain rates ranging from 2000 to 4000 s-1 base on the law of plastic forming. According to the experimental data, the model of strain hardening of 1020 steel is established, Scanning Electron Microscopy(SEM) is conducted, the mechanism of the work hardening of 1020 steel is clarified by analyzing microstructure variation of 1020 steel. It is found that the strain rate hardening effect of 1020 steel is stronger than the softening effect induced by increasing temperatures, the process of simulation cold-beating cause the grain shape of 1020 steel significant change and microstructure elongate significantly to form a fibrous tissue parallel to the direction of deformation, the higher strain rate, the more obvious grain refinement and the more hardening effect. Additionally, the change law of the work hardening rate is investigated, the relationship between dislocation density and strain, the relationship between work hardening rate and dislocation density is obtained. Results show that the change trend of the work hardening rate of 1020 steel is divided into two stages, the work hardening rate decreases dramatically in the first stage and slowly decreases in the second stage, finally tending toward zero. Dislocation density increases with increasing strain and strain rate, work hardening rate decreases with increasing dislocation density. The research results provide the basis for solving the problem of improving the surface quality and performance of workpieces under cold-beating formation of 1020 steel.

Parameter monitoring compensation system and method

DOEpatents

Barkman, William E.; Babelay, Edwin F.; DeMint, Paul D.; Hebble, Thomas L.; Igou, Richard E.; Williams, Richard R.; Klages, Edward J.; Rasnick, William H.

1995-01-01

A compensation system for a computer-controlled machining apparatus having a controller and including a cutting tool and a workpiece holder which are movable relative to one another along preprogrammed path during a machining operation utilizes sensors for gathering information at a preselected stage of a machining operation relating to an actual condition. The controller compares the actual condition to a condition which the program presumes to exist at the preselected stage and alters the program in accordance with detected variations between the actual condition and the assumed condition. Such conditions may be related to process parameters, such as a position, dimension or shape of the cutting tool or workpiece or an environmental temperature associated with the machining operation, and such sensors may be a contact or a non-contact type of sensor or a temperature transducer.

Shaping Cutter Original Profile for Fine-module Ratchet Teeth Cutting

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

System and method of adjusting the equilibrium temperature of an inductively-heated susceptor

DOEpatents

Matsen, Marc R; Negley, Mark A; Geren, William Preston

2015-02-24

A system for inductively heating a workpiece may include an induction coil, at least one susceptor face sheet, and a current controller coupled. The induction coil may be configured to conduct an alternating current and generate a magnetic field in response to the alternating current. The susceptor face sheet may be configured to have a workpiece positioned therewith. The susceptor face sheet may be formed of a ferromagnetic alloy having a Curie temperature and being inductively heatable to an equilibrium temperature approaching the Curie temperature in response to the magnetic field. The current controller may be coupled to the induction coil and may be configured to adjust the alternating current in a manner causing a change in at least one heating parameter of the susceptor face sheet.

Luminal surface fabrication for cardiovascular prostheses

NASA Technical Reports Server (NTRS)

Deininger, William D. (Inventor); Gabriel, Stephen B. (Inventor)

1988-01-01

A method is provided for forming a mold surface with microscopic upstanding pillars for molding the inside surface of a vascular prostheses (synthetic blood vessel). The mold article is formed from a quantity of Teflon (polytetrafluoroethylene) which has a polished, flat surface on which a gold film has been sputter deposited. A photoresist layer, which cannot adhere directly to Teflon, adheres to the gold. The photoresist is exposed and developed leaving a sputter resistant mask defining the desired pillar locations, and the resulting workpiece is ion etched to form the pillars in the Teflon. A synthetic blood vessel material is cast against the Teflon mold to form blind recesses on the inside of the synthetic blood vessel, with the recesses being of predetermined uniform cross section and present in a predetermined uniform pattern.

Method for curing polymers using variable-frequency microwave heating

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

Lauf, R.J.; Bible, D.W.; Paulauskas, F.L.

1998-02-24

A method for curing polymers incorporating a variable frequency microwave furnace system designed to allow modulation of the frequency of the microwaves introduced into a furnace cavity is disclosed. By varying the frequency of the microwave signal, non-uniformities within the cavity are minimized, thereby achieving a more uniform cure throughout the workpiece. A directional coupler is provided for detecting the direction of a signal and further directing the signal depending on the detected direction. A first power meter is provided for measuring the power delivered to the microwave furnace. A second power meter detects the magnitude of reflected power. Themore » furnace cavity may be adapted to be used to cure materials defining a continuous sheet or which require compressive forces during curing. 15 figs.« less

Calibration and prediction of removal function in magnetorheological finishing.

PubMed

Dai, Yifan; Song, Ci; Peng, Xiaoqiang; Shi, Feng

2010-01-20

A calibrated and predictive model of the removal function has been established based on the analysis of a magnetorheological finishing (MRF) process. By introducing an efficiency coefficient of the removal function, the model can be used to calibrate the removal function in a MRF figuring process and to accurately predict the removal function of a workpiece to be polished whose material is different from the spot part. Its correctness and feasibility have been validated by simulations. Furthermore, applying this model to the MRF figuring experiments, the efficiency coefficient of the removal function can be identified accurately to make the MRF figuring process deterministic and controllable. Therefore, all the results indicate that the calibrated and predictive model of the removal function can improve the finishing determinacy and increase the model applicability in a MRF process.

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

NASA Astrophysics Data System (ADS)

Prasetyo, Yudhi; Tauviqirrahman, Mohamad; Rusnaldy

2016-04-01

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

Method for curing polymers using variable-frequency microwave heating

DOEpatents

Lauf, Robert J.; Bible, Don W.; Paulauskas, Felix L.

1998-01-01

A method for curing polymers (11) incorporating a variable frequency microwave furnace system (10) designed to allow modulation of the frequency of the microwaves introduced into a furnace cavity (34). By varying the frequency of the microwave signal, non-uniformities within the cavity (34) are minimized, thereby achieving a more uniform cure throughout the workpiece (36). A directional coupler (24) is provided for detecting the direction of a signal and further directing the signal depending on the detected direction. A first power meter (30) is provided for measuring the power delivered to the microwave furnace (32). A second power meter (26) detects the magnitude of reflected power. The furnace cavity (34) may be adapted to be used to cure materials defining a continuous sheet or which require compressive forces during curing.

Design and fundamental understanding of Minimum Quantity Lubrication (MQL) assisted grinding using advanced nanolubricants

NASA Astrophysics Data System (ADS)

Kalita, Parash

Abrasive grinding is widely used across manufacturing industry for finishing parts and components requiring smooth superficial textures and precise dimensional tolerances and accuracy. Unlike any other machining operations, the complex thermo-mechanical processes during grinding produce excessive friction-induced energy consumption, heat, and intense contact seizures. Lubrication and cooling from grinding fluids is crucial in minimizing the deleterious effects of friction and heat to maximize the output part quality and process efficiency. The conventional flood grinding approach of an uneconomical application of large quantities of chemically active fluids has been found ineffective to provide sufficient lubrication and produces waste streams and pollutants that are hazardous to human health and environment. Application of Minimum Quantity Lubrication (MQL) that cuts the volumetric fluid consumption by 3-4 orders of magnitude have been extensively researched in grinding as a high-productivity and environmentally-sustainable alternative to the conventional flood method. However, the lubrication performance and productivity of MQL technique with current fluids has been critically challenged by the extreme thermo-mechanical conditions of abrasive grinding. In this research, an MQL system based on advanced nanolubricants has been proposed to address the current thermo-mechanical challenges of MQL grinding and improve its productivity. The nanolubricants were composed of inorganic Molybdenum Disulphide nanoparticles (≈ 200 nm) intercalated with organic macromolecules of EP/AW property, dispersed in straight (base) oils---mineral-based paraffin and vegetable-based soybean oil. After feasibility investigations into the grindability of cast iron using MQL with nanolubricants, this research focused on the fundamental understanding of tribological behavior and lubricating mechanisms of nanolubricants as a method to improve the productivity of MQL-assisted surface grinding of ductile iron and alloy steel. An extensive investigation on MQL-assisted grinding using vitrified aluminum oxide wheel under varied infeed and lubrication condition was carried out with the scope of documenting the process efficiency and lubrication mechanisms of the nanolubricants. Experimental results showed that MQL grinding with nanolubricants minimized the non-productive outputs of the grinding process by reducing frictional losses at the abrasive grain-workpiece interfaces, energy consumption, wheel wear, grinding zone temperatures, and friction-induced heat generation. Use of nanolubricants in MQL yielded superior productivity by producing surface roughness as low as 0.35 μm and grinding efficiencies that were four times higher as compared to those obtained from flood grinding. Repeatable formation of tribochemical films of antifriction, antiwear, and extreme pressure chemical species in between the contact asperities of abrasive crystals and work material was identified with nanolubricants. The tribological behavior was characterized by this synergistic effect of the antiwear, antifriction, and load carrying chemical species that endured grain-workpiece seizures and reduced adhesion friction between the contact surfaces. Delivery of organic coated Molybdenum Disulphide nanoparticles by anchoring on the natural porosity of the abrasive wheel and eventually, sliding-induced interfacial deformation into tribolayers and alignment at the grinding zone were established as the lubrication mechanisms of the nanolubricants. These mechanisms were further validated from tribological evaluations of lubricated cubic boron nitride (cBN) superabrasives-1045 steel sliding pairs on a reciprocating tribotest rig resembling the tool-lubricant-workpiece interactions of MQL-assisted grinding.

Ballistic-Failure Mechanisms in Gas Metal Arc Welds of Mil A46100 Armor-Grade Steel: A Computational Investigation

NASA Astrophysics Data System (ADS)

Grujicic, M.; Snipes, J. S.; Galgalikar, R.; Ramaswami, S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.

2014-09-01

In our recent work, a multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process was introduced. The model is of a modular type and comprises five modules, each designed to handle a specific aspect of the GMAW process, i.e.: (i) electro-dynamics of the welding-gun; (ii) radiation-/convection-controlled heat transfer from the electric-arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; (iii) prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; (iv) the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and (v) spatial distribution of the as-welded material mechanical properties. In the present work, the GMAW process model has been upgraded with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties controlling the ballistic-limit (i.e., penetration-resistance) of the weld. The model is upgraded through the introduction of the sixth module in the present work in recognition of the fact that in thick steel GMAW weldments, the overall ballistic performance of the armor may become controlled by the (often inferior) ballistic limits of its weld (fusion and heat-affected) zones. To demonstrate the utility of the upgraded GMAW process model, it is next applied to the case of butt-welding of a prototypical high-hardness armor-grade martensitic steel, MIL A46100. The model predictions concerning the spatial distribution of the material microstructure and ballistic-limit-controlling mechanical properties within the MIL A46100 butt-weld are found to be consistent with prior observations and general expectations.

A FEM simulation study of the solid state hydrostatic extrusion of PMMA

NASA Astrophysics Data System (ADS)

Costa, André L. M.; Riffel, Douglas B.; Misiolek, Wojciech Z.; Valberg, Henry S.

2018-05-01

Solid state hydrostatic extrusion (SSHE) of polymers below glass transition temperature is used to obtain highly oriented structures. Experimental studies on the SSHE of polymethyl-methacrylate (PMMA) have been made since early eighties but there is no information on internal temperature, stress and strain distribution. In this work we have made 3D FEM simulations of SSHE of PMMA by using the commercial DEFORM package with experimental flow curves and thermal properties from literature. The initial temperature of tooling and workpiece was 90°C, ram speeds were 1.0 and 10.0 mm/min with extrusion ratio R = 3.0. For a comparative analysis, SSHE simulation of the AA7108 aluminum alloy at 400°C was also performed. These ranges of parameters were chosen in order to encompass the parameters found in previously mentioned experiments. The best correlation with experimental hydrostatic pressure was verified for a shear friction coefficient at the material-conical die interface m = 0.50. Force-displacement curve for PMMA presented a constitutive and thermal softening in contrast to a constant force curve for aluminum. The internal temperature in the deformation zone increased in a characteristic "owl's face" profile in contrast to quasi-constant profile of aluminum alloy. In both PMMA and aluminum the stress is hydrostatic inside the container, but the stress profiles are significantly different inside the deformation zone. As expected, the strain and strain-rate profiles are practically the same for the two materials, but the temperature profile has promoted slightly differences in material flow. The velocity gradient from center to surface is higher in PMMA than aluminum. It's supposed that during hydrostatic extrusion solid PMMA has a characteristic thermally-inducted mechanical behavior.

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.

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.

Small-scale mechanical characterization of viscoelastic adhesive systems

NASA Astrophysics Data System (ADS)

Shean, T. A. V.

Aero engine hot end components are often covered with ceramic Thermal Barrier Coatings (TBCs). Laser drilling in the TBC coated components can be a source of service life TBC degradation and spallation. The present study aims to understand the mechanisms of TBC delamination and develop techniques to drill holes without damaging the TBC, Nimonic 263 workpieces coated with TBC are used in the experiments. Microwave non-destructive testing (NDT) is employed to monitor the integrity of the coating /substrate interfaces of the post-laser drilled materials. A numerical modelling technique is used to investigate the role of melt ejection on TBC delamination. The model accounts for the vapour and the assist gas flow effects in the process. Broadly, melt ejection induced mechanical stresses for the TBC coating / bond coating and thermal effects for the bond coating / substrate interfaces are found the key delamination mechanisms. Experiments are carried out to validate the findings from the model. Various techniques that enable laser drilling without damaging the TBC are demonstrated. Twin jet assisted acute angle laser drilling is one successful technique that has been analysed using the melt ejection simulation. Optimisation of the twin jet assisted acute angle laser drilling process parameters is carried out using Design of Experiments (DoE) and statistical modelling approaches. Finally, an industrial case study to develop a high speed, high quality laser drilling system for combustor cans is described. Holes are drilled by percussion and trepan drilling in TBC coated and uncoated Haynes 230 workpieces. The production rate of percussion drilling is significantly higher than the trepan drilling, however metallurgical hole quality and reproducibility is poor. A number of process parameters are investigated to improve these characteristics. Gas type and gas pressure effects on various characteristics of the inclined laser drilled holes are investigated through theoretical and experimental work.

Laser drilling of thermal barrier coated jet-engine components

NASA Astrophysics Data System (ADS)

Sezer, H. K.

Aero engine hot end components are often covered with ceramic Thermal Barrier Coatings (TBCs). Laser drilling in the TBC coated components can be a source of service life TBC degradation and spallation. The present study aims to understand the mechanisms of TBC delamination and develop techniques to drill holes without damaging the TBC, Nimonic 263 workpieces coated with TBC are used in the experiments. Microwave non-destructive testing (NDT) is employed to monitor the integrity of the coating /substrate interfaces of the post-laser drilled materials. A numerical modelling technique is used to investigate the role of melt ejection on TBC delamination. The model accounts for the vapour and the assist gas flow effects in the process. Broadly, melt ejection induced mechanical stresses for the TBC coating / bond coating and thermal effects for the bond coating / substrate interfaces are found the key delamination mechanisms. Experiments are carried out to validate the findings from the model. Various techniques that enable laser drilling without damaging the TBC are demonstrated. Twin jet assisted acute angle laser drilling is one successful technique that has been analysed using the melt ejection simulation. Optimisation of the twin jet assisted acute angle laser drilling process parameters is carried out using Design of Experiments (DoE) and statistical modelling approaches. Finally, an industrial case study to develop a high speed, high quality laser drilling system for combustor cans is described. Holes are drilled by percussion and trepan drilling in TBC coated and uncoated Haynes 230 workpieces. The production rate of percussion drilling is significantly higher than the trepan drilling, however metallurgical hole quality and reproducibility is poor. A number of process parameters are investigated to improve these characteristics. Gas type and gas pressure effects on various characteristics of the inclined laser drilled holes are investigated through theoretical and experimental work.

Laser speckle velocimetry for robot manufacturing

NASA Astrophysics Data System (ADS)

Charrett, Thomas O. H.; Bandari, Yashwanth K.; Michel, Florent; Ding, Jialuo; Williams, Stewart W.; Tatam, Ralph P.

2017-06-01

A non-contact speckle correlation sensor for the measurement of robotic tool speed is presented for use in robotic manufacturing and is capable of measuring the in-plane relative velocities between a robot end-effector and the workpiece or other surface. The sensor performance was assessed in the laboratory with the sensor accuracies found to be better than 0:01 mm/s over a 70 mm/s velocity range. Finally an example of the sensors application to robotic manufacturing is presented where the sensor was applied to tool speed measurement for path planning in the wire and arc additive manufacturing process using a KUKA KR150 L110/2 industrial robot.

Modeling of Particle Emission During Dry Orthogonal Cutting

NASA Astrophysics Data System (ADS)

Khettabi, Riad; Songmene, Victor; Zaghbani, Imed; Masounave, Jacques

2010-08-01

Because of the risks associated with exposure to metallic particles, efforts are being put into controlling and reducing them during the metal working process. Recent studies by the authors involved in this project have presented the effects of cutting speeds, workpiece material, and tool geometry on particle emission during dry machining; the authors have also proposed a new parameter, named the dust unit ( D u), for use in evaluating the quantity of particle emissions relative to the quantity of chips produced during a machining operation. In this study, a model for predicting the particle emission (dust unit) during orthogonal turning is proposed. This model, which is based on the energy approach combined with the microfriction and the plastic deformation of the material, takes into account the tool geometry, the properties of the worked material, the cutting conditions, and the chip segmentation. The model is validated using experimental results obtained during the orthogonal turning of 6061-T6 aluminum alloy, AISI 1018, AISI 4140 steels, and grey cast iron. A good agreement was found with experimental results. This model can help in designing strategies for reducing particle emission during machining processes, at the source.

Experimental study and FEM simulation of the simple shear test of cylindrical rods

NASA Astrophysics Data System (ADS)

Wirti, Pedro H. B.; Costa, André L. M.; Misiolek, Wojciech Z.; Valberg, Henry S.

2018-05-01

In the presented work an experimental simple shear device for cutting cylindrical rods was used to obtain force-displacement data for a low-carbon steel. In addition, and FEM 3D-simulation was applied to obtain internal shear stress and strain maps for this material. The experimental longitudinal grid patterns and force-displacement curve were compared with numerical simulation results. Many aspects of the elastic and plastic deformations were described. It was found that bending reduces the shear yield stress of the rod material. Shearing starts on top and bottom die-workpiece contact lines evolving in an arc-shaped area. Due to this geometry, stress concentrates on the surface of the rod until the level of damage reaches the critical value and the fracture starts here. The volume of material in the plastic zone subjected to shearing stress has a very complex shape and is function of a dimensionless geometrical parameter. Expressions to calculate the true shear stress τ and strain γ from the experimental force-displacement data were proposed. The equations' constants are determined by fitting the experimental curve with the stress τ and strain γ simulation point tracked data.

Effect of pin tool design on the material flow of dissimilar AA7075-AA6061 friction stir welds

NASA Astrophysics Data System (ADS)

Hasan, Mohammed M.; Ishak, M.; Rejab, M. R. M.

2017-10-01

Tool design is the most influential aspect in the friction stir welding (FSW) technology. Influence of pin tool geometry on material flow pattern are studied in this work during the FSW of dissimilar AA7075 and AA6061 aluminium alloys. Three truncated pin tool profiles (threaded, threaded with single flat, and unthreaded with single flat) were used to prepare the weldments. The workpieces were joined using a custom-made clamping system under 1100 rpm of spindle speed, 300 mm/min of traverse rate and 3° of tilt angle. The metallographic analysis showed that defect-free welds can be produced using the three pin tools with significant changes in the mixing stir zone structure. The results declared that the introducing of the flat on the cone of the probe deviates the pattern of the onion rings without changing the chemical composition of the created layers. This in turn improves the hardness distribution and tensile strength of the welded joint. It was also noted that both heat affected zone (HAZ) and thermal-mechanical affected zone (TMAZ) are similar in composition to their corresponding base materials (BM).

Permanent Magnet Ecr Plasma Source With Magnetic Field Optimization

DOEpatents

Doughty, Frank C.; Spencer, John E.

2000-12-19

In a plasma-producing device, an optimized magnet field for electron cyclotron resonance plasma generation is provided by a shaped pole piece. The shaped pole piece adjusts spacing between the magnet and the resonance zone, creates a convex or concave resonance zone, and decreases stray fields between the resonance zone and the workpiece. For a cylindrical permanent magnet, the pole piece includes a disk adjacent the magnet together with an annular cylindrical sidewall structure axially aligned with the magnet and extending from the base around the permanent magnet. The pole piece directs magnetic field lines into the resonance zone, moving the resonance zone further from the face of the magnet. Additional permanent magnets or magnet arrays may be utilized to control field contours on a local scale. Rather than a permeable material, the sidewall structure may be composed of an annular cylindrical magnetic material having a polarity opposite that of the permanent magnet, creating convex regions in the resonance zone. An annular disk-shaped recurve section at the end of the sidewall structure forms magnetic mirrors keeping the plasma off the pole piece. A recurve section composed of magnetic material having a radial polarity forms convex regions and/or magnetic mirrors within the resonance zone.

A comparison of force and acoustic emission sensors in monitoring precision cylindrical grinding; Technical Digest

NASA Astrophysics Data System (ADS)

Marsh, Eric R.; Couey, Jeremiah A.; Knapp, Byron R.; Vallance, R. R.

2005-05-01

Aerostatic spindles are used in precision grinding applications requiring high stiffness and very low error motions (5 to 25 nm). Forces generated during precision grinding are small and present challenges for accurate and reliable process monitoring. These challenges are met by incorporating non-contact displacement sensors into an aerostatic spindle that are calibrated to measure grinding forces from rotor motion. Four experiments compare this force-sensing approach to acoustic emission (AE) in detecting workpiece contact, process monitoring with small depths of cut, detecting workpiece defects, and evaluating abrasive wheel wear/loading. Results indicate that force measurements are preferable to acoustic emission in precision grinding since the force sensor offers improved contact sensitivity, higher resolution, and is capable of detecting events occurring within a single revolution of the grinding wheel.

Parameter monitoring compensation system and method

DOEpatents

Barkman, W.E.; Babelay, E.F.; DeMint, P.D.; Hebble, T.L.; Igou, R.E.; Williams, R.R.; Klages, E.J.; Rasnick, W.H.

1995-02-07

A compensation system is described for a computer-controlled machining apparatus having a controller and including a cutting tool and a workpiece holder which are movable relative to one another along a preprogrammed path during a machining operation. It utilizes sensors for gathering information at a preselected stage of a machining operation relating to an actual condition. The controller compares the actual condition to a condition which the program presumes to exist at the preselected stage and alters the program in accordance with detected variations between the actual condition and the assumed condition. Such conditions may be related to process parameters, such as a position, dimension or shape of the cutting tool or workpiece or an environmental temperature associated with the machining operation, and such sensors may be a contact or a non-contact type of sensor or a temperature transducer. 7 figs.

Research on reducing the edge effect in magnetorheological finishing.

PubMed

Hu, Hao; Dai, Yifan; Peng, Xiaoqiang; Wang, Jianmin

2011-03-20

The edge effect could not be avoided in most optical manufacturing methods based on the theory of computer controlled optical surfacing. The difference between the removal function at the workpiece edge and that inside it is also the primary cause for edge effect in magnetorheological finishing (MRF). The change of physical dimension and removal ratio of the removal function is investigated through experiments. The results demonstrate that the situation is different when MRF "spot" is at the leading edge or at the trailing edge. Two methods for reducing the edge effect are put into practice after analysis of the processing results. One is adopting a small removal function for dealing with the workpiece edge, and the other is utilizing the removal function compensation. The actual processing results show that these two ways are both effective on reducing the edge effect in MRF.

Prediction of turning stability using receptance coupling

NASA Astrophysics Data System (ADS)

Jasiewicz, Marcin; Powałka, Bartosz

2018-01-01

This paper presents an issue of machining stability prediction of dynamic "lathe - workpiece" system evaluated using receptance coupling method. Dynamic properties of the lathe components (the spindle and the tailstock) are assumed to be constant and can be determined experimentally based on the results of the impact test. Hence, the variable of the system "machine tool - holder - workpiece" is the machined part, which can be easily modelled analytically. The method of receptance coupling enables a synthesis of experimental (spindle, tailstock) and analytical (machined part) models, so impact testing of the entire system becomes unnecessary. The paper presents methodology of analytical and experimental models synthesis, evaluation of the stability lobes and experimental validation procedure involving both the determination of the dynamic properties of the system and cutting tests. In the summary the experimental verification results would be presented and discussed.