Nils Potthoff, Ankit Agarwal, F. Wöste, P. Wiederkehr, L. Mears
Tool wear plays a decisive role in achieving the required surface quality and dimensional accuracy during the machining of Inconel 718-based products. The highly stochastic phenomenon of tool wear, particularly in later stages, results in difficulty in predicting the failure point of the tool. The present research work aims to study this late-stage wear of the tool by generating consistent wear conditions and thereby decoupling the late-stage wear from the wear history. To do so, a multi-axis grinding operation is employed to create artificial tool wear that replicates the topology of natural wear occurring in the process. In order to evaluate the imitating ability of the proposed methodology, microscopic images in different wear states of naturally and contrived worn tools were analyzed. The methodology was validated by comparing the resulting process forces measured during end milling with the natural and contrived worn tool for different path strategies. Finally, a qualitative FE-analysis was conducted, and specific force coefficients for worn tool segments were determined through simulation.
{"title":"Evaluation of Contrived Wear Methodology in End Milling of Inconel 718","authors":"Nils Potthoff, Ankit Agarwal, F. Wöste, P. Wiederkehr, L. Mears","doi":"10.1115/1.4062603","DOIUrl":"https://doi.org/10.1115/1.4062603","url":null,"abstract":"\u0000 Tool wear plays a decisive role in achieving the required surface quality and dimensional accuracy during the machining of Inconel 718-based products. The highly stochastic phenomenon of tool wear, particularly in later stages, results in difficulty in predicting the failure point of the tool. The present research work aims to study this late-stage wear of the tool by generating consistent wear conditions and thereby decoupling the late-stage wear from the wear history. To do so, a multi-axis grinding operation is employed to create artificial tool wear that replicates the topology of natural wear occurring in the process. In order to evaluate the imitating ability of the proposed methodology, microscopic images in different wear states of naturally and contrived worn tools were analyzed. The methodology was validated by comparing the resulting process forces measured during end milling with the natural and contrived worn tool for different path strategies. Finally, a qualitative FE-analysis was conducted, and specific force coefficients for worn tool segments were determined through simulation.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48824156","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
High-entropy alloys (HEAs) are highly anticipated due to their excellent properties (e.g. high strength, high hardness, excellent wear resistance). However, compared with numerous studies on the design and properties of HEAs, the research on the machinability of HEAs is extremely rare, which limits the application of HEAs. In this work, grinding experiments of (FeCoNi)86Al7Ti7 dual-phase HEA workpieces were carried out, and the results are analysed from general machinability perspective (the effect of machining parameters on grinding force and surface roughness value) to a more in-depth perspective, including grinding induced changes in morphology and microstructure on ground surface and subsurface. With SEM and EBSD information of subsurface, the deformation mechanisms have been studied, including the role of the second phase (Ni2AlTi) in the grinding process, the material removal modes of the different phases and the morphology of the nanoprecipitates in the matrix, based on the completely opposite properties of different phases in HEA. It is noticed that the hard and brittle property of the second phase brings support to the material, reduces the plastic deformation, and also makes its own removal brittle, while the plastic matrix experiences shear deformation in grinding, which makes the nanoprecipitates in it assume different morphologies. These detailed findings could be of help to understand the effect of grinding on material properties so as to improve the machining quality of this material.
{"title":"Surface Integrity Analysis in Grinding of Dual-phase High Entropy Alloy","authors":"Xing Wang, Shu Zan, Qin Xu, Z. Liao","doi":"10.1115/1.4062604","DOIUrl":"https://doi.org/10.1115/1.4062604","url":null,"abstract":"\u0000 High-entropy alloys (HEAs) are highly anticipated due to their excellent properties (e.g. high strength, high hardness, excellent wear resistance). However, compared with numerous studies on the design and properties of HEAs, the research on the machinability of HEAs is extremely rare, which limits the application of HEAs. In this work, grinding experiments of (FeCoNi)86Al7Ti7 dual-phase HEA workpieces were carried out, and the results are analysed from general machinability perspective (the effect of machining parameters on grinding force and surface roughness value) to a more in-depth perspective, including grinding induced changes in morphology and microstructure on ground surface and subsurface. With SEM and EBSD information of subsurface, the deformation mechanisms have been studied, including the role of the second phase (Ni2AlTi) in the grinding process, the material removal modes of the different phases and the morphology of the nanoprecipitates in the matrix, based on the completely opposite properties of different phases in HEA. It is noticed that the hard and brittle property of the second phase brings support to the material, reduces the plastic deformation, and also makes its own removal brittle, while the plastic matrix experiences shear deformation in grinding, which makes the nanoprecipitates in it assume different morphologies. These detailed findings could be of help to understand the effect of grinding on material properties so as to improve the machining quality of this material.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45584087","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
E. Gongadze, Chris Dighton, Gregory Nash, Martin Moss, Brett Hemingway, J. Belnoue, S. Hallett
Composite materials and especially those made from pre-impregnated (prepreg) material are widely used in the aerospace industry. To achieve the tight assembly dimensional tolerances required, manufacturers rely on additional manufacturing steps like shimming or machining, which generate extra waste, are time-consuming and expensive. Prepreg sheets come naturally with fibre and resin volume content variability that leads manufacturers to guarantee cured ply thicknesses within a typical +/-5% margin of their nominal values. For thick laminates, this can equate to a thickness variability of as much as a few mm. To solve the issue, it is proposed to twin in-situ laser measurements of the uncured prepreg thickness with numerical simulations of the laminate autoclave consolidation and cure process and to adjust the number of additional sacrificial plies in the laminate based on the model predictions. Data for IM7/8552 and IM7/977-3 is presented to demonstrate the potential of the method to reach an almost exact target thickness for flat panels.
{"title":"Thickness control of autoclave-moulded composite laminates","authors":"E. Gongadze, Chris Dighton, Gregory Nash, Martin Moss, Brett Hemingway, J. Belnoue, S. Hallett","doi":"10.1115/1.4062581","DOIUrl":"https://doi.org/10.1115/1.4062581","url":null,"abstract":"\u0000 Composite materials and especially those made from pre-impregnated (prepreg) material are widely used in the aerospace industry. To achieve the tight assembly dimensional tolerances required, manufacturers rely on additional manufacturing steps like shimming or machining, which generate extra waste, are time-consuming and expensive. Prepreg sheets come naturally with fibre and resin volume content variability that leads manufacturers to guarantee cured ply thicknesses within a typical +/-5% margin of their nominal values. For thick laminates, this can equate to a thickness variability of as much as a few mm. To solve the issue, it is proposed to twin in-situ laser measurements of the uncured prepreg thickness with numerical simulations of the laminate autoclave consolidation and cure process and to adjust the number of additional sacrificial plies in the laminate based on the model predictions. Data for IM7/8552 and IM7/977-3 is presented to demonstrate the potential of the method to reach an almost exact target thickness for flat panels.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48626059","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Obtaining fully dense products with high strength in one step at room temperature by powder metallurgy (PM) is generally not possible. However, doing so would reduce manufacturing and energy costs substantially. In this work, we have attempted to achieve this on commercially pure aluminum by utilizing the friction-assisted lateral extrusion process (FALEP) which has the capability of producing sheets from bulk or powder metal in a single step, by applying large shear strain. The texture, microstructure, and mechanical properties of the fully compacted powder sample were examined and compared to the bulk-sheet's properties obtained also by FALEP. The powder-FALEP sample showed a smaller grain size and significantly higher strength. Simulations carried out by the Taylor-type lattice-curvature-based polycrystal model shed light on the texture characteristics of the obtained materials and were in good agreement with the experiments.
{"title":"Room-temperature single-step production of ultrafine-grained bulk metallic sheets from Al powder","authors":"A. Pariyar, Viet Q Vu, S. Kailas, L. Toth","doi":"10.1115/1.4062582","DOIUrl":"https://doi.org/10.1115/1.4062582","url":null,"abstract":"\u0000 Obtaining fully dense products with high strength in one step at room temperature by powder metallurgy (PM) is generally not possible. However, doing so would reduce manufacturing and energy costs substantially. In this work, we have attempted to achieve this on commercially pure aluminum by utilizing the friction-assisted lateral extrusion process (FALEP) which has the capability of producing sheets from bulk or powder metal in a single step, by applying large shear strain. The texture, microstructure, and mechanical properties of the fully compacted powder sample were examined and compared to the bulk-sheet's properties obtained also by FALEP. The powder-FALEP sample showed a smaller grain size and significantly higher strength. Simulations carried out by the Taylor-type lattice-curvature-based polycrystal model shed light on the texture characteristics of the obtained materials and were in good agreement with the experiments.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46029933","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Non-rigid compliant parts are widely used in industries today. One of the biggest challenges facing the industries is geometric variation management of these compliant parts, which directly impacts product quality and functionality. Existing rigid body based variation modeling is not suitable for compliant assembly while finite element analysis based methods have the disadvantage of requiring heavy computation efforts. In view of that, this paper develops a novel methodology to evaluate geometric variation propagation in multi-station compliant assembly based upon parametric space envelope (i.e. variation tool constructed from parametric curves). Three sources of variation: location-led positional variation, assembly deformation-induced variation and station transition caused variation are analyzed. Under proposal, geometric variations are modeled indirectly through a compact set of boundary control points. Compared with existing methods where geometric variation is modeled through targeting key feature points on the manufacturing part, the proposed approach brings modeling accuracy and computation efficiency. The effectiveness of the method is illustrated and verified through an industrial case study on a multi-station compliant panel assembly. The developed method provides industries a new way to manage geometric variation from compliant assembly.
{"title":"Modeling Variation in Multi-station Compliant Assembly using Parametric Space Envelope","authors":"C. Luo, Jiaqi Nie, P. Franciosa, D. Ceglarek","doi":"10.1115/1.4062579","DOIUrl":"https://doi.org/10.1115/1.4062579","url":null,"abstract":"\u0000 Non-rigid compliant parts are widely used in industries today. One of the biggest challenges facing the industries is geometric variation management of these compliant parts, which directly impacts product quality and functionality. Existing rigid body based variation modeling is not suitable for compliant assembly while finite element analysis based methods have the disadvantage of requiring heavy computation efforts. In view of that, this paper develops a novel methodology to evaluate geometric variation propagation in multi-station compliant assembly based upon parametric space envelope (i.e. variation tool constructed from parametric curves). Three sources of variation: location-led positional variation, assembly deformation-induced variation and station transition caused variation are analyzed. Under proposal, geometric variations are modeled indirectly through a compact set of boundary control points. Compared with existing methods where geometric variation is modeled through targeting key feature points on the manufacturing part, the proposed approach brings modeling accuracy and computation efficiency. The effectiveness of the method is illustrated and verified through an industrial case study on a multi-station compliant panel assembly. The developed method provides industries a new way to manage geometric variation from compliant assembly.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46391747","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Lattice structure metamaterials offer a variety of unique and tailorable properties, yet industrial adoption is slowed by manufacturability and inspection-related difficulties. Despite recent advances in laser powder bed fusion (LPBF) additive manufacturing (AM), the sub-millimeter features of lattices are at the edge of process capabilities and suffer from low geometric quality. To better understand their complex process-structure-property (PSP) relationships, octahedron structures were manufactured across a power spectrum, inspected, and mechanically tested. X-ray computed tomography (CT) was used to characterize lattice geometry, and demonstrated that lattice strut geometry measures, increased significantly as a function of laser power. Furthermore, lattices are shown to exhibit a direct correlation between laser power and mechanical performance metrics. Performance variations up to 60% are shown as a function of process parameters despite nominally identical geometry. Significant geometry variations are found to be the cause of performance variation, while material properties as measured by microindentation hardness are constant across the studied parameter range. PSP relationships are modeled, and the limitations of these models are explored. It was found that resulting models can predict mechanical performance based on geometric characteristics with R2 values of up to 0.86. Finally, mechanistic causes of observed performance changes are discussed.
{"title":"Process-Structure-Property Relationships of Laser Powder Bed Fusion Lattice Structures","authors":"E. Jost, J. Pegues, D. Moore, C. Saldana","doi":"10.1115/1.4062580","DOIUrl":"https://doi.org/10.1115/1.4062580","url":null,"abstract":"\u0000 Lattice structure metamaterials offer a variety of unique and tailorable properties, yet industrial adoption is slowed by manufacturability and inspection-related difficulties. Despite recent advances in laser powder bed fusion (LPBF) additive manufacturing (AM), the sub-millimeter features of lattices are at the edge of process capabilities and suffer from low geometric quality. To better understand their complex process-structure-property (PSP) relationships, octahedron structures were manufactured across a power spectrum, inspected, and mechanically tested. X-ray computed tomography (CT) was used to characterize lattice geometry, and demonstrated that lattice strut geometry measures, increased significantly as a function of laser power. Furthermore, lattices are shown to exhibit a direct correlation between laser power and mechanical performance metrics. Performance variations up to 60% are shown as a function of process parameters despite nominally identical geometry. Significant geometry variations are found to be the cause of performance variation, while material properties as measured by microindentation hardness are constant across the studied parameter range. PSP relationships are modeled, and the limitations of these models are explored. It was found that resulting models can predict mechanical performance based on geometric characteristics with R2 values of up to 0.86. Finally, mechanistic causes of observed performance changes are discussed.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46636559","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Q. Bai, Pengcheng Li, W. Tian, Jianxin Shen, Bo Li, Junshan Hu
Compared with a single manipulator manufacturing cell, a dual manipulator cooperative system has more advantages in reconfigurability and flexibility. However, there are calibration errors and multi-source disturbances in the collaborative process, which lead to the processing trajectory accuracy defects of large-scale associated machining features. To solve the above problems, a practical path tracking synchronous control algorithm is proposed based on position based visual servoing (PBVS) in this paper for the dual manipulator cooperative system, the proposed dynamic cross-coupled sliding mode controller (DCSMC) scheme can realize dynamic paths correction while executing the pre-planned paths. Moreover, since the cross-coupled technology is integrated into the proposed control algorithm for dynamic path tracking based on the real-time feedback of the highly repeatable 3D visual measurement instrument (VMI), both the tracking and synchronous errors of the dual manipulators converge to zero. Finally, the stability of the proposed controller has been verified by the Lyapunov method. In the end, the real-time line and circle path tracking experimental results using two industrial manipulators demonstrate that the proposed scheme can achieve better synchronous tracking accuracy than the independent control scheme.
{"title":"Vision guided dynamic synchronous path tracking control of dual manipulator cooperative system","authors":"Q. Bai, Pengcheng Li, W. Tian, Jianxin Shen, Bo Li, Junshan Hu","doi":"10.1115/1.4062546","DOIUrl":"https://doi.org/10.1115/1.4062546","url":null,"abstract":"\u0000 Compared with a single manipulator manufacturing cell, a dual manipulator cooperative system has more advantages in reconfigurability and flexibility. However, there are calibration errors and multi-source disturbances in the collaborative process, which lead to the processing trajectory accuracy defects of large-scale associated machining features. To solve the above problems, a practical path tracking synchronous control algorithm is proposed based on position based visual servoing (PBVS) in this paper for the dual manipulator cooperative system, the proposed dynamic cross-coupled sliding mode controller (DCSMC) scheme can realize dynamic paths correction while executing the pre-planned paths. Moreover, since the cross-coupled technology is integrated into the proposed control algorithm for dynamic path tracking based on the real-time feedback of the highly repeatable 3D visual measurement instrument (VMI), both the tracking and synchronous errors of the dual manipulators converge to zero. Finally, the stability of the proposed controller has been verified by the Lyapunov method. In the end, the real-time line and circle path tracking experimental results using two industrial manipulators demonstrate that the proposed scheme can achieve better synchronous tracking accuracy than the independent control scheme.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48811358","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Towards achieving control over the kerfing through abrasive waterjet submerged milling, there is a need to (i) understand the influence of the water column height on the kerf quality and (ii) develop a model for the prediction of the kerf characteristics. This study performs detailed experimentation to assess the kerf quality enhancement in submerged milling relative to the in-air on Al6061. From the modelling perspective, there are very limited efforts in developing a comprehensive model that includes both the jet flow dynamics and material removal models - this is the missing link. Towards this, a comprehensive model is proposed and validated for the prediction of kerf in in-air and submerged conditions by considering (i) jet dynamics and (ii) jet-material interaction. From the experimental results, it is observed that by adopting the submerged milling, the damaged region, top kerf width and edge radius got reduced by 20.3%, 13.53%, and 22.7%, respectively. However, this enhancement in the kerf quality is associated with a reduction in the centreline erosion depth (hmax) by 12.33% and a material removal rate by 24.52%. The material removal mechanism is more uniform and directed in the submerged milling, whereas in-air is random. The proposed model predicted the kerf cross-sectional profile in submerged milling and in-air with a mean absolute error of 60 μm and 57 μm, squared Pearson correlation coefficient of 0.97 and 0.99, and the hmax with a maximum error of 1.3% and 1.4%.
{"title":"Experimental investigation and modelling of the kerf profile in submerged milling by macro abrasive waterjet","authors":"R. Ravi, Deepu Kumar T. N., D. Srinivasu","doi":"10.1115/1.4062547","DOIUrl":"https://doi.org/10.1115/1.4062547","url":null,"abstract":"\u0000 Towards achieving control over the kerfing through abrasive waterjet submerged milling, there is a need to (i) understand the influence of the water column height on the kerf quality and (ii) develop a model for the prediction of the kerf characteristics. This study performs detailed experimentation to assess the kerf quality enhancement in submerged milling relative to the in-air on Al6061. From the modelling perspective, there are very limited efforts in developing a comprehensive model that includes both the jet flow dynamics and material removal models - this is the missing link. Towards this, a comprehensive model is proposed and validated for the prediction of kerf in in-air and submerged conditions by considering (i) jet dynamics and (ii) jet-material interaction. From the experimental results, it is observed that by adopting the submerged milling, the damaged region, top kerf width and edge radius got reduced by 20.3%, 13.53%, and 22.7%, respectively. However, this enhancement in the kerf quality is associated with a reduction in the centreline erosion depth (hmax) by 12.33% and a material removal rate by 24.52%. The material removal mechanism is more uniform and directed in the submerged milling, whereas in-air is random. The proposed model predicted the kerf cross-sectional profile in submerged milling and in-air with a mean absolute error of 60 μm and 57 μm, squared Pearson correlation coefficient of 0.97 and 0.99, and the hmax with a maximum error of 1.3% and 1.4%.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42810393","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In this study, a novel design scheme for a power skiving cutter and its grinding wheel profile is proposed based on the geometry of a target circular spline (CS) workpiece. First, a generalized mathematical model of a target CS tooth profile is expressed using a B-spline curve. Subsequently, the nominal cutting edge of the skiving cutter for generating an error-free CS is derived based on power-skiving kinematics. In addition, the axial profile of the grinding wheel for generating the derived nominal cutting edge is resolved based on lengthwise-reciprocating grinding kinematics. Numerical examples are presented to demonstrate the proposed design process for the skiving cutter and its grinding wheel. The profile accuracy of the CS yielded by the designed nominal cutting edge is computed to validate the proposed design processes. Moreover, errors of the skived CS profile resulting from various resharpening depths by grinding back the stepped rake face of the skiving cutter are investigated. Finally, to effectively extend the tool life of the skiving cutter, a compensation rolling angle is introduced into the CS skiving process.
{"title":"Design and Manufacture of Power Skiving Cutter from Target Circular Spline Geometry","authors":"Yun-Hao Cheng, Yi-Cheng Chen","doi":"10.1115/1.4062496","DOIUrl":"https://doi.org/10.1115/1.4062496","url":null,"abstract":"\u0000 In this study, a novel design scheme for a power skiving cutter and its grinding wheel profile is proposed based on the geometry of a target circular spline (CS) workpiece. First, a generalized mathematical model of a target CS tooth profile is expressed using a B-spline curve. Subsequently, the nominal cutting edge of the skiving cutter for generating an error-free CS is derived based on power-skiving kinematics. In addition, the axial profile of the grinding wheel for generating the derived nominal cutting edge is resolved based on lengthwise-reciprocating grinding kinematics. Numerical examples are presented to demonstrate the proposed design process for the skiving cutter and its grinding wheel. The profile accuracy of the CS yielded by the designed nominal cutting edge is computed to validate the proposed design processes. Moreover, errors of the skived CS profile resulting from various resharpening depths by grinding back the stepped rake face of the skiving cutter are investigated. Finally, to effectively extend the tool life of the skiving cutter, a compensation rolling angle is introduced into the CS skiving process.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46028409","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
D. Ambrosio, V. Wagner, G. Dessein, J. Vivas, O. Cahuc
Flow-related defects in friction stir welding are critical for the joints affecting their mechanical properties and functionality. One way to identify them, avoiding long and sometimes expensive destructive and non-destructive testing, is using machine learning tools with monitored physical quantities as input data. In this work, artificial neural network and decision tree models are trained, validated, and tested on a large dataset consisting of forces, torque, and temperature in the stirred zone measured when friction stir welding three aluminum alloys such as 5083-H111, 6082-T6, and 7075-T6. The built models successfully classified welds between sound and defective with accuracies over 95%, proving their usefulness in identifying defects on new datasets. Independently from the models, the temperature in the stirred zone is found to be the most influential parameter for the assessment of friction stir weld quality.
{"title":"Machine learning tools for flow-related defects detection in friction stir welding","authors":"D. Ambrosio, V. Wagner, G. Dessein, J. Vivas, O. Cahuc","doi":"10.1115/1.4062457","DOIUrl":"https://doi.org/10.1115/1.4062457","url":null,"abstract":"\u0000 Flow-related defects in friction stir welding are critical for the joints affecting their mechanical properties and functionality. One way to identify them, avoiding long and sometimes expensive destructive and non-destructive testing, is using machine learning tools with monitored physical quantities as input data. In this work, artificial neural network and decision tree models are trained, validated, and tested on a large dataset consisting of forces, torque, and temperature in the stirred zone measured when friction stir welding three aluminum alloys such as 5083-H111, 6082-T6, and 7075-T6. The built models successfully classified welds between sound and defective with accuracies over 95%, proving their usefulness in identifying defects on new datasets. Independently from the models, the temperature in the stirred zone is found to be the most influential parameter for the assessment of friction stir weld quality.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-05-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42089346","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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