CONTENTS

JOURNAL OF MACHINE ENGINEERING

o article: Innovative Metal Forming Technologies (Bartnicki J., Pater Z., Gontarz A., Tomczak J.),pp. 5-17
o article: Deformation of Aluminium Bronze by HPT and ECAP Methods (Gronostajski Z., Skubiszewski T., Zwierzchowski M.), pp. 18-28
o article: Thermal Modelling for Production of Hot Strip of Magnesium Alloy (Nam A., Prufert U., Kawalla R.), pp. 29-38
o article: Microstructure-Based Numerical Modelling of Manufacturing Processes of Nanolayered Materials (Muszka K., Madej L., Graca P., Stefanska-Kadziela M., Majta J.), pp. 39-52
o article: Microstructure Evaluations in Pearlitic Steels Wires Resulting from Modification of the Interoperation Annealing Process (Grygier D., Rutkowska-Gorczyca M., Jasinski R., Dudzinski W., Gershtein G.),pp. 53-62
o article: The Complex Computer System Based on Cellular Automata Method Designed to Support Modelling of Laminar Cooling Processes (Gołab R., Madej L., Pietrzyk M.), pp. 63-73
o article: Computer Software Tool for the Design of Optimal Thermal Cycles in the Continuous Annealing of DP Steels (Gorecki G., Madej L., Pietrzyk M.), pp. 74-83
o article: Computer Aided Development of the Innovative Incremental Forming Process (Szyndler J., Madej L., Grosman F.), pp. 84-93

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JOURNAL OF MACHINE ENGINEERING

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

INNOVATIVE METAL FORMING TECHNOLOGIES

Jarosław BARTNICKI¹, Zbigniew PATER¹, Andrzej GONTARZ¹, Janusz TOMCZAK^1
1Lublin University of Technology, Department of Computer Modelling and Metal Forming Technologies, Lublin, E-mail: j.bartnicki@pollub.pl

Abstract

In this paper the new metal forming technologies developed at Lublin University of Technology are presented. The team of Metal Forming and Numerical Modeling Department focus on finding new solutions for different parts manufacturing. Among them, the researchers were interested in rotational forming processes for full and hollow parts: cross wedge rolling, helical wedge rolling, rotary compression and rolling extrusion. Short descriptions of the chosen processes and realized research of them are shown.

Author Keywords :

metal forming, innovative processes, cross wedge rolling, helical wedge rolling, rotary compression, rolling extrusion

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

DEFORMATION OF ALUMINIUM BRONZE BY HPT AND ECAP METHODS

Zbigniew GRONOSTAJSKI¹, Tomasz SKUBISZEWSKI¹,Maciej ZWIERZCHOWSKI^1
1Wroclaw University of Technology, Institute of Production Engineering and Automation, Poland

Abstract

Aluminium bronzes BA1032 having a multiphase microstructure, is low-deformable materials with strength close to that of high-strength steels. The influence of high-pressure torsion (HPT) and equal channel angular pressing (ECAP) on aluminium bronze structure was presented. The HPT method was found to be unsuitable for the processing of the investigated aluminium bronzes. The studies have indicated that it is possible to deform multiphase aluminium bronzes BA1032 in the ECAP process at a temperature of 400-500°C. The deformation of the bronzes at lower temperatures encounters some difficulties - cracks appear which make repeated ECAP impossible.

Author Keywords :

aluminium bronzes, ECAP,strain, microstructure, grain size

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

THERMAL MODELLING FOR PRODUCTION OF HOT STRIP OF MAGNESIUM ALLOY

Alexander NAM¹, Uwe PRUFERT²,Rudolf KAWALLA^1
1Institute of Metal Forming, Technical University Bergakademie Freiberg, Germany and Department of Plastic Deformation of Special Alloys, National University of Science and Technology MISIS, Moscow, Russia, E-mail: aleksandr.nam@imf.tu-freiberg.de
²Institute of Numerical Mathematics and Optimisation, Technical University Bergakademie Freiberg, Germany

Abstract

The paper deals with a thermal modelling of a magnesium coil in the magnesium strip production. The magnesium coil heating is the preparation step for the magnesium hot strip rolling and occurs in the special air circulating furnace. The cooling of the coil takes place on the several steps such as a transport of coil after heating from the furnace to a mill coiler. The aim of the work is to develop a tool to accurately simulate the temperature distribution within coil during the magnesium coil heating in the furnace. The major thermal properties for material and furnace were determined indirectly based on experimental data. Simulation results are compared to data obtained from experimental trials.

Author Keywords :

magnesium coil heating, non-linear heat transfer, numerical simulation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

MICROSTRUCTURE-BASED NUMERICAL MODELLING OF MANUFACTURING PROCESSES OF NANOLAYERED MATERIALS

Krzysztof MUSZKA¹,Lukasz MADEJ¹, Paulina GRACA¹,Monika STEFANSKA-KADZIELA¹, Janusz MAJTA^1
1AGH University of Science and Technology, Cracow, Poland, E-mail: muszka@agh.edu.pl

Abstract

Recent development in the field of numerical modelling of innovative manufacturing processes, in which nanolayered materials can be produced, is presented in the paper. Combination of the Angular Accumulative Drawing, continuous wire drawing and wire flattening were used to produce thin nanolayers that will be used for subsequent production of nanolayered metal strips using Accumulative Roll Bonding process. Proposed methodology combines microstructural aspects of deformation such as strain-induced precipitation processes and development of dislocation substructures. Additionally, multiscale modelling approach based on the 3D Digital Materials Representation was utilized to support experimental research and to investigate inhomogeneous material behaviour during deformation. Proposed methodology provides a possibility of forming materials, which are e.g. difficult to form in a conventional manner. Advantages and limitations of the proposed model are summarized and discussed with respect to its potential application to precipitation strengthened bcc nanolayered materials.

Author Keywords :

nanolayered steel, severe plastic deformation, FEM modelling

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

MICROSTRUCTURE EVALUATIONS IN PEARLITIC STEELS WIRES RESULTING FROM MODIFICATION OF THE INTEROPERATION ANNEALING PROCESS

Dominika GRYGIER¹, Malgorzata RUTKOWSKA-GORCZYCA¹,Robert JASINSKI¹,Wlodzimierz DUDZINSKI¹,Gregory GERSHTEIN^2
1Wroclaw University of Technology, Division of Materials Science, Welding and Strength of Materials, Poland, E:-mail: dominika.grygier@pwr.edu.pl ²Leibniz Universität Hannover, Institute of Materials, Garbsen, Germany

Abstract

Pearlitic steels containing from some 0.8 to 0.95% C belong to the group of unalloyed steels of the quality class destined for cold drawing or rolling. At the same time, the steels are characterised with particularly low share of non-metallic inclusions and limited contents of chromium and nickel, which extend the pearlite reaction time. The pearlitic steel in the annealed state has the highest strength in relation to other unalloyed steels, therefore she have found application mainly as wire rods for springs, wires for car tire reinforcement and cables. However one of the issues widely discussed in literature is cracking of pearlitic steel subjected to plastic working, caused by high brittleness of the lamellar precipitations of hard cementite. This issue is extremely important because it affects significantly reduce fatigue strength. The paper presents proposals to modify the process of interoperation annealing in order to eliminate this problem.

Author Keywords :

pearlitic steel,cold drawing, cold rolling tempering, annealing

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

THE COMPLEX COMPUTER SYSTEM BASED ON CELLULAR AUTOMATA METHOD DESIGNED TO SUPPORT MODELLING OF LAMINAR COOLING PROCESSES

Rafal GOLAB¹, Lukasz MADEJ¹, Maciej PIETRZYK^1
1AGH University of Science and Technology, Faculty of Metals Engineering and Industrial Computer Science, Cracow, Poland, E:mail: rgolab@agh.edu.pl

Abstract

The user friendly computer system that have the capability of modelling material behaviour both at the macro and micro scales was developed in this work. The system was designed to predict microstructure evolution during phase transformation in laminar cooling conditions with the use of the multi scale cellular automata finite element (CAFE) model. The finite element (FE) part is based on the conventional Fourier type equation and is used to predict macroscopic temperature distribution. This is an input for the micro scale cellular automata (CA) model of austenite-ferrite phase transformation. To facilitate the research, proposed micro scale CA model was implemented within developed universal object-oriented programming framework CAF. Description of major assumptions and functionality of the developed numerical system including efficient Graphical User Interface (GUI) is presented in the paper. The intuitive visualization of data obtained in different length scales facilitates work with the software.

Author Keywords :

cellular automata, finite element method, cooling process

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

COMPUTER SOFTWARE TOOL FOR THE DESIGN OF OPTIMAL THERMAL CYCLES IN THE CONTINUOUS ANNEALING OF DP STEELS

Grzegorz GORECKI¹, Lukasz MADEJ¹, Maciej PIETRZYK^1
1AGH University of Science and Technology, Department of Applied Computer Science and Modelling, Cracow, Poland, E-mail: ggorecki@agh.edu.pl.

Abstract

The objective of the paper was development of the software tool, which can be used to design the best continuous annealing technology for DP steels in a fast and efficient way. The model of phase transformations during heating and cooling stages, which is the basis of this tool, is described briefly. Results of identification and validation of the model are presented, as well. Due to complex thermal cycles in the continuous annealing process and large number of the design variables, selection of the optimal technology is difficult. It is expected that the developed model will help to evaluate various technological variants and to compare them. To make this procedure more efficient, the user friendly software was developed. Basic principles and features of this tool are presented in the work. The main functionalities of the software compose simulation of phase transformations during thermal cycles and capability to apply simulations to design the best technological variant. Beyond this a data base, which stores material and technological information for all previously analysed cases, is included in the developed software. Graphical user interface is added to make the software easily accessible and user friendly.

Author Keywords :

DP steels, continuous annealing, virtual process

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

COMPUTER AIDED DEVELOPMENT OF THE INNOVATIVE INCREMENTAL FORMING PROCESS

Joanna SZYNDLER¹, Lukasz MADEJ¹, Franciszek GROSMAN^2
1AGH University of Science and Technology, Cracow, Poland, E-mail: joanna.szyndler@agh.edu.pl
²Silesian University of Technology, Gliwice, Poland

Abstract

Computer aided design of innovative incremental forming process dedicated to manufacturing integral elements for aerospace industry is the main aim of the present work. Description of the proposed incremental forging idea as well as details of the developed numerical models are presented within the paper. First, a simple model of a single anvil indentation was created to evaluate material behaviour under different pressing depths. Then a complete numerical model of developed incremental forming press was proposed. Finally, obtained results in the form of strain distribution and recorded forging loads are presented and compared with results from conventional forming model.

Author Keywords :

incremental forming,integral elements,numerical modelling

JOURNAL OF MACHINE ENGINEERING

o article: Assessment of Friction Incorporating Tool Wear Effect (Grzesik W., Zak K.), pp. 5-15
o article: 3D FEM Simulations and Experimental Studies of The Turning Process of Inconel 718 Superalloy (Nieslony P., Grzesik W., Zak K., Laskowski P.), pp. 16-26
o article: Finite Element Modelling of Burr Formation in Metal Cutting (Pres P., Skoczynski W., Stembalski M.), pp. 27-37
o article: ILlumination for Chatter Mark Detection Using Machine Vision (Szydlowski M., Powalka B., Berczynski S.), pp. 38-46
o article: Influence of Grinding Conditions on the Topographic Characteristic of Machined Surfaces (Zak K.), pp. 47-56
o article: Development of Polishing Technology Using Heat for Mirror-Like Surface of Aluminum (Takahashi S., Tanabe I., Fukuda N.), pp. 57-68
o article: Development of Perfectly Design System Using Taguchi Methods (Sakamoto H., Tanabe I., Takahashi S.), pp. 69-80
o article: Milling Tool Deformation Caused by Heating During the Cutting Process (Moravek M., Burian D., Brajer J., Vyroubal J.), pp. 81-92
o article: Milling Tools for Cutting Of Fiber-Reinforced Plastic (Kolar P., Masek P., Zeman P.), pp. 93-103
o article: On Use of Acoustic Emission in Monitoring of Under and Over Abrasion During a Water Jet Milling Process (Mikler J.), pp. 104-115
o article: A Service-Oriented Reconfigurable Process Monitoring System - Enabling Cyber Physical Systems (Morgan J., O'Donell G. E.), pp. 116-129

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JOURNAL OF MACHINE ENGINEERING

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

ASSESSMENT OF FRICTION INCORPORATING TOOL WEAR EFFECT

Wit GRZESIK¹, Krzysztof ZAK^1
1Opole University of Technology, Faculty of Mechanical Engineering, Poland

Abstract

This paper compares friction for orthogonal and non-orthogonal models developed for chamfered ceramic tools with a large negative rake angle. The new non-orthogonal friction model was tested for the machining of spheroidal cast iron (SCI) using coated nitride ceramic inserts. Friction coefficients were determined on the rake and flank face for fresh and worn ceramic inserts using the values of force components recorded during tool wear tests at different cutting speeds. In particular, the friction and normal forces acting on the rake and flank faces were computed. It was revealed that friction coefficients at the tool-chip and tool-workpiece interfaces change substantially with the tool wear progress and differ from that determined for orthogonal friction model.

Author Keywords :

friction, wear, cutting, silicon nitride ceramic tool, spheroidal cast iron

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

3D FEM SIMULATIONS AND EXPERIMENTAL STUDIES OF THE TURNING PROCESS OF INCONEL 718 SUPERALLOY

Piotr NIESLONY¹, Wit GRZESIK¹,Krzysztof ZAK¹, Piotr LASKOWSKI^2
1Opole University of Technology, Faculty of Mechanical Engineering, Poland
²Rzeszow University of Technology, Poland

Abstract

This paper is focused on the finite element analysis of machining of Inconel 718 superalloy in a non-orthogonal (3D) turning process. The cutting experiments were carried out on the cylindrical workpiece of Inconel 718 with the cutting speed of 60-90 m/min, the feed rate of 0.1 mm/rev and different depths of cut. The FEM simulations include the average and maximum interface temperatures, the resultant cutting force and its three components and the chip thickness obtained for the 3D turning process. The simulation results were compared with experimental data obtained in the non-orthogonal process. It was found that the experimental values of the cutting forces are underestimated (about 23-30%) in relation to the FEM simulation data. Additionally, it was noted that the cutting depth has a significant effect on the average interface temperature only when using a non-orthogonal turning process.

Author Keywords :

2D and 3D FEM simulation, cutting process, Inconel 718

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

FINITE ELEMENT MODELLING OF BURR FORMATION IN METAL CUTTING

Pawel PRES¹, Waclaw SKOCZYNSKI¹,Marek STEMBALSKI^1
1Wroclaw University of Technology, Institute of Production Engineering and Automation, Poland,

Abstract

The paper presents a two-dimensional FEM model of burr formation in metal cutting. Abaqus/Explicit software was used for the build of the model. The workpiece geometry, the tool and the cutting parameters were modelled. Physical properties and the method of deformation and fracture of the workpiece material is described using Johnson Cook's constitutive law and the ductile damage criterion. The simulation of the edge formation process during orthogonal cutting was carried out for different depths of cut and cutting speeds. The results of these simulations allowed the verification of the FEM model. The components of the resultant cutting force measured during the actual cutting process with the values of these forces determined based on FEM simulation of this process were compared. The geometry of burrs formed during the actual and simulated the edge forming process was assessed. The analysis showed that the FEM model built enabled a correct prediction of the shape of the workpiece edge and the estimation of geometric features of the edge.

Author Keywords :

orthogonal cutting, burr, FEM simulation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

ILLUMINATION FOR CHATTER MARK DETECTION USING MACHINE VISION

Michal SZYDLOWSKI¹, Bartosz POWALKA¹,Stefan BERCZYNSKI^1
1West Pomeranian University of Technology Szczecin, Szczecin, Poland

Abstract

Authors of this research present a new method for image acquisition using special illumination for milled surfaces. The presented method uses special light and camera setup to reveal chatter marks on processed surfaces. After the acquisition the images are digitally processed using a method based on Continuous Wavelet Transform. A milling experiment has been preformed for validation of the methods. The biggest advantage of this method is that it doesn't have to be manually set like other image processing methods used in chatter detection.

Author Keywords :

inspection, chatter detection,image processing, wavelet transform

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

INFLUENCE OF GRINDING CONDITIONS ON THE TOPOGRAPHIC CHARACTERISTIC OF MACHINED SURFACES

Krzysztof ZAK^1
1Opole University of Technology, Faculty of Mechanical Engineering, Poland

Abstract

This paper compares the ability of grinding processes to enhance functional properties of the surface textures produced. The main objective of such a comparison is to facilitate the decision about precision grinding operations. The experimental study performed includes two grinding operations using electro-corundum Al2O3 and CBN wheels. For this purpose, the topographic features of ground surfaces with the Sa roughness parameter of about 0.2?m were compared. Apart from the set of 3D roughness parameters, the frequency, fractal, wavelet and motif characteristics were analyzed.

Author Keywords :

surface texture, surface roughness, hard machining, grinding

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

DEVELOPMENT OF POLISHING TECHNOLOGY USING HEAT FOR MIRROR-LIKE SURFACE OF ALUMINUM

Satoshi TAKAHASHI¹, Ikuo TANABE²,Naoki FUKUDA^2
1Nagaoka University of Technology, Technical staff, Center for Integrated Technology Support, Nagaoka, Japan
²Nagaoka University of Technology, Dept. of Mechanical Engineering, Nagaoka, Japan

Abstract

Recently, high efficient solar power generation is required because eco-awareness is increasing. High efficient generation becomes possible by focusing sunlight on electric generating element, i.e. CPV (Concentrator photovoltaic). Although the concentrator is used for focusing sunlight, it demands large spherical surface with high solar reflectance, fine accuracy and lightweight. Aluminum is considered as suitable material for concentrator. However, mirror-like processing on large spherical surface is very difficult. Therefore, new polishing technology for aluminum was developed and evaluated in this paper.Main objective is to obtain high solar reflectance by improving surface roughness. As a trial study, workpiece was not large spherical but small and flat. Firstly, the polishing tool which attached polishing cloth was developed.Optimum polishing cloth for tool was investigated by trial and error approach. When workpiece was heated before starting polishing, a number of oxides were adhered to polishing cloth and surface roughness was improved efficiently.Then optimum polishing condition was decided by using design of experiments method. Finally, solar reflectance on polished surface was measured and evaluated. It is concluded from these results that (1) the developed polishing technology was effective for processing the mirror-like surface on the surface of aluminum, (2) 82% solar reflectance was obtained with developed polishing technology by improving surface roughness of workpiece.

Author Keywords :

polishing, aluminium, mirror-like surface,solar power, generation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

DEVELOPMENT OF PERFECTLY DESIGN SYSTEM USING TAGUCHI METHODS

Hideki SAKAMOTO¹, Ikuo TANABE²,Satoshi TAKAHASHI^3
1Nagaoka University of Technology, Dept. of Information Science and Control Engineering, Japan
²Nagaoka University of Technology, Dept. of Mechanical Engineering, Japan
³Nagaoka University of Technology, Educational affairs section, Mechanics and Machinery Group, Japan

Abstract

As swift development with low cost was required for the manufacturing in industry, CAE simulation was used to predict the result of the design process, and Taguchi methods was used to decide optimum conditions for minimizing the dispersion.In this study, the perfectly design system without trial production using CAE and Taguchi methods was developed and evaluated. Software for original Taguchi methods and software for productivity management were firstly created, these softwares were combined with established CAE, and software package was developed for estimating the optimum combination of design parameters. Then the quality and the functionality were advanced to gain the optimum condition for the maximum profit considering the function of the grading of products, the delinquent charge and the loss function in the quality engineering based on the developed software. The research results are summarized as follows. (1) Perfectly design system without trial production using Taguchi methods was developed for calculations of the grading products, adding the delinquent charge and the loss function. (2) The evaluation with Kami-copter contributes to the profit evaluation of the grading; the delinquent charge and the loss function with high dimensional accuracy and is evaluated effective on industry.

Author Keywords :

Taguchi methods, production, management,optimum condition, innovation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

MILLING TOOL DEFORMATION CAUSED BY HEATING DURING THE CUTTING PROCESS

Martin MORAVEK¹, David BURIAN¹,Jan BRAJER¹,Jiri VYROUBAL^1
1Research Center of Manufacturing Technology, Faculty of Mechanical Engineering, The Czech Technical University in Prague

Abstract

The presented paper describes an experiment dealing with the deformation of a milling tool caused by heating during the cutting process. Based on the literature review an experimental procedure is designed to simulate heating of the milling tool during machining. The experimental heating of the milling tool is realized using a laser beam. The frequency of laser radiation and the length of each pulse are selected in order to simulate the real cutting process. The output power of the laser radiation is 10W or 20W. During the experiment deformation and temperature of the tool are measured. In the second part of the presented article an experiment is carried out investigating the heating and deformation of the milling tool during real machining of an aluminium alloy. The experiment consists of several test cycles, when a different amount of material is removed. Deformations of the tool and also of the machine tool are measured immediately after milling, and during cooling to ambient temperature. The results clearly show that there is a significant temperature rise of the milling tool during the cutting process, which mainly causes milling tool extension in the axial direction. The conclusion of the experiment is that the thermal deformation of the milling tool during machining cannot be neglected, as it can also be a source of certain errors.

Author Keywords :

milling tool, laser beam, process, thermal distortions

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

MILLING TOOLS FOR CUTTING OF FIBER-REINFORCED PLASTIC

Petr KOLAR¹, Petr MASEK¹,Pavel ZEMAN^1
1Czech Technical University in Prague, Research Center of Manufacturing Technology, Prague, Czech Republic,

Abstract

Composites with thermoplastic matrix are used in a wide range of applications. Their production and application volume grows every year. The need for precision machining of a near-net-shape workpiece is a topical subject, which concerns many cutting tool developers. The main challenge lies in the combinations of the long tool life and perfectly machined surface of composite workpiece without the burrs or delamination. The fulfilment of these two options needs using of the specific cutting geometry and very stiff and solid material of the cutting tool which is resistant against the abrasion of the filament. This paper presents a case study for comparison of cutting tools for edge trimming operations. The burr size and the tool lifetime were evaluated for milling of two types of fibre reinforced thermoplastic composite materials: PPS/C and PEEK/C. The total machining costs were computed for specific cases.

Author Keywords :

thermoplastic composite, fibre, milling, PCD toolscemented carbide tools

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

ON USE OF ACOUSTIC EMISSION IN MONITORING OF UNDER AND OVER ABRASION DURING A WATER JET MILLING PROCESS

Jerzy MIKLER^1
1The Royal Institute of Technology, Stockholm, Sweden

Abstract

Water jet milling process is a new emerging technology with many interesting applications. Low cutting forces, no thermal distortion, process flexibility and ability to machine difficult to cut materials make it very attractive for many technological operations. However, its wider application is hindered by lack of proper solutions of process monitoring that would allow accurate control of the material removal process. The research contributions so far focused on use of acoustic emission, thus the purpose of this paper is an evaluation of the proposed strategies and analysis of applicability of acoustic emission for this purpose. An extensive amount of AE data was collected during waterjet machining with various feed rates, abrasive flows, and pump pressures, and analyzed with the aim to determine whether there exists any feature of the AE signal correlated with under- and over abrasion. Monitoring and control of removal rate is possible only if it is possible to discriminate between AE signal samples originating from different states of the abrasive process. In this paper I present results based on extensive one-way ANOVA study of the AE samples, showing, that the standard AE signal features proposed in the literature - the energy and statistics of the AE signal do not allow such discrimination, and are not suitable to monitor abnormalities of the abrasive process. The research covers also principle component analysis of the AE signal energy performed in the aim to study if there exists any subset of the energy allowing better discrimination between the investigated process states.

Author Keywords :

water jet abrasive milling, acoustic emission, signal analysis, water jet abrasive process control

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

A SERVICE-ORIENTED RECONFIGURABLE PROCESS MONITORING SYSTEM - ENABLING CYBER PHYSICAL SYSTEMS

Jeff MORGAN¹, Garret E. O'DONNELL^1
1Mechanical and Manufacturing Engineering Department, Trinity College Dublin, Dublin 2, Ireland

Abstract

Communication is an essential requirement for collaborative manufacturing systems. However the diversity of communication media and protocols in machine tools, automation equipment, and associated proprietary software, presents a challenge for enabling capable, extensible and re-configurable process monitoring systems. Additionally, as process control systems evolve from centralised hierarchical structures to decentralised heterarchical communities, enabling media and tools are required to provide interoperability between systems and subsystems. The focus of this research is to introduce a manufacturing decentralised process monitoring architecture that utilises a service-oriented architecture framework for network-wide dynamic data acquisition and distribution. The system design is created using a combination of service-oriented architecture topology and technical modelling. Service-oriented communication structure and capability is given particular focus, resulting in a comparative study of message structures and communication speeds. The resultant system is modular in structure, reconfigurable, network-distributable, interoperable, efficient, and meets real-time requirements.

Author Keywords :

communication, manufacturing system, process monitoring, decentralisation

JOURNAL OF MACHINE ENGINEERING

o article: Development of the modelling and numerical simulation of the thermal properties of machine tools (Jedrzejewski J., Kwasny W., Kowal Z., Winiarski Z.), pp. 5-20
o article: Coupled modelling for machine tool structural optimization (Sulitka M., Sindler J., Susen J.), pp. 21-34
o article: Development on technique regarding change of resonance frequency on machine tool for optimization of cutting condition (Da Cruz J. R., Tanabe I., Inoue Y.), pp. 35-47
o article: Advanced open CNC system with in process tool path compensation (Hascoet J.-Y., Rauch M.), pp. 48-57
o article: On counter measure of vibration for machine using alkaline water with polymer (De Sousa Gama V., Tanabe I., Takahashi S.), pp. 58-70
o article: Development of immersed machine tool and machining in the strong alkaline water for reduction of CO2 (Da Cruz J. R., Tanabe I., Sakaguchi N.), pp. 71-82
o article: Amplified Piezo Actuator APA® with viscoelastic material for machine tool semi-active damping system (Kras A., Bourgain F., Claeyssen F.), pp. 83-96
o article: A device for the experimental investigation of surface contact under load (Maciolka P., Jedrzejewski J., Grochowski M.), pp. 97-112
o article: Influence of filling type on strength of parts manufactured by Fused Deposition Modelling (Gorski F., Wichniarek R., Kuczko W.), pp. 113-125
o article: The influence of orientation of segmented die on clinch joints mechanical properties (Kaczynski P., Bartczak B.), pp. 126-136

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JOURNAL OF MACHINE ENGINEERING

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

DEVELOPMENT OF THE MODELLING AND NUMERICAL SIMULATION OF THE THERMAL PROPERTIES OF MACHINE TOOLS

Jerzy JEDRZEJEWSKI¹, Wojciech KWASNY¹, Zbigniew KOWAL¹, Zdzislaw WINIARSKI^1
1Wroclaw University of Technology, Faculty of Mechanical Enginering, Wroclaw, Poland

Abstract

This paper highlights the need for the holistic modelling of the thermal properties of machine tools to provide a good basis for the effective aiding of machine tool design and optimization. A brief history of this modelling and the idea of accurate modelling and its experimental verification are presented. Examples of the holistic modelling of drive units both isolated from the machine tool and interconnected with its structure are provided.

Author Keywords :

machine tool, modelling, numerical analysis, thermal properties

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

COUPLED MODELLING FOR MACHINE TOOL STRUCTURAL OPTIMIZATION

Matej SULITKA¹, Jaroslav SINDLER¹, Jindrich SUSEN^1
1Czech Technical University, Faculty of Mechanical Engineering, RCMT, Prague,

Abstract

Effective machine tool design needs to take into account various kinematic configurations and possible combinations of structural parts, which meet the requirements of both the structural properties on one hand and technology and cost limitation on the other hand. Prior to a detailed developing a certain machine tool structure, an expert based decision on the machine tool conception needs to be performed. A high number of design variants should be explored in a short time. Fulfilling those demands leads to developing a machine tool modular models, enabling easy changing the kinematic configuration or various structural parts. In the paper the techniques for effective component coupling and model order reduction using mode truncation or Krylov subspace based technique for creating the machine tool coupled models are introduced. Case studies considering real machine tool structures are given. High quality of Krylov subspace reduction technique in connection with multipoint constraint surface coupling is shown both in terms of dynamic properties of the reduced multibody model and a very low time demands at the same time.

Author Keywords :

mutlibody model, component coupling, finite element, harmonic analysis

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

DEVELOPMENT ON TECHNIQUE REGARDING CHANGE OF RESONANCE FREQUENCY ON MACHINE TOOL FOR OPTIMIZATION OF CUTTING CONDITION

Junior Raimundo DA CRUZ¹, Ikuo TANABE², Yamato INOUE^2
1Nagaoka University of Technology, Dept. of Information Science and Control Engineering
²Nagaoka University of Technology, Dept. of Mechanical Engineering

Abstract

Establishment and selection of proper cutting condition can improve tool life and final cutting result. Cutting speed, feed speed, depth of cut and selection of tools are conditions of cutting that determined the cutting accuracy. However, when the optimum cutting condition with selected cutting speed coincides with machine resonance frequency, large vibration will occur. Consequently, even small periodic of driving forces can produce large amplitude vibrations. The simple technique to lower resonant frequency of machine tool was developed in previous research by using mixture of water and polymer with 6wt% concentration. As it was difficult to obtain damping ratio when the concentration is larger than 6wt%, therefore, the aim of this paper is to change machine resonant frequency for optimizing cutting condition by improving mixture concentration of water and polymer. It is concluded from the results that (1) By controlling machine tool resonance frequency enable cutting speed to be used for processing at its optimum cutting condition (2) New damping value of polymer mixed with water was presented, (3) Machine vibration reduced as resonance of machine was successfully avoided and surface roughness was also improved.

Author Keywords :

cutting condition, water, PEO, resonance, damping ratio, surface roughness

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

ADVANCED OPEN CNC SYSTEM WITH IN PROCESS TOOL PATH COMPENSATION

Jean-Yves HASCOET¹, Matthieu RAUCH^1
1Institut Recherche Communications et Cybernetique Nantes (IRCCyN), UMR CNRS 6597, Ecole Centrale Nantes, Nantes, France

Abstract

Despite several technical advances over the last decade, CNC controlled manufacturing still bases upon outdated paradigms: manufacturing data are generated and transferred along a heterogeneous and divided CAD/CAM/CNC data chain. The role of the NC controller is limited to the execution of tool paths generated beforehand and the possibility of online tool path adaptation is not planned in legacy NC controllers. In contrast, practical observations make this legacy approach quite inappropriate in an industrial framework. Significant geometrical variability is sometimes observed both prior and after milling in parts that belong to the same batch. In that context, the integration of online tool path adaptation strategies appears to be essential. In this paper, a methodology for correcting the tool path in real-time thanks to measurements provided by a laser scanner moving with the tool is introduced. The resulting local information is used to approximate the workpiece exact geometry by using a POD (Prosper Orthogonal Decomposition) snapshot technique and to adjust the path in accordance. This method has the great advantage of taking into consideration geometrical features such as curvature, twist but also additional parameters whose impact on the tool path is significant (unexpected initial setup of the part for example). This method has been implemented on the advanced CNC programming platform of the laboratory, which hosts in particular a high speed machining centre equipped with an open NC controller.

Author Keywords :

open NC controller, simulation,manufacturing, tool path, compensation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

ON COUNTER MEASURE OF VIBRATION FOR MACHINE USING ALKALINE WATER WITH POLYMER

Valerio DE SOUSA GAMA¹, Ikuo TANABE¹, Satoshi TAKAHASHI^2
1Nagaoka University of Technology, Dept. of Mechanical Engineering, Japan ²Nagaoka University of Technology, Educational affairs section, Mechanics and Machinery Group, Japan

Abstract

In the 21st century, as it is important to produce the products with high accuracy, high quality and eco-friendly, the most of manufacturers need several daring plans, unique ideas and new technologies. For example, in machine tool technology, restraint of vibration on the machine tool was required for high accuracy and quality, and several countermeasures using costly equipment and large quantity of electrical energy were used for the restraint, however those countermeasures are not enough. Therefore a countermeasure of vibration for machine tool using alkaline water with polymer was developed and evaluated. Polyethylene oxide was used for the polymer because of the low cost and the safety for health. Relationship between the mixed polymer in the alkaline water and the damping ratio were firstly investigated. And the optimum percentage of the polymer was decided for restraint of vibration on a machine tool. Then the damper structures using alkaline water with polymer were development, and the three dampers were set for restraint of vibration in the small machine tool; those are the support units, the vise and the head stock. Each damper was evaluated regarding noise and vibration on the machine tool and surface roughness on a work piece in the experiment. It is concluded from the results that; (1) the optimum percentage of the polymer for the damper was 6 wt%, (2) the damper structures using alkaline water with polymer were very effective for restraint of both noise and vibration on the machine tool and smoothly surface on the work piece.

Author Keywords :

vibration, machine tool, damper, polymer, alkaline water

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

DEVELOPMENT OF IMMERSED MACHINE TOOL AND MACHINING IN THE STRONG ALKALINE WATER FOR REDUCTION OF CO2

Junior Raimundo DA CRUZ¹, Ikuo TANABE², Nobuya SAKAGUCHI^2
1Nagaoka University of Technology, Dept. of Information Science and Control Engineering, ²Nagaoka University of Technology, Dept. of Mechanical Engineering

Abstract

Nowadays, eco-friendly manufacture has become common request in the manufacturing and production. The excessive electric power associated with the usage of large amount of oil for cooling and lubrication during machining can increase the CO2 emission which is considered as large problem for environment. On the other hand, the presence of the unwanted vibration during machine can affect the quality of production. The influence of immersed machine tool in strong alkaline water has been investigated in previous work for normal machine operation when no vibration occurred. In present research, the influence of immersed condition to the vibration of the bench lathe machine was investigated. Thermal deformations of the spindle when operating bench lathe coincide with machine resonances were also measured for evaluation of accuracy. The calculation of CO2 emission using immersed bench lathe machine was done by comparing with the conventional machining. It is concluded from the results that; (1) Excellent cooling efficiency can be achieved by using strong alkaline water added with microbubble, (2) Vibration of machine tool was reduced during immersed condition, (3) Thermal deformation of the bench lathe was very small despite no-forced cooling was used, (4) The large number of CO2 that released annually can be reduced by immersed of machine tool.

Author Keywords :

vibration, microbubble, strong alkaline water,immersed machine, thermal deformation, CO2 emission

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

AMPLIFIED PIEZO ACTUATOR APA® WITH VISCOELASTIC MATERIAL FOR MACHINE TOOL SEMI-ACTIVE DAMPING SYSTEM

Aleksander KRAS¹, Frederic BOURGAIN¹, Frank CLAEYSSEN^1
1Cedrat Technologies, 59 Chemin du Vieux Chene, Inovallée, 38246 Meylan, France,

Abstract

Modern machine tools must achieve a high precision for a better surface texture and higher flexibility for wide range of machining requirements. To fulfill these requirements, a semi-active damping system for a new generation of machine tools is proposed. The new concept is partially based on the Amplified Piezo Actuators APA® from CEDRAT Technologies. With these actuators, the dynamic behavior (stiffness and damping) of structural body components of machine tools can be controlled and adjusted to the optimum parameters. To reduce the transfer of vibrations through the active elements, a viscoelastic material was used. This article presents test results performed on the APA® with viscoelastic material. A significant reduction of the vibrational amplitude at resonance frequency was observed with additional material. The optimized quantity of viscoelastic material reduces the full stroke of the actuator only by 10 percent. At the same time, the viscoelastic material has red the tests performed on the machine tool showed significant surface texture improvement with use of the amplified piezoelectric actuator.

Author Keywords :

actuator, piezoelectric, viscoelastic material, machine tool

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

A DEVICE FOR THE EXPERIMENTAL INVESTIGATION OF SURFACE CONTACT UNDER LOAD

Pawel MACIOLKA¹, Jerzy JEDRZEJEWSKI¹, Miroslaw GROCHOWSKI^1
1Wroclaw University of Technology, Faculty of Mechanical Engineering, Wroclaw, Poland

Abstract

The structure of a device for the investigation of the contact deformations of flat surfaces under normal load is described. The conditions, for which the device must satisfy in order to ensure normal load are defined. Errors which may occur during the loading of a rough specimen, relating to the mechanical structure of the device, the specimen itself and the measuring systems, are estimated. Finally, the device is subjected to testing which includes specimen roughness measurements before and after loading, the loading and unloading of the specimens in the device and again measuring their roughness. The device developed herein can be characterisedby its vacuum mounting method of the specimen and also by the accurate and simple loading mechanism, i.e., movable member.

Author Keywords :

contact mechanics, asperity deformation, measurement

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

INFLUENCE OF FILLING TYPE ON STRENGTH OF PARTS MANUFACTURED BY FUSED DEPOSITION MODELLING

Filip GORSKI¹, Radoslaw WICHNIAREK¹, Wieslaw KUCZKO^1
1Katedra Zarządzania i Inżynierii Produkcji, Politechnika Poznańska, Poland,

Abstract

Fused Deposition Modelling technology allows to produce elements of very complex shapes without any additional tooling, which is why it has a broad range of industrial applications. Possibility of manufacturing parts with controlled degree of internal filling allows to shorten the manufacturing time and reduce volume of used material. The paper presents influence of layer filling type on part capability of carrying loads and economical coefficients of the manufacturing process. A problem of mechanical properties is important especially in case of elements used as functional prototypes. The paper presents methodology and results of experimental strength tests of samples with various types of internal filling. As a build material for test samples, ABS material was used. Composite samples were also used - the ABS matrix produced by Fused Deposition Modelling was filled with chemically hardening polyurethane resin in a process developed by authors. The samples were subjected to destructive testing and their strength properties were compared.

Author Keywords :

rapid prototyping, fused deposition modelling, strength tests

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

THE INFLUENCE OF ORIENTATION OF SEGMENTED DIE ON CLINCH JOINTS MECHANICAL PROPERTIES

Pawel KACZYNSKI¹, Bartosz BARTCZAK^1
1Wroclaw University of Technology, Institute of Production Engineering and Automation, Forming Processes, Engineering Department, Wroclaw, Poland

Abstract

This paper presents the results of joining of 1,5 mm thick high-strength steel grades including DP600 and TRIP. Joints were manufactured using C-type clinching machine. The diameter of the tools used in joining process was selected according to the thickness of sheet metal plates. Shearing tests of manufactured joints were conducted with the use of universal testing machine. Bottom thickness of clinches amounted to: 0.6mm, 0.8mm and 1.0mm. Afterwards the joints were cut through in three different planes: two orthogonal and one intermediate. The influence of orientation of die opening plane on the value of the thickness of the neck and the width of the undercut was analyzed. Those parameters are directly responsible for joints shear and transverse tensile strength. The distinct influence of the orientation of die opening plane on the investigated parameters were presented.

Author Keywords :

clinch joint, undercut, neck

JOURNAL OF MACHINE ENGINEERING

o article: Integration of Machining Mechanistic Models into CAM Software (Sarasua J. A., Cascon I.),pp. 5-17
o article: A Method of Identification of Complex Cutting Forces Acting in Unstable Cuutting Process (Bach P., Polacek M., Chvojka P., Burian D., Drobilek J.),pp. 18-28
o article: Both-Side Drive of a Ball Screw Feed Axis-Verification of the Theoretical Assumptions (Matyska V.),pp. 29-41
o article: Slot Machining of T16AL4V with Trochoidal Milling Technique (Patil P., Polishetty A., Goldberg M., Littlefair G., Nomani J. ),pp. 42-54
o article: Monitoring of Cutting Process in End Milling of Hard and Brittle Materials (Shimana K., Kondo E., Yoshidome A., Yamashita., Kawano Y.),pp. 55-64
o article: Chatter Suppression in a High Speed Magnetic Spindle by Adding Damping (Uriate L., Etxaniz I., Iturbe I., Zatarain M., Munoa J.),pp. 65-74
o article: Analytical Time-Domain Model for Tool Point Dynamics in Turning (Berglind L., Zliegert J.),pp. 75-94
o article: Integration of Discontinuous Milling Operations into the Flow Production of Sheet Metal Ptofiles (Schmidt S., Abele E.),pp. 95-102

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JOURNAL OF MACHINE ENGINEERING

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

INTEGRATION OF MACHINING MECHANISTIC MODELS INTO CAM SOFTWARE

Jon Ander SARASUA¹, Itxaso CASCON^1
1IK4-Tekniker, Advanced Manufacturing Technologies, Eibar, Spain

Abstract

Due to the increasing requirements of 5-axis machined products, collision simulation is not enough to ensure final quality. Hence, machining simulation models have been developed and commercialized in the last years. Mechanistic (semiempirical) models give approximate estimations of cutting forces during a whole tool path and, even not being very accurate, they are very useful to detect critical tool path steps, adapt cutting parameters and avoid machine overload. The main problem of most of these models is the fact that they work isolated from CAM programs and so, all the required information must be manually imported and refreshed. This paper presents the integration of an open programmed mechanistic model into commercial CAM software. CAM simulates material removal process, while the model calculates and plots cutting efforts, and power. The whole simulation is performed into CAM environment and any kind of change in the process (tool, material, tool path, cutting speed, etc.) is automatically transferred to the mechanistic model. In the end, the user gets a CNC code that ensures not only collision avoidance, but also adequate process conditions.

Author Keywords :

simulation, mechanistic, modelling,CAM integration

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

A METHOD OF IDENTIFICATION OF COMPLEX CUTTING FORCES ACTING IN UNSTABLE CUTTING PROCESS

Pavel BACH¹, Milos POLACEK¹,Petr CHVOJKA¹,David BURIAN¹,Jiri DROBILEK^1
1CTU, Faculty of Mechanical Engineering, RCMT, Prague, Czech Republic

Abstract

The calculations of machining stability limit currently known do not provide a precise prediction of chatter-free cutting conditions. The inaccuracy is probably caused by mathematical models of dynamic forces acting on the cutting process during unstable machining. These models need to be modified. A new analysis of experimental data measured by one of the authors, M. Poláček, in the 1968-1974 period, forecasted an existence of several dynamic forces, which are mutually phase-shifted, thus complex. This fact has not been thoroughly investigated previously. As the assumed forces cannot be calculated from any equations, they must be identified experimentally. This research paper proposes a theoretical method of an experimental identification of these forces. The new model is intended to be used in the future for the development of a more accurate calculation of stability diagram.

Author Keywords :

chatter, stability inaccuracy, complex cutting forces,forces identification

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

BOTH-SIDE DRIVE OF A BALL SCREW FEED AXIS – VERIFICATION OF THE THEORETICAL ASSUMPTIONS

Vojtech MATYSKA^1
1CTU, Faculty of Mechanical Engineering, RCMT, Prague, Czech Republic

Abstract

A parallel run of two drives connected in synchronous position control is mainly used in feed axes of gantry machine tools in order to compensate skewing of the gantry. Other reasons for using this concept include increasing rigidity, improving dynamics or achieving thermal symmetry. In most cases these applications use separate position measuring for each drive. Therefore both drives are equivalent in terms of regulation conditions. Due to the mainly used symmetrical design of the axis, the mechanical structure of drives and regulation schema connected to them are also identical. This paper aims to show the results of using two permanent magnet synchronous motors (PMSM) as two drives of the ball screw axis, which is typically and sufficiently controlled with only one drive. The following topics are discussed in this paper: changes in the mechanical structure and its dynamic behavior, effects of this concept on drive regulation and improvements in regulation parameters.

Author Keywords :

both-side drive, synchronous control, cascade regulation, eigen and locked-motor frequencies, eigenmodes

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

SLOT MACHINING OF TI6AL4V WITH TROCHOIDAL MILLING TECHNIQUE

Prasad PATIL¹, Ashwin POLISHETTY¹, Moshe GOLDBERG¹, Guy LITTLEFAIR¹,Junior NOMANI^1
1DEAKIN UNIVERSITY, School of Engineering, Waurn Ponds, Australia

Abstract

Titanium usage for aerospace growing day by day as application of titanium and its alloys covers wide range. Most of the aerospace components made up of wall structure involves lot of pocket slot milling since those components are monolithic components, eliminating need to manufacture multiple pieces for assembly into one final part. The increasing complexity of titanium parts used in aviation industry, increasing demand for productive manufacturing methods like trochoidal milling. This paper aims at evaluating its potential in slot milling for Ti6Al4V component by conducting experiments on 5-axis CNC machine. This study focuses on Productivity, Quality and Machine Tool Dynamics.

Author Keywords :

titanium, trochoidal, slot milling, TI6AL4V, machining

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

MONITORING OF CUTTING PROCESS IN END MILLING OF HARD AND BRITTLE MATERIALS

Kenji SHIMANA¹, Eiji KONDO², Ai YOSHIDOME¹, Shunichi YAMASHITA¹,Yoshihiro KAWANO^1
1Kagoshima National College of Technology, Department of Electronic Control Engineering, Kagoshima, Japan
²Kagoshima University, Graduate School of Science and Engineering, Kagoshima, Japan

Abstract

Glass materials have been widely used in optical components in recent years. The purpose of this study was to develop an effective method for real-time detection of the state of cutting tools used in end milling of hard brittle materials. Cutting tests were performed to identify parameters that are useful in monitoring micro tool wear in glass milling. A specific component of the cutting force was found to be related to the progression of tool wear. Furthermore, using fast Fourier transform (FFT) analysis, the peak amplitudes of the cutting forces were found to occur at a specific frequency.

Author Keywords :

glass milling, micromachining, brittle materials, end mill

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

CHATTER SUPPRESSION IN A HIGH SPEED MAGNETIC SPINDLE BY ADDING DAMPING

Luis URIARTE¹, Inigo ETXANIZ¹, Ion ITURBE¹, Mikel ZATARAIN²,Jokin MUNOA^2
1IK4-TEKNIKER, Mechatronics Dept., Eibar, Basque Country, Spain ²IK4-IDEKO, Dynamics & Control Dept., Elgoibar, Basque Country, Spain

Abstract

Magnetic bearings are used in several applications, but they didn’t succeed in the machine tool industry, due basically to thei low damping, with its associated low chatter free cutting capacity. This work shows the development of a high speed milling spindle supported on magnetic bearings with high chatter resistance. That is achieved by using control strategies which add damping to the bearings. Excitation by means of the magnetic bearings is used to identify its dynamic behaviour and to optimize the damping parameters. Finally the results of the industrial validation are presented; showing an increase of six times in the cutting capacity.

Author Keywords :

magnetic bearings, spindle,damping

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

ANALYTICAL TIME-DOMAIN MODEL FOR TOOL POINT DYNAMICS IN TURNING

Luke BERGLIND¹, John ZIEGERT^1
1UNCC, Faculty of Mechanical Engineering, Charlotte, NC, USA

Abstract

An analytical time domain solution is developed to model the dynamic response of a tool during a simple turning operation. The time domain solution developed in this paper relies on the superposition principal under the linear assumption to construct the time response of single mode, single degree of freedom cutting tool. The results from the analytical solution are compared with those generated using numerical time domain simulations and it is found that the two solutions converge as the time step used in the numerical simulation decreases.

Author Keywords :

chatter, turning, analytical model, time domain

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2014, Poland

INTEGRATION OF DISCONTINUOUS MILLING OPERATIONS INTO THE FLOW PRODUCTION OF SHEET METAL PROFILES

Sebastian SCHMIDT¹, Eberhard ABELE^1
1Institute of Production Management, Technology and Machine Tools (PTW), Technische Universität Darmstadt, Germany

Abstract

This paper is about the integration of discontinuous milling operations into the continuous flow production line of branched sheet metal profiles in an integral design. A major challenge is the non-existing possibility to clamp the work piece due to its constant feed. The machining "on the fly" itself is only possible through synchronizing the movement of the machine tools axes with the continuous feed of the sheet metal profile.

Author Keywords :

milling, HSC, continuous flow production