Search results

Filters

  • Journals
  • Authors
  • Keywords
  • Date
  • Type

Search results

Number of results: 44
items per page: 25 50 75
Sort by:
Download PDF Download RIS Download Bibtex

Abstract

Artificial neural network (ANN), a Computational tool that is frequently applied in the modeling and simulation of manufacturing processes. The emerging forming technique of sheet metal which is typically called single point incremental forming (SPIF) comes into the map and the research interest towards its technological parameters. The surface quality of the end product is a major issue in SPIF, which is more critical with the hard metals. The part of the brass metal is demanded in many industrial uses because of its high load-carrying capacity and its wear resistance property. Considering the industrial interest and demand of the brass metal products, the present study is done with the SPIF experiment on calamine brass Cu67Zn33 followed by an ANN analysis for predicting the absolute surface roughness. The modeling result shows a close agreement with the measured data. The minimum and maximum errors are found in experiment 3 and experiment 7 respectively. The error of predicted roughness is found in the range of –30.87 to 20.23 and the overall coefficient of performance of ANN modeling is 0.947 which is quite acceptable.
Go to article

Authors and Affiliations

Manish Oraon
1
Vinay Sharma
1

  1. Birla Institute of Technology, Faculty of Production Engineering, India
Download PDF Download RIS Download Bibtex

Abstract

Surface roughness has an important influence on the service performance and life of parts. Areal surface roughness has the advantage of accurately and comprehensively characterizing surface microtopography. Understanding the relationship and distinction between profile and areal surface roughness is conducive to deepening the study of areal surface roughness and improving its application. In this paper, the concepts, development, and applications of surface roughness in the profile and the areal are summarized from the aspect of evaluation parameters. The relationships and differences between surface roughness in the profile and the areal are analyzed for each aspect, and future development trends are identified.
Go to article

Authors and Affiliations

Baofeng He
1
Siyuan Ding
1
Zhaoyao Shi
1

  1. Beijing University of Technology, Faculty of Materials and Manufacturing, Beijing Engineering Research Center of Precision Measurement Technology and Instruments, 100 Ping Le Yuan, Chaoyang District, Beijing 100124, China
Download PDF Download RIS Download Bibtex

Abstract

In this present study, the effect of the shot peening process on fatigue life, surface hardness and corrosion properties of a low carbon alloy steel is examined at room temperature. The research article addresses the effect of shot peening by varying the process parameters such as peening distance and pressure with amachrome as shots. The experiment is designed by means of full factorial design. The experimental result reveals that the pressure and distance are the most significant factors in the shot peening process. The results illustrate that the average pressure of 7 bar and distance of 100 mm improves fatigue life by 1.5% of unpeened material under 20 Hz frequency while corrosion resistance improves by 4% with unpeening of the low carbon alloy steel by using amachrome as a shot.
Go to article

Bibliography

  1.  K. Miková, S. Bagherifard, O. Bokuvka, M. Guagliano, and L. Trško, “Fatigue behavior of X70 microalloyed steel after severe shot peening”, Int. J. Fatigue 55, 33‒42 (2013).
  2.  H. Kovacı, Y.B. Bozkurt, A.F. Yetim, M. Aslan, and A. Çelik, “The effect of surface plastic deformation produced by shot peening on corrosion behavior of a low-alloy steel”, Surf. Coat. Technol. 360, 78‒86 (2019).
  3.  O. Unal, Effect of pre-heat treatment on fatigue behavior of severe shot peened and plasma nitrided SAE4140 steel”, J. Aeronaut. Space Technol. 11(1), 57‒63 (2018).
  4.  O. Takakuwa and H. Soyama, “Effect of residual stress on the corrosion behavior of austenitic stainless steel”, Adv. Chem. Eng. Sci. 5(1), 62 (2014).
  5.  A.A. Ahmed, M. Mhaede, M. Wollmann, and L. Wagner, “Effect of micro shot peening on the mechanical properties and corrosion behavior of two microstructure Ti–6Al–4V alloy”, Appl. Surf. Sci. 363, 50‒58 (2016).
  6.  V. Azar, B. Hashemi, and M.R. Yazdi, “The effect of shot peening on fatigue and corrosion behavior of 316L stainless steel in Ringer’s solution”, Surf. Coat. Technol. 204(21‒22), 3546‒3551 (2010).
  7.  B. Hashemi, M.R. Yazdi, and V. Azar, “The wear and corrosion resistance of shot peened– nitrided 316L austenitic stainless steel”, Mater. Des. 32(6), 3287‒3292 (2011).
  8.  S.M. Hassani-Gangaraj, A. Moridi, M. Guagliano, A. Ghidini, and M. Boniardi, “The effect of nitriding, severe shot peening and their combination on the fatigue behavior and micro- structure of a low-alloy steel”, Int. J. Fatigue 62, 67‒76 (2014).
  9.  O. Hatamleh, J. Lyons, and R. Forman, “Laser peening and shot peening effects on fatigue life and surface roughness of friction stir welded 7075‐T7351 aluminum”, Fatigue Fract. Eng. Mater. Struct. 30(2), 115‒130 (2007).
  10.  M. Hilpert and L. Wagner, “Corrosion fatigue behavior of the high-strength magnesium alloy AZ 80”, J. Mater. Eng. Perform. 9(4), 402‒407 (2000).
  11.  S. Kalainathan, S. Sathyajith, and S. Swaroop, “Effect of laser shot peening without coating on the surface properties and corrosion behavior of 316L steel”, Opt. Lasers Eng. 50(12), 1740‒1745 (2012).
  12.  S.A. Khan, M.S. Bhuiyan, Y. Miyashita, Y. Mutoh, and T. Koike, “Corrosion fatigue behavior of die-cast and shot-blasted AM60 magnesium alloy”, Mater. Sci. Eng. A 528(4‒5), 1961‒1966 (2011).
  13.  G.H. Majzoobi, J. Nemati, A.N. Rooz, and G.H. Farrahi, “Modification of fretting fatigue behavior of AL7075–T6 alloy by the application of titanium coating using IBED technique and shot peening”, Tribol. Int. 42(1), 121‒129 (2009).
  14.  Y. Shadangi, K. Chattopadhyay, S.B. Rai, and V. Singh, “Effect of LASER shock peening on microstructure, mechanical properties and corrosion behavior of interstitial free steel”, Surf. Coat. Technol. 280, 216‒224 (2015).
  15.  Y. Tan, G. Wu, J.M. Yang, and T. Pan, “Laser shock peening on fatigue crack growth behaviour of aluminium alloy”, Fatigue Fract. Eng. Mater. Struct. 27(8), 649‒656 (2004).
  16.  C. Ye, S. Suslov, B.J. Kim, E.A. Stach, and G.J. Cheng, “Fatigue performance improvement in SAE4140 steel by dynamic strain aging and dynamic precipitation during warm laser shock peening”, Acta Mater. 59(3), 1014‒1025 (2011).
  17.  Standard practice for cleaning, descaling and passivation of stainless steels parts, equipment and systems, A380, Annual Book of ASTM Standards, American Society for Testing and Materials, 1999
  18.  C. Liu, H. Zheng, X. Gu, B. Jiang, and J. Liang, “Effect of severe shot peening on corrosion behavior of AZ31 and AZ91 magnesium alloys”, J. Alloy. Compd. 770 500‒506 (2019).
  19.  R. Ebner, P. Gruber, W. Ecker, O. Kolednik, M. Krobath, and G. Jesner, “Fatigue damage mechanisms and damage evolution near cyclically loaded edges”, Bull. Pol. Ac.: Tech. 58(2), 267‒279 (2010).
  20.  Standard test method for micro indentation hardness of materials, E384-99, Annual Book of ASTM Standards, American Society for Testing and Materials, 1999.
Go to article

Authors and Affiliations

C. Selva Senthil Prabhu
1
P. Ashoka Varthanan
2
T. Ram Kumar
1

  1. Department of Mechanical Engineering, Dr. Mahalingam College of Engineering and Technology, Pollachi – 642003, India
  2. Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Coimbatore – 642003, India
Download PDF Download RIS Download Bibtex

Abstract

In this paper, an experimental surface roughness analysis in milling of tungsten carbide using a monolithic torus cubic boron nitride (CBN) tool is presented. The tungsten carbide was received using direct laser deposition technology (DLD). The depth of cut (ap), feed per tooth (fz) and tool wear (VBc) influence on surface roughness parameters (Ra, Rz) were investigated. The cutting forces and accelerations of vibrations were measured in order to estimate their quantitative influence on Ra and Rz parameters. The surface roughness analysis, from the point of view of milling dynamics was carried out. The dominative factor in the research was not feed per tooth fz (according to a theoretical model) but dynamical phenomena and feed per revolution f connected with them.

Go to article

Authors and Affiliations

Paweł Twardowski
Download PDF Download RIS Download Bibtex

Abstract

The paper presents the results of investigations of the growth of protective coating on the surface of ductile iron casting during the hot-dip

galvanizing treatment. Ductile iron of the EN-GJS-600-3 grade was melted and two moulds made by different technologies were poured to

obtain castings with different surface roughness parameters. After the determination of surface roughness, the hot-dip galvanizing

treatment was carried out. Based on the results of investigations, the effect of casting surface roughness on the kinetics of the zinc coating

growth was evaluated. It was found that surface roughness exerts an important effect on the thickness of produced zinc coating

Go to article

Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
Download PDF Download RIS Download Bibtex

Abstract

Surface roughness parameter prediction and evaluation are important factors in determining the satisfactory performance of machined surfaces in many fields. The recent trend towards the measurement and evaluation of surface roughness has led to renewed interest in the use of newly developed non-contact sensors. In the present work, an attempt has been made to measure the surface roughness parameter of different machined surfaces using a high sensitivity capacitive sensor. A capacitive response model is proposed to predict theoretical average capacitive surface roughness and compare it with the capacitive sensor measurement results. The measurements were carried out for 18 specimens using the proposed capacitive-sensor-based non-contact measurement setup. The results show that surface roughness values measured using a sensor well agree with the model output. For ground and milled surfaces, the correlation coefficients obtained are high, while for the surfaces generated by shaping, the correlation coefficient is low. It is observed that the sensor can effectively assess the fine and moderate rough-machined surfaces compared to rough surfaces generated by a shaping process. Furthermore, a linear regression model is proposed to predict the surface roughness from the measured average capacitive roughness. It can be further used in on-machine measurement, on-line monitoring and control of surface roughness in the machine tool environment.

Go to article

Authors and Affiliations

A. Murugarajan
G. Samuel
Download PDF Download RIS Download Bibtex

Abstract

The prediction of machined surface parameters is an important factor in machining centre development. There is a great need to elaborate a method for on-line surface roughness estimation [1-7]. Among various measurement techniques, optical methods are considered suitable for in-process measurement of machined surface roughness. These techniques are non-contact, fast, flexible and tree-dimensional in nature.

The optical method suggested in this paper is based on the vision system created to acquire an image of the machined surface during the cutting process. The acquired image is analyzed to correlate its parameters with surface parameters. In the application of machined surface image analysis, the wavelet methods were introduced. A digital image of a machined surface was described using the one-dimensional Digital Wavelet Transform with the basic wavelet as Coiflet. The statistical description of wavelet components made it possible to develop the quality measure and correlate it with surface roughness [8-11].

For an estimation of surface roughness a neural network estimator was applied [12-16]. The estimator was built to work in a recurrent way. The current value of the Ra estimation and the measured change in surface image features were used for forecasting the surface roughness Ra parameter. The results of the analysis confirmed the usability of the application of the proposed method in systems for surface roughness monitoring.

Go to article

Authors and Affiliations

Anna Zawada-Tomkiewicz
Download PDF Download RIS Download Bibtex

Abstract

A numerical solution is presented to investigate the influence of the geometry and the amplitude of the transverse ridge on the characteristics of elastohydrodynamic lubrication for point contact problem under steady state condition. Several shapes of ridges with different amplitudes are used in the stationary case, such as flattop ridge, cosine wave ridge and sharp ridge of triangular shape. Results of film thickness and pressure distributions of the aforementioned ridge feature are presented at different locations through an elastohydrodynamically lubricated contact zone for different amplitude of the ridge. Simulations were performed using the Newton-Raphson iteration technique to solve the Reynolds equation. The numerical results reveal that, to predict optimum solution for lubricated contact problem with artificial surface roughness, the geometrical characteristics of the ridge should have profiles with smooth transitions such as those of a cosine wave shape with relatively low amplitude to reduce pressure spike and therefore cause the reduction in the film thickness. The position of the location of the ridge across the contact zone and the amplitude of the ridge play an important role in the formation of lubricant film thickness and therefore determine the pressure distribution through the contact zone.

Go to article

Bibliography

[1] R. Gohar and H. Rahnejat. Fundamentals of Tribology. Imperial College Press, London, 2008.
[2] N. Patir and H.S. Cheng. An average flow model for determining effects of three-dimensional roughness on partial hydrodynamic lubrication. Journal of Lubrication Technology, 100(1):12–17, 1978. doi: 10.1115/1.3453103.
[3] D. Epstein, T. Yu, Q.J. Wang, L.M. Keer, H.S. Cheng, S. Liu, S.J. Harris, and A. Gangopadhyay. An efficient method of analyzing the effect of roughness on fatigue life in mixed-EHL contact. Tribology Transactions, 46(2):273–281, 2003. doi: 10.1080/10402000308982626.
[4] Q.J. Wang, D. Zhu, H.S. Cheng, T. Yu, X. Jiang, and S. Liu. Mixed lubrication analyses by a macro-micro approach and a full-scale mixed EHL model. Journal of Tribology, 126(1):81–91, 2004. doi: 10.1115/1.1631017.
[5] M. Masjedi and M.M. Khonsari. On the effect of surface roughness in point-contact EHL: formulas for film thickness and asperity load. Tribology International, 82(Part A):228–244, 2015. doi: 10.1016/j.triboint.2014.09.010.
[6] Y.Z. Hu and D. Zhu. A full numerical solution to the mixed lubrication in point contacts. Journal of Tribology, 122(1):1–9, 2000. doi: 10.1115/1.555322.
[7] B. Jacod, C.H. Venner, and P.M. Lugt. Influence of longitudinal roughness on friction in EHL contacts. Journal of Tribology, 126(3):473–481, 2004. doi: 10.1115/1.1705664.
[8] P. Yang, J. Cui, Z.M. Jin, and D. Dowson. Influence of two-sided surface waviness on the EHL behavior of rolling/sliding point contacts under thermal and non-Newtonian conditions. Journal of Tribology, 130(4):041502, 2008. doi: 10.1115/1.2958078.
[9] J. Wang, C.H. Venner, and A.A. Lubrecht. Amplitude reduction in EHL line contacts under rolling sliding conditions. Tribology International, 44(12):1997–2001, 2011. doi: 10.1016/j.triboint.2011.08.009.
[10] C.H. Venner and A.A. Lubrecht. Numerical simulation of a transverse ridge in a circular EHL contact under rolling/sliding. Journal of Tribology, 116(4):751–761, 1994. doi: 10.1115/1.2927329.
[11] M.J.A. Holmes, H.P. Evans, T.G. Hughes, and R.W. Snidle. Transient elastohydrodynamic point contact analysis using a new coupled differential deflection method Part 1: Theory and validation. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 217(4):289–304, 2003. doi: 10.1243/135065003768618641.
[12] A. Félix-Quiñonez, P. Ehret, and J.L. Summers. Numerical analysis of experimental observations of a single transverse ridge passing through an elastohydrodynamic lubrication point contact under rolling/sliding conditions. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 218(2):109–123, 2004. doi: 10.1177/135065010421800206.
[13] A. Félix-Quiñonez, P. Ehret, J.L. Summers, and G.E. Morales-Espejel. Fourier analysis of a single transverse ridge passing through an elastohydrodynamically lubricated rolling contact: a comparison with experiment. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 218(1):33–43, 2004. doi: 10.1243/135065004322842816.
[14] M. Kaneta, H. Nishikawa and K. Matsuda. Behaviour of transverse ridges passing through a circular EHL conjunction. In: Snidle R.W., Evans H.P. (eds) IUTAM Symposium on Elastohydrodynamics and Micro-elastohydrodynamics, pages 189–200, Cardiff, UK, 1–3 September, 2004. doi: 10.1007/1-4020-4533-6_13.
[15] I. Křupka, M. Hartl, L. Urbanec, and J. Čermák. Single dent within elastohydrodynamic contact – comparison between experimental and numerical results. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 221(6):635–644, 2007. doi: 10.1243/13506501JET276.
[16] X. Feng Wang, R.F. Hu, W. Shang and F. Zhao. Experimental and numerical investigation on single dent with marginal bump in EHL point contacts. Industrial Lubrication and Tribology, 69(2):798-807, 2017.
[17] I. Ficza, P. Sperka, and M. Hartl. Transient calculations in elastohydrodynamically lubricated point contacts. Engineering Mechanics, 21(5):311–319, 2014.
[18] P. Sperka. In-situ studium zmeny topografie trecích povrchu v elastohydrodynamickém kontaktu (In-situ Study of Surface Topography changes in Elastoydrodynamic Contact). Ph.D. Thesis. Brno University of Technology, Czech Republic, 2011. (in Czech).
[19] F. Ali, M. Kaneta, I. Křupka, and M. Hartl. Experimental and numerical investigation on the behavior of transverse limited micro-grooves in EHL point contacts. Tribology International, 84:81–89, 2015. doi: 10.1016/j.triboint.2014.11.025.
[20] P. Sperka, I. Křupka, and M. Hartl. Prediction of shallow indentation effects in a rolling-sliding ehl contact based on amplitude attenuation theory. Tribology Online, 12(1):1–7, 2017. doi: 10.2474/trol.12.1.
[21] D. Kostal, P. Sperka, I. Křupka, and M. Hartl. Artificial surface roughness deformation in the starved EHL contacts. Tribology Online, 13(1):1–7, 2018. doi: 10.2474/trol.13.1.
[22] T. Hultqvist, A. Vrcek, P. Marklund, B. Prakash, and R. Larsson. Transient analysis of surface roughness features in thermal elastohydrodynamic contacts. Tribology International, 141:105915, 2020. doi: 10.1016/j.triboint.2019.105915.
[23] M.F. Al-Samieh and H. Rahnejat. Nano-lubricant film formation due to combined elastohydrodynamic and surface force action under isothermal conditions. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 215(9):1019–1029, 2001. doi: 10.1177/095440620121500902.
[24] M.F. Al-Samieh. Effect of changing ellipiticity ratio on the formation of ultra-thin lubricating film. Tribology in Industry, 39(4):431–443, 2017. doi: 10.24874/ti.2017.39.04.02.
[25] M.F. Al-Samieh. Surface roughness effects for newtonian and non-Newtonian lubricants. Tribology in Industry, 41(1):56–63, 2019. doi: 10.24874/ti.2019.41.01.07.
[26] D. Dowson and G.R. Higginson. A numerical solution to the elastohydrodynamic problem. Journal of Mechanical Engineering Science, 1(1):6–15, 1959. doi: 10.1243/JMES_JOUR_1959_001_004_02.
[27] C.J.A. Roelands. Correlation aspects of viscosity-temperature-pressure relationship of lubricating oils. Ph.D. Thesis. Delft University of Technology, The Netherlands, 1966.
Go to article

Authors and Affiliations

Mohamed F. Abd Al-Samieh
1

  1. Mechanical Design & Production Department, Military Technical College, Cairo, Egypt.
Download PDF Download RIS Download Bibtex

Abstract

In this paper, the authors present surface roughness profile assessment using continuous wavelet transform (CWT). Roughness profiles after turning and rough and finish belt grinding of hardened (62HRC) AISI 52100 steel are analyzed. Both Morlet and “Mexican hat” analyzing wavelets are used for the assessment of extrema and frequency distribution. The results of the CWT as a function of profile and momentary wavelet length are presented. It is concluded that CWT can be useful for the analysis of the roughness profiles generated by cutting and abrasive machining processes.

Go to article

Authors and Affiliations

Sebastian Brol
Wit Grzesik
Download PDF Download RIS Download Bibtex

Abstract

This paper explores the parametric appraisal and machining performance optimization during drilling of polymer nanocomposites reinforced by graphene oxide/carbon fiber. The consequences of drilling parameters like cutting velocity, feed, and weight % of graphene oxide on machining responses, namely surface roughness, thrust force, torque, delamination (In/Out) has been investigated. An integrated approach of a Combined Quality Loss concept, Weighted Principal Component Analysis (WPCA), and Taguchi theory is proposed for the evaluation of drilling efficiency. Response surface methodology was employed for drilling of samples using the titanium aluminum nitride tool. WPCA is used for aggregation of multi-response into a single objective function. Analysis of variance reveals that cutting velocity is the most influential factor trailed by feed and weight % of graphene oxide. The proposed approach predicts the outcomes of the developed model for an optimal set of parameters. It has been validated by a confirmatory test, which shows a satisfactory agreement with the actual data. The lower feed plays a vital role in surface finishing. At lower feed, the development of the defect and cracks are found less with an improved surface finish. The proposed module demonstrates the feasibility of controlling quality and productivity factors.

Go to article

Bibliography

[1] Y.A. Roy, K. Gobivel, K.S.V Sekar, and S.S. Kumar. Impact of cutting forces and chip microstructure in high speed machining of carbon fiber – Epoxy composite tube. Archives of Metallurgy and Materials, 62(3):1771–1777, 2017. doi: 10.1515/amm-2017-0269.
[2] R. Sengupta, M. Bhattacharya, S. Bandyopadhyay, and A.K. Bhowmick. A review on the mechanical and electrical properties of graphite and modified graphite reinforced polymer composites. Progress in Polymer Science, 36(5):638–670, 2011. doi: 10.1016/j.progpolymsci.2010.11.003.
[3] P.F. Mayuet, F. Girot, A. Lamíkiz, S.R. Fernández-Vidal, J. Salguero, and M. Marcos. SOM/SEM based characterization of internal delaminations of CFRP samples machined by AWJM. Procedia Engineering, 132:693–700, 2015. doi: 10.1016/j.proeng.2015.12.549.
[4] A. Caggiano. Machining of fibre reinforced plastic composite materials. Materials, 11(3):442, 2018. doi: 10.3390/ma11030442.
[5] V. Sonkar, K. Abhishek, S. Datta, and S.S. Mahapatra. Multi-objective optimization in drilling of GFRP composites: A degree of similarity approach. Procedia Materials Science, 6:538–543, 2014. doi: 10.1016/j.mspro.2014.07.068.
[6] P. Kuppan, A. Rajadurai, and S. Narayanan. Influence of EDM process parameters in deep hole drilling of Inconel 718. The International Journal of Advanced Manufacturing Technology, 38(1–2):74–84, 2008. doi: 10.1007/s00170-007-1084-y.
[7] K. Abhishek, S. Datta, and S.S. Mahapatra. Multi-objective optimization in drilling of CFRP (polyester) composites: Application of a fuzzy embedded harmony search (HS) algorithm. Measurement, 77:222–239, 2016. doi: 10.1016/j.measurement.2015.09.015.
[8] B.C. Routara, S.D. Mohanty, S. Datta, A. Bandyopadhyay, and S.S. Mahapatra. Combined quality loss (CQL) concept in WPCA-based Taguchi philosophy for optimization of multiple surface quality characteristics of UNS C34000 brass in cylindrical grinding. The International Journal of Advanced Manufacturing Technology, 51(1–4):135–143, 2010. doi: 10.1007/s00170-010-2599-1.
[9] M.K. Das, K. Kumar, T.K. Barman, and P. Sahoo. Optimization of MRR and surface roughness in PAC of EN 31 steel using weighted principal component analysis. Procedia Technology, 14:211–218, 2014. doi: 10.1016/j.protcy.2014.08.028.
[10] S. Grieu, A. Traoré, M. Polit, and J. Colprim. Prediction of parameters characterizing the state of a pollution removal biologic process. Engineering Applications of Artificial Intelligence, 18(5):559–573, 2005. doi: 10.1016/j.engappai.2004.11.008.
[11] S.D. Lahane, M.K. Rodge, and S.B. Sharma. Multi-response optimization of wire-EDM process using principal component analysis. IOSR Journal of Engineering, 2(8):38–47, 2012. doi: 10.9790/3021-02833847.
[12] R. Ramanujam, K. Venkatesan, V. Saxena, R. Pandey, T. Harsha, and G. Kumar. Optimization of machining parameters using fuzzy based principal component analysis during dry turning operation of inconel 625 – A hybrid approach. Procedia Engineering, 97:668–676, 2014. doi: 10.1016/j.proeng.2014.12.296.
[13] H. Yang, R. Luo, S. Han, and M. Li. Effect of the ratio of graphite/pitch coke on the mechanical and tribological properties of copper-carbon composites. Wear, 268(11–12):1337–1341, 2010. doi: 10.1016/j.wear.2010.02.007.
[14] R.K. Verma, P.K. Pal, and B.C. Kandpal. Machining performance optimization in drilling of GFRP composites: A utility theory (UT) based approach. In: Proceedings of 2016 International Conference on Control, Computing, Communication and Materials, pages 1–5, Allahbad, India, 21-22 Oct. 2016. doi: 10.1109/ICCCCM.2016.7918255.
[15] K. Palanikumar, J.C. Rubio, A. Abrão, A. Esteves, and J.P. Davim. Statistical analysis of delamination in drilling Glass Fiber-Reinforced Plastics (GFRP). Journal of Reinforced Plastics and Composites, 27(15):1615–1623, 2008. doi: 10.1177/0731684407083012.
[16] P.E. Faria, J.C. Campos Rubio, A.M. Abrão, and J.P. Davim. Dimensional and geometric deviations induced by drilling of polymeric composite. Journal of Reinforced Plastics and Composites, 28(19):2353–2363, 2009. doi: 10.1177/0731684408092067.
[17] V.N. Gaitonde, S.R. Karnik, J.C.C. Rubio, W. de Oliveira Leite, and J.P. Davim. Experimental studies on hole quality and machinability characteristics in drilling of unreinforced and reinforced polyamides. Journal of Composite Materials, 48(1):21–36, 2014. doi: 10.1177/0021998312467552.
[18] Niharika, B.P. Agrawal, I.A. Khan, and Z.A. Khan. Effects of cutting parameters on quality of surface produced by machining of titanium alloy and their optimization. Archive of Mechanical Engineering, 63(4):531–548, 2016. doi: 10.1515/meceng-2016-0030.
[19] S. Chakraborty and P.P. Das. Fuzzy modeling and parametric analysis of non-traditional machining processes. Management and Production Engineering Review, 10(3):111–123, 2019. doi: 10.24425/mper.2019.130504.
[20] S. Prabhu and B.K. Vinayagam. Multiresponse optimization of EDM process with nanofluids using TOPSIS method and Genetic Algorithm. Archive of Mechanical Engineering, 63(1):45–71, 2016. doi: 10.1515/meceng-2016-0003.
[21] D. Palanisamy and P. Senthil. Optimization on turning parameters of 15-5PH stainless steel using taguchi based grey approach and TOPSIS. Archive of Mechanical Engineering, 63(3):397–412, 2016. doi: 10.1515/meceng-2016-0023.
[22] M.S. Węglowski. Experimental study and response surface methodology for investigation of FSP process. Archive of Mechanical Engineering, 61(4):539–552, 2014. doi: 10.2478/meceng-2014-0031.
[23] H. Majumder, T.R. Paul, V. Dey, P. Dutta, and A. Saha. Use of PCA-grey analysis and RSM to model cutting time and surface finish of Inconel 800 during wire electro discharge cutting. Measurement, 107:19–30, 2017. doi: 10.1016/j.measurement.2017.05.007.
[24] P.K. Kharwar and R.K. Verma. Grey embedded in artificial neural network (ANN) based on hybrid optimization approach in machining of GFRP epoxy composites. FME Transactions, 47(3):641–648, 2019. doi: 10.5937/fmet1903641P.
[25] R. Arun Ramnath, P.R. Thyla, N. Mahendra Kumar, and S. Aravind. Optimization of machining parameters of composites using multi-attribute decision-making techniques: A review. Journal of Reinforced Plastics and Composites, 37(2):77–89, 2018. doi: 10.1177/0731684417732840.
[26] K. Żak. Cutting mechanics and surface finish for turning with differently shaped CBN tools. Archive of Mechanical Engineering, 64(3):347–357, 2017. doi: 10.1515/meceng-2017-0021.
[27] R. Bielawski, M. Kowalik, K. Suprynowicz, W. Rządkowski, and P. Pyrzanowski. Experimental study on the riveted joints in Glass Fibre Reinforced Plastics (GFRP). Archive of Mechanical Engineering, 64(3):301–313, 2017. doi: 10.1515/meceng-2017-0018.
[28] A.K. Parida, R. Das, A.K. Sahoo, and B.C. Routara. Optimization of cutting parameters for surface roughness in machining of GFRP composites with graphite/fly ash filler. Procedia Materials Science, 6:1533–1538, 2014. doi: 10.1016/j.mspro.2014.07.134.
[29] M.C. Yip, Y.C. Lin, and C.L. Wu. Effect of multi-walled carbon nanotubes addition on mechanical properties of polymer composites laminate. Polymers and Polymer Composites, 19(2–3):131–140, 2011.
[30] I. Burmistrov, N. Gorshkov, I. Ilinykh, D. Muratov, E. Kolesnikov, S. Anshin, I. Mazov, J.-P. Issi, and D. Kusnezov. Improvement of carbon black based polymer composite electrical conductivity with additions of MWCNT. Composites Science and Technology, 129:79–85, 2016. doi: 10.1016/j.compscitech.2016.03.032.
[31] N.S. Mohan, A. Ramachandra, and S. M. Kulkarni. Influence of process parameters on cutting force and torque during drilling of glass-fiber polyester reinforced composites. Composite Structures, 71(3–4):407–413, 2005. doi: 10.1016/j.compstruct.2005.09.039.
[32] R. Bhat, N. Mohan, S. Sharma, R.A. Agarwal, A. Rathi, and K.A. Subudhi. Multi-response optimization of the thrust force, torque and surface roughness in drilling of glass fiber reinforced polyester composite using GRA-RSM. Materials Today: Proceedings, 19:333–338, 2019. doi: 10.1016/j.matpr.2019.07.608.
[33] T. Miyake, K. Mukae, and M. Futamura. Evaluation of machining damage around drilled holes in a CFRP by fiber residual stresses measured using micro-Raman spectroscopy. Mechanical Engineering Journal, 3(6):1–16, 2016. doi: 10.1299/mej.16-00301.
[34] G.V.G. Rao, P. Mahajan, and N. Bhatnagar. Micro-mechanical modeling of machining of FRP composites – Cutting force analysis. Composites Science and Technology, 67(3–4):579–593, 2007. doi: 10.1016/j.compscitech.2006.08.010.
[35] R.K. Verma, K. Abhishek, S. Datta, P.K. Pal, and S.S. Mahapatra. Multi-response optimization in machining of GFRP (epoxy) composites: An integrated approach. Journal for Manufacturing Science and Production, 15(3):267–292, 2015. doi: 10.1515/jmsp-2014-0054.
[36] K. Pearson. On lines and planes of closest fit to systems of points in space. The London, Edinburgh, and Dublin Philosophical Magazine and Journal of Science, 2(11):559–572, 1901. doi: 10.1080/14786440109462720.
[37] D. Zhao, H. Qi, and J. Pan. A predication analysis of the factors influencing minimum ignition temperature of coal dust cloud based on principal component analysis and support vector machine. Archives of Mining Sciences, 64(2):335–350, 2019. doi: 10.24425/ams.2019.128687.
[38] M. Ukamanal, P.C. Mishra, and A.K. Sahoo. Effects of spray cooling process parameters on machining performance AISI 316 steel: a novel experimental technique. Experimental Techniques, 44(1):19–36, 2020. doi: 10.1007/s40799-019-00334-y.
[39] G. Karuna Kumar, C. Maheswara Rao, and V.V.S. KesavaRao. Application of WPCA & CQL methods in the optimization of mutiple responses. Materials Today: Proceedings, 18:25–36, 2019. doi: 10.1016/j.matpr.2019.06.273.
[40] D. Das, P.C. Mishra, S. Singh, A.K. Chaubey, and B.C. Routara. Machining performance of aluminium matrix composite and use of WPCA based Taguchi technique for multiple response optimization. International Journal of Industrial Engineering Computations, 9(4):551–564, 2018. doi: 10.5267/j.ijiec.2017.10.001.
[41] S.D. Mohanty, S.S. Mahapatra, and R.C. Mohanty. PCA based hybrid Taguchi philosophy for optimization of multiple responses in EDM. SADHANA, 44(1):1–9, 2019. doi: 10.1007/s12046-018-0982-z.
[42] U.A. Khashaba. Delamination in drilling GFR-thermoset composites. Composite Structures, 63(3–4):313–327, 2004. doi: 10.1016/S0263-8223(03)00180-6.
[43] L. Gemi, S. Morkavuk, U. Köklü, and D.S. Gemi. An experimental study on the effects of various drill types on drilling performance of GFRP composite pipes and damage formation. Composites Part B: Engineering, 172:186–194, 2019. doi: 10.1016/j.compositesb.2019.05.023.
[44] L. Li, C. Yan, H. Xu, D. Liu, P. Shi, Y. Zhu, G. Chen, X. Wu, and W. Liu. Improving the interfacial properties of carbon fiber–epoxy resin composites with a graphene-modified sizing agent. Journal of Applied Polymer Science, 136(9):1–10, 2019. doi: 10.1002/app.47122.
[45] U. Aich, R.R. Behera, and S. Banerjee. Modeling of delamination in drilling of glass fiber-reinforced polyester composite by support vector machine tuned by particle swarm optimization. International Journal of Plastics Technology, 23(1):77–91, 2019. doi: 10.1007/s12588-019-09233-8.
[46] D. Kumar and K.K. Singh. Investigation of delamination and surface quality of machined holes in drilling of multiwalled carbon nanotube doped epoxy/carbon fiber reinforced polymer nanocomposite. Journal of Materials: Design and Applications, 233(4):647–663, 2019. doi: 10.1177/1464420717692369.
[47] P. Kyratsis, A.P. Markopoulos, N. Efkolidis, V. Maliagkas, and K. Kakoulis. Prediction of thrust force and cutting torque in drilling based on the response surface methodology. Machines, 6(2):24, 2018. doi: 10.3390/MACHINES6020024.
[48] C.C. Tsao. Thrust force and delamination of core-saw drill during drilling of carbon fiber reinforced plastics (CFRP). The International Journal of Advanced Manufacturing Technology, 37(1–2):23–28, 2008. doi: 10.1007/s00170-007-0963-6.
[49] A.M. Abrão, J.C.C. Rubio, P.E. Faria, and J.P. Davim. The effect of cutting tool geometry on thrust force and delamination when drilling glass fibre reinforced plastic composite. Materials & Design, 29(2):508–513, 2008. doi: 10.1016/j.matdes.2007.01.016.
[50] A. Janakiraman, S. Pemmasani, S. Sheth, C. Kannan, and A.S.S. Balan. Experimental investigation and parametric optimization on hole quality assessment during drilling of CFRP/GFRP/Al stacks. Journal of The Institution of Engineers (India): Series C, 101:291–302, 2020. doi: 10.1007/s40032-020-00563-w.
[51] S.Y. Park, W.J. Choi, C.H. Choi, and H.S. Choi. Effect of drilling parameters on hole quality and delamination of hybrid GLARE laminate. Composite Structures, 185:684–698, 2018. doi: 10.1016/j.compstruct.2017.11.073.
[52] R. Świercz, D. Oniszczuk-Świercz, J. Zawora, and M. Marczak. Investigation of the influence of process parameters on shape deviation after wire electrical discharge machining. Archives of Metallurgy and Materials, 64(4):1457–1462, 2019. doi: 10.24425/amm.2019.130113.
[53] K. Palanikumar. Modeling and analysis of delamination factor and surface roughness in drilling GFRP composites. Materials and Manufacturing Processes, 25(10):1059–1067, 2010. doi: 10.1080/10426910903575830.
[54] S.K. Rathore, J. Vimal, and D.K. Kasdekar. Determination of optimum parameters for surface roughness in CNC turning by using GRA-PCA. International Journal of Engineering, Science and Technology, 10(2):37–49, 2018. doi: 10.4314/ijest.v10i2.5.
[55] A. Gok. A new approach to minimization of the surface roughness and cutting force via fuzzy TOPSIS, multi-objective grey design and RSA. Measurement, 70:100–109, 2015. doi: 10.1016/j.measurement.2015.03.037.
[56] N.L. Bhirud and R.R. Gawande. Optimization of process parameters during end milling and prediction of work piece temperature rise. Archive of Mechanical Engineering, 64(3):327–346, 2017. doi: 10.1515/meceng-2017-0020.
[57] B.A. Rezende, F. de Castro Magalhães, and J.C. Campos Rubio. Study of the measurement and mathematical modelling of temperature in turning by means equivalent thermal conductivity. Measurement, 152:107275, 2020. doi: 10.1016/j.measurement.2019.107275.
[58] A. Bhattacharya, S. Das, P. Majumder, and A. Batish. Estimating the effect of cutting parameters on surface finish and power consumption during high speed machining of AISI 1045 steel using Taguchi design and ANOVA. Production Engineering, 3(1):31–40, 2009. doi: 10.1007/s11740-008-0132-2.
[59] A. Taşkesen and K. Kütükde. Experimental investigation and multi-objective analysis on drilling of boron carbide reinforced metal matrix composites using grey relational analysis. Measurement, 47:321–330, 2014. doi: 10.1016/j.measurement.2013.08.040.
[60] B.B. Nayak, K. Abhishek, S.S. Mahapatra, and D. Das. Application of WPCA based Taguchi method for multi-response optimization of abrasive jet machining process. Materials Today: Proceedings, 5(2):5138–5144, 2018. doi: 10.1016/j.matpr.2017.12.095.
[61] K. Palanikumar, L. Karunamoorthy, and N. Manoharan. Mathematical model to predict the surface roughness on the machining of glass fiber reinforced polymer composites. Journal of Reinforced Plastics and Composites, 25(4):407–419, 2006. doi: 10.1177/0731684405060568.
[62] R. Świercz, D. Oniszczuk-Świercz, and L. Dabrowski. Electrical discharge machining of difficult to cut materials. Archive of Mechanical Engineering, 65(4):461–476, 2018. doi: 10.24425/ame.2018.125437.
[63] A. Hamdi, S.M. Merghache, and T. Aliouane. Effect of cutting variables on bearing area curve parameters (BAC-P) during hard turning process. Archive of Mechanical Engineering, 67(1):73–95, 2020. doi: 10.24425/ame.2020.131684.
[64] V. Kavimani, K.S. Prakash, and T. Thankachan. Influence of machining parameters on wire electrical discharge machining performance of reduced graphene oxide/magnesium composite and its surface integrity characteristics. Composites Part B: Engineering, 167:621–630, 2019. doi: 10.1016/j.compositesb.2019.03.031.
[65] Y. Quan and L. Sun. Investigation on drilling-induced delamination of CFRP with infiltration method. Advanced Materials Research, 139–141:55–58, 2010. doi: 10.4028/www.scientific.net/AMR.139-141.55.
[66] O. Isbilir and E. Ghassemieh. Delamination and wear in drilling of carbon-fiber reinforced plastic composites using multilayer TiAlN/TiN PVD-coated tungsten carbide tools. Journal of Reinforced Plastics and Composites, 31(10):717–727, 2012. doi: 10.1177/0731684412444653.
Go to article

Authors and Affiliations

Kumar Jogendra
1
Rajesh Kumar Verma
1
Arpan Kumar Mondal
2

  1. Department of Mechanical Engineering, Madan Mohan Malaviya University of Technology, Gorakhpur, India.
  2. Department of Mechanical Engineering, National Institute of Technical Teachers Training and Research, Kolkata, India.
Download PDF Download RIS Download Bibtex

Abstract

Titanium alloy (Ti-6Al-4V) has been extensively used in aircraft turbine-engine components, aircraft structural components, aerospace fasteners, high performance automotive parts, marine applications, medical devices and sports equipment. However, wide-spread use of this alloy has limits because of difficulty to machine it. One of the major difficulties found during machining is development of poor quality of surface in the form of higher surface roughness. The present investigation has been concentrated on studying the effects of cutting parameters of cutting speed, feed rate and depth of cut on surface roughness of the product during turning of titanium alloy. Box-Behnken experimental design was used to collect data for surface roughness. ANOVA was used to determine the significance of the cutting parameters. The model equation is also formulated to predict surface roughness. Optimal values of cutting parameters were determined through response surface methodology. A 100% desirability level in the turning process for economy was indicated by the optimized model. Also, the predicted values that were obtained through regression equation were found to be in close agreement to the experimental values.

Go to article

Authors and Affiliations

Niharika Niharika
B.P. Agrawal
Iqbal A. Khan
Zahid A. Khan
Download PDF Download RIS Download Bibtex

Abstract

Titania dioxide (TiO2) layers were synthesized via the acid-catalysed sol-gel route using titania (IV) ethoxide, and then annealed at temperatures varying in the range of 150–700 °C. The research concerned the effect of annealing temperature on the structure of TiO2 layers, their surface morphology, and their optical properties. Further, X-ray diffractometry, and Raman spectroscopy were used to determine the structure of TiO2 layers. Scanning electron and atomic force microscopy were used to study the surface morphology of TiO2 layers. Transmittance, reflectance, absorption edge, and optical homogeneity were investigated by UV-VIS spectrophotometry, while the refractive index and thicknesses of TiO2 layers were measured using a monochromatic ellipsometer. Chromatic dispersion characteristics of the complex refractive index were determined using spectroscopic ellipsometry. Structural studies have shown that the TiO2 layers annealed at temperatures up to 300 °C are amorphous, while those annealed at temperatures exceeding 300 °C are polycrystalline containing only anatase nanocrystals with sizes increasing from 6 to 20 nm with the increase of the annealing temperature. Investigations on the surface morphology of TiO2 layers have shown that the surface roughness increases with the increase in annealing temperature. Spectrophotometric investigations have shown that TiO2 layers are homogeneous and the width of the indirect optical band gap varies with annealing temperature from 3.53 eV to 3.73 eV.

Go to article

Authors and Affiliations

Magdalena Zięba
1
ORCID: ORCID
Cuma Tyszkiewicz
1
ORCID: ORCID
Ewa Gondek
2
ORCID: ORCID
Katarzyna Wojtasik
2
ORCID: ORCID
Jacek Nizioł
3
ORCID: ORCID
Dominik Dorosz
4
ORCID: ORCID
Bartłomiej Starzyk
4
ORCID: ORCID
Patryk Szymczak
4
ORCID: ORCID
Wojciech Pakieła
5
ORCID: ORCID
Roman Rogoziński
1
ORCID: ORCID
Paweł Karasiński
1
ORCID: ORCID

  1. Department of Optoelectronics. Silesian University of Technology, ul. B. Krzywoustego 2, 44-100 Gliwice, Poland
  2. Department of Physics, Cracow University of Technology, ul. Podchorążych 1, 30-084 Kraków, Poland
  3. Faculty of Physics and Applied Computer Science, AGH University of Science and Technology, al. Mickiewicza 30, 30-059 Krakow, Poland
  4. Faculty of Materials Science and Ceramics AGH University of Science and Technology, al. Mickiewicza 30, 30-059 Krakow, Poland
  5. Department of Engineering Materials and Biomaterials, Silesian University of Technology, ul. Konarskiego 18a, 44-100 Gliwice, Poland
Download PDF Download RIS Download Bibtex

Abstract

The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.

Go to article

Authors and Affiliations

D. Bańkowski
ORCID: ORCID
S. Spadło
Download PDF Download RIS Download Bibtex

Abstract

This article proposes these of vibratory machining to Ti-6Al-4V titanium alloy as finishing treatment. Titanium alloy was used in the aerospace industry, military, metallurgical, automotive and medical processes, extreme sports and other. The three-level three-factor Box-Behnken experiment examined the influence of machining time of vibratory machining, the type of mass finishing media used and the initial state of the surface layer on the mass loss, geometric structure of the surface, micro hardness and the optimal process parameters were determined. Considerations were given the surfaces after milling, after cutting with a band saw and after the sanding process. The experiment used three types of mass finishing media: polyester, porcelain and metal. Duration of vibratory machining treatment was assumed to be 20, 40, 60 minutes. The form profiles before and after vibratory machining were determined with the Talysurf CCI Lite - Taylor Hobson optical profiler. Future tests should concern research to carry out tests using abrasive pastes with a larger granulation of abrasive grains, to carry out tests for longer processing times and to determine the time after which the parameters of geometrical structure of the surface change is unnoticeable.

Go to article

Authors and Affiliations

D. Bańkowski
ORCID: ORCID
S. Spadło
Download PDF Download RIS Download Bibtex

Abstract

In this scientific paper it is presented the statistical analysis of the experimental data obtained by the study of the influence of the cutting parameters exerted in end-milling process on the surface roughness. The surface roughness parameter is measured in the cutting feed direction and against it. The parameters of the cutting process, the number of levels and their values were established. Based on these parameters, the research was designed on a complete factorial experiment, randomized with seven blocks. The surface roughness values were measured using a roughness tester. The research method used involved the Romanovski test. The aim of this test was to identify the data affected by aberrant errors, to remove them from the samples and then to repeat the tests for the remaining data strings until all values met the conditions imposed by the test.
Go to article

Authors and Affiliations

Mihail Aurel Țîțu
ORCID: ORCID
A.B. Pop
1
ORCID: ORCID

  1. Technical University of Cluj-Napoca, Northern University Centre of Baia Mare, Faculty of Engineering – Department of Engineering and Technology Management, 62A, Victor Babes Street, 430083, Baia Mare, Maramures, Romania
Download PDF Download RIS Download Bibtex

Abstract

Since fatigue cracks nucleate and initiate generally at the surface of the rotary components such as blades and discs, the surface condition is the most important factor affecting the fatigue life. Surface scratches are suitable sites for stress concentrations and therefore the nucleation stage of fatigue cracks will be shortened. In the present work, the influence of surface roughness on the low cycle fatigue life behavior of nickel-based superalloy Rene®80 at the temperature of 900°C was evaluated. Results of low cycle fatigue tests (LCF) under strain-controlled condition at 900°C for R = εmin/εmax = 0 and strain rate of 2×10 –3 s –1, at a total strain range of 1.2% showed an inverse relationship between fatigue strength and surface roughness of the specimens. In this study, increasing the surface roughness of Rene®80 from 0.2 μm to 5.4 μm led to the decline in the final LCF life from 127 cycles to 53 cycles which indicated a 58.3% reduction in fatigue life at the same condition. Fractography evaluation also exhibited that fatigue cracks initiated from the notch in the rough specimens, whereas in the smooth specimen fatigue cracks nucleated from the internal imperfections and carbides.
Go to article

Authors and Affiliations

Mohammad Mehdi Barjesteh
1
ORCID: ORCID

  1. Malek Ashtar University of Technology (MUT), Faculty of Material and Manufacturing Technologies, Tehran 15875-1774, Iran
Download PDF Download RIS Download Bibtex

Abstract

Surface roughness is an important indicator in the evaluation of machining and product quality, as well as a direct factor affecting the performance of components. A rapidly developing filtering technology has become the main means of extracting surface roughness. The International Organization for Standardization (ISO) is constantly updating and improving the standard system for filtering technology in order to meet the requirements of technological development. Based on the filters already accepted by the international standard ISO 16610, this study briefly introduces the filtering principle of each filter, reviews the development of each filter in the application of surface roughness, and compares the advantages and limitations of their individual performances. The application range of each filter is summarized and, finally, the future direction of the digital filtering used in surface roughness is extrapolated.
Go to article

Authors and Affiliations

Baofeng He
1
Haibo Zheng
1
Siyuan Ding
1
Ruizhao Yang
1
Zhaoyao Shi
1

  1. Beijing University of Technology, Faculty of Materials and Manufacturing, Beijing Engineering Research Center of Precision Measurement Technology and Instruments, 100 Ping Le Yuan, Chaoyang District, Beijing 100124, China
Download PDF Download RIS Download Bibtex

Abstract

Workpiece surface roughness measurement based on traditional machine vision technology faces numerous problems such as complex index design, poor robustness of the lighting environment, and slow detection speed, which make it unsuitable for industrial production. To address these problems, this paper proposes an improved YOLOv5 method for milling surface roughness detection. This method can automatically extract image features and possesses higher robustness in lighting environments and faster detection speed. We have effectively improved the detection accuracy of the model for workpieces located at different positions by introducing Coordinate Attention (CA). The experimental results demonstrate that this study’s improved model achieves accurate surface roughness detection for moving workpieces in an environment with light intensity ranging from 592 to 1060 lux. The average precision of the model on the test set reaches 97.3%, and the detection speed reaches 36 frames per second.
Go to article

Authors and Affiliations

Xiao Lv
1
Huaian Yi
1
Runji Fang
1
Shuhua Ai
1
Enhui Lu
2

  1. School of Mechanical and Control Engineering, Guilin University of Technology, Guilin, 541006,People’s Republic of China
  2. School of Mechanical Engineering, Yangzhou University, Yangzhou, 225009, People’s Republic of China
Download PDF Download RIS Download Bibtex

Abstract

Current vision-based roughness measurement methods are classified into two main types: index design and deep learning. Among them, the computation procedure for constructing a roughness correlation index based on image data is relatively difficult, and the imaging environment criteria are stringent and not universally applicable. The roughness measurement method based on deep learning takes a long time to train the model, which is not conducive to achieving rapid online roughness measurement. To tackle with the problems mentioned above, a visual measurement method for surface roughness of milling workpieces based on broad learning system was proposed in this paper. The process began by capturing photos of the milling workpiece using a CCD camera in a normal lighting setting. Then, the train set was augmented with additional data to lower the quantity of data required by the model. Finally, the broad learning system was utilized to achieve the classification prediction of roughness. The experimental results showed that the roughness measurement method in this paper not only had a training speed incomparable to deep learning models, but also could automatically extract features and exhibited high recognition accuracy.
Go to article

Authors and Affiliations

Runji Fang
1
Huaian Yi
1
Shuai Wang
1
Yilun Niu
1

  1. School of Mechanical and Control Engineering, Guilin University of Technology, Guilin, 541006, People’s Republic of China
Download PDF Download RIS Download Bibtex

Abstract

We present a prototype of a simple, low-cost setup for a fast scatterometric surface texture measurements. We used a total integrated scatter method (TIS) with a semiconductor laser (λ =  638 nm) and a Si photodiode. Using our setup, we estimated the roughness parameters Rq for two reference surfaces (Al mirrors with flatness λ/10) and seven equal steel plates to compare. The setup is easily adaptable for a fast, preliminary manufacturing quality control. We show is possible to construct a low-cost measurement system with nanometric precision.

Go to article

Authors and Affiliations

D. Kucharski
H. Zdunek
Download PDF Download RIS Download Bibtex

Abstract

This paper presents a comparative study on the effects of the in-situ surface modifications performed on “H” type microfluidic systems obtained via additive manufacturing. The microsystem was printed using a polylactic acid filament on an Ender-5 Pro printer. The surface modification of the main channel was done using chloroform by two different methods: vapor smoothing and flushing. The obtained surface roughness was studied using an optical microscope and the ImageJ software, as well as scanning electron microscopy. The effect of the channel surface treatment upon the characteristics of the fluid flow was assessed. The microfluidic systems were used for the dynamic study of biofilm growth of Candida albicans (ATCC 10231). The influence of the surface roughness of the main channel on the formation and growth of the biofilm was studied using quantitative methods, scanning electron microscopy imaging as well as optical coherence tomography.
Go to article

Authors and Affiliations

A. Csapai
1
ORCID: ORCID
D.-A. Țoc
2
ORCID: ORCID
V. Pașcalău
1
ORCID: ORCID
V. Toșa
1
ORCID: ORCID
D. Opruța
3
ORCID: ORCID
F. Popa
1
ORCID: ORCID
C. Popa
ORCID: ORCID

  1. Materials Science and Engineering Department, Technical University of Cluj-Napoca, 103-105 Muncii Ave., 400641 Cluj-Napoca, Romania
  2. Iuliu Hatieganu University of Medicine and Pharmacy, 8 Victor Babeș Street, 400000 Cluj-Napoca, Romania
  3. Thermal Engineering Department, Technical University of Cluj-Napoca, 103-105 Muncii Ave., 400641 Cluj-Napoca, Romania
Download PDF Download RIS Download Bibtex

Abstract

Flap peening (FP) is a cold working technique used to apply a compressive force using small shots, this will lead to enhance the surface properties that it can sustain for long life during working conditions. In this study, several aircraft aluminum alloys materials namely; 2219 T6, 2024 T6, 7075T6, and 6061 T6 were flap peened under different rotational speeds. The effect of rotational speed on the average surface roughness (Ra) and average surface micro hardness have been investigated. As seen by the Scanning Electron Microscope SEM phots that the hardness of peened layer is increased. It was found that as the flap peening speeds increase the percent change in surface roughness (Ra) increases, and the percent change in surface micro hardness decreases. The maximum increase in Ra occurs in 2219 T80 and the minimum in 6061 T6 alloys, and for hardness, it is reported that the maximum occurs in 6061 T6 and the minimum in 2019 T80 alloy.
Go to article

Authors and Affiliations

Nabeel Abu Shaban
1
ORCID: ORCID
Nabeel Alshabatat
2
Safwan Al-Qawabah
1
ORCID: ORCID

  1. Al-Zaytoonah University of Jordan, Mechanical Engineering Department, Amman, Jordan
  2. Tafila Technical University, Mechanical Engineering Department, Tafila 66110, Jordan
Download PDF Download RIS Download Bibtex

Abstract

The Inconel 718 alloys, which are primarily temperature resistant, are widely used in aviation, aerospace and nuclear industries. The study on dry cutting processes for this alloy becomes difficult due to its high hardness and low thermal conductivity, wherein, most of the heat transfers due to friction are accumulated over the tool surface. Further, several challenges like increased cutting force, developing high temperature and rapid tool wear are observed during its machining process. To overcome these, the coated tool inserts are used for machining the superalloys. In the present work, the cemented carbide tool is coated with chemical vapor deposition multi-layering Al 2O 3/TiCN under the dry cutting environment. The machining processes are carried out with varying cutting speeds: 65, 81, 95, and 106 m/min, feed rate 0.1 mm/rev, and depth of cut 0.2 mm. The variation in the cutting speeds can attain high temperatures, which may activate built-up-edge development which leads to extensive tool wear. In this context, the detailed chip morphology and its detailed analysis are carried out initially to understand the machining performance. Simultaneously, the surface roughness of the machined surface is studied for a clear understanding of the machining process. The potential tool wear mechanism in terms of abrasion, adhesion, tool chip off, delaminating of coating, flank wear, and crater wear is extensively identified during the processes. From the results, it is observed that the machining process at 81 m/min corresponds to a better machining process in terms of lesser cutting force, lower cutting temperature, better surface finish, and reduced tool wear than the other machining processes.
Go to article

Bibliography

[1] R.M. Arunachalam, M.A. Mannan, and A.C. Spowage. Surface integrity when machining age hardened Inconel 718 with coated carbide cutting tools. International Journal of Machine Tools and Manufacture, 44(14):1481–1491, 2004. doi: 10.1016/j.ijmachtools.2004.05.005.
[2] L. Li, N. He, M.Wang, and Z.G.Wang. High-speed cutting of Inconel 718 with coated carbide and ceramic inserts. Journal of Materials Processing Technology, 129(1–3):127–130, 2002. doi: 10.1016/S0924-0136(02)00590-3.
[3] E.O. Ezugwu. Key improvements in the machining of difficult-to-cut aerospace superalloys. International Journal of Machine Tools and Manufacture, 45(12–13):1353–1367, 2005. doi: 10.1016/j.ijmachtools.2005.02.003.
[4] T. Kitagawa, A. Kubo, and K. Maekawa. Temperature and wear of cutting tools in high-speed machining of Inconel and Ti–6Al–6V–2Sn. Wear, 202(2):142–148, 1997. doi: 10.1016/S0043-1648(96)07255-9.
[5] S. Chinchanikar, S.S. Kore, and P. Hujare. A review on nanofluids in minimum quantity lubrication machining. Journal of Manufacturing Processes, 68(A):56–70, 2021. doi: 10.1016/j.jmapro.2021.05.028.
[6] A.C. Okafor and T.O. Nwoguh. Comparative evaluation of soybean oil–based MQL flow rates and emulsion flood cooling strategy in high-speed face milling of Inconel 718. The International Journal of Advanced Manufacturing Technology, 107(9–10):3779–3793, 2020. doi: 10.1007/s00170-020-05248-3.
[7] J. Kaminski and B. Alvelid. Temperature reduction in the cutting zone in water-jet assisted turning. Journal of Materials Processing Technology, 106(1–3):68–73, 2000. doi: 10.1016/S0924-0136(00)00640-3.
[8] A. Marques, M. Paipa Suarez, W. Falco Sales, and Á. Rocha Machado. Turning of Inconel 718 with whisker-reinforced ceramic tools applying vegetable-based cutting fluid mixed with solid lubricants by MQL. Journal of Materials Processing Technology, 266:530–543, 2019. doi: 10.1016/j.jmatprotec.2018.11.032.
[9] A. Suárez, L.N. López de Lacalle, R. Polvorosa, F. Veiga, and A. Wretland. Effects of highpressure cooling on the wear patterns on turning inserts used on alloy IN718. Materials and Manufacturing Processes, 32(6):678–686, 2017. doi: 10.1080/10426914.2016.1244838.
[10] R. Polvorosa, A. Suárez, L.N. López de Lacalle, I. Cerrillo, A. Wretland, and F. Veiga: Tool wear on nickel alloys with different coolant pressures: Comparison of Alloy 718 andWaspaloy. Journal of Manufacturing Processes, 26:44–56, 2017. doi: 10.1016/j.jmapro.2017.01.012.
[11] A.R.C. Sharman, J.I. Hughes, and K. Ridgway. Surface integrity and tool life when turning Inconel 718 using ultra-high pressure 786 and flood coolant systems. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 222(6):653–664, 2008. doi: 10.1243/09544054JEM936.
[12] W.H. Pereira and S. Delijaicov. Surface integrity of Inconel 718 turned under cryogenic conditions at high cutting speeds. The International Journal of Advanced Manufacturing Technology, 104:2163–2177, 2019. doi: 10.1007/s00170-019-03946-1.
[13] H. González, O. Pereira, L.N. López de Lacalle, A. Calleja, I. Ayesta, and J. Muñoa. Flankmilling of integral blade rotors made in Ti6Al4V using cryo CO2 and minimum quantity lubrication. ASME. Journal of Manufacturing Science and Engineering, 143(9):091011, 2021. doi: 10.1115/1.4050548.
[14] A. Devillez, F. Schneider, S. Dominiak, D. Dudzinski, and D. Larrouquere. Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools. Wear, 262(7–8):931–942, 2007. doi: 10.1016/j.wear.2006.10.009.
[15] N.R. Dhar, M.W. Islam, S. Islam, and M.A.H. Mithu. The influence of minimum quantity of lubrication (MQL) on cutting temperature, chip and dimensional accuracy in turning AISI- 1040 steel. Journal of Materials Processing Technology, 171(1):93–99, 2006. doi: 10.1016/j.jmatprotec.2005.06.047.
[16] D. Dudzinski, A. Devillez, A. Moufki, D. Larrouquère,V. Zerrouki, and J. Vigneau. A review of developments towards dry and high speed machining of Inconel 718 alloy. International Journal of Machine Tools and Manufacture, 44(4):439–456, 2004. doi: 10.1016/S0890-6955(03)00159-7.
[17] I.A. Choudhury and M.A. El-Baradie. Machining nickel base super alloys: Inconel 718. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 212(3):195–206, 1998. doi: 10.1243/0954405981515617.
[18] S.K. Thandra and S.K. Choudhury. Effect of cutting parameters on cutting force, surface finish and tool wear in hot machining. International Journal of Machining and Machinability of Materials, 7(3-4):260–273, 2010. doi: 10.1504/IJMMM.2010.033070.
[19] L.N. Lopez de Lacalle, J.A. Sanchez, A. Lamikiz, and A. Celaya. Plasma assisted milling of heatresistant superalloys. ASME Journal of Manufacturing Science and Engineering, 126(2):274– 285, 2016. doi: 10.1115/1.1644548.
[20] M.C. Shaw. Metal Cutting Principles. Clarendon, Oxford, 1984.
[21] E.O. Ezugwu, J. Bonney, and Y. Yamane. An overview of the machinability of aeroengine alloys. Journal of Materials Processing Technology, 134(2):233–253, 2003. doi: 10.1016/S0924-0136(02)01042-7.
[22] A. Jawaid, S. Koksal, and S. Sharif. Wear behavior of PVD and CVD coated carbide tools when face milling Inconel 718. Tribology Transactions, 43(2):325–331, 2000. doi: 10.1080/10402000008982347.
[23] T. Sugihara, H. Tanaka, and T. Enomoto. Development of novel CBN cutting tool for high speed machining of Inconel 718 focusing on coolant behaviors. Procedia Manufacturing, 10:436–442, 2017. doi: 10.1016/j.promfg.2017.07.021.
[24] G.A. Ibrahim, C.H.C. Haron, J.A. Ghani, A.Y.M. Said, and M.Z.A. Yazid. Performance of PVD-coated carbide tools when turning Inconel 718 in dry machining. Advances in Mechanical Engineering, 3:790975, 2011. doi: 10.1155/2011/790975.
[25] Z.P. Hao, Y.H. Fan, J.Q. Lin, and Z.X Yu. Wear characteristics and wear control method of PVD-coated carbide tool in turning Inconel 718. The International Journal of Advanced Manufacturing Technology, 78(5–8):1329–1336, 2015. doi: 10.1007/s00170-014-6752-0.
[26] B. Zhang, M.J. Njora, and Y. Sato. High-speed turning of Inconel 718 by using TiAlN- and (Al, Ti) N-coated carbide tools. The International Journal of Advanced Manufacturing Technology, 96(5–8):2141–2147, 2018. doi: 10.1007/s00170-018-1765-8.
[27] F. Zemzemi, J. Rech, W.B. Salem, A. Dogui, and P. Kapsa. Identification of friction and heat partition model at the tool-chip-workpiece interfaces in dry cutting of an Inconel 718 alloy with CBN and coated carbide tools. Advances in Manufacturing Science and Technology, 38(1):5-22, 2014. doi: 10.2478/amst-2014-0001.
[28] W. Grzesik, J. Małecka, Z. Zalisz, K. Zak, and P. Niesłony. Investigation of friction and wear mechanisms of TiAlV coated carbide against Ti6Al4V Titanium alloy using pin-on-disc tribometer. Archive of Mechanical Engineering, 63(1):114-127, 2016. doi: 10.1515/meceng-2016-0006.
[29] V. Bushlya, F. Lenrick, A. Bjerke, H. Aboulfadl, M. Thuvander; J.-E. Ståhl, and R. M’Saoubi: Tool wear mechanisms of PcBN in machining Inconel 718: Analysis across multiple length scale. CIRP Annals, 70(1):73–78, 2021. doi: 10.1016/j.cirp.2021.04.008.
[30] A.R.F. Oliveira, L.R.R. da Silva, V. Baldin, M.P.C. Fonseca, R.B. Silva, and A.R. Machado: Effect of tool wear on the surface integrity of Inconel 718 in face milling with cemented carbide tools. Wear, 476:203752, 2021. doi: 10.1016/j.wear.2021.203752.
[31] A.K.M.N. Amin, S.A. Sulaiman, and M.D. Arif. Development of mathematical model for chip serration frequency in turning of stainless steel 304 using RSM. Advanced Materials and Process Technology, 217-219:2206–2209, 2012. doi: .
[32] J. Hua, and R. Shivpuri. Prediction of chip morphology and segmentation during the machining of titanium alloys. Journal of Materials Processing Technology, 150(1-2):124–133, 2004. doi: 10.1016/j.jmatprotec.2004.01.028.
[33] K. Lin, W. Wang, R. Jiang and Y. Xiong. Effect of tool nose radius and tool wear on residual stresses distribution while turning in situ TiB2/7050Al metal matrix composites. The International Journal of Advanced Manufacturing Technology, 100:143–151, 2019. doi: 10.1007/s00170-018-2742-y.
[34] K. Mahesh, J.T. Philip, S.N. Joshi and B. Kuriachen. Machinability of Inconel 718: A critical review on the impact of cutting temperatures. Materials and Manufacturing Processes, 36(7):753–791, 2021. doi: 10.1080/10426914.2020.1843671.
[35] V. Sivalingam Y. Zhao, R. Thulasiram, J. Sun, G. Kai, and T. Nagamalai. Machining behaviour, surface integrity and tool wear analysis in environment friendly turning of Inconel 718 alloy. Measurement,174:109028, 2021. doi: 10.1016/j.measurement.2021.109028.
[36] Z. Peng, X. Zhang, and D. Zhang. Performance evaluation of high-speed ultrasonic vibration cutting for improving machinability of Inconel 718 with coated carbide tools. Tribology International, 155:106766, 2021. doi: 10.1016/j.triboint.2020.106766.
[37] D.G. Flom, R. Komanduri, and M. Lee. High-speed machining of metals. Annual Review of Material Science, 14:231–278, 1984. doi: 10.1146/annurev.ms.14.080184.001311.
[38] N.L. Bhirud and R.R. Gawande. Optimization of process parameters during end milling and prediction of work piece temperature rise. Archive of Mechanical Engineering, 64(3):327–346, 2017. doi: 10.1515/meceng-2017-0020.
[39] R.S. Pawade, S.S. Joshi, P.K. Brahmankar, and M. Rahman. An investigation of cutting forces and surface damage in high-speed turning of Inconel 718. J ournal of Materials Processing Technology, 192-193:139–146, 2007. doi: 10.1016/j.jmatprotec.2007.04.049.
[40] A. Shokrani, V. Dhokia, and S.T. Newman. Environmentally conscious machining of difficultto- machine materials with regard to cutting fluids. International Journal of Machine Tools and Manufacture, 57:83–101, 2012. doi: 10.1016/j.ijmachtools.2012.02.002.
[41] Y.S. Liao, H.M. Lin, and J.H. Wang. Behaviors of end milling Inconel 718 superalloy by cemented carbide tools. Journal of Materials Processing Technology, 201(1–3):460–465, 2008. doi: 10.1016/j.jmatprotec.2007.11.176.
[42] R. Komanduri and T.A. Schroeder. On shear instability in machining a nickel-iron base superalloy. Journal of Engineering for Industry, 108(2):93–100. 1986. doi: 10.1115/1.3187056.
[43] R. Rakesh and S. Datta. Machining of Inconel 718 using coated wc tool: effects of cutting speed on chip morphology and mechanisms of tool wear. Arabian Journal for Science and Engineering, 45:797–816, 2020. doi: 10.1007/s13369-019-04171-4.
[44] S. Belhadi, T. Mabrouki, J.F. Rigal, and L. Boulanouar. Experimental and numerical study of chip formation during straight turning of hardened AISI 4340 steel. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 219(7):515– 524, 2005. doi: 10.1243/095440505X32445.
[45] A. Thakur and S. Gangopadhyay. Evaluation of micro-features of chips of Inconel 825 during dry turning with uncoated and chemical vapour deposition multilayer coated tools. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 232(6):979–994, 2018. doi: 10.1177/0954405416661584.
[46] M. Rahman,W.K.H. Seah, and T.T. Teo. The machinability of Inconel 718. Journal of Materials Processing Technology, 63(1–3):199–204, 1997. doi: 10.1016/S0924-0136(96)02624-6.
[47] S.P. Sahoo and S. Datta. Dry machining performance of AA7075-T6 alloy using uncoated carbide and MT-CVD TiCN-Al2O3 coated carbide Inserts. Arabian Journal of Science and Engineering,45:9777–9791, 2020. doi: 10.1007/s13369-020-04947-z.
[48] H.Z. Li, H. Zeng, and X.Q. Chen. An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts. Journal of Materials Processing Technology, 180(1–3):296–304, 2006. doi: 10.1016/j.jmatprotec.2006.07.009.
Go to article

Authors and Affiliations

Shailesh Rao Agari
1

  1. Department of Industrial and Production Engineering, The National Institute of Engineering, Mysuru, Karnataka, India
Download PDF Download RIS Download Bibtex

Abstract

The motion of a ring pack on a thin oil film covering a cylinder liner has been analysed. In contrast to the previous paper [8], which considered only hydrodynamic phenomena, in the present paper a mixed lubrication case is also taken into account. Equations describing the mixed lubrication problem based on the empirical mathematical model formulated in works of Patir, Cheng [5], [6] and Greenwood, Trip [2] have been combined and used in this paper. Results of numerical simulations of this phenomenon have been presented. The model of ring motion considered takes the following phenomena into account: hydrodynamic and contact forces, spring and gas forces and the local motion of each ring in piston grooves. Differences between the motion of the ring on a thick and thin oil film are analysed and discussed.
Go to article

Authors and Affiliations

Andrzej Wolff
Janusz Piechna
ORCID: ORCID

This page uses 'cookies'. Learn more