TechSolve (United States)

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Abstract The process mechanics phenomena play an important role in all metal cutting processes. Conditions are changing progressively not only to high velocities and deformation, but also to the interfacial friction between two different materials — tool and workpiece, and inside the same material, as a result of material flow with high temperatures. It will be shown, that during the ploughing effect in the interface between tool and chips there are two different kinds of friction, external and internal friction. All the existent models ignore this reality. Therefore, an alternative must be found to model the real phenomena during metal plastic flow in a more appropriate manner. In this study, we will consider the cutting process in fundamental terms based only on mathematics and physics. In connection with this fundamental development a question arises, “Which parameters are the best for characterizing the cutting process and can the equations be proven after processing, because nearly each parameter will disappear, such as stress, strain, friction or temperatures etc.”? It might be that only the plastic material deformation in connection with the external and internal friction can be identified and visualized after the cutting process for comparing the developed theoretical result with the experimental result of the chip formation region. That leads to the fact that, as long as agreement between theoretical and experimental result can be demonstrated, there is evidence that stress and strain, as well as friction and temperatures are correctly estimated. Therefore, this paper is focused on the plastic deformation ds in the plastic region during the cutting process. This plastic deformation will be expressed for the non-stationary, dynamic cutting process with non-uniform feed (toolworkpiece contact evolving from rubbing to material separation) and chip flow. This process behavior is relevant for the milling operation of metals as well as for carbon composites with glass fibers. For carbon composites with glass fibers, additional environmental and human safety aspects will arise, as described in this paper.

We have demonstrated flexible GeSn metal–semiconductor–metal (MSM) photodetectors (PDs) by exploring the effect of mechanical strain on their optoelectronic properties.

Brass is known for excellent machinability, but its ultimate productivity potential with high speed machining requires further study.An extensive testing program was conducted in laboratory and production settings on representative brass rod alloys using modern machine tools.Machinability data collected for turning, drilling and milling offers new insights on the effects of increasing speed, feed rate and depth of cut on tool life, efficiency, surface integrity and chip formation.The results show that advancements in machine tool technology, coupled with the underutilized high speed machining capabilities of brass, offer new opportunities for manufacturers to become more productive and profitable.

The aim of this research is to study droplet spray characteristics of an atomization-based cutting fluid (ACF) spray system including droplet entrainment angle and flow development regions with respect to three ACF spray parameters, viz., droplet and gas velocities, and spray distance. ACF spray experiments are performed by varying droplet and gas velocities. The flow development behavior is studied by modeling the droplets entrainment mechanism, and the density and distribution of the droplets across the jet flare. Machining experiments are also performed in order to understand the effect of the droplet spray behavior on the machining performances, viz., tool life/wear, and surface roughness during turning of a titanium alloy, Ti-6Al-4V. Experiments and the modeling of flow development behavior reveal that a higher droplet velocity and a smaller gas velocity result in smaller droplet entrainment angle leading to a gradual and early development of the co-flow with a smaller density and a better distribution of the droplet across the jet flare. Machining experiments also show that a higher droplet velocity, a lower gas velocity and a longer spray distance significantly improve the machining performances such as tool life and wear, and surface finish.

CNC machine tools have contributed in a very large extent, to the rise in highly ingenious manufacturing processes. The advent of automation into the CNC manufacturing procedures has ensured the tremendous improvements on the efficiency front over the past few decades. But the sine qua non of a successful industry lies in its ability to facilitate continuous technology change and development to maintain its edge in the competitive arena. The manufacturing community across the globe has realized the vast potential, integrated systems provide in terms of compatibility, interoperability, safety, repeatability, quality to withstand the rising competition and cost effective manufacturing. The call for an improved, vastly superior, ‘smart’ manufacturing system is greater than ever before. The Smart Machine Program Initiative (SMPI) at TechSolve, Cincinnati aims at establishing a supervisory control to monitor and regulate distinct process modules that will result in higher productivity and better quality. Additionally, functionality is also added into the CNC system because of enhanced data interactions between the component subsystems. As a first step in this direction, TechSolve has initiated an integration module to bring together Tool Condition Monitoring (TCM) Technologies with data from Intelligent Process Planning (IPP) as the inputs. The paper starts with the detailed overview of the SMPI project, the supervisory system and its importance. It then proceeds to explain how integration was bought about between TCM and IPP modules by using predicted power during the cut as a premise for calibration tool cuts. It also proceeds to explain how the integration added functionality in terms of monitoring tool alarms and adaptive control by using a good tool in place of a bad tool. The paper also proceeds to explain how the incorporation of the health index of tool holder can also enhance the functionality of the integration module. The paper concludes by setting down an agenda for future work and proposing the benefits of the supervisory system to the Smart Machine.

This study investigates the feasibility of monitoring tool wear and surface finish based on force signal by conducting a set of experiments in turning operations. Our study shows that the force signal appears curvi-linear with both uniform and maximal tool wear and shifts systematically across different cutting conditions; the force frequency spectrum contains extra information yet proves difficult to interpret and utilize; the surface finish behaves rather erratic. Three modeling techniques, multi-layer neural networks, adaptive neural-fuzzy inference system and multiple linear regressions are all capable of capturing the underlying force-wear dependency. Inferences are made regarding some essential issues, e.g. wear classification versus continuous wear estimation, force, vibration, acoustic emission versus sensor fusion. The study also suggests that a monitoring scheme should ultimately link measured signals to workpiece geometry inaccuracy rather than just to tool wear parameters. Additionally greater efforts should be directed to the integration of tool wear monitoring and geometry tolerances control.

Review Articles Some Observations on the Past and Present of Research on Machining and Grinding M. Eugene Merchant M. Eugene Merchant Institute of Advanced Manufacturing Sciences, 1111 Edison Drive, Cincinnati OH 45216-2265 Search for other works by this author on: This Site PubMed Google Scholar Author and Article Information M. Eugene Merchant Institute of Advanced Manufacturing Sciences, 1111 Edison Drive, Cincinnati OH 45216-2265 Appl. Mech. Rev. Mar 1993, 46(3): 72-73 (2 pages) https://doi.org/10.1115/1.3121402 Published Online: March 1, 1993 Article history Online: April 29, 2009

ADVERTISEMENT RETURN TO ISSUEPREVArticleNEXT3-(2-Carboxyindol-3-yl)propionic acid derivatives: antagonists of the strychnine-insensitive glycine receptor associated with the N-methyl-D-aspartate receptor complexFrancesco G. Salituro, Boyd L. Harrison, Bruce M. Baron, Philip L. Nyce, Kenneth T. Stewart, and Ian A. McDonaldCite this: J. Med. Chem. 1990, 33, 11, 2944–2946Publication Date (Print):November 1, 1990Publication History Published online1 May 2002Published inissue 1 November 1990https://doi.org/10.1021/jm00173a003RIGHTS & PERMISSIONSArticle Views519Altmetric-Citations39LEARN ABOUT THESE METRICSArticle Views are the COUNTER-compliant sum of full text article downloads since November 2008 (both PDF and HTML) across all institutions and individuals. These metrics are regularly updated to reflect usage leading up to the last few days.Citations are the number of other articles citing this article, calculated by Crossref and updated daily. Find more information about Crossref citation counts.The Altmetric Attention Score is a quantitative measure of the attention that a research article has received online. Clicking on the donut icon will load a page at altmetric.com with additional details about the score and the social media presence for the given article. Find more information on the Altmetric Attention Score and how the score is calculated. Share Add toView InAdd Full Text with ReferenceAdd Description ExportRISCitationCitation and abstractCitation and referencesMore Options Share onFacebookTwitterWechatLinked InReddit PDF (409 KB) Get e-Alerts Get e-Alerts