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Robotic Drilling of Aluminum Alloy 铝合金的机器人钻孔
IF 1.3 Q2 Engineering Pub Date : 2023-07-27 DOI: 10.3311/ppme.22757
Fouad Messaoudi, A. Djebara, Mohamed Djennane
This paper presents an experimental approach to evaluate the ability of a six-axis industrial robot to drill aluminum alloy parts. A strategy based on statistical tests has been studied to quantify and predict the relative contribution of cutting parameters on cutting force and shape errors during drilling. This technique is based on the identification of relevant sources of error during high-speed robotic fitting. The machining quality was quantified in terms of dimensional and geometric tolerance, chip formation and evacuation, burr formation, edge build-up, tool wear and surface damage. Statistical analysis of the experimental results reveals a strong dependence between part accuracy and drilling force. An experimental model was developed to represent and predict the cutting force during drilling and an accurate error prediction capability was distinguished. It was found that at high cutting speed and feed rate, the cutting force was the main source of error affecting the accuracy of the machined parts. Verification experiments are performed, and the results reveal that dimensional defects are significantly reduced by a heat treatment effect (90 HRE) and the thrust force decreases with an increase in cutting speed. The recommended cutting speed for robotic drilling is 6000 rpm with a feed rate of 0.15 mm/min. This study provides important technical guidance for improving the robotic drilling of aluminum alloy in practice.
本文提出了一种评估六轴工业机器人钻削铝合金零件能力的实验方法。研究了一种基于统计试验的策略,以量化和预测切削参数对切削力和形状误差的相对贡献。该技术基于对高速机器人装配过程中相关误差源的识别。加工质量被量化为尺寸和几何公差、切屑形成和清除、毛刺形成、边缘积聚、刀具磨损和表面损伤。实验结果的统计分析表明,零件精度与钻削力之间有很强的相关性。建立了表征和预测钻削过程中切削力的实验模型,具有准确的误差预测能力。研究发现,在高切削速度和进给速度下,切削力是影响加工精度的主要误差来源。验证实验结果表明,热处理效果(90 HRE)显著减小了尺寸缺陷,推力随切削速度的增加而减小。机器人钻孔的推荐切削速度为6000转/分钟,进给速度为0.15毫米/分钟。该研究为实际改进铝合金机器人钻孔技术提供了重要的技术指导。
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引用次数: 0
Experimental Investigation on Churning Power Loss of Splash Lubricated Worm Gear 飞溅润滑蜗轮搅拌功率损失的实验研究
IF 1.3 Q2 Engineering Pub Date : 2023-07-24 DOI: 10.3311/ppme.19965
H. Chothani, K. Maniya
Churning power losses are a complex phenomenon that produces critical power losses when considering the splash lubrication of gear units. This article describes the method to investigate the churning power loss in a worm gearbox. A particular test rig was designed and fabricated to experiment on single start worm gear incompletely submerged in an oil bath. The direct torque measurement technique was used to determine the churning power losses. Experiments have been conducted to determine the impact of a variety of operating conditions on churning power losses, including worm speeds, gear immersion depth, lubricant temperatures, and lubricant type (mineral and synthetic). It was found that the churning losses were significantly affected by the worm shaft orientation, speed of gear, and the depth of immersion (static head). The lubricant's temperature is more essential than the type of lubricant in terms of churning power loss.
搅拌功率损失是一种复杂的现象,当考虑到齿轮单元的飞溅润滑时,会产生临界功率损失。本文介绍了蜗杆齿轮箱搅拌功率损失的研究方法。设计并制作了一套特殊的试验台,用于单起动蜗轮不完全浸没在油浴中的试验。采用直接扭矩测量技术测定搅拌功率损耗。实验确定了各种工况对搅拌功率损失的影响,包括蜗杆转速、齿轮浸泡深度、润滑剂温度和润滑剂类型(矿物和合成)。研究发现,蜗杆轴向、齿轮转速和浸泡深度(静水头)对搅拌损失有显著影响。在搅拌功率损失方面,润滑剂的温度比润滑剂的类型更重要。
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引用次数: 0
The Comparison of Effects of Liquid Carbon Dioxide and Conventional Flood Cooling on the Machining Conditions During Milling of Nickel-based Superalloys 液态二氧化碳与常规冷却对镍基高温合金铣削加工条件影响的比较
IF 1.3 Q2 Engineering Pub Date : 2023-07-17 DOI: 10.3311/ppme.22265
G. Kónya, Z. Kovács
In this scientific study, the authors have dealt with the slot milling of nickel-based superalloys. These alloys are among the most difficult materials to machine and are widely used in aerospace and energy industries. Due to the properties of the material, slot milling is a particular problem because tool wear happens quickly, and tool breakages are common. When these superalloys are machined, very high temperatures occur in the cutting zone, which cannot leave due to the extremely poor thermal conductivity of the material and will therefore transfer to the edges of the cutting tool, causing it to anneal, break off and fail. So, the researchers initiated a new field of research: cryogenically-assisted machining. In this paper, the authors used two cooling methods, the conventional flood cooling and cryogenic cooling with liquid carbon-dioxide (LCO2). The effects of these cooling methods were tested focusing on the cutting forces, tool wear, chip morphology and surface roughness of the bottom of the slots. The aim was to determine the best cooling methods for these materials. Based on the results, it can be concluded that, LCO2 has a negative effect on cutting forces, tool life and surface roughness. It only has a positive effect on chip formation. It can be see that, the lubricating effect has a greater impact on tool life, tool load and surface roughness of the milled slots than cooling.
本文对镍基高温合金的槽铣削工艺进行了研究。这些合金是最难加工的材料之一,广泛应用于航空航天和能源工业。由于材料的特性,槽铣削是一个特殊的问题,因为刀具磨损发生得很快,刀具断裂是常见的。当这些高温合金被加工时,切削区会出现非常高的温度,由于材料的导热性极差,这些温度无法离开,因此会转移到刀具的边缘,导致其退火、断裂和失效。因此,研究人员开创了一个新的研究领域:低温辅助加工。在本文中,作者采用了两种冷却方法,即常规的洪水冷却和液态二氧化碳(LCO2)低温冷却。研究了不同冷却方式对切削力、刀具磨损、切屑形貌和槽底表面粗糙度的影响。目的是确定这些材料的最佳冷却方法。结果表明,LCO2对切削力、刀具寿命和表面粗糙度均有负面影响。它只对切屑的形成有积极的影响。由此可见,与冷却相比,润滑对刀具寿命、刀具负荷和铣削槽表面粗糙度的影响更大。
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引用次数: 1
Investigation of Weld Forces and Strength of Friction Stir Welded Polypropylene 搅拌摩擦焊接聚丙烯的焊接力和强度研究
IF 1.3 Q2 Engineering Pub Date : 2023-07-13 DOI: 10.3311/ppme.21899
Gábor Róbert Stadler, G. Szebényi, R. Horváth
Friction stir welding (FSW) is an advanced joining technology specifically developed for welding materials that are difficult to weld (e.g. polymers). Over the last two decades, more and more research has been published on the applicability and development of the technique on polymeric materials. The aim of the present study is to investigate the applicability of the method for welding polymeric materials and to analyse the effect of the parameters of FSW. In the tests, 4 mm thick polypropylene sheets were welded by varying two welding parameters (tool speed (n) and feed rate (vf)) in four levels. Thus, a complete experimental design with 16 measurement points was created. During the welding process, the force components on the tool/workpiece were measured, from which the resultant welding force was calculated and the strength of the joints was characterized by tensile testing. The ratio of the tensile strength of the joints and the tensile strength of the material were used to characterise the process in terms of joint efficiency. During welding, the axial force component (Fz) was the dominant force value. The resultant forces (Fe) decreased with increasing n, while they increased with increasing vf. The tensile strength of the joint, and hence the bonding efficiency, improved with increasing n, while it deteriorated with increasing vf. The ratio derived from the ratio of n to vf was also analysed, with an increase in the ratio showing a decreasing trend in the resulting weld strength and an improving trend in the bonding efficiency.
搅拌摩擦焊(FSW)是一种先进的连接技术,专门用于焊接难以焊接的材料(如聚合物)。在过去的二十年里,越来越多的研究发表了该技术在高分子材料上的适用性和发展。本研究的目的是探讨该方法在焊接高分子材料时的适用性,并分析摩擦焊参数对焊接效果的影响。在试验中,通过改变两个焊接参数(刀具速度(n)和进给速度(vf))在四个水平上焊接4mm厚的聚丙烯板。这样就形成了一个包含16个测点的完整实验设计。在焊接过程中,测量工具/工件上的力分量,由此计算焊接合力,并通过拉伸试验表征接头的强度。接头的抗拉强度和材料的抗拉强度的比率被用来表征接头效率方面的过程。焊接过程中,轴向力分量(Fz)为主导力值。合力(Fe)随n的增大而减小,随vf的增大而增大。随着n的增加,接头的抗拉强度提高,从而提高了结合效率,而随着vf的增加,接头的抗拉强度降低。对n / vf的比值也进行了分析,比值的增大表明焊接强度有减小的趋势,而结合效率有提高的趋势。
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引用次数: 0
Design and Analysis of EN19 Centre Crankshaft EN19型中心曲轴的设计与分析
IF 1.3 Q2 Engineering Pub Date : 2023-07-11 DOI: 10.3311/ppme.22724
Akash Gaikwad, Umesh Chavan
Crankshaft is the one of the most important components in internal combustion engines, it converts the translation motion of piston generated due to gas force into rotational moment of engine shaft though oscillatory motion of connecting rod. It mostly experiences the bending and torsional moment. The present research is focused on investigation of alternative material for crankshafts. Material EN19 is considered in this study and strength performance is verified under different operating conditions. Analytical design calculations, 3D modelling and analysis of EN19 crankshaft is carried out under maximum bending moment and maximum torque. 3D modeling and analysis was done in Creo parametric software and Ansys respectively. The compressive stresses, Von-Mises stresses, shear stresses and deformation in crankshaft are found to be within the permissible limits. Result shows cost effective material EN19 can be used as one of the alternative materials for crankshaft as it satisfies the all-strength requirements.
曲轴是内燃机中最重要的部件之一,它通过连杆的振荡运动,将气动力作用下活塞的平移运动转化为发动机轴的转动力矩。它主要经历弯曲和扭转力矩。目前的研究重点是曲轴替代材料的研究。本研究考虑材料EN19,并在不同工况下验证其强度性能。在最大弯矩和最大扭矩条件下,对EN19曲轴进行了解析设计计算、三维建模和分析。在Creo参数化软件和Ansys软件中分别进行了三维建模和分析。曲轴的压应力、冯-米塞斯应力、剪切应力和变形均在允许范围内。结果表明,经济型材料EN19能够满足全强度要求,可作为曲轴的替代材料之一。
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引用次数: 0
The Advantages of Fuzzy Control for Heat Pumps Systems 热泵系统模糊控制的优点
IF 1.3 Q2 Engineering Pub Date : 2023-07-07 DOI: 10.3311/ppme.22687
R. Sánta, J. Simon, L. Garbai
Application of fuzzy control has been observed in various engineering fields due to its ability to handle uncertainties and non-linearities. In this study, the advantages of using fuzzy control in heat pump systems are being investigated. Specifically, the performance of a heat pump system with a conventional proportional-integral-derivative (PID) controller is being compared to that of a heat pump system with a fuzzy logic controller. It has been demonstrated by the results that the fuzzy control-based heat pump system offers better performance in terms of energy efficiency, temperature control, and overall system stability. This study contributes to the understanding of the potential benefits of fuzzy control-based heat pump systems and provides a foundation for further research in this area.
模糊控制由于具有处理不确定性和非线性的能力,在各种工程领域得到了广泛的应用。本研究探讨了模糊控制在热泵系统中的优点。具体来说,将采用传统比例-积分-导数(PID)控制器的热泵系统与采用模糊逻辑控制器的热泵系统的性能进行了比较。结果表明,基于模糊控制的热泵系统在能源效率、温度控制和整体系统稳定性方面具有更好的性能。本研究有助于了解基于模糊控制的热泵系统的潜在效益,并为该领域的进一步研究奠定了基础。
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引用次数: 0
Investigation of the Effect of Heat Treatment Time in Case of Recrystallization of Al99.5 热处理时间对Al99.5再结晶影响的研究
IF 1.3 Q2 Engineering Pub Date : 2023-06-30 DOI: 10.3311/ppme.22823
Dorottya Varga, A. Szlancsik
In this study the effect of heat treatment time was investigated in case of recrystallization of Al99.5 material samples. Two different type were manufactured based on the previously applied cold forming. 12% and 24% cold forming was applied to the samples before the heat treatment procedure, which was always at 570 °C and cooled in water. Six different heat treatment time were investigated, namely 5, 10, 30, 60, 120 and 240 minutes. After the recrystallization procedure the microstructure and the mechanical properties were determined. It was found that in the case of the 12% cold formed samples after 30-minute-long heat treatment there were still signs of the original microstructure, however it does not affect the mechanical properties. The yield strength and the ultimate tensile strength were independent of the heat treatment time; they were only dependent on the grain size which was expected. A strong dependency can be discovered between the elongation at break and the heat treatment time. A tangent hyperbolic function was fitted on the measured data, which showed that the asymptote was ~29% for both type of samples. This is a 25% increase compared to the 5-minute-long heat treatment time samples, and this value was reached after ~120 minutes. Another result was that the elongation at break dependency on the grain size is decreasing with increasing heat treatment time.
研究了热处理时间对Al99.5材料再结晶的影响。基于先前应用的冷成形,制造了两种不同的类型。热处理前分别对试样进行12%和24%的冷成形处理,热处理温度始终为570℃,并在水中冷却。研究了5、10、30、60、120和240分钟6种不同的热处理时间。再结晶后,测定了合金的显微组织和力学性能。结果表明,12%的冷成形试样经过30分钟的热处理后,仍有原始组织的痕迹,但不影响其力学性能。屈服强度和极限抗拉强度与热处理时间无关;它们只依赖于预期的晶粒尺寸。断裂伸长率与热处理时间之间存在很强的相关性。对实测数据拟合了正切双曲函数,结果表明两类样品的渐近线均为~29%。与5分钟的热处理时间样品相比,这增加了25%,并且在~120分钟后达到该值。随着热处理时间的延长,断口伸长率随晶粒尺寸的增大而减小。
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引用次数: 0
New Top Land Computing Method for Spiral Bevel Gears 螺旋锥齿轮顶面计算新方法
IF 1.3 Q2 Engineering Pub Date : 2023-06-09 DOI: 10.3311/ppme.22287
M. Várkuli, G. Bognár, J. Szente
In this study, we present two methods for determining the top land of bevel gears. One of them that can be found in the professional literature is based on the Tredgold's virtual cylindrical gear model and, corresponding to this, deals with a limited accuracy. The alternative method developed by us is based on a mathematical modelling of the manufacturing process and involves in the computing of the top land dimensions theoretically perfect surface models.
本文提出了确定锥齿轮顶角的两种方法。其中一个可以在专业文献中找到的是基于Tredgold的虚拟圆柱齿轮模型,与此相对应,处理有限的精度。我们开发的替代方法是基于制造过程的数学建模,并涉及计算理论上完美的表面模型的顶部陆地尺寸。
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引用次数: 0
Multi-Dimensional Bisection Method in HIL Environment: Stability and Chatter Prediction in Turning HIL环境下的多维平分法:车削稳定性和颤振预测
IF 1.3 Q2 Engineering Pub Date : 2023-05-16 DOI: 10.3311/ppme.19579
B. Béri, D. Bachrathy, G. Stépán
In turning operations, the harmful small-amplitude but high-frequency chatter vibrations are identified in hardware-in-the-loop (HIL) experimental environment by means of the application of a multi-dimensional bisection method. The dummy workpiece clamped to the real main spindle is excited by contactless electromagnetic actuators and the response of the workpiece is detected by laser-based sensors. According to the present and the stored previous positions of the rotating workpiece, the desired cutting force characteristic along with the surface regeneration effect can be emulated by means of a high-performance real target computer. While the conventional experimental results in the HIL environment identify the stability limits of the cutting operation accurately only in a high-resolution grid of the technological parameters, the embedded bisection method reduces significantly both the size of the required grid and the time duration of the measurement by path following the boundaries of the linear loss of stability. Based on this technique, the experimental stability boundary of the emulated turning process is presented in a wide range of spindle speeds.
在车削加工实验环境中,应用多维对分法识别了有害的小振幅高频颤振。利用非接触式电磁致动器对夹紧在真实主轴上的假工件进行激励,并利用激光传感器检测工件的响应。根据旋转工件的当前位置和存储的先前位置,利用高性能实靶计算机可以模拟所需的切削力特性以及表面再生效果。传统的HIL环境实验结果只能在高分辨率的工艺参数网格中准确地确定切割操作的稳定性极限,而嵌入式对分方法通过沿着线性稳定性损失边界的路径显著减少了所需网格的大小和测量的时间持续时间。在此基础上,给出了在大转速范围内模拟车削过程的实验稳定性边界。
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引用次数: 1
Improving Optical Damage Analysis of Knee Implants from an Engineering Perspective 从工程角度改进膝关节植入物的光学损伤分析
IF 1.3 Q2 Engineering Pub Date : 2023-04-18 DOI: 10.3311/ppme.21734
I. Nemes-Károly, G. Szebényi
In our studies we analyzed the wear and damages of 15 explanted total knee implants. For this purpose, we first reviewed the relevant literature, which showed that most of the available articles are rather medical and do not contain relevant information from an engineering point of view, and those that are relevant from an engineering point of view are rather outdated from today's point of view. Therefore, we have developed an optical damage analysis that can be used to filter out results that are relevant and comparable from an engineering point of view. Our damage analysis was based on an existing and well-established method, which is now outdated and therefore, its further development was highly justified. The developed optical damage analysis was then used to test our samples. We drew conclusions, and based on these conclusions, we suggested how to improve further the systems we investigated.
在我们的研究中,我们分析了15个全膝关节植入物的磨损和损伤。为此,我们首先回顾了相关文献,这些文献表明,大多数可用的文章都是相当医学的,不包含从工程角度来看的相关信息,而那些从工程角度来看相关的文章从今天的角度来看是相当过时的。因此,我们开发了一种光学损伤分析,可用于从工程角度过滤出相关和可比较的结果。我们的损害分析是基于现有的和完善的方法,现在已经过时,因此,它的进一步发展是非常合理的。然后使用开发的光学损伤分析来测试我们的样品。我们得出结论,并根据这些结论,我们建议如何进一步改进我们所调查的系统。
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引用次数: 0
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