Mark Forte, M. Eisenhour, Ryan M. Malkowski, P. Radhakrishnan, David C. Brown
3D printing is widely used in prototyping projects, but low-cost, open-type 3D printers can produce defects, wasting time and material. This project’s goal was to develop a system to detect defects automatically during the printing process to prevent that waste. We developed DaR3D, a monitoring system that can detect slippage in 3D printed parts and alert the user as soon as it is detected. The system’s environment consists of a webcam fixed to a custom 3D printed mount, an enclosure, and lighting. A variety of defect detection algorithms were researched. DaR3D’s detection algorithm acquires an image from OctoLapse, removes the background, then uses statistical analysis to compare it to a previous image. If the images are different enough, the algorithm determines that slippage has occurred. The resulting system correctly identifies slippage in prints with 89.6% accuracy, using samples from two different 3D printers and many different printed models. The paper will discuss the process, challenges and planned future work.
{"title":"Detecting Defects in Low-Cost 3D Printing","authors":"Mark Forte, M. Eisenhour, Ryan M. Malkowski, P. Radhakrishnan, David C. Brown","doi":"10.1115/imece2022-96111","DOIUrl":"https://doi.org/10.1115/imece2022-96111","url":null,"abstract":"\u0000 3D printing is widely used in prototyping projects, but low-cost, open-type 3D printers can produce defects, wasting time and material. This project’s goal was to develop a system to detect defects automatically during the printing process to prevent that waste. We developed DaR3D, a monitoring system that can detect slippage in 3D printed parts and alert the user as soon as it is detected. The system’s environment consists of a webcam fixed to a custom 3D printed mount, an enclosure, and lighting. A variety of defect detection algorithms were researched. DaR3D’s detection algorithm acquires an image from OctoLapse, removes the background, then uses statistical analysis to compare it to a previous image. If the images are different enough, the algorithm determines that slippage has occurred. The resulting system correctly identifies slippage in prints with 89.6% accuracy, using samples from two different 3D printers and many different printed models. The paper will discuss the process, challenges and planned future work.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"31 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115964624","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Md. Saidur Rahman Roney, N. Ahsan, H. Sezer, Joseph Tang, S. Kaul, H. Ahmed
Laser powder bed fusion (LPBF) is an Additive Manufacturing (AM) process that uses a laser beam to solidify powder particles following a predefined pattern on a powder bed to build a part layer-by-layer as per a CAD model. In LPBF, the moving heat source and the rapid solidification cause nonuniform variations in temperature along the build part. This transient and moving heating and cooling process causes uneven expansion and shrinkage of the part that leads to the development of residual stresses in the part. The residual stresses depend on the thermal history of the part and may eventually lead to part distortion, crack initiation, warpage, etc. The present study represents the effect of altering the scan pattern layer-by-layer on the residual stress. Furthermore, a novel alternating double pass spiral scan pattern is introduced and compared with alternating island zigzag, alternating zigzag, regular zigzag, and spiral out-center patterns on the basis of thermal distribution and residual stress. Numerical approach is used to solve the governing equations. It is observed that residual stress greatly depends on thermal distribution. The variation in inherent residual stress is found to be lower for alternating zigzag pattern than regular zigzag pattern due to more even thermal distribution. Furthermore, the novel pattern also effectively distributes the heat which contributes to the reduction of inherent residual stress from the first layer. On the other hand, it is found that the alternating island zigzag scan pattern increases island temperature that can prevent rapid solidification. Overall, the findings of this study can be helpful in understanding the effects of altering scan directions layer-by-layer and in identifying a scan strategy that can enhance the usability of the powder bed fusion additive manufacturing technology.
{"title":"Modeling Thermal Behavior and Residual Stress for Layer-by-Layer Rotated Scan Direction in Laser Powder Bed Fusion Process","authors":"Md. Saidur Rahman Roney, N. Ahsan, H. Sezer, Joseph Tang, S. Kaul, H. Ahmed","doi":"10.1115/imece2022-95355","DOIUrl":"https://doi.org/10.1115/imece2022-95355","url":null,"abstract":"\u0000 Laser powder bed fusion (LPBF) is an Additive Manufacturing (AM) process that uses a laser beam to solidify powder particles following a predefined pattern on a powder bed to build a part layer-by-layer as per a CAD model. In LPBF, the moving heat source and the rapid solidification cause nonuniform variations in temperature along the build part. This transient and moving heating and cooling process causes uneven expansion and shrinkage of the part that leads to the development of residual stresses in the part. The residual stresses depend on the thermal history of the part and may eventually lead to part distortion, crack initiation, warpage, etc. The present study represents the effect of altering the scan pattern layer-by-layer on the residual stress. Furthermore, a novel alternating double pass spiral scan pattern is introduced and compared with alternating island zigzag, alternating zigzag, regular zigzag, and spiral out-center patterns on the basis of thermal distribution and residual stress. Numerical approach is used to solve the governing equations. It is observed that residual stress greatly depends on thermal distribution. The variation in inherent residual stress is found to be lower for alternating zigzag pattern than regular zigzag pattern due to more even thermal distribution. Furthermore, the novel pattern also effectively distributes the heat which contributes to the reduction of inherent residual stress from the first layer. On the other hand, it is found that the alternating island zigzag scan pattern increases island temperature that can prevent rapid solidification. Overall, the findings of this study can be helpful in understanding the effects of altering scan directions layer-by-layer and in identifying a scan strategy that can enhance the usability of the powder bed fusion additive manufacturing technology.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"36 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134002739","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Diffractive optical elements (DOEs) are important flat optics for light phase modulation and are widely used in sensors, spectrometers, and optical designs. DOEs are fabricated mainly by nanofabrication, such as lithography, in clean rooms. This paper reports a novel 3D printing method to fabricate DOEs in minutes using low-cost 3D printers. The as-printed gratings were cleaned and drop coated to achieve a flat surface. A collimated 520nm laser beam passed through the printed samples successfully generated the designed diffraction patterns. The results validated the functionality of the gratings. The printed DOE did not degrade by UV curing, which indicates the stability of the gratings fabricated by the proposed method. Besides, another kind of DOE, Fresnel axicon, was 3D printed with different printing strategy and reasonable diffraction pattern was observed.
{"title":"3D Printing Diffraction Gratings and Fresnel Axicons","authors":"Junyu Hua, Yujie Shan, Huachao Mao","doi":"10.1115/imece2022-95889","DOIUrl":"https://doi.org/10.1115/imece2022-95889","url":null,"abstract":"\u0000 Diffractive optical elements (DOEs) are important flat optics for light phase modulation and are widely used in sensors, spectrometers, and optical designs. DOEs are fabricated mainly by nanofabrication, such as lithography, in clean rooms. This paper reports a novel 3D printing method to fabricate DOEs in minutes using low-cost 3D printers. The as-printed gratings were cleaned and drop coated to achieve a flat surface. A collimated 520nm laser beam passed through the printed samples successfully generated the designed diffraction patterns. The results validated the functionality of the gratings. The printed DOE did not degrade by UV curing, which indicates the stability of the gratings fabricated by the proposed method. Besides, another kind of DOE, Fresnel axicon, was 3D printed with different printing strategy and reasonable diffraction pattern was observed.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132628916","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Undeformed chip thickness plays a very important role in studying the materials remove mechanism in flexible belt grinding and predicting ground surface roughness. A calculation model that can be used to effectively predict the undeformed chip thickness in flexible belt grinding is established based on the height distribution of abrasive grains. It can lay the foundation for in-depth study of belt grinding mechanism. In this model, the real contact arc length is derived based on the elastic deformation of the contact area between the abrasive belt and workpiece. The real depth of cut prediction model is introduced considering the belt grinding processing characteristics. Based on the established undeformed chip thickness model, a ground surface roughness calculation model is further reached, and a series of verification experiments are carried out. The results show that the predicted value and the measured value have the same trend basically under different grinding process parameters. The error of the predicted value is mostly distributed between 5% and 16%, which proved the reliability of the developed models preliminary.
{"title":"Investigation of Undeformed Chip Thickness Model and Surface Roughness Prediction in Belt Grinding","authors":"Heng Li, Lai Zou, Wenxi Wang, Mingcong Li","doi":"10.1115/imece2022-94921","DOIUrl":"https://doi.org/10.1115/imece2022-94921","url":null,"abstract":"\u0000 Undeformed chip thickness plays a very important role in studying the materials remove mechanism in flexible belt grinding and predicting ground surface roughness. A calculation model that can be used to effectively predict the undeformed chip thickness in flexible belt grinding is established based on the height distribution of abrasive grains. It can lay the foundation for in-depth study of belt grinding mechanism. In this model, the real contact arc length is derived based on the elastic deformation of the contact area between the abrasive belt and workpiece. The real depth of cut prediction model is introduced considering the belt grinding processing characteristics. Based on the established undeformed chip thickness model, a ground surface roughness calculation model is further reached, and a series of verification experiments are carried out. The results show that the predicted value and the measured value have the same trend basically under different grinding process parameters. The error of the predicted value is mostly distributed between 5% and 16%, which proved the reliability of the developed models preliminary.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130151435","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
3D bioprinting is a promising field in regenerating patient-specific tissues and organs due to its inherent capability of releasing biocompatible materials encapsulating living cells in a predefined location. Due to the diverse characteristics of tissues and organs in terms of microstructures and cell types, a multi-nozzle extrusion-based 3D bioprinting system has gained popularity. The investigations on interactions between various biomaterials and cell-to-material can provide relevant information about the scaffold geometry, cell viability, and proliferation. Natural hydrogels are frequently used in bioprinting materials because of their high-water content and biocompatibility. However, the dominance of liquid characteristics of only-hydrogel materials makes the printing process challenging. Polycaprolactone (PCL) is the most frequently used synthetic biopolymer. It can provide mechanical integrity to achieve dimensionally accurate fabricated scaffolds, especially for hard tissues such as bone and cartilage scaffolds. In this paper, we explored various multi-material bioprinting strategies with our recently proposed bio-inks and PCL intending to achieve dimensional accuracy and mechanical aspects. Various strategies were followed to co-print natural and synthetic biopolymers and interactions were analyzed between them. The dependence of scaffold geometry on the printing process parameters of synthetic polymer and the rheological properties of natural polymers were identified. The successful application of this research can help achieve dimensionally accurate scaffolds.
{"title":"A Bio-Printing Strategy to Fabricate Geometrically Accurate 3d Scaffolds","authors":"Connor Quigley, Slesha Tuladhar, Md. Ahasan Habib","doi":"10.1115/imece2022-95300","DOIUrl":"https://doi.org/10.1115/imece2022-95300","url":null,"abstract":"\u0000 3D bioprinting is a promising field in regenerating patient-specific tissues and organs due to its inherent capability of releasing biocompatible materials encapsulating living cells in a predefined location. Due to the diverse characteristics of tissues and organs in terms of microstructures and cell types, a multi-nozzle extrusion-based 3D bioprinting system has gained popularity. The investigations on interactions between various biomaterials and cell-to-material can provide relevant information about the scaffold geometry, cell viability, and proliferation. Natural hydrogels are frequently used in bioprinting materials because of their high-water content and biocompatibility. However, the dominance of liquid characteristics of only-hydrogel materials makes the printing process challenging. Polycaprolactone (PCL) is the most frequently used synthetic biopolymer. It can provide mechanical integrity to achieve dimensionally accurate fabricated scaffolds, especially for hard tissues such as bone and cartilage scaffolds. In this paper, we explored various multi-material bioprinting strategies with our recently proposed bio-inks and PCL intending to achieve dimensional accuracy and mechanical aspects. Various strategies were followed to co-print natural and synthetic biopolymers and interactions were analyzed between them. The dependence of scaffold geometry on the printing process parameters of synthetic polymer and the rheological properties of natural polymers were identified. The successful application of this research can help achieve dimensionally accurate scaffolds.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123280397","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
R. Shanmugam, Geethapriyan T., M. Thangaraj, M. Ramoni
Abrasive Water jet Machining finds its application on extensive range of materials. Both ductile and brittle materials can be machined by this process, but the material removal is different in both the cases, i.e., by Ductile fracture and Brittle fracture respectively. When it comes to brittle materials, conventional machining processes cannot be used due to a number of limitations of the material. Thus, non-conventional machining is a rather preferable choice for brittle materials. However, the quality of machining might vary, as it is dependent on some input parameters such as — Abrasive size, Water jet Pres-sure and Abrasive Flow rate. The quality of the machining for a drilling operation is evaluated based on the hole parameters i.e. — Circularity, Taper ratio, Overcut and Material Removal Rate (MRR). The process parameters are varied in accordance to the desirable outcome to be obtained. Outcomes like MRR and circularity are required to be maximized, whereas Taper ratio and Overcut have to be minimized. The effects and interactions between different parameters on the outcomes are studied using Analysis of Variance (ANOVA).
{"title":"Enhancing the Performance Measures of Abrasive Water Jet Machining on Drilling Acrylic Glass Material","authors":"R. Shanmugam, Geethapriyan T., M. Thangaraj, M. Ramoni","doi":"10.1115/imece2022-95675","DOIUrl":"https://doi.org/10.1115/imece2022-95675","url":null,"abstract":"\u0000 Abrasive Water jet Machining finds its application on extensive range of materials. Both ductile and brittle materials can be machined by this process, but the material removal is different in both the cases, i.e., by Ductile fracture and Brittle fracture respectively. When it comes to brittle materials, conventional machining processes cannot be used due to a number of limitations of the material. Thus, non-conventional machining is a rather preferable choice for brittle materials. However, the quality of machining might vary, as it is dependent on some input parameters such as — Abrasive size, Water jet Pres-sure and Abrasive Flow rate. The quality of the machining for a drilling operation is evaluated based on the hole parameters i.e. — Circularity, Taper ratio, Overcut and Material Removal Rate (MRR). The process parameters are varied in accordance to the desirable outcome to be obtained. Outcomes like MRR and circularity are required to be maximized, whereas Taper ratio and Overcut have to be minimized. The effects and interactions between different parameters on the outcomes are studied using Analysis of Variance (ANOVA).","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131518764","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
R. Urbanic, Bob Hedrick, Hamoon Ramezani, Sandy N. El Moghazi, Marzie Saghafi
For service parts, production runs are ‘on demand’, and managing the inventory for components or the tooling is expensive. Additive manufacturing (AM) processes lend themselves to this application as their key strength is the ability to fabricate components with no tooling or fixtures. However, several AM processes require significant post processing to remove support materials as well as generate the required surface finishes and feature tolerances. The main purpose of this research is to determine whether a directed energy deposition (DED) AM solution can be used to manufacture selected components that are presently cast, machined, or forged using hybrid manufacturing build solutions, where machining operations are introduced as required. Select DED AM processes are used to fabricate a near net shape, and either final machining or interspersed machining operations are included. A product-process classification schema is introduced to cluster similar build strategies. This provides the background for the decomposition approaches and the process planning strategies. The build times and material usage are included and component redesign is discussed to facilitate the manufacturing process and optimize the design. This is ongoing research and, in future work, an analysis of the heat maps and the resulting mechanical and physical properties will be evaluated for these components.
{"title":"Hybrid Manufacturing Decomposition Rules and Programming Strategies for Service Parts","authors":"R. Urbanic, Bob Hedrick, Hamoon Ramezani, Sandy N. El Moghazi, Marzie Saghafi","doi":"10.1115/imece2022-95560","DOIUrl":"https://doi.org/10.1115/imece2022-95560","url":null,"abstract":"\u0000 For service parts, production runs are ‘on demand’, and managing the inventory for components or the tooling is expensive. Additive manufacturing (AM) processes lend themselves to this application as their key strength is the ability to fabricate components with no tooling or fixtures. However, several AM processes require significant post processing to remove support materials as well as generate the required surface finishes and feature tolerances. The main purpose of this research is to determine whether a directed energy deposition (DED) AM solution can be used to manufacture selected components that are presently cast, machined, or forged using hybrid manufacturing build solutions, where machining operations are introduced as required. Select DED AM processes are used to fabricate a near net shape, and either final machining or interspersed machining operations are included. A product-process classification schema is introduced to cluster similar build strategies. This provides the background for the decomposition approaches and the process planning strategies. The build times and material usage are included and component redesign is discussed to facilitate the manufacturing process and optimize the design. This is ongoing research and, in future work, an analysis of the heat maps and the resulting mechanical and physical properties will be evaluated for these components.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130759525","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Grinding offers specific advantages in comparison with other machining processes. The trend in industrial production toward higher productivity with increased part accuracy, using harder-to-machine materials, naturally leads to the increasing use of grinding to solve many material removal challenges. However, current technological advancements and innovation trends require science-based solutions capable to provide accurate models of the chip formation process, enabling optimization and control. The aim of this paper is to develop an adequate chip-formation model resulting in a realistic grinding chip with corresponding influence on the workpiece. The developed fundamental equations in metal plasticity are relevant for each material and their alloys; so that the total chip-flow with discontinuity and corresponding body forces can be solved. In addition, the resulting self-hardening effect, as well as the created temperatures — due to the deformation process — will be discussed and presented. Despite the large number of investigations and simulations, there is still no clarity on these subjects. The newly developed mathematical equations for strain and stress lead to square grid deformation in the chip formation zone, and this grid deformation will not disappear after completing the grinding process, so that the theoretical developments can be compared with practical results. As long as the created theoretical result will fit the practical result, we can be sure that we are on a relevant, realistic path. This will be presented for two different materials AlMg5 and the carbon steel C45. For the material AlMg5 we get a chip with integration of different plastic layers bonding together as a complete spherical grinding chip. The result is characterized by higher grinding forces, rough and thermally influenced workpiece surface. Quite contrary is the chip formation of the carbon steel C45. As a result of self-blockade at the interface between material and cutting edge, a segmented chip will follow with dynamic forces and a chattering process influencing the total machine behavior as well as the workpiece roundness and resulting surface. Finally, a high agreement between the developed theoretical and experimental results could be documented.
{"title":"Modeling and Simulation of Chip-Flow in Grinding of Different Materials – AlMg5 and C45","authors":"W. Lortz, Radu Pavel","doi":"10.1115/imece2022-95233","DOIUrl":"https://doi.org/10.1115/imece2022-95233","url":null,"abstract":"\u0000 Grinding offers specific advantages in comparison with other machining processes. The trend in industrial production toward higher productivity with increased part accuracy, using harder-to-machine materials, naturally leads to the increasing use of grinding to solve many material removal challenges. However, current technological advancements and innovation trends require science-based solutions capable to provide accurate models of the chip formation process, enabling optimization and control. The aim of this paper is to develop an adequate chip-formation model resulting in a realistic grinding chip with corresponding influence on the workpiece. The developed fundamental equations in metal plasticity are relevant for each material and their alloys; so that the total chip-flow with discontinuity and corresponding body forces can be solved. In addition, the resulting self-hardening effect, as well as the created temperatures — due to the deformation process — will be discussed and presented. Despite the large number of investigations and simulations, there is still no clarity on these subjects. The newly developed mathematical equations for strain and stress lead to square grid deformation in the chip formation zone, and this grid deformation will not disappear after completing the grinding process, so that the theoretical developments can be compared with practical results. As long as the created theoretical result will fit the practical result, we can be sure that we are on a relevant, realistic path. This will be presented for two different materials AlMg5 and the carbon steel C45. For the material AlMg5 we get a chip with integration of different plastic layers bonding together as a complete spherical grinding chip. The result is characterized by higher grinding forces, rough and thermally influenced workpiece surface. Quite contrary is the chip formation of the carbon steel C45. As a result of self-blockade at the interface between material and cutting edge, a segmented chip will follow with dynamic forces and a chattering process influencing the total machine behavior as well as the workpiece roundness and resulting surface. Finally, a high agreement between the developed theoretical and experimental results could be documented.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"102 3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116636065","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In this paper, an extensive literature review of sustainable machining using different minimum quantity lubrication (MQL) variants is presented. Nowadays, sustainable development (SD) is referred as a common global issue. Sustainability concept in machining is linked with two major goals. The first goal is to reduce the environmental impact by reducing the energy consumption in the process. The second goal is to reduce the consumption of hazardous non-biodegradable materials. During machining, it was evident that when the cutting of material takes place, it increases the heat produced due to plastic shear deformation and friction. In dry machining, the tool wear and surface roughness are very high and it is not practical to use this method. So, there is a need to introduce a coolant or lubricant in the cutting zone to control or reduce the cutting temperature. Conventional cutting fluids are referred as non-biodegradable in nature and high disposal cost is associated with them as well. The researchers found that Minimum quality lubricant (MQL) is an appropriate way to remove the heat from the work material and chips formed in this case are almost dry. Minimum quantity lubrication (MQL) has been emerged as a potential solution for the second goal. MQL is being popular in the metal cutting sector because of its ability to provide improved machinability while being sustainable at the same time. The main topic discussed in this article is to reduce the quantity of lubricant for the machining usage to move forward towards a cleaner and greener machining process. The research community also observed that when moving towards the superalloys primarily used in the aerospace and aircraft industry MQL technique is not efficient. Using the MQL technique, the friction is reduced by this lubricant film, but it does not take away the heat generated from the work material and tool. Due to this reason, several variants of MQL were developed. These variants include advanced oil on water (OoW) droplet MQL, minimum quantity cooling lubricant (MQCL), and nano MQL etc. In MQCL coolant is used at the lower temperature, which is air or water, to remove the extra amount of heat from the work material. The current study compared performance of all these MQL variants. It has also been observed that MQL operating parameters and jet arrangements can significantly affect the machining performance. The current study will provide a detailed comprehensive review about the performance of these variants.
{"title":"Current Research Trends in Variants of Minimum Quantity Lubrication (MQL): A Review","authors":"Shafahat Ali, S. Pervaiz, S. Kannan","doi":"10.1115/imece2021-73656","DOIUrl":"https://doi.org/10.1115/imece2021-73656","url":null,"abstract":"\u0000 In this paper, an extensive literature review of sustainable machining using different minimum quantity lubrication (MQL) variants is presented. Nowadays, sustainable development (SD) is referred as a common global issue. Sustainability concept in machining is linked with two major goals. The first goal is to reduce the environmental impact by reducing the energy consumption in the process. The second goal is to reduce the consumption of hazardous non-biodegradable materials. During machining, it was evident that when the cutting of material takes place, it increases the heat produced due to plastic shear deformation and friction. In dry machining, the tool wear and surface roughness are very high and it is not practical to use this method. So, there is a need to introduce a coolant or lubricant in the cutting zone to control or reduce the cutting temperature. Conventional cutting fluids are referred as non-biodegradable in nature and high disposal cost is associated with them as well. The researchers found that Minimum quality lubricant (MQL) is an appropriate way to remove the heat from the work material and chips formed in this case are almost dry. Minimum quantity lubrication (MQL) has been emerged as a potential solution for the second goal. MQL is being popular in the metal cutting sector because of its ability to provide improved machinability while being sustainable at the same time. The main topic discussed in this article is to reduce the quantity of lubricant for the machining usage to move forward towards a cleaner and greener machining process. The research community also observed that when moving towards the superalloys primarily used in the aerospace and aircraft industry MQL technique is not efficient. Using the MQL technique, the friction is reduced by this lubricant film, but it does not take away the heat generated from the work material and tool.\u0000 Due to this reason, several variants of MQL were developed. These variants include advanced oil on water (OoW) droplet MQL, minimum quantity cooling lubricant (MQCL), and nano MQL etc. In MQCL coolant is used at the lower temperature, which is air or water, to remove the extra amount of heat from the work material. The current study compared performance of all these MQL variants. It has also been observed that MQL operating parameters and jet arrangements can significantly affect the machining performance. The current study will provide a detailed comprehensive review about the performance of these variants.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"50 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127093491","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The current work is an extension of the work published at IMECE2020. The study presents the innovative patented technique to reduce the springback in channel deformation. Springback is one of the common defects in sheet metal forming and is a constant research area due to continuous push on lightweight to decrease the fuel consumption and decrease the environmental impact. To follow the federal environmental guidelines the option is either use the lower density material or use the lower gages of advance high strength materials. In both cases springback will be an issue as the lower density material will be having lower modulus of elasticity and even the elastic values are higher in the higher strength material, with respect to strength the elastic recovery increases. With these many challenges with the materials and their properties which influences the springback, other possible innovative forming processes are applying electricity through the material after forming and before the release of the load, performing warm or hot forming, die compensation, etc. One such innovative and patented process which is studied in the paper is using rollers in the tool i.e., in die and punch during the forming process. During the channel deformation process the punch and die rollers rotate with a given rotations. The rollers are also set to rotate in either clockwise or counterclockwise direction. In IMECE2020 the work was published on considering the single roller rotation value in all cases i.e., from Case3 to 10. In this paper, four more roller rotations were studied to see the effect of tool roller rotation on the springback. The process was simulated in ABAQUS finite element software. The springback profile, springback angle and stresses in the channel were studied. It was found that with increasing the roller rotations the springback decreases.
{"title":"A Numerical Study on Effect of Tool Roller Rotation on Channel Springback","authors":"C. Nikhare","doi":"10.1115/imece2021-69888","DOIUrl":"https://doi.org/10.1115/imece2021-69888","url":null,"abstract":"\u0000 The current work is an extension of the work published at IMECE2020. The study presents the innovative patented technique to reduce the springback in channel deformation. Springback is one of the common defects in sheet metal forming and is a constant research area due to continuous push on lightweight to decrease the fuel consumption and decrease the environmental impact. To follow the federal environmental guidelines the option is either use the lower density material or use the lower gages of advance high strength materials. In both cases springback will be an issue as the lower density material will be having lower modulus of elasticity and even the elastic values are higher in the higher strength material, with respect to strength the elastic recovery increases. With these many challenges with the materials and their properties which influences the springback, other possible innovative forming processes are applying electricity through the material after forming and before the release of the load, performing warm or hot forming, die compensation, etc. One such innovative and patented process which is studied in the paper is using rollers in the tool i.e., in die and punch during the forming process. During the channel deformation process the punch and die rollers rotate with a given rotations. The rollers are also set to rotate in either clockwise or counterclockwise direction. In IMECE2020 the work was published on considering the single roller rotation value in all cases i.e., from Case3 to 10. In this paper, four more roller rotations were studied to see the effect of tool roller rotation on the springback. The process was simulated in ABAQUS finite element software. The springback profile, springback angle and stresses in the channel were studied. It was found that with increasing the roller rotations the springback decreases.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"17 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127500881","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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