As a critical component of the propellant tank, the tank bottom is subjected to complex loads such as internal pressure and vibration and has high requirements for structural load-bearing capacity. Hydroforming deep drawing is one of the techniques for the integral forming of the tank bottom. As the tank bottom is a large-size thin-walled structure, defects such as cracks and wrinkles are prone to occur during the hydroforming deep drawing process. Aiming at reducing these defects, the hydraulic pressure loading path and blank holder force loading path of the hydroforming deep drawing process are studied, and a multi-objective optimization method is proposed to improve the surface accuracy and thickness distribution uniformity of the tank bottom. The complex loading path curve optimization problem is transformed into a functional relationship between hydraulic pressure and blank holder force with time. The hydraulic pressure and blank holder force at each time node are used as design variables, and the maximum wall thickness reduction rate, rupture trend factor, wrinkle height, and wrinkle trend factor are used as optimization targets. The radial basis function (RBF) neural network is used to establish the approximate model between the loading path and the optimization target, and the multi-objective particle swarm optimization (MOPSO) algorithm is used to optimize the solution. Taking the hemispherical tank bottom as an example, the optimal hydraulic pressure loading path and blank holder force loading path are obtained, and the quality of the formed part is improved.
{"title":"Multi-objective optimization of loading path for sheet hydroforming of tank bottom","authors":"Zaifang Zhang, Liang Zhou, Feng Xu, Xiwu Sun, Zhichao Zhang","doi":"10.1177/09544054231181281","DOIUrl":"https://doi.org/10.1177/09544054231181281","url":null,"abstract":"As a critical component of the propellant tank, the tank bottom is subjected to complex loads such as internal pressure and vibration and has high requirements for structural load-bearing capacity. Hydroforming deep drawing is one of the techniques for the integral forming of the tank bottom. As the tank bottom is a large-size thin-walled structure, defects such as cracks and wrinkles are prone to occur during the hydroforming deep drawing process. Aiming at reducing these defects, the hydraulic pressure loading path and blank holder force loading path of the hydroforming deep drawing process are studied, and a multi-objective optimization method is proposed to improve the surface accuracy and thickness distribution uniformity of the tank bottom. The complex loading path curve optimization problem is transformed into a functional relationship between hydraulic pressure and blank holder force with time. The hydraulic pressure and blank holder force at each time node are used as design variables, and the maximum wall thickness reduction rate, rupture trend factor, wrinkle height, and wrinkle trend factor are used as optimization targets. The radial basis function (RBF) neural network is used to establish the approximate model between the loading path and the optimization target, and the multi-objective particle swarm optimization (MOPSO) algorithm is used to optimize the solution. Taking the hemispherical tank bottom as an example, the optimal hydraulic pressure loading path and blank holder force loading path are obtained, and the quality of the formed part is improved.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"77 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"89911498","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}
Pub Date : 2023-06-30DOI: 10.1177/09544054231185155
Pramod Adishesha, D. Lawrence K., J. Mathew
Machining signals from the Force dynamometer, Acoustic Emission (AE), and Accelerometer are acquired and fused to develop Machine Learning (ML) models for tool wear monitoring of TiAlN-PVD coated carbide inserts. Milling experiments were performed on Inconel 617 with varied process parameter combinations until the tool flank wear met the failure criterion. Support Vector Regression, Random Forest Regression, and Long Short-Term Memory models are developed and compared based on a combination of sensor data fusion for tool wear predictions. It is observed that the Random Forest Regression approach can predict the tool wear with 94% accuracy compared to Support Vector Regression (85%) and Long Short-Term Memory (84%) models while using three-sensor data fusion. Further, the two-sensor data combination was used to test the relative efficacy of all the three developed machine learning tool wear models and found that the force dynamometer and the AE sensor fared better for Random Forest Regression and Long Short-Term Memory models in comparison to Support Vector Regression. For Support Vector Regression-based tool wear predictive models, force dynamometer and accelerometer data fusion performed better.
{"title":"The multi-sensor-based measurement of machining signals and data fusion to develop predictive tool wear models for TiAlN-PVD coated carbide inserts during end milling of Inconel 617","authors":"Pramod Adishesha, D. Lawrence K., J. Mathew","doi":"10.1177/09544054231185155","DOIUrl":"https://doi.org/10.1177/09544054231185155","url":null,"abstract":"Machining signals from the Force dynamometer, Acoustic Emission (AE), and Accelerometer are acquired and fused to develop Machine Learning (ML) models for tool wear monitoring of TiAlN-PVD coated carbide inserts. Milling experiments were performed on Inconel 617 with varied process parameter combinations until the tool flank wear met the failure criterion. Support Vector Regression, Random Forest Regression, and Long Short-Term Memory models are developed and compared based on a combination of sensor data fusion for tool wear predictions. It is observed that the Random Forest Regression approach can predict the tool wear with 94% accuracy compared to Support Vector Regression (85%) and Long Short-Term Memory (84%) models while using three-sensor data fusion. Further, the two-sensor data combination was used to test the relative efficacy of all the three developed machine learning tool wear models and found that the force dynamometer and the AE sensor fared better for Random Forest Regression and Long Short-Term Memory models in comparison to Support Vector Regression. For Support Vector Regression-based tool wear predictive models, force dynamometer and accelerometer data fusion performed better.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"103 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"87903173","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}
Pub Date : 2023-06-25DOI: 10.1177/09544054231181158
C. Ozoegwu
This paper upgrades the original closed-form models of cutting force for general-helix milling tools for higher accuracy and demonstrates an application of the upgraded models in closed-form modeling of cutting power. The proposed models are shown to be numerically exact for the conventional fixed helix angle milling tools while the original models are not even though they are more accurate than the numerical methods. Errors of 0.00%, 12.15%, and 50.66% are recorded for an upgraded closed-form model, the equivalent original closed-form model, and an equivalent numerical method. Higher accurate applicability of the upgraded closed-form models to variable helix tools is also demonstrated for the harmonic case. Typical errors of 1.37%, 4.84%, and 9.94% are recorded for an upgraded closed-form model, the equivalent original closed-form model, and an equivalent numerical method. The proposed closed-form cutting force models are used to formulate new closed-form cutting power models for general-helix cylindrical milling tools which are applied in numerical evaluation of average cutting power. Evaluated data sets of average cutting power (seen to agree with published values) and spindle speed are then used in empirical calibration of average milling machine power demand. The high goodness-of-fit of the models with three published measured data sets are reflected in the high [Formula: see text] values of 0.9980, 0.9834, and 0.9472 and low mean percentage errors (MPE) of −0.1247, −0.4137, and −0.6242.
{"title":"Upgraded closed-form cutting force models for general-helix cylindrical milling tools with application to cutting power and energy demand modeling","authors":"C. Ozoegwu","doi":"10.1177/09544054231181158","DOIUrl":"https://doi.org/10.1177/09544054231181158","url":null,"abstract":"This paper upgrades the original closed-form models of cutting force for general-helix milling tools for higher accuracy and demonstrates an application of the upgraded models in closed-form modeling of cutting power. The proposed models are shown to be numerically exact for the conventional fixed helix angle milling tools while the original models are not even though they are more accurate than the numerical methods. Errors of 0.00%, 12.15%, and 50.66% are recorded for an upgraded closed-form model, the equivalent original closed-form model, and an equivalent numerical method. Higher accurate applicability of the upgraded closed-form models to variable helix tools is also demonstrated for the harmonic case. Typical errors of 1.37%, 4.84%, and 9.94% are recorded for an upgraded closed-form model, the equivalent original closed-form model, and an equivalent numerical method. The proposed closed-form cutting force models are used to formulate new closed-form cutting power models for general-helix cylindrical milling tools which are applied in numerical evaluation of average cutting power. Evaluated data sets of average cutting power (seen to agree with published values) and spindle speed are then used in empirical calibration of average milling machine power demand. The high goodness-of-fit of the models with three published measured data sets are reflected in the high [Formula: see text] values of 0.9980, 0.9834, and 0.9472 and low mean percentage errors (MPE) of −0.1247, −0.4137, and −0.6242.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"15 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"79716478","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}
Pub Date : 2023-06-23DOI: 10.1177/09544054231182175
Muhammad Rizal, J. A. Ghani, H. Usman, M. Dirhamsyah, A. Z. Mubarak
This study focused on the development and testing of a stationary dynamometer using force-sensing elements capable of measuring three axes of cutting force during milling operations. The force-sensing element was based on the Maltese cross-beam concept but has been improved and modified to increase sensitivity and reduce interference or cross-talk error. A Finite element analysis was conducted to study strain distribution and determine sensor positions in the force-sensing element. By using four force-sensing elements and several piezoresistive strain sensors, a stationary dynamometer prototype was constructed. A series of calibration tests were performed to evaluate the dynamometer’s sensitivity, linearity, hysteresis, and repeatability over three orthogonal axes. The dynamometer’s dynamic features and functionality for milling applications were examined through modal analysis and real milling tests. Additionally, the end-milling and slot-milling cutting force values were compared to those of a reference dynamometer (Kistler 9129AA). Overall, the experimental results indicated that the proposed stationary dynamometer is a reliable and accurate alternative for measuring cutting force during machining operations and other force measurements.
{"title":"Development and testing of a stationary dynamometer using cross-beam-type force-sensing elements for three-axis cutting force measurement in milling operations","authors":"Muhammad Rizal, J. A. Ghani, H. Usman, M. Dirhamsyah, A. Z. Mubarak","doi":"10.1177/09544054231182175","DOIUrl":"https://doi.org/10.1177/09544054231182175","url":null,"abstract":"This study focused on the development and testing of a stationary dynamometer using force-sensing elements capable of measuring three axes of cutting force during milling operations. The force-sensing element was based on the Maltese cross-beam concept but has been improved and modified to increase sensitivity and reduce interference or cross-talk error. A Finite element analysis was conducted to study strain distribution and determine sensor positions in the force-sensing element. By using four force-sensing elements and several piezoresistive strain sensors, a stationary dynamometer prototype was constructed. A series of calibration tests were performed to evaluate the dynamometer’s sensitivity, linearity, hysteresis, and repeatability over three orthogonal axes. The dynamometer’s dynamic features and functionality for milling applications were examined through modal analysis and real milling tests. Additionally, the end-milling and slot-milling cutting force values were compared to those of a reference dynamometer (Kistler 9129AA). Overall, the experimental results indicated that the proposed stationary dynamometer is a reliable and accurate alternative for measuring cutting force during machining operations and other force measurements.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"13 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"82495221","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}
Pub Date : 2023-06-23DOI: 10.1177/09544054231180653
Luke Osmond, I. Cook, David Curtis, T. Slatter
In this study, an investigation has been conducted to fully characterise for the first time the tribological benefits of adding two different types of chemical vapour deposition (CVD) coatings to silicon aluminium oxynitride milling inserts with a chemical composition of (Si3N4 + Al2O3 + Y2O3), known by the trade abbreviation ‘SiAlON’, typically used to cut difficult to machine materials such as Inconel 718. The experimental tests compared the tool life, material removed and wear resistance of the two different CVD coated inserts against that of uncoated SiAlON ceramic milling inserts. Coating A was a multilayer CVD coating and had a composition of (TiN + TiCN + Al2O3), Coating B was a bilayer CVD coating and had a composition of (Al2O3 + TiN). It was determined that at 900 m/min the uncoated SiAlON ceramic milling inserts exhibited the least amount of wear and variation in cutting force when milling precipitation hardened Inconel 718 samples. Coating A demonstrated significantly lower adhesion to the SiAlON substrate but had higher tool life and material removal rates, Coating B demonstrated excellent adhesion to the SiAlON substrate. The interfacial bonding of Coating B allowed for much higher adhesion to the substrate, but it suffered from much lower tool life and higher rates of rake and flank face wear. The flank wear measurements concluded a cutting speed of 900 m/min to be the optimum cutting speed for machining Inconel 718 with uncoated SiAlON ceramic milling inserts.
{"title":"Tool life and wear mechanisms of CVD coated and uncoated SiAlON ceramic milling inserts when machining aged Inconel 718","authors":"Luke Osmond, I. Cook, David Curtis, T. Slatter","doi":"10.1177/09544054231180653","DOIUrl":"https://doi.org/10.1177/09544054231180653","url":null,"abstract":"In this study, an investigation has been conducted to fully characterise for the first time the tribological benefits of adding two different types of chemical vapour deposition (CVD) coatings to silicon aluminium oxynitride milling inserts with a chemical composition of (Si3N4 + Al2O3 + Y2O3), known by the trade abbreviation ‘SiAlON’, typically used to cut difficult to machine materials such as Inconel 718. The experimental tests compared the tool life, material removed and wear resistance of the two different CVD coated inserts against that of uncoated SiAlON ceramic milling inserts. Coating A was a multilayer CVD coating and had a composition of (TiN + TiCN + Al2O3), Coating B was a bilayer CVD coating and had a composition of (Al2O3 + TiN). It was determined that at 900 m/min the uncoated SiAlON ceramic milling inserts exhibited the least amount of wear and variation in cutting force when milling precipitation hardened Inconel 718 samples. Coating A demonstrated significantly lower adhesion to the SiAlON substrate but had higher tool life and material removal rates, Coating B demonstrated excellent adhesion to the SiAlON substrate. The interfacial bonding of Coating B allowed for much higher adhesion to the substrate, but it suffered from much lower tool life and higher rates of rake and flank face wear. The flank wear measurements concluded a cutting speed of 900 m/min to be the optimum cutting speed for machining Inconel 718 with uncoated SiAlON ceramic milling inserts.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"51 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"74077056","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}
Pub Date : 2023-06-18DOI: 10.1177/09544054231180659
Youjun An, Chuwei Li, Xiaohui Chen, Yinghe Li, Ziye Zhao, H. Cao
To relive the pressure of electricity grid during the peak period, time-of-use (TOU) pricing strategy has been implemented in industries to encourage manufacturers to transfer some processing tasks from peak periods to non-peak periods, and the due date of each job cannot be violated. Under these contexts, this paper addresses a speed-scaling single machine scheduling problem with due date constraint to minimize the total electricity cost (TEC). More precisely, the main innovative works are described as follows: (1) seven critical problem properties (including four theorems and three lemmas) based on different processing time window forms are formally derived; and (2) a property-based genetic algorithm (PGA) with hybrid initialization method is designed according to the characteristics of the studied problem. In the numerical experiments, the Taguchi method of design-of-experiment is employed to seek the optimal combination of four key parameters in PGA. Subsequently, the effectiveness and superiority of the proposed hybrid initialization method and problem properties are separately demonstrated by randomly generated 20 instances. After that, compared with other two traditional scheduling strategies, the proposed energy-efficient strategy can save at least 16% of TEC on average. Next, a relaxation coefficient (CR) is designed to measure the intrinsic link between TEC and the instance parameters (i.e. the due date and normal processing time). Finally, a real case is presented to verify the benefits of the proposed PGA algorithm and variable processing speeds, and the results show that the newly generated scheduling scheme based on the proposed PGA can reduce up to 46.36% of TEC compared with the existing company’s scheduling scheme.
{"title":"An optimal energy-efficient scheduling with processing speed selection and due date constraint in a single-machine environment","authors":"Youjun An, Chuwei Li, Xiaohui Chen, Yinghe Li, Ziye Zhao, H. Cao","doi":"10.1177/09544054231180659","DOIUrl":"https://doi.org/10.1177/09544054231180659","url":null,"abstract":"To relive the pressure of electricity grid during the peak period, time-of-use (TOU) pricing strategy has been implemented in industries to encourage manufacturers to transfer some processing tasks from peak periods to non-peak periods, and the due date of each job cannot be violated. Under these contexts, this paper addresses a speed-scaling single machine scheduling problem with due date constraint to minimize the total electricity cost (TEC). More precisely, the main innovative works are described as follows: (1) seven critical problem properties (including four theorems and three lemmas) based on different processing time window forms are formally derived; and (2) a property-based genetic algorithm (PGA) with hybrid initialization method is designed according to the characteristics of the studied problem. In the numerical experiments, the Taguchi method of design-of-experiment is employed to seek the optimal combination of four key parameters in PGA. Subsequently, the effectiveness and superiority of the proposed hybrid initialization method and problem properties are separately demonstrated by randomly generated 20 instances. After that, compared with other two traditional scheduling strategies, the proposed energy-efficient strategy can save at least 16% of TEC on average. Next, a relaxation coefficient (CR) is designed to measure the intrinsic link between TEC and the instance parameters (i.e. the due date and normal processing time). Finally, a real case is presented to verify the benefits of the proposed PGA algorithm and variable processing speeds, and the results show that the newly generated scheduling scheme based on the proposed PGA can reduce up to 46.36% of TEC compared with the existing company’s scheduling scheme.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"24 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"83578239","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}
Pub Date : 2023-06-15DOI: 10.1177/09544054231182174
Yoon-Jae Cho, Hyeon-Il Kim, Y. Kim, S. Yoo, Byoung-Hee Kim, Dong-Ho Lee
This study addresses multi-stage hybrid flow shop scheduling in which a job is reworked if the queue time between two arbitrary stages exceeds an upper limit. The problem is to determine the allocations of jobs to machines at each stage and the start times of jobs and rework setups/operations when incurred. A mixed integer programming model is proposed for each of the makespan and the total tardiness measures. Then, because the problem is NP-hard, a scheduling mechanism is proposed that consists of three phases: (a) filtering the jobs to be delayed; (b) searching the jobs to be reworked; and (c) dispatching non-delayed and delayed jobs sequentially. Simulation results show that the mechanism proposed in this study outperforms the conventional dispatching approach in the high rework setup time case for the makespan problem and low/high setup time cases for the tardiness problem. The best priority rules of the mechanism under each of the measures are also reported.
{"title":"A scheduling mechanism for hybrid flow shops with reworks under general queue time limits","authors":"Yoon-Jae Cho, Hyeon-Il Kim, Y. Kim, S. Yoo, Byoung-Hee Kim, Dong-Ho Lee","doi":"10.1177/09544054231182174","DOIUrl":"https://doi.org/10.1177/09544054231182174","url":null,"abstract":"This study addresses multi-stage hybrid flow shop scheduling in which a job is reworked if the queue time between two arbitrary stages exceeds an upper limit. The problem is to determine the allocations of jobs to machines at each stage and the start times of jobs and rework setups/operations when incurred. A mixed integer programming model is proposed for each of the makespan and the total tardiness measures. Then, because the problem is NP-hard, a scheduling mechanism is proposed that consists of three phases: (a) filtering the jobs to be delayed; (b) searching the jobs to be reworked; and (c) dispatching non-delayed and delayed jobs sequentially. Simulation results show that the mechanism proposed in this study outperforms the conventional dispatching approach in the high rework setup time case for the makespan problem and low/high setup time cases for the tardiness problem. The best priority rules of the mechanism under each of the measures are also reported.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"49 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"78289155","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}
Pub Date : 2023-06-15DOI: 10.1177/09544054231180353
Yacine Hamiche, N. Zeroudi
The present work is motivated by the fact that for predicting the cutting forces which arise under various cutting conditions, workpiece-tool pairs, machining depths and tool orientation, numerical methods are slower and less efficient than analytical methods. In addition, recent developments in Computer Assisted Machining (CAM) techniques have enabled analytical methods to be applied even with complex workpiece geometry. The method developed in this paper is both practical and inexpensive. It is based on an analytical method using only few approximations and uses the toolpath file as the main information source for the machined surface. This method takes into account both tool position and orientation in a 5-axis finishing milling process with ball-end cutter, independent of the machining parameters and the couple of tool-workpiece materials. However, this calculation must be supplemented by a mechanistic approach in order to obtain results equivalent to those of the experiment. The result is a model which is implemented in a program allowing the visualization of the cutting forces along a given path. The program is easy to apply in practical cases with the possibility of implementing it in a machining software.
{"title":"Predicting cutting forces in 5-axis milling of sculptured surfaces directly from a CAM tool path","authors":"Yacine Hamiche, N. Zeroudi","doi":"10.1177/09544054231180353","DOIUrl":"https://doi.org/10.1177/09544054231180353","url":null,"abstract":"The present work is motivated by the fact that for predicting the cutting forces which arise under various cutting conditions, workpiece-tool pairs, machining depths and tool orientation, numerical methods are slower and less efficient than analytical methods. In addition, recent developments in Computer Assisted Machining (CAM) techniques have enabled analytical methods to be applied even with complex workpiece geometry. The method developed in this paper is both practical and inexpensive. It is based on an analytical method using only few approximations and uses the toolpath file as the main information source for the machined surface. This method takes into account both tool position and orientation in a 5-axis finishing milling process with ball-end cutter, independent of the machining parameters and the couple of tool-workpiece materials. However, this calculation must be supplemented by a mechanistic approach in order to obtain results equivalent to those of the experiment. The result is a model which is implemented in a program allowing the visualization of the cutting forces along a given path. The program is easy to apply in practical cases with the possibility of implementing it in a machining software.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"137 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"77814170","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}
Pub Date : 2023-06-14DOI: 10.1177/09544054231179852
Weitai Huang, Yi-Siang Chen
In this research, a built-in actuated ultrasonically assisted turning (UAT) system was developed. The structure design and turning parameters of the system were optimized to improve its efficiency. Finite element analysis and robust design are used in the system structure design to optimize the system structure. The primary purpose of this optimization is to achieve the best tooltip vibration displacement of the system. When the natural frequency mode of the system is 23.7 kHz, the best-simulated tool tip vibration displacement for computer-aided engineering is 4.16 μm; at an input voltage of 100 V, it is 3.91 µm, the error percentage is 6.39%, and the accuracy is very high. Afterward, we conducted an optimization study on the turning parameters of heat-treated die steel. The best turning force is 8.658 N, the turning temperature is 354.9°C, and the surface roughness is 0.394 μm. Compared with conventional turning, our UAT system can reduce the turning force by 92.32%, the turning temperature by 30.43%, the surface roughness by 42.89%, and the tool wear by 95.22%. The comparison results show that our UAT system can significantly improve the efficiency of post-hot die steel turning.
{"title":"Research on die steel after turning heat treatment of built-in actuation ultrasonically assisted turning system","authors":"Weitai Huang, Yi-Siang Chen","doi":"10.1177/09544054231179852","DOIUrl":"https://doi.org/10.1177/09544054231179852","url":null,"abstract":"In this research, a built-in actuated ultrasonically assisted turning (UAT) system was developed. The structure design and turning parameters of the system were optimized to improve its efficiency. Finite element analysis and robust design are used in the system structure design to optimize the system structure. The primary purpose of this optimization is to achieve the best tooltip vibration displacement of the system. When the natural frequency mode of the system is 23.7 kHz, the best-simulated tool tip vibration displacement for computer-aided engineering is 4.16 μm; at an input voltage of 100 V, it is 3.91 µm, the error percentage is 6.39%, and the accuracy is very high. Afterward, we conducted an optimization study on the turning parameters of heat-treated die steel. The best turning force is 8.658 N, the turning temperature is 354.9°C, and the surface roughness is 0.394 μm. Compared with conventional turning, our UAT system can reduce the turning force by 92.32%, the turning temperature by 30.43%, the surface roughness by 42.89%, and the tool wear by 95.22%. The comparison results show that our UAT system can significantly improve the efficiency of post-hot die steel turning.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"9 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"84309423","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}
Pub Date : 2023-06-10DOI: 10.1177/09544054231179278
Qinghe Guan, Yong Lu, Qiushi Li, Jining Li, Zhenchi Wang
This study investigated the wear prediction of BTA drills for laminated Inconel 625 deposited metal and FeCr alloy materials using 3D finite element modelling. High interface temperature owing to increased cutting speed enhances the abrasive wear mechanism of Inconel 625, while FeCr alloy exhibits a predominantly adhesive wear mechanism. The interface temperature and normal pressure required as inputs for tool-wear prediction were obtained using response surface methodology (RSM), which was developed by combining the central composite design (CCD) with finite element method simulation. This approach significantly improved the computational efficiency and provides accurate predictions with the calibrated friction model. A modified Usui wear model was established considering the sensitivity of temperature to wear rate for Inconel 625. A significant improvement in prediction accuracy was observed compared with the original Usui equation. The proposed tool-wear prediction model was validated through experimental tests. The maximum predicted flank wear width deviations for the outer and intermediate edges of BTA drill were 2% and 7%, respectively. The results demonstrate the effectiveness of the proposed BTA drill wear-prediction approach for laminated materials with different wear characteristics, providing theoretical guidance for cutting-parameter optimisation and tool-replacement strategies.
{"title":"Wear prediction of BTA drill based on finite element method for drilling laminated Inconel 625 deposited metal and FeCr alloy material","authors":"Qinghe Guan, Yong Lu, Qiushi Li, Jining Li, Zhenchi Wang","doi":"10.1177/09544054231179278","DOIUrl":"https://doi.org/10.1177/09544054231179278","url":null,"abstract":"This study investigated the wear prediction of BTA drills for laminated Inconel 625 deposited metal and FeCr alloy materials using 3D finite element modelling. High interface temperature owing to increased cutting speed enhances the abrasive wear mechanism of Inconel 625, while FeCr alloy exhibits a predominantly adhesive wear mechanism. The interface temperature and normal pressure required as inputs for tool-wear prediction were obtained using response surface methodology (RSM), which was developed by combining the central composite design (CCD) with finite element method simulation. This approach significantly improved the computational efficiency and provides accurate predictions with the calibrated friction model. A modified Usui wear model was established considering the sensitivity of temperature to wear rate for Inconel 625. A significant improvement in prediction accuracy was observed compared with the original Usui equation. The proposed tool-wear prediction model was validated through experimental tests. The maximum predicted flank wear width deviations for the outer and intermediate edges of BTA drill were 2% and 7%, respectively. The results demonstrate the effectiveness of the proposed BTA drill wear-prediction approach for laminated materials with different wear characteristics, providing theoretical guidance for cutting-parameter optimisation and tool-replacement strategies.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"36 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"91131149","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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