Editorial Board Vol. 16 No. 5 May 2017 Contents · K K Rajagopal M Chellamalai V Shanmugaraj V G Yoganath ... . Bibliography ... Annamalai, VE; Lakshminarayanan, AK

Contents Vol. 16 No. 5 May 2017

Technical Papers

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Editorial Board

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Bank: State Bank of India, Yeshwanthpur Branch, APMC Yard, BengaluruIFSC Code: SBIN0003297Nature of Account: Current AccountAccount No: 10521862015

Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same.

ChairmanS Satish Kumar

Technical Paper Review PanelK K RajagopalM ChellamalaiV ShanmugarajV G Yoganath S K Verma

EditorMallikarjun G

Editorial AssistantsShashi Rekha NMala RC

Editorial Advisory Committee

S UshaN BalashanmugamS Arumugasamy B R MohanrajDr. C K Srinivasa, Honorary Member

• Parametric optimization of friction stir lap welding of AA5083-AA6082 using multi criteria decision making method

Hema P, Yamini Priya P and Reddeiah M

3

• Bionics as an inspiration for machine tool structure - A review

S Syath Abuthakeer, S Revanth Kumar and R Monish Arvind 10

Patent Abstracts: Friction Stir Welding Method 16

Technology Trends 22

Select Bibliography: Friction Stir Welding 25

Calendar of Events 28

Photo Gallery: Vintage Machine: E W Bliss Co., Automatic Shearing Machine for Muck Bars, 1894

31

Manufacturing Technology Abstracts 32

Select Bibliography of Standards: Friction Stir Welding 56

IPR News: Govt extends Start-ups Intellectual Property Protection Scheme for 3 years till March 2020

58

Manufacturing Technology Today (MTT) Journal hosted Online @ "i-Scholar" digital library

URL: http://www.i-scholar.in/index.php/MTT/index

Bibliography

Manufacturing Technology Today, Vol. 16, No. 5, May 2017 25

SELECT BIBLIOGRAPHY: FRICTION STIR WELDING

1. Developing Empirical Relationship to Predict the Strength of Friction Stir Lap Welded Joints of AA2014-T6 Aluminum Alloy

Rajendran, C; Srinivasan, K; Balasubramanian, V; Balaji, H; Selvaraj, P [Manufacturing Technology Today, V 15, N 3, 2016, Starting page 12, 12 Pages] Rec. No: 110980

2. Predicting corrosion rate of weld nugget (Stir Zone) of friction stir welded dissimilar joints of aluminium – magnesium alloys

Kamal Jayaraj, R; Malarvizhi, S; Balasubramanian, V [Manufacturing Technology Today, V 15, N 4, 2016, Starting page 20, 9 Pages] Rec. No: 110979

3. Performance of plasma transferred Arc hard faced friction stir welding tools for joining AA7075-T6 aluminium alloy

Baskaran, A; Shanmugam, K; Balasubramanian, V [Manufacturing Technology Today, V 15, N 5, 2016, Starting page 17, 10 Pages] Rec. No: 111040

4. Influence of welding speed on tensile and impact properties of friction stir welded high strength low alloy steel joints

Ragu Nathan, S; Malarvizhi, S; Balasubramanian, V; Rao, AG [Manufacturing Technology Today, V 15, N 6, 2016, Starting page 15, 10 Pages] Rec. No: 110982

5. Prediction of unit process life cycle inventory (UPLCI) energy consumption in a friction stir weld

Shrivastava, Amber; Overcash, Michael; Pfefferkorn, Frank E [J of Manufacturing Processes, V 18, 2015, Starting page 46, 9 Pages] Rec. No: 110588

6. Friction stir lap joining of 2198 aluminum–lithium alloy with weaving and pulsing variants

Gibson, BT; Ballun, MC; Cook, GE; Strauss, AM

[J of Manufacturing Processes, V 18, 2015, Starting page 12, 11 Pages] Rec. No: 110580

7. Characterisation of tool shape and rotational speed for increased speed during friction stir welding of AA2024-T3

Trimble, D; O’Donnell, GE; Monaghan, J [J of Manufacturing Processes, V 17, 2015, Starting page 141, 10 Pages] Rec. No: 110656

8. Friction stir welding of copper alloys by PTA hardfaced tungsten carbide tools

Baskaran, A; Shanmugam, K; Balasubramanian, V [Manufacturing Technology Today, V 14, N 11, 2015, Starting page 3, 9 Pages] Rec. No: 111042

9. Developing empirical relationship to predict the strength of friction stir spot welded dissimilar joints of aluminum and magnesium alloys

Manickam, S; Rajendran, C; Balasubramanian, V [Manufacturing Technology Today, V 14, N 11, 2015, Starting page 12, 9 Pages] Rec. No: 110984

10. Effect of tool pin profiles on joint characteristics of under water friction stir welded AA2519-T87 aluminium alloy

Sree Sabari, S; Balasubramanian, V; Malarvizhi, S [Manufacturing Technology Today, V 14, N 11, 2015, Starting page 21, 8 Pages] Rec. No: 110985

11. Comparison between riveted joints and friction stir welded joints of AA2014 aluminum alloy

Rajendran, C; Srinivasan, K; Balasubramanian, V; Balaji, H; Selvaraj, P [Manufacturing Technology Today, V 14, N 12, 2015, Starting page 3, 6 Pages] Rec. No: 110986

12. Aluminum alloy foam core sandwich panels fabricated from die casting aluminum alloy by friction stir welding route

Friction stir welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material. Heat is generated by friction between the rotating tool and the workpiece material, which leads to a softened region near the FSW tool.

Bibliography

Manufacturing Technology Today, Vol. 16, No. 5, May 201726

Hangai, Yoshihiko; Kamada, Hiroto; Utsunomiya, Takao; Kitahara, Soichiro; Kuwazuru, Osamu; Yoshikawa, Nobuhiro [J of Materials Processing Technology, V 214, N 9, 2014, Starting page 1928, 7 Pages] Rec. No: 110460

13. Friction stir welding: Process, automation, and control

Gibson, BT; Lammlein, DH; Prater, TJ; Longhurst, WR; Cox, CD; Ballun, MC; Dharmaraj, KJ; Cook, GE; Strauss, AM [J of Manufacturing Processes, V 16, N 1, 2014, Starting page 56, 18 Pages] Rec. No: 109993

14. Experimental investigation on flexural behavior of friction stir welded high density polyethylene sheets

Azarsa, Ehsan; Mostafapour, Amir [J of Manufacturing Processes, V 16, N 1, 2014, Starting page 149, 7 Pages] Rec. No: 109987

15. Method for double-sided friction stir spot welding

Cox, Chase D; Gibson, Brian T; DeLapp, David R; Strauss, Alvin M; Cook, George E [J of Manufacturing Processes, V 16, N 2, 2014, Starting page 241, 7 Pages] Rec. No: 110113

16. Comparison of mechanical properties of pure copper welded using friction stir welding and tungsten inert gas welding

Lin, Jau-Wen; Chang, Hsi-Cherng; Wu, Ming-Hsiu [J of Manufacturing Processes, V 16, N 2, 2014, Starting page 296, 9 Pages] Rec. No: 110116

17. Fatigue crack growth in the welding nugget of FSW joints of a 6060 aluminum alloy

D’Urso, G; Giardini, C; Lorenzi, S; Pastore, T [J of Materials Processing Technology, V 214, N 10, 2014, Starting page 2075, 10 Pages] Rec. No: 110837

18. Friction stir welding assisted by electrical joule effect

Santos, Telmo G; Miranda, RM; Vilaça, Pedro [J of Materials Processing Technology, V 214, N 10, 2014, Starting page 2127, 7 Pages] Rec. No: 110845

19. Combined temperature and force control for robotic friction stir welding

Fehrenbacher, Axel; Smith, Christopher B; Duffie, Neil A; Ferrier, Nicola J; Pfefferkorn, Frank E; Zinn, Michael R [J of Manufacturing Sci & Engg: ASME Trans, V 136, N 2, 2014, Starting page 021007, 15 Pages] Rec. No: 110895

20. Measurement of tool-workpiece interface temperature distribution in friction stir

welding Fehrenbacher, Axel; Schmale, Joshua R;

Zinn, Michael R; Pfefferkorn, Frank E [J of Manufacturing Sci & Engg:ASME Trans, V 136, N 2, 2014, Starting page 021009, 8 Pages] Rec. No: 110893

21. Analytical bonding criteria for joint integrity prediction in friction stir welding of aluminum alloys

Gianluca Buffa; Sergio Pellegrino; Livan Fratini [J of Materials Processing Technology, V 214, N 10, 2014, Starting page 2102, 10 Pages] Rec. No: 110855

22. Simultaneous measurement of tool torque, traverse force and axial force in friction stir welding

Su, H; Wu, CS; Pittner, A; Rethmeier, M [J of Manufacturing Processes, V 15, N 4, 2013, Starting page 495, 6 Pages] Rec. No: 109749

23. Effect of hardening laws and thermal softening on modeling residual stresses in FSW of aluminum alloy 2024-T3

Sonne, MR; Tutum, CC; Hattel, JH; Simar, A; de Meester, B [J of Materials Processing Technology, V 213, N 3, 2013, Starting page 477, 10 Pages] Rec. No: 109546

24. Influence of tool shoulder geometry on properties of friction stir welds in thin copper sheets

Galvão, I; Leal, RM; Rodrigues, DM; Loureiro, A [J of Materials Processing Technology, V 213, N 2, 2013, Starting page 129, 7 Pages] Rec. No: 109543

25. Experimental analysis of friction stir forming for dissimilar material joining application

Lazarevic, Sladjan; Miller,Scott F; Li, Jingjing; Carlson, Blair E [J of Manufacturing Processes, V 15, N 4, 2013, Starting page 616, 9 Pages] Rec. No: 109682

26. Mechanical properties of friction stir processed AA6061 alloy by shear punch test

Elangovan, K; Vijayaragavan, S; Rohit, S; Mohammed Irfaan, F [Manufacturing Technology Today, V 12, N 5, 2013, Starting page 5, 9 Pages] Rec. No: 109629

27. Evaluation of micro structure and tensile shear load of friction stir spot welded automotive steel

Elangovan, K; Annamalai, VE; Lakshminarayanan, AK [Manufacturing Technology Today, V 12, N 8, 2013, Starting page 16, 6 Pages] Rec. No: 109631

28. Micro hardness variation studies for dissimilar

Bibliography


Friction Stir Welding of AA7075-T651 and AA6061-T651 related to Tool Pin Profiles

Ravikumar,S; Seshagiri Rao, V; Prakash,S [Manufacturing Technology Today, V 12, N 9, 2013, Starting page 14, 8 Pages] Rec. No: 109632

29. Joining of nano-composite using friction stir welding

Nitin Panaskar; Bhupesh K Ram; Abhay Sharma [Manufacturing Technology Today, V 12, N 10, 2013, Starting page 5, 6 Pages] Rec. No: 109633

30. Gap tolerance allowance and robotic operational window for friction stir butt welding of AA6061

Wanjara, P; Monsarrat, B; Larose, S [J of Materials Processing Technology, V 213, N 4, 2013, Starting page 631, 10 Pages] Rec. No: 109746

31. On the selection of constitutive laws used in modeling friction stir welding

Kuykendall, Katherine; Nelson, Tracy; Sorensen, Carl [Int J of Machine Tools & Manufacture, V 74, 2013, Starting page 74, 12 Pages] Rec. No: 109859

32. Torque, temperature and hardening precipitation evolution in dissimilar friction stir welds between 6061-T6 and 2014-T6 aluminum alloys

Jonckheere, Caroline; Meester, Bruno de; Denquin, Anne; Simar, Aude [J of Materials Processing Technology, V 213, N 6, 2013, Starting page 826, 12 Pages] Rec. No: 109860

33. Experimental investigation on friction stir welding of AA 6082 alloy using Taguchi technique.

Ravindra Reddy, P V R; Radhakrishna Prasad, P; Chandra Mohan Reddy, G; Sarotham Reddy, A; Srikanth, K [Manufacturing Technology Today, V 11, N 9, 2012, Starting page 5, 6 Pages] Rec. No: 108812

34. The Influence of friction stir welding process idealization on residual stress and distortion predictions for future airframe assembly simulations.

McCune, RW; Murphy, A; Price, M; Butterfield, J [J of Manufacturing Sci & Engg: ASME Trans, V 134, N 3, 2012, Starting page 031011, 9 Pages] Rec. No: 108770

35. Force generation during friction stir welding of AA2024-T3

Trimble, D; Monaghan, J; O’donnell, GE [CIRP Annals, V 61, N 1, 2012, Starting page 9, 4 Pages] Rec. No: 109172

36. Understanding the role of FSW process parameters on strength properties of ferritic stainless steel joints.

Lakshminarayanan, AK; Balasubramanian, V [Manufacturing Technology Today, V 10, N 2, 2011, Starting page 10, 9 Pages] Rec. No: 105738

37. Prediction of friction stir welding process parameters for joining aluminium alloys AA 7075-T651 and AA 6061-T651.

Ravikumar, S; Seshagiri Rao, V; Muruganandam, D; Shushil Lal Das [Manufacturing Technology Today, V 10, N 8, 2011, Starting page 3, 10 Pages] Rec. No: 108134

38. The identification of the key enablers for force control of robotic friction stir welding.

Longhurst, WR, Strauss, AM; Cook, GE [J of Manufacturing Sci & Engg: ASME Trans, V 133, N 3, 2011, Starting page 031008-1, 11 Pages] Rec. No: 108263

39. Understanding the material flow path of friction stir welding process using unthreaded tools.

Lorrain, O; Favier, V; Zahrouni, H; Lawjaniec, D [J of Materials Processing Tech, V 210, N 4, 2010, Starting page 603, 07 Pages] Rec. No: 106549

40. Experimental investigations on the influence of the position of plates in FSW for dissimilar aluminium alloys.

Kandasamy, J; Govindaraju, M; Hussain, Rajesham, S [Manufacturing Technology Today, V 9, N 7-8, 2010, Starting page 3, 8 Pages] Rec. No: 105555

41. Friction model for friction stir welding process simulation: Calibrations from welding experiments.

Assidi, M; Fourment, L; Guerdoux, S; Nelson, T [Int J of Machine Tools & Manufacture, V 50, N 2, 2010, Starting page 143, 13 Pages] Rec. No: 105607

42. Production of wire via friction extrusion of aluminium alloy machining chips.

Tang, W; Reynolds, AP [J of Materials Processing Technology, V 210, N 15, 2010, Starting page 2231, 7 Pages] Rec. No: 105727

43. Model relating tool torque and its associated power and specific energy to rotation and forward speeds during friction stir welding / processing.

Cui, S; Chen, ZW; Robson, JD [Int J of Machine Tools & Manufacture, V 50, N 12, 2010, Starting page 1023, 8 Pages] Rec. No: 105926 ◘

Events


NATIONAL

19 - 20 May 2017International Conference On Advances in Mechanical Engineering 2017-01Ponjesly College of Engineering, Nagercoil, Kanyakumari, TamilnaduContact: Tel: +919486118554 & +919486358554 Email: [email protected] Web: http://www.djicame.org

3 Jun 2017SARC-Intl Conf on Recent Development in Mechanical & Industrial Engineering (ICRDMIE)MysoreContact: South Asian Research Center-SARCTel: +91-8280047487 Email: [email protected] Web: http://sarc.net.in

3 Jun 2017ieeeforum - International Conference on Nanoscience & Nanotechnology (IC2N)Hotel Krishna Palace, 96/98, Sleater Road, Nana Chowk, MumbaiContact: ieeeforumEmail: [email protected] Web: http://ieeeconference.com

4 Jun 2017ITR- International Conference on Mechanical and Production Engineering ICMPE-2017JW Marriott Hotel, Plot no: 6, -B, Dakshin Marg, Sector 35, Chandigarh-160035Contact: ITR, Tel: +91-8280047487 Email: [email protected] Web: http://itresearch.org.in

08 - 10 Jun 2017International trade fair for automation in production and assemblyBombay Convention & Exhibition Centre BCEC, Western Express Highway, Mumbai, MaharashtraContact: Messe Frankfurt Trade Fairs India Pvt. Ltd.215 Atrium, B-Wing, 2nd Floor, C-420, Andheri Kurla Road, Andheri East 400093 MumbaiTel: +91 (0)22 61445900 Fax: +91 (0)22 61445999Email: [email protected] Web: www.tradefairdates.com

08 - 10 Jun 2017SPS Automation 2017-3rd EditionBombay Convention & Exhibition Centre, MumbaiContact: Messe Frankfurt Trade Fairs India Pvt Ltd, Gala Impecca, 5th Floor, Chakala, Andheri (E), Andheri Kurla Road, Mumbai 400093Tel: +91 22 6144 5900 Fax: +91 22 6144 5999Email: [email protected] Web: www.in.messefrankfurt.com

25 Jun 2017WRFER - International Conference on Mechanical & Production Engineering (ICMPE)Hotel Annamalai International, 479, Kamaraj Salai, Saram, Pondicherry - 605 013Contact: WRFER, Tel: +918280862844 Email: [email protected] Web: http://wrfer.org

25 Jun 2017Techhnoarete Intl - Intl Conf On Current Research In Electronics, Computer Science, Information Technology And Mechanical Engg (ICECSITME-17)The Avenue Regent, 39/2026, M. G. Road, Ernakulam, Kochi, Kerala 682017Contact: Technoarete International, Tel: +91-9040697662 Email: [email protected] Web: http://technoarete.com

25 Jun 2017IRF-Intl Conference on Civil, Mechanical, Biological and Medical Engineering (ICMBME - 2017)Hotel grand sarovar, A K Plaza; Goregaon West, Mumbai, Maharashtra 400062Contact: IRF, Tel: +91-8280047487 Email: [email protected] Web: http://irfconference.org

25 Jun 2017ITR- International Conference on Mechanical and Production Engineering ICMPE-2017Hotel Akshaya, Waltair Station Rd, Opp to DRM office, next to Manikanta sweets, Dondaparthi, VizagContact: ITR, Tel: +91-8280047487 Email: [email protected] Web: http://itresearch.org.in

30 Jun 2017ISETE-Intl Conf On Recent Innovations In

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INTERNATIONALElectrical, Electronics, Computer, Information, Communication & Mech Engg - ICRIEECICME-2017Hotel Siddhartha Inn, 90, Central Avenue, Near Agrasen Square, Gandhibagh, Nagpur, MaharashtraContact: ISETE, Tel: +91-9040697662 Email: [email protected] Web: http://isete.org

27 - 29 Jul 2017IMHLS - India Material Handling & Logistics ShowPragati Maidan Exhibition Center, Mathura Road, 110002, New DelhiContact: Reed Manch Exhibitions Ltd., 1st Floor, A 78, Sector -4, 201301 NoidaTel: +91 (0)120 4273921 Fax: +91 (0)120 4273922Email: [email protected] Web: www.reedmanch.com

28 - 31 Jul 20177th IMTOS-India Machine Tools Show 2017Pragati Maidan, New DelhiContact: K and D Communication Ltd.,CORPORATE OFFICE: 3rd Floor, Kailash-A, Sumangalam Society, Above HDFC Bank, Opp. Drive-In Cinema, Bodakdev, Ahmedabad, GujaratTel: +91-79-40048594 Fax: +91-79-40305602Email: [email protected], [email protected] Web: http://kdclglobal.com

28 - 31 Jul 2017India Machine Tools New Delhi: Intl trade fair for machine tools, material handling, robotics and automationPragati Maidan Exhibition Center, Mathura Road, 110002, New DelhiContact: K & D Communication Ltd., 4th Floor, Chinubhai House, 7-B Amrutbaug Society, AhmedabadTel: +91 (0)79 26469725 Fax: +91 (0)79 26403087Email: [email protected] Web: kdclglobal.com

04 - 06 Aug 2017International trade fair for wood and wood-processing industryChennai Trade Center, Poonamali High Road, 600010 Chennai, Tamil NaduContact: Business Live, 9G, RR Flats, Bharathi Nagar 1st Street, North Usman Road, ChennaiTel: +91 (0)44 28344851 Fax: +91 (0)44 28344852Email: [email protected] Web: www.businesslive.in

23 - 26 May 2017Trade fair for manufacturing machinery and technologyBEC Bilbao Exhibition Center, Ronda de Azkue 1, 48902 Barakaldo, Bizcay, Basque Country, SpainContact: Bilbao Exhibition Centre, Ronda de Azkue 148902 Barakaldo, SpainTel: +34 (0)94 4040000 Fax: +34 (0)94 4040001Email: [email protected] Web: www.bilbaoexhibitioncentre.com

24 - 27 May 2017ASsean International Machine Tools & Metalworking Technology ExhibitionPutra World Trade Center, 41, Jalan Tun Ismail, 50480 Kuala Lumpur, Kuala Lumpur, MalaysiaContact: Trade Link ITE Sdn Bhd, F-1-48, Jalan PJU 1A/347301 Petaling Jaya, MalaysiaEmail: [email protected] Web: www.tradelink.com.my

29 May - 02 Jun 2017European Society for Precision Engineering & NanotechnologyEast Midlands Conference Centre & Orchard Hotel, University Park, Beeston Ln., NG72RJ Nottingham, Nottingham, England, United Kingdom of Great Britain and Northern IrelandContact: European Society for Precision Engineering & Nanotechnology, Cranfield University Campus, Building 90, College Road, Cranfield, United Kingdom of Great Britain and Northern IrelandEmail: [email protected] Web: www.euspen.eu

30 May - 02 Jun 2017Fair for mouldingMesse Stuttgart, Messepiazza 1, 70629 Stuttgart, Baden-Wurttemberg, GermanyContact: Landesmesse Stuttgart GmbH, Messepiazza 170629 Stuttgart, GermanyTel: +49 (0)711 185600 Fax: +49 (0)711 185602440Email: [email protected] Web: www.messe-stuttgart.de

06 - 09 Jun 2017Trade fair for metallurgy, metal processing and foundry technology

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Poznan International Fair Grounds, Glogowska Street 14, 60734 Poznan, Greater Poland, PolandContact: Poznan International Fair Ltd., ul. Glogowska 1460734 Poznan, PolandTel: +48 (0)61 8692000 Fax: +48 (0)61 8692999Email: [email protected] Web: www.mtp.pl

13 - 16 Jun 2017Exhibition of the metal and metallurgical industryShanghai New International Expo Centre - SNIEC,2345 Long Yang Road Pudong Area, Shanghai, ChinaContact: Hannover Milano Fairs Shanghai Ltd.301 B&Q Pudong Office Tower 393 Yinxiao Road, Pudong 201204 Shanghai, ChinaTel: +86 (0)21 50456700 Fax: +86 (0)21 50459355Email: [email protected] Web: www.hmf-china.com

21 - 22 Jun 2017Regional trade fair for the manufacturing industry | regional FairMesse Kassel, Damaschkestr. 55, 34121 Kassel, Hesse, GermanyContact: Carl Hanser Verlag GmbH & Co. KG, Kolbergerstr. 22, 81679 Munich, GermanyTel: +49 (0)89 998300 Fax: +49 (0)89 984809Email: [email protected] Web: www.hanser.de

21 - 23 Jun 2017Trade fair for mechanical components and materials technologyTokyo Big Sight, 3-21-1 Ariake Kotu-ku, 135-0063 Tokyo, JapanContact: Reed Exhibitions Japan Ltd., 1-26-2 Nishishinjuku163-0570 Tokyo, JapanTel: + 81 (3) 33498501 Fax: + 81 (3) 33498599Email: [email protected] Web: www.reedexpo.co.jp

21 - 24 Jun 2017International trade fair for metal productionFiere di Verona, Viale del Lavoro 8, 37135 Verona, Verona, Veneto, ItalyContact: Veronafiere, Viale del Lavoro 8, Verona, ItalyTel: +39 (0)45 8298111 Fax: +39 (0)45 8298288Email: [email protected] Web: www.veronafiere.it

21 - 24 Jun 2017Exhibition and Conference for toolingBITEC - Bangkok International Trade & Exhibition

Center, 88 Bangna-Trad Road, Bang Na, 10260 Bangko, Bangkok, ThailandContact: Reed Tradex, 32nd fl., Sathorn Nakorn Tower, 100/68-69 North Sathon Road Silom10500 Bangkok, ThailandTel: +66 (0)2 6867299 Fax: +66 (0)2 6867288Email: [email protected] Web: www.reedtradex.com

25 - 29 Jun 2017Trade fair for thermal processesMesse Düsseldorf, Stockumer Höfe, 40474 Düsseldorf, North Rhine-Westphalia, GermanyContact: Messe Düsseldorf GmbH, Stockumer Kirchstr. 6140474 Düsseldorf, GermanyTel: +49 (0)211 456001 Fax: +49 (0)211 4560668Email: [email protected] Web: www.messe-duesseldorf.de

25 - 29 Jun 2017Trade fair for casting productsMesse Düsseldorf, Stockumer Höfe, 40474 Düsseldorf, North Rhine-Westphalia, GermanyContact: Messe Düsseldorf GmbH, Stockumer Kirchstr. 6140474 Düsseldorf, GermanyTel: +49 (0)211 456001 Fax: +49 (0)211 4560668Email: [email protected] Web: www.messe-duesseldorf.de

25 - 29 Jun 2017Metallurgy trade fairMesse Düsseldorf, Stockumer Höfe, 40474 Düsseldorf, North Rhine-Westphalia, GermanyContact: Messe Düsseldorf GmbH, Stockumer Kirchstr. 6140474 Düsseldorf, GermanyTel: +49 (0)211 456001 Fax: +49 (0)211 4560668Email: [email protected] Web: www.messe-duesseldorf.de

28 - 30 Jun 2017International Sheet metal machinery, Forging, Stamping and Setting Equipment ExhibitionChina Import & Export Fair Pazhou Complex,No. 380, Yuejiang Zhong Road, 510000 Guangzhou, Guangdong, ChinaContact: Julang Exhibition Co. Ltd., Huaming Road 29, Pearl River New City, Tianhe District, Guangzhou, ChinaTel: +86 (0)20 38620792 Fax: +86 (0)20 38620781Email: [email protected] Web: www.julang.com.cn ◘

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

COATING & FINISHING 33

FORMING 33

JOINING & ASSEMBLY 34

LASERS 34

MACHINE TOOLS 35

MACHINING 35

NON TRADITIONAL MACHINING 37

GRINDING 38

LASER MACHINING 41

LASER WELDING 42

MANUFACTURING SYSTEMS 43

MATERIALS & TREATMENT 44

MEASUREMENT & TESTING 44

COMPUTER NUMERICAL CONTROL 45

NANO TECHNOLOGY 46

PRODUCT DESIGN & MANUFACTURE 48

TOOLS & TOOLING 52

BIOMEDICAL ENGINEERING 55

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

COATING & FINISHING

111133 On ultrasonic assisted abrasive flow finishing of bevel gearsVenkatesh, G; Apurbba Kumar Sharma, Pradeep Kumar [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 29, Pages 10] Finishing of bevel gears is an important requirement in many machining shop floors. Variants of abrasive flow machining (AFM) could be plausible solutions for finishing such parts with intricate geometries. In the present work, a relatively new variant of AFM called ultrasonically assisted abrasive flow machining (UAAFM) technique was employed to finish bevel gears made of EN8 steel. An analysis of the process has been presented with suitable illustrations. A finite element simulation of the behavior of the medium during finishing of bevel gears using the UAAFM process has been presented. A 3D model was constructed to simulate the flow of medium through the outer wall of the gear tooth surface using computational fluid dynamics (CFD) approach. The velocity, pressure and temperature values along the length of the workpiece were computed for both UAAFM and the conventional AFM processes. Further, the effectiveness of the process was investigated through experimental trials by conducting a comparison study between classical AFM and UAAFM. Ultrasonic frequency, extrusion pressure, processing time and the media flow rate were considered as the input variables while improvements in surface finish and material removal were considered as the monitored outputs. Results confirm that improvements in surface roughness and material removal are significantly higher than those obtained with conventional abrasive flow machining. The study further reveals that, the applied high frequency (ultrasonic) vibration to the workpiece has the maximum influence on the process responses among the variables considered.

111134 Wear behaviour of steel coatings produced by friction surfacingPereira, D; Gandra, J; Pamies-Teixeira, J; Miranda, RM; Vilaça, P [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2858, Pages 11] Friction surfacing was performed to produce multi-layer coatings of

AISI 1024, AISI 1045 and AISI H13 over mild steel substrates where a continuous joining was achieved between adjacent layers and between the clad and the substrate. Microscopic and hardness characterization revealed the presence of bainitic and martensitic microstructures which influenced the hardness of the coatings. The study aimed to determine which material combination was more wear-resistant. The analysis suggested that AISI 1024 presents the least wear, both in terms of friction coefficient and wear rate. This is due to the formation of adherent protective oxide layer which is not present in both the AISI 1045 and AISI H13 steels.

FORMING

111135 A new method of determining forming limit diagram for sheet materials by gas blow formingMitukiewicz, G; Anantheshwara, K; Zhou, G; Mishra, RK; Jain, MK [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2960, Pages 11] A new methodology is proposed to obtain forming limit diagrams (FLDs) of sheet materials using gas blow forming process at elevated temperatures. Tension–tension side of the forming FLD is achieved by using circular as well as elliptical dies of different aspect ratios. To achieve tension–compression side of FLD un-bonded bi-layer specimen with slots are utilized. The widths between the slots are varied to achieve different strain paths. A correlation is established between the hemispherical punch-based tests and GBF tests of samples with slots to achieve different strain paths. FLDs for automotive AZ31 magnesium sheet at 300 °C and 400 °C in two different orientations are determined. Increase in forming limits of AZ31 with increase in temperature is observed.

111136 1-Shot hot stamping of ultra-high strength steel parts consisting of resistance heating, forming, shearing and die quenchingMori, Ken-ichiro; Maeno, Tomoyoshi; Yamada, Hiroaki; Matsumoto, Hayato [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 124, Pages 8] A 1-shot hot stamping process consisting of resistance heating, forming, shearing and die quenching was developed to produce small- and medium-size ultra-

Abstracts


high strength steel parts. A rectangular sheet was resistance-heated to obtain a uniform distribution of temperature, and just after the end of heating, a sequence of forming, shearing and die quenching was performed by one shot to prevent the drop in temperature. An ultra-high strength steel spur gear having a hardness of 540 HV2 was produced by 1-shot hot stamping composed of heating, blanking and die quenching. The rollover was improved by partial compression of the blanked gear. An ultra-high strength stainless steel part having a hardness of 580 HV2 was produced by 1-shot hot stamping consisting of the heating, bending, shearing and die quenching, and no springback and quenching distortion of the produced part were observed by holding at the bottom dead centre of the press. An operation for thickening the edge of the punched hole was included in 1-shot hot stamping to improve the strength of a product.

JOINING & ASSEMBLY

111137 Hybrid-heat effects on electrical-current aided friction stir welding of steel, and Al and Mg alloysLuo, Jian; Chen, Wei; Fu, Gen [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 3002, Pages 11] Electrical current aided friction stir welding (EFSW) is based on increasing heat generation during welding by adding a resistant heat source. The influence of current intensity to surface shaped features on welding seam was discussed. The comparison between AZ31B joints and Al 7075 joints was conducted. For the AZ31B joints, the resistant heat source promoted significant grain refinement and hardness improvement in the weld nugget zone (WNZ). It also increased plastic deformation during welding. For the Al 7075 joints, the grain size in the WNZ and heat affected zone (HAZ) increased slightly with the increase in electric current intensity. EFSW was proven to be suitable for joining high-strength alloys, such as 2Cr13Mn9Ni4 and Q235B. High microhardness values were obtained at both sides of the mechanical interlock zone.

111138 Fluxless arc weld-brazing of aluminium alloy to steelKrishna P Yagati; Ravi N Bathe; Koteswararao V Rajulapati; K Bhanu Sankara Rao; G Padmanabham [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2949, Pages 10] In this work, joining of aluminium alloy AA6061-T6

to Interstitial Free steel using pulsed gas metal arc welding process has been attempted. The effect of different surface conditions of steel (viz, galvanized, galvanealed and uncoated) and gap between the sheets on braze joint formation have been investigated. Galvanized steel surface showed good bead width, joint formation and lap shear strength compared to the other two combinations. Interface gap has not affected the wetting behaviour significantly but presence of a gap of 300 µm or so helped in escape of zinc vapour during the process there by avoiding formation of any crevice or macroporosity in the joint. Features and properties of the joint are characterized by metallography, fractography, energy dispersive spectroscopy (EDS) and lap shear tests. Load carrying capacity of Al-Galvanized steel was highest (222 N/mm of seam length) compared to other combinations, aided by better wetting due to presence of Zn on the surface and minimum porosity due to interfacial gap provided during brazing.

LASERS

111139 Laser ablation of titanium alloy under a thin and flowing water layerTangwarodomnukun, V; Likhitangsuwat, P; Tevinpibanphan, O; Dumkum, C [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 14, Pages 15] Underwater laser ablation has become an alternative machining process that is able to reduce the thermal damage in work materials caused by lasers. However, the disturbance of water to the laser beam is a crucial concern for the ablation performance in water and cut surface quality obtained. In this study, a new laser ablation technique has been proposed, in which a waterjet was applied to impinge the top workpiece surface in order to form a thin and flowing water layer. With the assist of such water layer during the laser ablation, the redeposition and heat-affected zone can be minimized. Titanium alloy (Ti–6Al–4V) selected as a work sample was grooved by using a nanosecond-pulse laser under different machining conditions. The cut geometry and heat-affected zone were observed and analyzed to justify the process performance. The metallurgical change and cracks that occurred on and underneath the groove surface were also investigated in this study. The experimental results revealed that a clean cut with less thermal damage can be obtained when the workpiece was ablated by a laser under the flowing water layer. In addition, a narrower

Abstracts


and deeper groove can be fabricated when a higher waterjet flow rate was applied. The laser ablation under the flowing water layer developed in this study could be a potential method for machining titanium alloy or even other thermal-sensitive materials.

111140 Effect of energy density and feeding speed on micro-hole drilling in C/SiC composites by picosecond laserLiu, Yongsheng; Wang, Chunhui; Li, Weinan; Zhang, Litong; Yang, Xiaojun; Cheng, Guanghua; Zhang, Qing [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 3131, Pages 10] The effect of energy density and feeding speed on micro-holes was investigated, which were machined in C/SiC composites by picosecond laser. Morphologies and elemental compositions of the machined holes in 2 mm and 3 mm thickness specimens were analyzed. The results indicated that both energy density and feeding speed had remarkable effect on the quality of micro-holes, especially on the exit side and cross-section of micro-holes. While the circularity of drilling holes on the entry side was affected by the energy density and feeding speed slightly. Additionally, the machining debris also played an important role in the quality of micro-holes. The micro-holes were consisted with three elements C, Si, and O, and those predominantly attributed to Csingle bondC (sp2), Csingle bondC (sp3) and Sisingle bondO bonds. Moreover, the laser machining process was discussed, which was responsible for the formation of the debris.

111141 A time based method for predicting the workpiece surface micro-topography under pulsed laser ablationGilbert, D; Stoesslein, M; Axinte, D; Butler-Smith, P; Kell, J [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 3077, Pages 12] The generation of micro-features in a predictable and repeatable manner by use of pulsed laser ablation requires an understanding of the temporal and energetic distributions of the laser beam upon the workpiece surface. Modelling the response of the material to known energetic and kinematic parameters of the pulsed laser ablation process can be carried out in a discretised time-based approach, allowing the workpiece topography to be simulated mathematically to reflect a real-life process. Considerations of the antecedent workpiece surface texture such as increases in irradiated area due to the surface gradient, and increases in laser spot size due to beam divergence throughout the elevation of

the workpiece are used to predict energy densities and hence the resultant ablated depth and texture of the targeted surfaces. A fully calibrated Yb:YAG pulsed fibre laser (SPI G3.0 RM) was used to validate the model on three materials, highlighting the models strengths for different material types. It was found that Ni based workpieces presented redeposition phenomena under these laser ablation conditions. To analyse the model without redeposition, validations trials on materials that do not present such side effects, e.g. diamond, were carried out and differences were found to be up to 9.39%.

MACHINE TOOLS

111142 In-process tool point FRF identification under operational conditions using inverse stability solutionÖzsahin, O; Budak, E; Özgüven, HN [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 64, Pages 10] Self-excited vibrations of machine tools during cutting result in process instability, poor surface finish and reduced material removal rate. In order to obtain stability lobe diagrams to avoid chatter vibrations, tool point frequency response function (FRF) must be determined. In classical machine tool studies, tool point FRF is obtained experimentally or analytically for the idle state of the machine. However, during cutting operations, discrepancies are frequently observed between the stability diagrams predicted by using the FRFs measured at the idle state and the actual stability of the process. These deviations can be attributed to the changes in machine tool dynamics under cutting conditions which are difficult to measure. In this study, a new identification method is proposed for the identification of in-process tool point FRFs. In this method, experimentally determined chatter frequency and corresponding axial depth of cut are used in order to identify tool point FRF. The proposed method is applied to a real machining center and by using chatter tests it is demonstrated that the tool point FRF can be accurately identified under operational conditions.

MACHINING

111143 Role of phase transformation in chip segmentation during high speed machining of dual phase titanium alloysZhang, XP; Shivpuri, R; Srivastava, AK [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 3048, Pages 19] Chip

Abstracts


segmentation during machining of titanium alloys is primarily due to adiabatic shear localization associated with thermally driven a–ß phase transformation at extremely high speeds. Current constitutive material models used in simulating the machining process ignore the role of phase transformation in shear localization and its influence on the material associated dynamic response. This research presents a new phase approach to chip segmentation that includes a recently developed constitutive material model based on the self-consistent method (SCM) that accounts for material composition, as well as a–ß phase transformation, during machining. This SCM-based model is implemented in the finite element framework to validate and predict the effects of starting material property, cutting speeds, uncut chip thicknesses, rake angles, tool radius, and friction coefficients on the strains, temperatures and ß volume fractions in chip segmentation. It confirms that cutting speed and uncut chip thickness have great impact, rake angle has less effect, tool radius and friction coefficient have the least effects on chip segmentation. However, tool geometry as well as machining parameters have great influence on the machined surface in terms of temperature magnitude, affected depth and the associated a–ß phase transformation.

111144 Experimental studies on drilling tool load and machining quality of C/SiC composites in rotary ultrasonic machiningDing, Kai; Fu, Yucan; Su, Honghua; Chen, Yan; Yu, Xizhai; Ding, Guozhi [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2900, Pages 8] Carbon fiber reinforced silicon carbide matrix (C/SiC) composites have great potential in space applications because of their excellent properties such as low density, superior wear resistance and high temperature resistance. However, the use of C/SiC has been hindered seriously because of its poor machining characteristics. With an objective to improve the machining process of C/SiC composites, rotary ultrasonic machining (RUM) and conventional drilling (CD) tests with a diamond core drill were conducted. The effects of ultrasonic vibration on mechanical load and machining quality were studied by comparing the drilling force, torque, quality of holes exit and surface roughness of drilled holes between the two processes. The results showed that the drilling force and torque for RUM were reduced by 23% and 47.6%, respectively of those for CD. In addition, the reduction in drilling force and torque decreased gradually with increasing spindle speed, while

they changed slightly with increasing feed rate. Under identical conditions, RUM gave better holes exit than CD. Moreover, because of the lower lamellar brittle fracture and pit originating from carbon fibers fracture, the roughness of surface of drilled holes obtained with RUM was lower than CD and the maximum reduction was 23%.

111145 Modeling and analysis of helical groove grinding in end mill machiningLi, Guochao; Sun, Jie; Li, Jianfeng [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 3067, Pages 10] Helical groove geometry has important influence on the performance of end mills. It is the hardest and most time-consuming grinding process in end mill manufacture. This paper reports a graphical analysis method to obtain the structure parameters and geometric shapes of helical grooves with the known wheel geometry and position. Mathematical models are presented to describe the wheel geometry and position (including orientation and location) in space. A family of wheel surfaces is calculated and a scattered point set in the cross section plane is deduced according to the grinding path. Finally, an original algorithm for the cross sectional outline profile identification is given using graphical method. To verify this method, a calculation program programmed using MATLAB programming is developed. This study provides a fundamental understanding for the groove grinding process, based on this, the influence of different grinding process parameters on groove geometry (including radial rake angle, groove width and core radius) is discussed.

111146 Spindle speed ramp-up test: A novel experimental approach for chatter stability detectionGrossi, N; Scippa, A; Sallese, L; Sato, R; Campatelli, G [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 221, Pages 10] Chatter is one of the most limiting factors in improving machining performances. Stability Lobe Diagram (SLD) is the most used tool to select optimal stable cutting parameters in order to avoid chatter occurrence. Its prediction is affected by reliability of input data such as machine tool dynamics or cutting coefficients that are difficult to be evaluated accurately, especially at high speed. This paper presents a novel approach to experimentally evaluate SLD without requiring specific knowledge of the process; this approach is called here Spindle Speed Ramp-up (SSR) test. During this test spindle speed is

Abstracts


ramped up, and chatter occurrence is detected by the Order Analysis technique. As result one single test ensures optimal spindle speed identification at one cutting condition, while if few tests are performed the entire SLD could be obtained. Results of the method applied to slotting operation on aluminum are provided and a comparison between different measurements devices is presented. This quick, easy-to-use and efficient test is suitable for industrial application: no knowledge of the process is required, different sensors can be used such as accelerometer, dynamometer or microphone.

111147 Machining of hardened steel—Experimental investigations, performance modeling and cooling techniques: A reviewChinchanikar, Satish; Choudhury, SK [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 95, Pages 15] The researchers have worked on many facets of machining of hardened steel using different tool materials and came up with their own recommendations. Researchers have tried to investigate the effects of cutting parameters, tool materials, different coatings and tool geometry on different machinability aspects like, the tool life, surface roughness, cutting forces, chip morphology, residual stresses and the tool–chip interface temperature under dry and/or semi-dry and/or flood cooling environment during machining of hardened steels while many of them have ventured to characterize the wear phenomenon. Good amount of research has been performed on an analytical and/or numerical and/or empirical modeling of the cutting forces, tool–chip interface temperature, and tool wear under orthogonal/oblique cutting conditions during machining of hardened steels. This paper presents a comprehensive literature review on machining of hardened steels using coated tools, studies related to hard turning, different cooling methods and attempts made so far to model machining performance(s) so as to give proper attention to the various researcher works.

111148 Time domain prediction of milling stability according to cross edge radiuses and flank edge profilesKo, Jeong Hoon [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 74, Pages 12] This article proposes a time domain model for predicting an end milling stability considering process damping caused by a variety of cross edge radiuses and flank profiles. The time domain model of calculating indentation areas, as well as regenerative dynamic uncut chips, is

formulated for the prediction of the stabilizing effect induced by interference areas between the edge profiles and undulation left on a workpiece. The interference area generates forces against the vibration motion, which acts as a damping effect. In the model, the present and previous angular position of cross radiuses and flank edge profiles are located to calculate the dynamic uncut chip as well as indentation area based on a time history of the dynamic cutter center position. The phenomenon that chatter is damped according to cross edge radiuses and flank edge profiles is successfully simulated with the proposed dynamic model and validated through the extensive experimental tests.

111149 Position geometric error modeling, identification and compensation for large 5-axis machining center prototypeZhong, Gaoyan; Wang, Chaoqun; Yang, Shoufeng; Zheng, Enlai; Ge, Yanyan [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 142, Pages 9] This paper presents a position geometric error modeling, identification and compensation method for large 5-axis machining center prototype. First, regarding the prototype as a rigid multi-body system, a geometric error model has been established, which supports the identification of position geometric error associated with a translational axis by using laser interferometer, and a rotational axis by using laser tracker. Second, based on this model, an improved identification approach named as virtual rigid-body is put forward for calculating positioning error of each large translational axis. Detailed derivation of a generalized matrix equation is given. Third, analytical models based on the least-squares theory were adopted to compute error values at an arbitrary position for error compensation. Finally, the identified position geometric errors were compensated by using recursive software-based error compensation method. The results show that the position accuracy of large machining center prototype has been improved with compensation and up to the design requirements.

NON TRADITIONAL MACHINING

111150 Geometric prediction of conic tool in micro-EDM milling with fix-length compensation using simulationZhang, Lenan; Du, Jianyi; Zhuang, Xiaoshun; Wang, Zhiliang; Pei, Jingyu [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 86, Pages 9] Micro-EDM milling is an

Abstracts


effective machining process for three-dimensional micro-cavity of high hardness materials. However, tools wear sharply in micro-milling, thus several compensation methods are applied. The present study examines the fix-length compensation method, and the initial experiments show that a cone-shaped tool end is formed with this compensation method. Because the cone angle is of great importance in the determination of the fix-length compensation parameters in the machining procedure, a clear explanation of the forming mechanism and precise prediction are of great necessity. First, the tool and the workpiece were geometrically and mathematically modeled as two-dimensional matrices. Second, the machining process was divided into three parts including sparking, horizontal feeding and vertical feeding. Finally, a series of experiments were conducted in order to verify the accuracy of the simulation. The results show that the relative error of the simulation compared to the experimental data is within 4% under most machining conditions. The developed model can thus be used to predict the machined surface of the tool and the workpiece and can also provide a better understanding for the mechanism of the cone shaped tool end.

GRINDING

111151 Experimental study on grinding force and grinding temperature of Aermet 100 steel in surface grinding

Yao, Changfeng; Wang, Ting; Xiao, Wei; Huang, Xinchun; Ren, Junxue [J of M a t e r i a l s P r o c e s s i n g T e c h n o l o g y , v 214, n 11, Nov 2014, Starting

Page 2191, Pages 9] This paper investigates grinding force and grinding temperature of ultra-high strength steel Aermet 100 in conventional surface grinding using a single alumina wheel, a white alumina wheel and a cubic boron nitride wheel. First, mathematical models of grinding force and grinding temperature for three wheels were established. Then, the role of chip formation force and friction force in grinding force was investigated and thermal distribution in contact zone between workpiece and wheel was analyzed based on the mathematical model. The experimental result indicated that the minimum

grinding force and the maximum grinding force ratio under the same grinding parameters can be achieved when using a CBN wheel and a single alumina wheel, respectively. When the phenomenon of large grinding force and high grinding temperature appeared, the workpiece material would adhere locally to the single alumina wheel. Grinding temperature was in a high state under the effect of two main aspects: poor thermal properties of grinding wheel and low coolant efficiency. The predicted value of grinding force and grinding temperature were compared with those experimentally obtained and the results show a reasonable agreement.

111152 Hardness control of grind-hardening and finishing grinding by means of area-based specific energy

Alonso, U; Ortega, N; Sanchez, JA; Pombo, I; Izquierdo, B; Plaza, S [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 24, Pages 10] The grind-hardening

process uses the heat generated within the grinding zone in order to produce surface hardening of the workpiece. However, after the process, workpieces present dimensional inaccuracies and poor surface roughness. Thus, a final grinding operation has to be performed. For an industrial implementation of the whole process, two problems need to be solved. On the one hand, on-line control of the hardness penetration depth (HPD) should be achieved. On the other hand, excessive softening of the workpiece has to be avoided during the finishing grinding. This paper, firstly, investigates the feasibility of using the area based grinding energy (View the MathML sourceEc?) for the prediction of the HPD. Surface grind-hardening tests carried out on 100Cr6, 42CrMo4 and AISI 1045 steels have shown that, for all the tested parameter sets, a linear correlation exists between View the MathML sourceEc? and HPD. Furthermore, the slope of this linear relationship can be estimated from the chemical composition of the hardened steel based on the equivalent carbon number. On the other hand, the influence of varying wheel dressing conditions on the View the MathML sourceEc?–HPD relationship is analysed. Secondly, it has been found that a relationship exists between View the MathML sourceEc? and the surface softening during the

Abstracts


finishing grinding operation. This relationship is independent of the grinding parameter combination when the maximum undeformed chip thickness is over a threshold value. Thus, View the MathML sourceEc? is a very appropriate parameter to control both the hardening and the finishing process of grind-hardened workpieces.

111153 Depth-of-cut errors in ELID surface grinding of zirconia-based ceramics

Tang, H; Deng, ZH; Guo, YS; Qian, J; Reynaerts, D [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 34, Pages 8] Based on the analysis of a surface grinding system and

the material removal mechanism, a mathematic model has been proposed to predict the accumulated error between the total set depth-of-cut (DoC) and the total actual depth-of-cut (ADoC) in multi-pass surface grinding of zirconia-based ceramic materials. Design of Experiments (DoE) approach has been implemented to carry out experiments. The influence of the set DoC of each grinding pass, the total set DoC, and the grinding wheel velocity on the accumulated errors in ADoC has been investigated in detail in surface grinding of zirconia-based ceramics both with electrolysis in-process dressing (ELID) and without ELID. It has been observed that the accumulated DoC errors increase faster in the first few passes and gradually reach a saturation after a certain total DoCs (about 8–10 grinding passes) and a higher step DoC leads to a faster (fewer passes) saturation of the accumulated DoC errors. Compared to grinding without ELID, it has been found that ELID-grinding is characterized with better process stability and ELID offers positive effects on material removal rate (MRR), especially in case of removing large volume of material with the same grinding parameters.

111154 Study on micro-topographical removals of diamond grain and metal bond in dry electro-contact discharge dressing of coarse diamond grinding wheelLu, YJ; Xie, J; Si, XH [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 118, Pages 13] A coarse diamond grinding wheel is able to perform smooth surface grinding with high

and rigid grain protrusion, but it is very difficult to dress it. Hence, the dry electro-c o n t a c t discharge (ECD) is proposed to

dress #46 diamond grinding wheel for dry grinding of carbide alloy. The objective is to understand micro-topographical removals of diamond grain and metal bond for self-optimizing dressing. First, the pulse power and direct-current (DC) power were employed to perform dry ECD dressing in contrast to mechanical dressing; then the micro-topographies of diamond grains and metal bond were recognized and extracted from measured wheel surface, respectively; finally, the relationship between impulse discharge parameters and micro-topographical removals was investigated with regard to grain cutting parameters, dry grinding temperature and ground surface. It is shown that the dry ECD dressing along with spark discharge removal may enhance the dressing efficiency by about 10 times and dressing ratio by about 34 times against the mechanical dressing along with cutting removal. It averagely increases grain protrusion height by 12% and grain top angle by 23%, leading to a decrease 37% in grinding temperature and a decrease 46% in surface roughness. Compared with the DC-25V power along with arc discharges, the Pulse-25V power removes the metal bond at 0.241 mm3/min by utilizing discharge energy by 73% and diamond grain at 0.013 mm3/min through surface graphitization, respectively, leading to high and uniform grain protrusion. It is confirmed that the impulse discharge parameters are likely to control the microscopic grain protrusion topography for efficient dressing according to their relations to the micro-removal of metal bond.

111155 Effect of grinding-induced cyclic heating on the hardened layer generation in the plunge grinding of a cylindrical componentLiu, Mei; Nguyen, Thai; Zhang, Liangchi; Wu, Qiong; Sun, Dale [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 55, Pages 9] This paper discusses the effects of the grinding-induced cyclic heating on the properties of the hardened layer in a plunge cylindrical grinding process on the high strength steel EN26. It was found that a multi-pass grinding brings about a uniform and continuous hardened layer along the circumference of the cylindrical

Abstracts


workpiece. An increase of the number of grinding passes, leads to a thicker layer of hardening, a larger compressive residual stress and a deeper plastic deformation zone. Within the plastic deformation zone, the martensitic grains are refined by the thermo-mechanical loading, giving rise to a hardness of 12.5% higher than that from a conventional martensitic transformation. The coupled effects of heat accumulation and wheel wear in the multi-pass grinding are the main causes for the thickening of the hardened layer. A too small infeed per workpiece revolution would result in insufficient grinding heat, and in turn, bring about an undesirable tempered hardened layer and a reduction of its hardness.

111156 Performance evaluation of Ti–6Al–4V grinding using chip formation and coefficient of friction under the influence of nanofluids

Setti, Dinesh; Sinha, Manoj Kumar; Ghosh, Sudarsan; Venkateswara Rao, P [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 237, Pages 12] Nanofluid, fluid suspensions of nanometer sized particles are revolutionizing the field of heat transfer area. Addition of nano-particles to the base fluid also alters the lubricating properties by reducing the friction. In grinding process, friction between the abrasive grains and the workpiece is a key issue governing the main grinding output. It has a direct influence on grinding force, power, specific energy and wheel wear. Moreover, high friction force increases the heat generation and lead to thermal damage in the surface layer of the ground work. Hence, any effort towards the friction control will enhance the component quality significantly. In this study, nanofluid as metal working fluid (MWF) is made by adding 0.05, 0.1, 0.5 and 1% volume concentration of Al2O3 and CuO nano-particles to the water during the surface grinding of Ti–6Al–4V in minimum quantity lubrication (MQL) mode. Surface integrity of ground surface, morphology of the wheel,

and chip formation characteristics are studied using surface profilometer, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and stereo zoom microscopy (SZM). Coefficient of friction was estimated On-Machine using the measured forces. The results showed that the type of nanoparticle and its concentration in base fluid and the MQL flow rate play a significant role in reducing friction. Application of nanofluid leads to the reduction of tangential forces and grinding zone temperature. The cooling effect is also evident from the short C-type chip formation. MQL application with Al2O3 nanofluid helps in effective flushing of chip material from the grinding zone, thereby solving the main problem during the grinding of Ti–6Al–4V.

111157 Assessment of spray quality from an external mix nozzle and its impact on SQL grinding performanceShiva Sai, S; Manoj Kumar, K; Ghosh, A [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 132, Pages 10] Spray quality is the critical factor which decides the efficacy of Small Quantity Lubrication (SQL) technology in a high specific energy involved machining process like grinding. Yet, the understanding about spray quality, the actual process mechanics and its effect on machining performance is inadequate. The present work is an attempt to establish a correlation between the spray input variables, quality of the spray and machining performance of SQL grinding through modelling and experiments. Using computational fluid dynamic techniques, the variation of droplet size, droplet velocity, number of droplets and heat transfer coefficient have been analysed at different input parameters and the computed trends have been verified and validated. CFD modelling of spray indicates that it is possible to produce aerosol medium with high heat dissipation ability at moderately high air pressure and low flow rate. It also shows that any increase in atomising air pressure favourably leads to notable increase in wetting area and also results in substantial enhancement in heat dissipation ability. Reduction of residual stress is thus remarkably good. On the other hand, grinding fluid flow rate, if increased, offers significantly better lubricity and reduces the grinding force which also reduces tensile residual stress. Short spell grinding test results are found to be in good agreement with CFD results.

111158 The influence of speed on material

Abstracts


removal mechanism in high speed grinding with single gritTian, Lin; Fu, Yucan; Xu, Jiuhua; Li, Haiyan; Ding, Wenfeng [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 192, Pages 10] In this paper, the effect of speed on material removal was investigated by single grit grinding of the GH4169 super alloy which is difficult to machine, with a new test method. During the tests the whole material removal process, was observed and then the critical thickness of chip formation was quantitatively analyzed. In order to provide insight into the speed effect, the grinding forces, chip formation and pile-up ratio were investigated. It was found that the stages of material removal process changed with the grinding speed, and the graphical relationships between grinding speed and the critical thickness of chip formation, grinding forces and the pile-up ratio were found to have a common characteristic, namely a common turnover point which was about 100 m/s. This trend in the results is attributed to alternating predominance between the strain hardening and thermal softening effects. The results of this study demonstrated that the grinding speed has a significant impact on material removal mechanism, and also provide a basis for sound understanding of the high speed grinding process of difficult to cut materials.

LASER MACHINING

111159 Effect of molten pool boundaries on the mechanical properties of selective laser melting parts

Shifeng, Wen; Shuai, Li; Qingsong, Wei; Yan, Chunze; Sheng, Zhang; Yusheng, Shi [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2660, Pages 8] Selective laser melting (SLM) manufactures components through the overlapping of multi-track and multi-layer molten pools of metal powders, resulting in two types of molten pool boundaries (MPBs), “layer–layer” and “track–track” MPBs, remaining in SLM parts. The microstructure of MPBs exhibits a complex and regular spatial topological structure. There is a coarse grain zone below the

MPBs and nonmetallic elements (C, O, Si) near the MPBs are in an unstable state. Long and thin columnar grains with the same orientations distribute on two sides of the “layer–layer” MPBs, whereas the columnar grains on both sides of “track–track” MPBs have different orientations. The “track–track” MPBs are short and intersect with “layer–layer” MPBs at some points and form acute angles, where cracks are initiated when applied with external loads. The effect of the MPBs on microscopic slipping, macroscopic ductility and fracture mechanism of the SLM parts made along different directions, which were exerted a tensile loading in the as-built condition without heat treatment, was analyzed and evaluated using slip theory and experiments. The results reveal that the MPBs have a significant impact on the microscopic slipping at the loading, macroscopic plastic behavior and fracture mode, and are one of the main reasons for the obvious anisotropy and low ductility of SLM parts.

111160 Tailoring surface quality through mass and momentum transfer modeling using a volume of fluid method in selective laser melting of TiC/AlSi10Mg powderDai, Donghua; Gu, Dongdong [Int J

of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 95, Pages 13] A selective laser melting (SLM) physical model of coupled radiation transfer and

thermal diffusion is proposed, which provides a local temperature field. A strong difference in thermal conductivity between the powder bed and dense material is taken into account. Both thermo-capillary force and recoil pressure induced by the material evaporation, which are the major driving forces for the melt flow, are incorporated in the formulation. The effect of the laser energy input per unit length (LEPUL) on the temperature distribution, melt pool dynamics, surface tension and resultant surface morphology has been investigated. It shows that the surface tension plays a crucial role in the formation of the terminally solidified surface morphology of the SLM-processed part. The higher surface tension of the lower temperature metal near the edge of the melt pool and the thermal-capillary force induced by the surface

Abstracts


temperature gradient tend to pull the molten metal away from the center of the melt pool. For a relatively high LEPUL of 750 J/m, the molten material in the center of the melt pool has a tendency to flow towards the rear part, resulting in the stack of molten material and the attendant formation of a poor surface quality. For an optimized processing condition, LEPUL=500 J/m, a complete spreading of the molten material driven by the surface tension is obtained, leading to the formation of a fine and flat melt pool surface. The surface quality and morphology are experimentally acquired, which are in a good agreement with the results predicted by simulation.

111161 Mesoscopic simulation model of selective laser melting of stainless steel powder

Khairallah, Saad A; Anderson, Andy [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2627, Pages 10] A 3D mesoscopic model is developed to simulate selective laser melting processes using the ALE3D multi-physics code. We study the laser-induced melting of a random bed of stainless steel 316 particles on a solid substrate (1000 µm × 300 µm × 50 µm) and its solidification into either a continuous track or a discontinuous track as a result of Plateau–Rayleigh instability. Our approach couples thermal diffusion to hydrodynamics and accounts for temperature dependent material properties and surface tension, as well as the random particle distribution. The simulations give new physical insight that should prove useful for development of continuum models, where the powder is homogenized. We validate our approach against the experiment and find that we match the main laser track characteristics.

LASER WELDING

111162 Large spot laser assisted GMA brazing–fusion welding of aluminum alloy to galvanized steelQin, Guoliang; Lei, Zhen; Su, Yuhu; Fu, Banglong; Meng, Xiangmeng; Lin, Shangyang [J of Materials

Processing Technology, v 214, n 11, Nov 2014, Starting Page 2684, Pages 9] Through positioning the leading laser as an auxiliary role, and the trailing arc as the main heat source, aluminum alloy (Al) was joined to galvanized steel plate with lap joint. The brazed seam width w increased with the increasing of heat input. The appropriate laser-wire distance Dlw and defocusing distance df to obtain the good fusion weld appearance were 5 mm and +20 mm, respectively. The fracture position of tensile test sample was divided into brazed interface fracture (P < 0.6 kW) and HAZAl fracture (P > 0.6 kW). The maximum tensile strength of dissimilar joint reached 75% of that of Al. The shear strength was mainly decided by heat input, and the brazed seam had the highest microhardness. Joining mechanism of this process was summarized into two factors: the effective function of laser and the metallurgical function of zinc. Compared to gas metal arc welding (GMAW), large spot laser assisted GMA process improved weld appearance and enhanced the process stability and its time-efficiency.

111163 Microstructure and mechanical properties of a laser welded low carbon–stainless steel jointEsfahani, M Nekouie; Coupland, J; Marimuthu, S [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2941, Pages 8] This article reports on an experimental investigation to understand and subsequently control the alloying composition in laser welding of austenitic stainless steel and low carbon steel. An energy dispersive spectrometer was used to analyse the alloying composition, while microscopy and tensile tests were used to study the microstructure, and mechanical performance of the welded joint respectively. The investigation revealed that above a certain specific point energy the material within the melt pool is well mixed and the laser beam position can be used to control the mechanical properties of the joint. This finding was confirmed using a numerical model based on computational fluid dynamics (CFD) of melt pool dynamics. Strategies to control the composition leading to dramatic changes in hardness, microstructure and mechanical properties of the dissimilar laser welded joint are discussed.

111164 Scaling law for penetration depth in laser weldingKim, Jaehun; Ki, Hyungson [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2908, Pages 7] A simple scaling

Abstracts


law for penetration depth in laser welding is proposed considering heat flow characteristics and multiple reflections. First, a process parameter is identified that is proportional to the surface temperature during laser processing, and the parameter is modified by accounting for the effect of multiple reflections. As a result, the normalized penetration depth is expressed as a function of a single parameter that is a combination of laser intensity, interaction time and an indicator of the strength of multiple reflections. The obtained scaling law is applicable not only to conduction mode welding but also to keyhole mode welding, and provides insight into why and how penetration depth changes in a particular way. Systematic and extensive welding experiments were conducted using a 2 kW multi-mode fiber laser and two types of steels. The experimental results were in good agreement with the proposed scaling law.

111165 Hybrid laser-arc welding of advanced high-strength steelLiu, Wei; Ma, Junjie; Yang, Guang; Kovacevic, Radovan [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2823, Pages 11] This study investigated the synergetic effect between laser beam and electrical arc during hybrid welding by using a spectral diagnostic technique. The synergetic effect increased the energy density in the keyhole and deepened the weld penetration, resulting in a lower plasma electron temperature. The metal transfer mode was a globular one at a small offset distance while a spray mode was achieved with an increase in the offset distance. The decrease in the arc voltage and arc current due to the synergetic effect caused this transition from spray to globular modes. Globular transfer mode destabilized the molten pool and keyhole with the large droplet impingement, leading to the formation of porosity in the corresponding weld bead. The presence of porosity was on-line detected by identifying serious fluctuations in the Fe I electron temperature signals based on the fact that the instability of the molten pool and keyhole is strongly related to the signals coming from the plasma.

111166 Trailing heat sink effects on residual stress and distortion of pulsed laser welded Hastelloy C-276 thin sheetsGuo, Yuquan; Wu, Dongjiang; Ma, Guangyi; Guo, Dongming [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2891, Pages 9] A three-dimensional finite element model (FEM) was established to reveal the thermal-mechanical behaviors of pulsed

laser welding (PLW) with and without trailing heat sink. Experiments were carried out to measure the welding temperature histories, residual distortions and solidification profiles. The simulation results agree well with the corresponding experimental measurements. The peak values of the temperature and transient longitudinal tensile stresses valleys in the weld increase as the cooling intensity increases from 5000 to 15,000 W/(m2 K), while those of the temperature and transient longitudinal compressive stresses near the weld decrease. The peak values of the longitudinal residual compressive stresses and plastic strains, and the maximum deflections in longitudinal and transverse direction decrease as the cooling intensity increases from 5000 to 15,000 W/(m2 K). The magnitudes of the transverse shrinkage distortions increase as the cooling intensity increases from 5000 to 15,000 W/(m2 K). The proper cooling intensity to reduce the residual stresses and distortions of the PLW with the trailing heat sink is detected at 10,000 W/(m2 K). The trailing heat sink is technically feasible for actual pulsed laser restraint welding in Hastelloy C-276 thin sheet structures.

MANUFACTURING SYSTEMS

111167 Research on manufacturing method of CNC plunge milling for spur face-gearYang, Xiao-yu; Tang, Jin-yuan [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 3013, Pages 7] As flexible, universal, and efficient rough machining is a fundamental technology for face-gear precision manufacturing, the plunge milling method for spur face-gear processing is studied in this paper. Based on the principles of differential geometry and gear meshing, the mathematical model of the spur face-gear is established. The plunge milling cutter is used to copy the gear shaper and the spur face-gear is processed through multi-group envelops. The swing angle range ??t of the copying curve and the radical feed range of the spindle ?lt are calculated through the research on the distribution of the contact line between the gear shaper and the spur face-gear, and the NC machining code of the spur face-gear is obtained based on the principle of NC programming. The feasibility of the plunge milling method for the face-gear and the correctness of the NC processing code presented in this paper are verified through the simulation processing test based on the Vericut software. Overall, an effective approach to the highly efficient plunge milling for

Abstracts


the spur face-gear is provided in this paper.

MATERIALS & TREATMENT

111168 Numerical and experimental analysis of 3D spot induction hardening of AISI 1045 steelGao, Kai; Qin, Xunpeng; Wang, Zhou; Chen, Hao; Zhu, Shengxiao; Liu, Yanxiong; Song, Yanli [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2425, Pages9] In order to analyze and predict the material property of AISI 1045 steel during spot induction hardening (SIH), a 3D electro-magnetic model coupled temperature fields with time-dependent boundary conditions was developed using finite element simulation software ANSYS. A magnetizer mounted at single-turn copper coil inductor, the calculation of the material hardness and the prediction of phase transformation were taken into account in this model via defined material laws. The phenomenology model in this work presented a novel and simplified way to predict the temperature, the hardness and phase transformation in SIH process. In situ temperature and current measurement as well as hardness and microstructure analyses were carried out to verify this model.

111169 Effect of wetting behavior on generation of uniform aluminum droplets obtained by pneumatic drop-on-demand technique

Zuo, Han-song; Li, He-jun; Qi, Le-hua; Luo, Jun; Zhong, Song-yi; Li, Hai-peng [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2566, Pages 10] Micro metal droplet is the basic building block of three-dimensional metal parts fabricated by micro droplet deposition

manufacturing (MDDM) technique. In this paper, the effect of wetting behavior between liquid metal and spray nozzle on the generation of micro aluminum droplets produced by pneumatic drop-on-demand (DOD) technique was investigated by simulation and experiment. A finite element model of liquid–gas flow was established based on the improved level set method (LSM). Then the generation of micro liquid aluminum droplets under different wetting conditions was simulated. A series of spraying

experiments were also performed on micro droplet deposition experiment platform. The results show that the generation and flight of micro aluminum droplets are influenced by wetting condition between liquid metal and the nozzle surface significantly. Additionally, the effect of wetting behavior on the droplet size was analyzed to achieve the smallest building block. It was found that the droplet radius decreased with the increase of contact angle exponentially, which agreed with the numerical calculation and experiment results. On this basis, a wettability criterion was proposed for selecting nozzle materials. These works would be helpful for the processing optimization and equipment improvement of MDDM technique.

MEASUREMENT & TESTING

111170 Accuracy enhancement of five-axis machine tool based on differential motion matrix: Geometric error modeling, identification and compensationFu, Guoqiang; Fu, Jianzhong; Xu, Yuetong; Chen, Zichen; Lai, Jintao [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 170, Pages 12] This paper presents the precision enhancement of five-axis machine tools according to differential motion matrix, including geometric error modeling, identification and compensation. Differential motion matrix describes the relationship between transforming differential changes of coordinate frames. Firstly, differential motion matrix of each axis relative to tool is established based on homogenous transformation matrix of tool relative to each axis. Secondly, the influences of errors of each axis on accuracy of tool are calculated with error vector of each axis. The sum of these influences is integration of error components of machine tool in coordinate system of tool. It endows the error modeling clear physical meaning. Moreover, integrated error components are transformed to coordinate frame of working table for integrated error transformation matrix of machine tools. Thirdly, constructed Jacobian is established using differential motion matrix of each axis without extra calculation to compensate the integrated error components of tool. It makes compensation easy and convenient with reuse of intermediate. Fourthly, six-circle method of ballbar is developed based on differential motion matrix to identify all ten error components of each rotary axis. Finally, the experiments are carried out on SmartCNC500 five-axis machine tool to testify the effectiveness of proposed accuracy

Abstracts


enhancement with differential motion matrix.

111171 A method of testing position independent geometric errors in rotary axes of a five-axis machine tool using a double ball barJiang, Xiaogeng; Cripps, Robert J [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 151, Pages 8] Ensuring that a five-axis machine tool is operating within tolerance is critical. However, there are few simple and fast methods to identify whether the machine is in a “usable” condition. This paper investigates the use of the double ball bar (DBB) to identify and characterise the position independent geometric errors (PIGEs) in rotary axes of a five-axis machine tool by establishing new testing paths. The proposed method consists of four tests for two rotary axes; the A-axis tests with and without an extension bar and the C-axis tests with and without an extension bar. For the tests without an extension bar, position errors embedded in the A- and C-axes are measured first. Then these position errors can be used in the tests with an extension bar, to obtain the orientation errors in the A- and C-axes based on the given geometric model. All tests are performed with only one axis moving, thus simplifying the error analysis. The proposed method is implemented on a Hermle C600U five-axis machine tool to validate the approach. The results of the DBB tests show that the new method is a good approach to obtaining the geometric errors in rotary axes, thus can be applied to practical use in assembling processes, maintenance and regular checking of multi-axis CNC machine tools.

111172 Identification and compensation of geometric errors of rotary axes on five-axis machine by on-machine measurementBi, Qingzhen; Huang, Nuodi; Sun, Chao; Wang, Yuhan; Zhu, Limin; Ding, Han [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 182, Pages 10] The geometric errors of rotary axes are the fundamental errors of a five-axis machine tool. They directly affect the machining accuracy, and require periodical measurement, identification and compensation. In this paper, a precise calibration and compensation method for the geometric errors of rotary axes on a five-axis machine tool is proposed. The automated measurement is realized by using an on-the-machine touch-trigger technology and an artifact. A calibration algorithm is proposed to calibrate geometric errors of rotary axes based on the relative displacement of the measured reference point. The geometric errors are individually separated

and the coupling effect of the geometric errors of two rotary axes can be avoided. The geometry error of the artifact as well as its setup error has little influence on geometric error calibration results. Then a geometric error compensation algorithm is developed by modifying the numeric control (NC) source file. All the geometric errors of the rotary errors are compensated to improve the machining accuracy. The algorithm can be conveniently integrated into the post process. At last, an experiment on a five-axis machine tool with table A-axis and head B-axis structure validates the feasibility of the proposed method.

COMPUTER NUMERICAL CONTROL

111173 Manufacture of Optimized Face-Hobbed Spiral Bevel Gears on Computer Numerical Control Hypoid GeneratorSimon, Vilmos V [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 031008, Pages 9] In this study, a method is proposed for the advanced manufacture of face-hobbed spiral bevel gears on CNC hypoid generators with optimized tooth surface geometry. An optimization methodology is applied to systematically define optimal head cutter geometry and machine tool settings to introduce optimal tooth modifications. The goal of the optimization is to simultaneously minimize tooth contact pressures and angular displacement error of the driven gear (the transmission error). The optimization is based on machine tool setting variation on the cradle-type generator conducted by optimal polynomial functions. An algorithm is developed for the execution of motions on the CNC hypoid generator using the relations on the cradle-type machine. Effectiveness of the method was demonstrated by using a face-hobbed spiral bevel gear example. Significant reductions in the maximum tooth contact pressure and in the transmission errors were obtained.

111174 Multitool and Multi-Axis Computer Numerically Controlled Accumulation for Fabricating Conformal Features on Curved Surfaces

Pan, Yayue; Zhou, Chi; Chen, Yong; Partanen, Jouni [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 031007, Pages 14] In

Abstracts


engineering systems, features such as textures or patterns on curved surfaces are common. In addition, such features, in many cases, are required to have shapes that are conformal to the underlying surfaces. To address the fabrication challenge in building such conformal features on curved surfaces, a newly developed additive manufacturing (AM) process named computer numerically controlled (CNC) accumulation is investigated by integrating multiple tools and multiple axis motions. Based on a fiber optical cable and a light source, a CNC accumulation tool can have multi-axis motion, which is beneficial in building conformal features on curved surfaces. To address high resolution requirement, the use of multiple accumulation tools with different curing sizes, powers, and shapes is explored. The tool path planning methods for given cylindrical and spherical surfaces are discussed. Multiple test cases have been performed based on a developed prototype system. The experimental results illustrate the capability of the newly developed AM process and its potential use in fabricating conformal features on given curved surfaces.

NANO TECHNOLOGY

111175 Laser-assisted replication of large-area nanostructures

Nagato, Keisuke; Takahashi, Ken; Sato, Toshimi; Choi, Junho; Hamaguchi, Tetsuya; Nakao, Masayuki [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2444, Pages 6] We proposed and demonstrated a high-throughput fabrication method for large-area nanostructured polymers. The mold used consists of a quartz substrate and a nanostructured diamond-like carbon (DLC) thin film. A laser is irradiated from the back of the mold and only the DLC surface is directly heated. Then the surface of a polymethyl methacrylate (PMMA) film pressed by the mold is melted and the nanostructures are replicated. In this method, replication can be achieved with a low amount of heat and a short cycle time compared with conventional thermal replication. The effects of the laser power

density, irradiation time, and environmental temperature on the replication area were experimentally investigated via the spot irradiation of a laser. Furthermore, the temperature distribution around the surfaces of the mold and polymer was investigated by performing numerical simulations. By scanning the laser, we successfully demonstrated the replication of a 500-nm-pitch pattern on a PMMA film with an area of 10 × 10 mm2 in about 10 s. This technique is expected to lead to the high-throughput and low-energy fabrication of large-area nanostructured optical films.

111176 Quantitative characterization and influence of parameters on surface topography in metal micro-droplet deposition manufactureQi, Le-hua; Zhong, Song-yi; Luo, Jun; Zhang, Dai-cong; Zuo, Han-song [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 206, Pages 8] Metal micro-droplet deposition manufacture has potential applications and attracts increasing attention in wide areas. By quantitatively describing and predicting the surface topography, the influence of parameters on surface quality could be studied effectively. In present work, a new approach aimed to the characterization of part surface topography was proposed and the evaluation indexes such as arithmetic average height (Ra) and stratification angle (?) were used to characterize the surface topography. Based on the surface geometrical profile, two prediction models were developed to calculate the evaluation indexes of part surface. Then experiments for fabricating thin wall parts were conducted and the evaluation indexes were measured experimentally. By comparing the experimental values with the predicted results, the mechanism of process parameters affecting surface topography was investigated. The results indicated that the top surface was mainly affected by scan step (Wd) which also could be represented by overlap ratio (µ). While overlap ratio was larger than 25.7%, excessive overlap resulting in poor surface topography occurred and the prediction model was invalid. In another hand, the side surface was mainly affected by offset distance (Wo) which also could be represented by offset ratio (t). If offset ratio was too large, the ending side would collapse resulting in poor side surface topography and the prediction model would fail to calculate the side surface roughness. The experiment results indicated that collapse would occur while offset ratio was larger than 54.5%. In the last, the surface roughness of a cubic object was measured and the results

Abstracts


demonstrated that the method proposed in present work was useful for evaluating surface quality of 3D object.

111177 Nanosized polycrystalline diamond cladding for surface protection of zirconium nuclear fuel tubes

Kratochvílová, I; Škoda, R; Škarohlíd, J; Ashcheulov, P; Jäger, A; Racek, J; Taylor, A; Shao, L [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2600, Pages 6] A 300 nm thick polycrystalline diamond layer has been used for protection of zirconium alloy nuclear fuel cladding against undesirable oxidation with no loss of chemical stability and preservation of its functionality. Deposition of polycrystalline diamond layer was carried out using microwave plasma enhanced chemical vapor deposition apparatus with linear antenna delivery (which enables deposition of PCD layers over large areas). Polycrystalline diamond coated zirconium alloy fuel tubes were subjected to corrosion tests to replicate nuclear reactor conditions, namely irradiation and hot steam oxidation. Stable radiation tolerance of the polycrystalline diamond layer and its protective capabilities against hot steam oxidation of the zirconium alloy were confirmed. Finally, the use of polycrystalline diamond layers as a sensor of specific conditions (temperature/pressure dependent phase transition) in nuclear reactors is suggested.

111178 Acceleration of regeneration treatment for nanostructured bainitic steel by rotary impacting trailed weldingFang, K; Yang, JG; Song, KJ; Liu, XS; Fang, HY [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 2935, Pages 6] The method called rotary impacting trailed welding (RITW) was proposed to accelerate the regeneration treatment of nanostructured bainitic steel welded joint. Stress and strain behaviors of welding metal under this mechanical process were analyzed using finite element software. Rotary and impacting could simultaneously take effect to generate large plastic deformation in the welded joint. Detailed changes of microstructures in

the welded joints were characterized by optical microscopy and scanning electron microscopy. Results show that the large deformation of austenite in the welded joint can accelerate the bainite transformation and reduce the regeneration time. Meanwhile, large shear deformation in the austenite generated during welding has a strong effect on the bainite growth, which results in curved bainite plates.

111179 Temperature changes of copper nanoparticle ink during flash light sintering

Park, Sung-Hyeon; Chung, Wan-Ho; Kim, Hak-Sung [J of M a t e r i a l s P r o c e s s i n g Technology, v 214, n 11, Nov 2014, Starting Page 2730, Pages 9] The c o p p e r nanoparticle ink was coated on p o l y i m i d e substrates using a

doctor blade method. The films thus formed were then sintered by flash light irradiation at room temperature under ambient conditions. The flash light energy was varied from 2 J/cm2 to 12 J/cm2. To measure the temperature change, a non-inverting amplifier circuit with an op-amp and a type-K thermocouple was devised. The sheet resistance change was simultaneously monitored using a Wheatstone bridge circuit. An analytical temperature calculation was conducted, considering the heat transfer phenomena during the flash light irradiation. As the results, the temperature of the copper nanoparticle films was reached to (318 °C) in 10 ms at the flash light irradiation energy higher than 12 J/cm2 and they were melted and fully sintered. The analytical solutions of the temperature profile of copper nanoparticles film and polyimide substrate (maximum temperature of copper nanoparticles film and polyimide substrates are 279 °C and 140 °C, respectively) in which the latent heats for phase changes of the copper nanoparticles and the binder (PVP) were concerned, agrees well with the experimentally measured temperature profiles of them (maximum temperature of copper nanoparticles film and polyimide substrates are 318 °C and 135 °C, respectively). The analytical calculation method proposed, could be used to design the flash light sintering variables applicable to various low-temperature flexible substrates.

Abstracts


PRODUCT DESIGN & MANUFACTURE

111180 Designing the Spindle Parameters of Vortex Spinning by Modeling the Fiber/Air Two-Phase Flow

Pei, Zeguang [Journal of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 031012, Pages 9] Vortex spinning

is a novel technology which produces short- staple yarns by utilizing high-speed swirling airflow. The structure of the spindle plays an important role in vortex spinning in terms of its effect on the resulting yarn properties. In this paper, a two-dimensional fluid-structure interaction (FSI) model for the fiber/air two-phase flow is presented to design the two spindle parameters—the spindle cone angle and spindle diameter by evaluating their effects on the fiber dynamics in the flow field inside the twisting system and the resulting yarn tenacity. The coupling between the fiber and airflow is solved and the motional characteristics of the fiber are obtained. It is found that the fiber moves downstream in a varying wavy shape and its spreaded trailing portion is then in a helical motion to form the yarn. The results also show that the increase of the spindle cone angle has a negative effect on the tenacity of the produced vortex yarn. The increased spindle diameter gives rise to the decreased vortex yarn tenacity. The numerical results can provide an explanation for the experimental results reported by previous studies.

111181 Integral design of contour error model and control for biaxial systemWu, Jianhua; Xiong, Zhenhua; Ding, Han [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 159, Pages 11] This paper focuses on the contour following accuracy improvement for biaxial systems using cross-coupled control (CCC). It proposes an integral design method including contour error model, contour control effort distribution and the CCC algorithm. First, a contour error model using the contour algebraic equation and its partial derivatives is established without the small tracking error

assumption. This model satisfies the condition that it equals to zero if and only if the real contour error value vanishes, which makes perfect contour following become possible in theory. Then, in order to decouple the contour following the feed-direction tracking, contour control effort distribution is decided to be in line with the normal vector at the desired point. Through expanding the proposed contour error model with Taylor series to make it be related to tracking errors of both axes, the stability condition of CCC is analyzed by the contour error transfer function (CETF). Experiments are carried out on an X–Y motion stage to verify the proposed method. The results show that it improves the contour following accuracy greatly in various conditions, even when large tracking errors occur.

111182 Scheme for Numerical Representation of Graph Structures in Engineering DesignWyatt, David F; Wynn, David C; Clarkson, P John [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011010, Pages 13] Graph structures are fundamental in many aspects of design. This paper discusses a way to improve access to design spaces of graph structures, by converting graph structures into numerical values and vice versa. Mathematical properties of such conversions are described, and those that are desirable are identified. A candidate conversion algorithm, Indexed Stacked Blocks, is proposed. Its use and benefits are illustrated through an example graph-structure design problem. The example demonstrates that such conversions allow design spaces of graph structures to be visualized, sampled, and evaluated. In principle, they also allow other powerful numerical techniques to be applied to the design of graph-structure-based systems.

111183 High Dimensional Model Representation With Principal Component AnalysisHajikolaei, Kambiz Haji; Wang, G Gary [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011003, Pages 11] In engineering design, spending excessive amount of time on physical experiments or expensive simulations makes the design costly and lengthy. This issue exacerbates when the design problem has a large number of inputs, or of high dimension. High dimensional model representation (HDMR) is one powerful method in approximating high dimensional, expensive, black-box (HEB) problems. One existing HDMR implementation, random sampling HDMR (RS-HDMR), can build an HDMR model from random sample points with a linear combination

Abstracts


of basis functions. The most critical issue in RS-HDMR is that calculating the coefficients for the basis functions includes integrals that are approximated by Monte Carlo summations, which are error prone with limited samples and especially with nonuniform sampling. In this paper, a new approach based on principal component analysis (PCA), called PCA-HDMR, is proposed for finding the coefficients that provide the best linear combination of the bases with minimum error and without using any integral. Several benchmark problems of different dimensionalities and one engineering problem are modeled using the method and the results are compared with RS-HDMR results. In all problems with both uniform and nonuniform sampling, PCA-HDMR built more accurate models than RS-HDMR for a given set of sample points.

111184 Design and Experimental Validation of Compact, Quick-Response Shape Memory Alloy Separation Device

Zhang, Xiaoyong; Yan, Xiaojun; Yang, Qiaolong [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011009, Pages 9] The shape memory alloy (SMA)-actuated separation devices that are currently used in small satellites were usually designed to handle large

separation loads. As a result, they have complex structures, large footprints, and high power consumptions. In this paper, we report a simpler and more compact separation device. A design methodology for the load-shifting SMA actuator (LSSA) used in a device was developed. Four prototypes were fabricated and tested to demonstrate the design concept and the LSSA design methodology. Experiments showed that this separation device has the merits of a quick response time, compact size, and simple structure, which give it potential for small-satellite applications.

111185 Kriging-Interpolated Level-Set Approach for Structural Topology OptimizationHamza, Karim; Aly, Mohamed; Hegazi, Hesham [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011008, Pages 12] Level-set approaches are a family of domain classification techniques that rely on defining a scalar level-set function (LSF), then carrying out the classification based on the value of the function relative to one

or more thresholds. Most continuum topology optimization formulations are at heart, a classification problem of the design domain into structural materials and void. As such, level-set approaches are gaining acceptance and popularity in structural topology optimization. In conventional level set approaches, finding an optimum LSF involves solution of a Hamilton-Jacobi system of partial differential equations with a large number of degrees of freedom, which in turn, cannot be accomplished without gradients information of the objective being optimized. A new approach is proposed in this paper where design variables are defined as the values of the LSF at knot points, then a Kriging model is used sto interpolate the LSF values within the rest of the domain so that classification into material or void can be performed. Perceived advantages of the Kriging-interpolated level-set (KLS) approach include alleviating the need for gradients of objectives and constraints, while maintaining a reasonable number of design variables that is independent from the mesh size. A hybrid genetic algorithm (GA) is then used for solving the optimization problem(s). An example problem of a short cantilever is studied under various settings of the KLS parameters in order to infer the best practice recommendations for tuning the approach. Capabilities of the approach are then further demonstrated by exploring its performance on several test problems.

111186 Development of a Multistage Reliability-Based Design Optimization Method

Paulson, Eric J; Starkey, Ryan P [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011007, Pages 8] Complex system acquisition and its associated technology development have a troubled recent history. The modern acquisition timeline consists of conceptual, preliminary, and detailed design followed by system test and production. The evolving nature of the estimates of system performance, cost, and schedule during this extended process may be a significant contribution to recent issues. The recently proposed multistage reliability-based design optimization (MSRBDO) method promises mprovements over reliability-based design optimization (RBDO) in achieved objective function

Abstracts


value. In addition, its problem formulation more closely resembles the evolutionary nature of epistemic design uncertainties inherent in system design during early system acquisition. Our goal is to establish the modeling basis necessary for applying this new method to the engineering of early conceptual/preliminary design. We present corrections in the derivation and solutions to the single numerical example problem published by the original authors, Nam and Mavris, and examine the error introduced under the reduced-order reliability sampling used in the original publication. MSRBDO improvements over the RBDO solution of 10–36% for the objective function after first-stage optimization are shown for the original second-stage example problem. A larger 26–40% improvement over the RBDO solution is shown when an alternative comparison method is used than in the original. The specific implications of extending the method to arbitrary m-stage problems are presented, together with a solution for a three-stage numerical example. Several approaches are demonstrated to mitigate the computational cost increase of MSRBDO over RBDO, resulting in a net decrease in calculation time of 94% from an initial MSRBDO baseline algorithm.

111187 Spectral Characterization of Hierarchical Modularity in Product Architectures1

Sarkar, Somwrita; Dong, Andy; Henderson, James A; Robinson, PA [J of Mechanical D e s i g n , v 136, n 1, Jan 2014, Starting Page 011006, Pages 12] Despite the importance of the architectural modularity of products and systems, existing m o d u l a r i t y metrics or

algorithms do not account for overlapping and hierarchically embedded modules. This paper presents a graph theoretic spectral approach to characterize the degree of modular hierarchical-overlapping organization in the architecture of products and complex engineered systems. It is shown that the eigenvalues of the adjacency matrix of a product architecture graph can reveal layers of hidden modular or hierarchical

modular organization that are not immediately visible in the predefined architectural description. We use the approach to analyze and discuss several design, management, and system resilience implications for complex engineered systems.

111188 Enabling Flexibility in Engineering Systems: A Taxonomy of Procedures and a Design FrameworkCardin, Michel-Alexandre [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011005, Pages 14] This paper presents a five-phase taxonomy of systematic procedures to enable flexibility in the design and management of engineering systems operating under uncertainty. The taxonomy integrates contributions from surveys, individual articles, and books from the literature on engineering design, manufacturing, product development, and real options analysis obtained from professional e-index search engines. Thirty design procedures were classified based on the kind of early conceptual activities they support: baseline design, uncertainty recognition, concept generation, design space exploration, and process management. Each procedure is evaluated based on ease of use to enable flexibility analysis, whether it can be used directly in collaborative design activities, and has a proven applicability record in industry and research. The organizing principles integrate the procedures into a cohesive and systematic design framework. Demonstration applications on engineering systems case studies show that it helps designers select relevant procedures in different phases of the design process, depending on the context, available analytical resources, and objectives. In turn, the case studies show that the design framework helps generate concepts with improved lifecycle performance compared to baseline concepts. The taxonomy provides guidance to organize ongoing research efforts, and highlights potential contribution areas in this field of engineering design research.

111189 Product Resynthesis: Knowledge Discovery of the Value of End-of-Life Assemblies and Subassemblies

Kang, Sung Woo; Sane, C h i n m a y ; Vasudevan, N i t i s h ; T u c k e r , Conrad S [Journal of

Abstracts


Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011004, Pages 14] The trends of increasing waste and comparatively low growth of waste treatment methodologies have created the need for better utilization of the products we deem unfit for use. The options available for utilizing end-of-life (EOL) products are currently restricted to reusing, recycling, remanufacturing, and permanent disposal. In this work, the authors propose a new EOL option called resynthesis that utilizes existing waste from EOL products in a novel way through the synthesis of assemblies / sub assemblies across multiple domains (i.e., consumer electronics, health care, automotive, etc.). The resynthesis of assemblies/subassemblies is achieved by quantifying their similarities (form and function) across multiple domains. A mixed-integer linear model is developed to determine the optimal EOL strategy for each component/subassembly. As a means of verifying the EOL decision, the value of the “new” resynthesized product is compared with the value that would be derived if the individual subassemblies were reused, remanufactured, recycled, or disposed. A case study involving an electronic mouse is used to validate the proposed methodology and to demonstrate its practicality as an alternate enterprise level EOL option.

111190 Priming Designers to Communicate SustainabilityShe, Jinjuan; MacDonald, Erin [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011001, Pages 12] Priming is a psychological experimental technique that uses an artifact, exposure, or experience to stimulate cognitive accessibility of specific mental content. Design techniques that use priming stimuli have thus far focused on generating more features, novel features, and relevant features and addressing latent customer needs. This article presents a design technique that uses priming specifically to help designers to communicate sustainability via design at an early stage in the design process. The authors have determined that sustainable products face a special challenge in the market because thoughtful sustainability features such as decreased energy usage, use of recycled materials, or manufacturing considerations are sometimes “hidden” from the customer. As green marketing messages are not always trusted, another approach is to communicate sustainability to the customer through product features. We propose and test a new design technique that uses psychological priming to help designers generate product

features that communicate sustainability to the customer. The technique involves performing a sensory- and sustainability heightening activity before generating ideas for product features. We investigate priming stimuli in the form of a questionnaire and a collage activity and compare these techniques along with other existing priming-based techniques to a control condition. The new technique is proven to be more effective in helping designers generate product features that communicate sustainability, as judged by both experts and consumers.

111191 Product Design Retrieval by Matching Bills of Materials

Kashkoush, M; ElMaraghy, H [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 011002, Pages 10] A new automatic design retrieval method that identifies the legacy product design most similar to a new one is proposed. Matching phylogenetic trees has been utilized in biological science for decades and is referred to as “tree reconciliation.” A new application of this approach in manufacturing is presented where legacy designs are retrieved based on reconciliation of trees representing products bill of materials (BOM). A product BOM is a structured tree, which represents its components and their hierarchal relationships; hence, it captures the contents and structure of assembled products. Making use of data associated with the retrieved designs also helps speed-up other downstream planning activities such as process planning, hence improving planning efficiency. A chemical processing centrifugal pump is used as a case study for illustration. The results obtained using the proposed method is compared with those recently published on BOM trees matching for further analysis and verification. This novel method is less computationally complex than available state-of-the-art algorithms.

Abstracts


TOOLS & TOOLING

111192 Real-time tool wear monitoring in milling using a cutting condition independent method

Nouri, Mehdi; Fussell, Barry K; Ziniti, Beth L; Linder, Ernst [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 1, Pages 13] This

paper describes a new method to monitor end milling tool wear in real-time by tracking force model coefficients during the cutting process. The behavior of these coefficients are shown to be independent from the cutting conditions and correlated with the wear state of the cutting tool. The tangential and radial force model coefficients are normalized and combined into a single parameter for wear monitoring. A number of experiments with different workpiece materials are run to investigate the feasibility of tool wear monitoring using this method. We show that this method can be used in real-time to track tool wear and detect the transition point from the gradual wear region to the failure region in which the rate of wear accelerates.

111193 Molecular dynamics modelling of brittle–ductile cutting mode transition: Case study on silicon carbide

Xiao, Gaobo; To, Suet; Zhang, Guoqing [Int J of Machine Tools & M a n u f a c t u r e , v 88, Jan 2015, Starting Page 214, Pages 9] The mechanism of b r i t t l e – d u c t i l e

cutting mode transition has received much attention over the past two decades. Due to the difficulties in directly observing the cutting zone during the brittle–ductile cutting mode transition by experimental techniques, many molecular dynamics (MD) studies have been conducted to investigate the atomicscale details of the phenomena, e.g. phase transformation, stress distribution and crack initiation, mostly under nanoscale undeformed chip thicknesses. A research gap is that direct MD modelling of the transition

under practical undeformed chip thicknesses was not achieved in previous studies, due to the limitations in both computation capability and interaction potential. Important details of the transition under practical undeformed chip thicknesses thereby remain unclear, e.g. the location of crack formation and the stress distribution. In this study, parallel MD codes based on graphics processing units (GPU) are developed to enable large-scale MD simulations with multi-million atoms. In addition, an advanced interaction potential which reproduces brittle fracture much more accurately is adopted. As a result, the direct MD simulation of brittle–ductile cutting mode transition is realised for the first time under practical undeformed chip thicknesses. The MD-modelled critical undeformed chip thickness is verified by a plunge cutting experiment. The MD modelling shows that tensile stress exists around the cutting zone and increases with undeformed chip thickness, which finally induces brittle fractures. The location of crack formation and direction of propagation varies with undeformed chip thickness in the MD simulations, which agrees with the surface morphologies of the taper groove produced by the plunge cutting experiment. This study contributes significantly to the understanding of the details involved in the brittle–ductile cutting mode transition.

111194 Size effect and minimum chip thickness in micromilling

Oliveira, Fernando Brandão de; Rodrigues, Alessandro Roger; Coelho, Reginaldo Teixeira; de Souza, Adriano Fagali [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 39, Pages 16] This paper compares the size effect behaviour in micro- and macromilling by applying Analysis of Variance on the specific cutting force (kc) and relating it with the tool

Abstracts


edge radius (re), workpiece roughness (Ra), cutting force and chip formation when cutting slots in AISI 1045 steel. Size effect is observed in micromilling through hyper-proportional increase of the specific cutting force for feeds per tooth (f) lower than endmill edge radius, reaching levels of grinding process (~70 GPa) when f?re/10. This particular milling condition does not produce chips. The minimum uncut chip thickness (hmin) varied between 22% and 36% of the endmill edge radius. This range was determined by proposing a curve (kc/Raversus f/re) where specific cutting force becomes amplified (size effect) due to workpiece roughness association. In addition to the minimum uncut chip thickness, there is a cutting thickness between hmin and re that optimizes workpiece surface integrity and not only forms the chip completely. This thickness may be as important as hmin. Besides this, a relation between deformation mechanisms during chip formation and cutting force oscillations is proposed for micromilling and also related to tool tip radius (re). This cutting force behaviour enables the determination of certain characteristic chip thicknesses including hmin. Finally, it is concluded that minimum uncut chip thickness varies practically from 1/4 to 1/3 of tool cutting edge, regardless of workpiece material, tool geometry, mechanical machining process and technique used for measuring or estimating hmin, i.e. numerical, analytical or experimental.

111195 Tool design guidelines for the equal channel angular swaging (ECAS) process

Görtan, Mehmet Okan; Groche, Peter [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2220, Pages 13] A new severe plastic deformation (SPD) process of “equal channel angular swaging” (ECAS) is

developed by combining the conventional equal channel angular pressing with the incremental bulk metal forming method rotary swaging. The ECAS tool system contains four forming zones in a single forming pass. In the current study, the effect of the multi-stage forming process on both the strain distribution and the material deformation is investigated by means of finite element (FE) simulations and these simulations are verified with model experiments. The results serve as tool design guidelines for the ECAS process.

111196 Diffusion Theory Applied to Tool-Life Stochastic Modeling Under a Progressive Wear ProcessBraglia, Marcello; Castellano, Davide [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 031010, Pages 12] In this paper, a novel approach to the derivation of the tool-life distribution, when the tool useful life ends after a progressive wear process, is presented. It is based on the diffusion theory and exploits the Fokker–Planck equation. The Fokker–Planck coefficients are derived on the basis of the injury theory assumptions. That is, tool-wear occurs by detachment of small particles from the tool working surfaces, which are assumed to be identical and time-independent. In addition, they are supposed to be small enough to consider the detachment process as continuous. The tool useful life ends when a specified total volume of material is thus removed. Tool-life distributions are derived in two situations: (i) both Fokker–Planck coefficients are time-dependent only and (ii) the diffusion coefficient is neglected and the drift is wear-dependent. Theoretical results are finally compared to experimental data concerning flank wear land in continuous turning of a C40 carbon steel bar adopting a P10 type sintered carbide insert. The adherence to the experimental data of the tool-life distributions derived exploiting the Fokker–Planck equation is satisfactory. Moreover, the tool-life distribution obtained, when the diffusion coefficient is neglected and the drift is wear-dependent, is able to well-represent the wear behavior at intermediate and later times.

111197 Influences of chip serration on micro-topography of machined surface in high-speed cuttingSu, Guosheng; Liu, Zhanqiang; Li, Liang; Wang, Bing [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 202, Pages 6] Saw-tooth

Abstracts


chip changes from macroscopically continuous ribbon to separated segments with the increase of cutting speed. The aim of this study is to find the correlations between chip morphology and machined surface micro-topography at different chip serration stages encountered in high speed cutting. High strength alloy steel AerMet100 was employed in orthogonal cutting experiments to obtain chips at different serration stages and corresponding machined surfaces. The chips and machined surfaces obtained were then examined with optical microscope (OM), scanning electron microscope (SEM), and white light interferometer (WLI). The result shows that chip serration causes micro-waves on machined surface, which increases machined surface roughness. However, wave amplitudes (surface roughness) at different serration stages are different. The principal factor influencing wave amplitude is the thickness of the sawed segment (tooth) of saw-tooth chip. With cutting parameters in this study, surface roughness contributed by chip serration ranges from 0.39 µm to 1.85 µm. This may bring on serious problems in the case of trying to replace grinding with high-speed cutting in rough machining. Some suggestions have been proposed to control the chip serration-caused surface roughness in high-speed cutting based on the results of the current study.

111198 The estimation of cutting forces and specific force coefficients during finishing ball end milling of inclined surfaces

Wojciechowski, Szymon [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 110, Pages 14] The majority of cutting force models applied for the ball end milling process

includes only the influence of cutting parameters (e.g. feedrate, depth of cut, cutting speed) and estimates forces on the basis of coefficients calibrated during slot milling. Furthermore, the radial run out phenomenon is predominantly not considered in these models. However this approach can induce excessive force estimation errors, especially during finishing ball end milling of sculptured surfaces. In addition, most of cutting force models is formulated for the ball end milling process with axial depths of cut exceeding 0.5 mm and thus, they are not oriented directly to the finishing processes. Therefore, this paper proposes an accurate cutting force model applied for the finishing ball end milling, which includes also the influence of surface inclination and cutter’s run out. As part of this work the new method of specific force coefficients calibration has been also developed. This approach is based on the calibration during ball end milling with various surface inclinations and the application of instantaneous force signals as an input data. Furthermore, the analysis of specific force coefficients in function of feed per tooth, cutting speed and surface inclination angle was also presented. In order to determine geometrical elements of cut precisely, the radial run out was considered in equations applied for the calculation of sectional area of cut and active length of cutting edge. Research revealed that cutter’s run out and surface inclination angle have significant influence on the cutting forces, both in the quantitative and qualitative aspect. The formulated model enables cutting force estimation in the wide range of cutting parameters, assuring relative error’s values below 16%. Furthermore, the consideration of cutter’s radial run out phenomenon in the developed model enables the reduction of model’s relative error by the 7% in relation to the model excluding radial run out.

111199 Modeling the mechanics and dynamics of arbitrary edge drillsAhmadi, K; Savilov, A [Int J of Machine Tools & Manufacture, v 89, Feb 2015, Starting Page 208, Pages 13] This paper presents a new approach for modelling the cutting forces and chatter stability limits in drills with arbitrary lip geometry. The oblique cutting geometry at each point on the drill lip is modelled using parametric curve equations. The cutting force and process damping coefficients at different parts of the drill lip are identified empirically; the cutting force coefficients are

Abstracts


identified from non-symmetric drilling tests, and the process damping coefficients are identified from chatter-free orthogonal turning tests. The presented approach provides a practical method for modelling the cutting forces and vibration stability without needing the detailed geometry of drill lips. The accuracy of presented model in predicting lateral and torsional-axial chatter stability limits is verified by conducting drilling tests using drills with various edge geometries.

111200 WC/Co Tool Wear in Dry Turning of Commercially Pure Aluminium

Wang, Xin; Kwon, Patrick Y [Journal of Manufacturing Sci & E n g g : A S M E Trans, v 136, n 3, Jun 2014, Starting Page 031006, Pages 7] Dry turning of commercially pure aluminum was performed with carbide inserts to generate tool wear. Thus, the wear on the carbides tools

were generated by purely interacting with aluminum and without any abrasive, which would be the baseline wear for all aluminum alloys. The flank wear was the main mode, which increased with the cutting speed and decreased as the grain size of the carbides increases. Two types of tool wear pattern have been observed with scanning electron microscopy (SEM) and laser scanning confocal microscope (LSCM): (1) the cavities left from the carbide grains which were dislodged by the adhered layer of the work material and (2) the abrasion on the flank surface caused by the dislodged carbide grains. The width of the scoring marks was correlated with the carbide grain size, which corroborates the abrasion by the dislodged carbide grains from the carbide tool. Energy-dispersive X-ray spectroscopy (EDX) showed that the concentration of the cobalt binder was reduced on the worn area of the insert. The preferential wear of the cobalt binder is believed to facilitate the carbide grain pull-out. Therefore, the wear

mechanism in turning pure aluminum is a combination of adhesion and abrasion.

BIOMEDICAL ENGINEERING

111201 Austenite–martensite phase transformation of biomedical Nitinol by ball burnishing

Fu, CH; Sealy, MP; Guo, YB; Wei, XT [J of Materials Processing Technology, v 214, n 12, Dec 2014, Starting Page 3122, Pages 9] Nitinol has received considerable attention for biomedical and aerospace applications due to its shape memory and superelastic properties. Shape memory and superelasticity are induced in Nitinol by transforming austenite into martensite. Austenite can transform to martensite by applying stress or heat. One promising method to initiate a stress induced phase transformation is ball burnishing. In this study, phase transformation of Nitinol (Ni50.8Ti49.2) (at.%) by ball burnishing at various forces was investigated. Burnishing tracks were characterized and microstructures in the subsurface were investigated. Also, a corresponding burnishing simulation was performed to gain insight into the phase transformation mechanism of Nitinol by burnishing ◘

Documents

Editorial Board Vol. 16 No. 5 May 2017 Contents · K K Rajagopal M Chellamalai V Shanmugaraj V G Yoganath ... . Bibliography ... Annamalai, VE; Lakshminarayanan, AK