Editorial Board Contents - CMTI-India · Bank: State Bank of India, Yeshwanthpur Branch, APMC Yard,...

Contents Vol. 16 No. 4 April 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

• Comparison of optimum cutting parameters in machining die steel (EN 31) by using gray relational analysis and TOPSIS

Hemantha Kumar A and Krishnaiah G

3

• Determination of minimum corrosion conditions for the stir zone of friction stir welded AZ31B magnesium alloy

Kamal Jayaraj R, MalarvizhI S, Balasubramanian V12

Calendar of Events 22

Technology Trends 25

Select Bibliography: Surface Roughness (Ra) 28

Photo Gallery: Vintage Machine: E. E. Garvin & Co., Milling & Screw Slotting Machine, 1880

30

Manufacturing Technology Abstracts 31

Patent Abstracts: Hardness Testing 51

Select Bibliography of Standards: Hardness Test 57

IPR News: New Site to Guide Young Inventors Applying for Patents

58

Around CMTI C1

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

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

Events

Manufacturing Technology Today, Vol. 16, No. 4, April 201722

NATIONAL

05 - 06 May 2017International Conference on Automation, Robotics and MechatronicsDepartment of Mechatronics Engineering,SRM University, Kattankulathur Campus,Kattankulathur, ChennaiContact: SRM UniversityEmail: [email protected] Web: http://www.icarms2017.com

12 - 14 May 20175th Year- Industrial & Engineering Expo (Indexpo) –Indore-2017Brilliant Convention Center, IndoreContact: Mr. R. K. Agrawal (+919425054216)Show Project Manager(s)Indore Infoline (P) Ltd, INFO HOUSE, 246, Greater Brijeshwari, Opp. Sch. No. 140, Indore – 452016Tel: 91-731-2703000/4093000 Email: [email protected] Web: www.indoreinfoline.in

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

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

08 - 10 Jun 2017International trade fair for automation in production and assemblyBombay Convention & Exhibition Centre BCEC,

Western Express Highway, 400063 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: http://www.tradefairdates.com

28 - 31 Jul 2017India Machine Tools New Delhi: International 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

09 - 12 Aug 2017Intl exhibition and conference for automationBombay Convention & Exhibition Centre BCEC, Western Express Highway, 400063 Mumbai, MaharashtraContact: IED Communications Ltd.64, Empire Building D N Road, Fort, MumbaiTel: +91 (0)22 22079567 Email: [email protected] Web: www.iedcommunications.com

10 - 13 Aug 2017Delhi Machine Tool Expo - 2017'Empower Manufacturing'Pragati Maidan, New DelhiContact: IMTMA (Indian Machine Tool Manufactuers Association), 10th Mile, Tumkur Road, BangaloreTel: +91 80-6624 6600 Fax: +91 80-66246661Email: [email protected] Web: http://www.mtx.co.in, www.biec.in

08 - 10 Sep 2017International Exhibition on Engineering and ManufacturingBombay Convention & Exhibition Centre BCEC, Western Express Highway, 400063 Mumbai, MaharashtraContact: International Trade and Exhibitions India Pvt. Ltd.

Events

Manufacturing Technology Today, Vol. 16, No. 4, April 2017 23

INTERNATIONAL11th Floor, Kailash Building Kasturba Gandhi Marg110001 New DelhiEmail: [email protected] Web: itei.in

08 - 10 Sep 2017International Machine Tools ExpoBombay Convention & Exhibition Centre BCEC,Western Express Highway, 400063 Mumbai, MaharashtraContact: ITEI International Trade and Exhibitions India Pvt. Ltd., E519 Floral Deck Plaza, Central MIDC Road, Opp SEEPZ 400093 MumbaiTel: +91 (0)22 28398000 Fax: +91 (0)22 28390502Email: [email protected] Web: www.itei.in

14 - 16 Sep 2017IndiaCorr Expo Greater Noida: The corrugated manufacturing showIndia Exposition Center, Plot No. 25,27,28,29, Knowledge Park, Greater Noida, Uttar PradeshContact: 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

29 Sep - 01 OctEngineering Expo Pune: International trade fair for mechanical engineeringAuto Cluster Exhibition Center, 411019 Pune, MaharashtraContact: Network18 Media & Investments Ltd.15 Kasturba Gandhi Marg, 110001 New Delhi, Tel: +91 (011) 41506112 Fax: +91 (011) 41506115Email: [email protected] Web: https://www.tradefairdates.com

06 - 10 Dec 2017International trade fair for machine tools and engineeringThe Exhibition Centre, Vibran Gujarat Exhibition Ground, 3382107 Gandhinagar, GujaratContact: K & D Communication Ltd.4th Floor, Chinubhai House, 7-B Amrutbaug Society, 380014 AhmedabadTel: +91 (0)79 26469725 Fax: +91 (0)79 26403087Email: [email protected] Web: kdclglobal.com

02 - 04 May 2017Trade fair for manufacturing equipmentCintermex, Ave. Fundidora 501 col. Obrera, 64010 Monterrey, Nuevo León, MexicoContact: FMA Fabricators & Manufacturers Ass. Int.833 Featherstone Rd., 61107 Rockford, USATel: +1 (8)15 3998775 Email: [email protected] Web: www.fmanet.org

02 - 06 May 2017International trade fair for metal packagingMesse Essen, Norbertstr., 45131 Essen, North Rhine-Westphalia, GermanyContact: Messe Essen GmbH, Norbertstr. 45131 Essen, GermanyTel: +49 (0)201 72440 Fax: +49 (0)201 7244248Email: [email protected] Web: http://www.tradefairdates.com

09 - 12 May 2017International Trade Exhibition of Machine Manufacturing and Welding TechnologyHungexpo - Budapest Fair Center, Albertirsai út 10., H-1101 Budapest, Budapest, HungaryContact: Hungexpo C.Co.Ltd., Albertirsai út 10H-1101 Budapest, HungaryTel: +36 (0)1 2636000 Fax: +36 (0)1 2636098Email: [email protected] Web: www.hungexpo.hu

09 - 12 May 2017Trade fair of mechanical engineeringPVA Expo Praha, Beranových 667, 19900 Prague, Prague, Czech RepublicContact: ABF, a.s., Mimonská 64519000 Prague, Czech RepublicTel: +420 (0)222 891135 Fax: +420 (0)222 891191Email: [email protected] Web: www.abf.cz

15 - 19 May 2017International exhibition for materials processing technologies, machines and toolsExpocentre Fairgrounds, Krasnopresenskaya nab., 14, 123100 Moscow, Moscow, Russian FederationContact:

Events


Expocentre, 14, Krasnopresnenskaya nab123100 Moscow, Russian FederationTel: +7 (4)95 7953799 Fax: +7 (4)95 7953946Email: [email protected] Web: www.expocentr.ru

16 - 18 May 2017International trade fair for the metalworking and processingEastern States Exposition,1305 Memorial Avenue, MA 01089 West Springfield, Massachusetts, USAContact: Society of Manufacturing Engineers SMEOne SME Drive, MI 48121 Dearborn, USATel: +1 (3)13 4253000 Fax: +1 (3)13 4253400Email: [email protected] Web: www.sme.org

17 - 20 May 2017International trade fair for production technology and machinery for sheet metal productionBITEC - Bangkok International Trade & Exhibition Center, 88 Bangna-Trad Road, Bang Na, 10260 Bangkok, Bangkok, ThailandContact: UBM Asia Thailand Co., Ltd., 503/23 KSL Tower, 14th Fl., Sri Ayuthaya Rd., 10400 Bangkok, ThailandTel: +66 (0)2642 6911 Fax: +66 (0)2642 691920Email: [email protected] Web: www.ubmthailand.com

17 - 20 May 2017Metal Show Bucharest: Fair of the metalworking industryRomexpo Exhibition Center, 65-67 Marasti Boulevard, 011465 Bucharest, Bucharest, RomaniaContact: Euroexpo, Garlei Street, Intact Building, 2nd floorBucharest, RomaniaTel: +40 (0)21 4091849 Fax: +40 (0)21 4091854Email: [email protected] Web: www.euroexpo.ro

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, Spain

Tel: +34 (0)94 4040000 Fax: +34 (0)94 4040001Email: [email protected] Web: www.bilbaoexhibitioncentre.com

23 - 26 May 2017International Exhibition of Casting & MetallurgyInternational Exhibition Center Agrokomplex,Výstavná 4, 94901 Nitra, Nitriansky, Slovak RepublicContact: Agrokomplex-Výstavníctvo, Výstavná 49401 Nitra, Slovak RepublicTel: +421 (3)7 65721113 Fax: +421 (3)7 7335859Email: [email protected] Web: www.agrokomplex.sk

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 GmbHMessepiazza 1, 70629 Stuttgart, GermanyTel: +49 (0)711 185600 Fax: +49 (0)711 185602440Email: [email protected] Web: www.messe-stuttgart.de ◘

Bibliography


SELECT BIBLIOGRAPHY: SURFACE ROUGHNESS (Ra)

1. Evaluation of thrust force and surface roughness in drilling of Al-2219/B4C/Gr metal matrix composites

Suresh, R [Manufacturing Technology Today, V 15, N 7, 2016, Starting page 15, 7 Pages] Rec. No: 110993

2. Conservation law of surface roughness in single point diamond turning

Zong, WJ; Huang, YH; Zhang, YL; Sun, T [Int J of Machine Tools & Manufacture, V 84, 2014, Starting page 58, 6 Pages] Rec. No: 110500

3. Monitoring the tool wear, surface roughness and chip formation occurrences using multiple sensors in turning

Bhuiyan, MSH; Choudhury, IA; Dahari, M [J of Manufacturing Systems, V 33, N 4, 2014, Starting page 476, 12 Pages] Rec. No: 110457

4. Effect of spindle speed, feed-rate and machining time to the surface roughness and burr formation of Aluminum Alloy 1100 in micro-milling operation

Kiswanto, G; Zariatin, DL; Ko, TJ [J of Manufacturing ProcessesJ of Manufacturing Processes, V 16, N 4, 2014, Starting page 435, 16 Pages] Rec. No: 110381

5. Study on surface roughness model and surface forming mechanism of ceramics in quick point grinding

Ma, Lianjie; Gong, Yadong; Chen, Xiaohui [Int J of Machine Tools & Manufacture, V 77, 2014, Starting page 82, 11 Pages] Rec. No: 110320

6. Modeling of material removal rate and surface roughness in finishing of bevel gears by electrochemical honing process

Shaikh, Javed Habib; Jain, Neelesh Kumar [J of Materials Processing Technology, V 214, N 2, 2014, Starting page 200, 10 Pages] Rec. No: 110054

7. Ductile fracture and free surface roughening behaviors of pure copper foils for micro/meso-scale forming

Furushima, Tsuyoshi; Tsunezaki, Hitomi; Manabe, Ken-ichi; Alexsandrov, Sergei [Int J of Machine Tools & Manufacture, V 76, 2014, Starting page 34, 15 Pages] Rec. No: 110026

8. Optimization of metal foils surface finishing using vibration-assisted micro-forging

Bai, Yang; Yang, Ming [J of Materials Processing Technology, V 214, N 1, 2014, Starting page 021, 8 Pages] Rec. No: 110018

9. Modeling and predicting of surface roughness

for generating grinding gear Chen, Haifeng; Tang, Jinyuan; Zhou, Wei

[J of Materials Processing Technology, V 213, N 5, 2013, Starting page 717, 5 Pages] Rec. No: 109820

10.Effect of tip size on the measured Ra of surface roughness specimens with rectangular profiles

Song, J; Renegar, TB; Soons, J; Muralikrishnan, B; Villarrubia, J; Zheng, A; Vorburger, TV [Precision Engg, V 38, N 1, 2014, Starting page 217, 4 Pages] Rec. No: 109791

11. Surface roughness analysis, modelling and prediction in selective laser melting

Strano, Giovanni; Hao, Liang; Everson, Richard M; Evans, Kenneth E [J of Materials Processing Technology, V 213, N 4, 2013, Starting page 589, 9 Pages] Rec. No: 109710

12.Modelling of surface finish and material removal rate in rough honing

Buj-Corral, Irene; Vivancos-Calvet, Joan; Coba-Salcedo, Milton [Precision Engg, V 38, N 1, 2014, Starting page 100, 9 Pages] Rec. No: 109693

13.Correlating surface roughness, tool wear and tool vibration in the milling process of hardened steel using long slender tools

Marcelo Mendes de Aguiar, Anselmo Eduardo Diniz, Robson Pederiva [Int J of Machine Tools & Manufacture, V 68, 2013, Starting page 1, 10 Pages] Rec. No: 109674

14. Investigation on the influence of tool-tip vibration on surface roughness and its representative measurement in ultra-precision diamond turning

H. Wang, S. To, C.Y. Chan [Int J of Machine Tools & Manufacture, V 69, 2013, Starting page 20, 10 Pages] Rec. No: 109661

15.Mathematical modeling and analysis of surface roughness in EDM of AA6061wt. 15% B4CP MMC through RSM

Thangadurai, KR; Dr. Asha, A [Manufacturing Technology Today, V 12, N 9, 2013, Starting page 5, 9 Pages] Rec. No: 109644

16.Multi response optimization of surface roughness and tool wear in turning Al/SiC particulate metal matrix composites using taguchi grey relational analysis

Santosh Tamang; M Chandrasekaran [Manufacturing Technology Today, V 12, N 4, 2013, Starting page 14, 8 Pages]

Bibliography


Rec. No: 10964317. Investigation on mechanism of metal foil

surface finishing with vibration-assisted micro-forging

Yang Bai, Ming Yang [J of Materials Processing Technology, V 213, N 3, 2013, Starting page 330, 7 Pages] Rec. No: 109582

18.Analysis of forces and surface roughness in magnetic abrasive finishing with a ball-end tool

Sathua, Chandra Sekhar; Jain, VK; Ramkumar, J; Sidpara, Ajay [Int J of Precision Technology, V 3, N 2, 2013, Starting page 131, 12 Pages] Rec. No: 109178

19.Prediction and optimization of surface roughness in micro turning using response surface methodology and genetic algorithm

Sooraj, VS; Rahman, Mustafizur; Mathew Jose [COPEN 6 2009 - Proceedings 6th Int Conf. on Precis, 2009, Starting page B-11, 7 Pages] Rec. No: 109121

20. Influence of cutting parameters on surface roughness, metal removal rate and power consumption on EN353 with coated tools by ANOVA

Sharma, AVNL; Diwakar Reddy, V; Venkata Subbaiah, K [Manufacturing Technology Today, V 12, N 3, 2013, Starting page 10, 14 Pages] Rec. No: 109090

21. Influence of vegetable oil based cutting fluids on tool wear and surface roughness in turning EN8 steel using tungsten carbide tool

Pinto, Thomas; Milton, George; Rao, Gangadhar [Manufacturing Technology Today, V 12, N 2, 2013, Starting page 05, 6 Pages] Rec. No: 109087

22.Sensitivity analysis of surface roughness of AISI 1040 carbon steel in dry turning operation with PVD tool using Taguchi method

Diwakar Reddy, V; Bhanu Prakash, D; Bhanodaya Reddy, G; Krishnaiah, G [Manufacturing Technology Today, V 11, N 12, 2012, Starting page 05, 7 Pages] Rec. No: 109086

23.Comparison of central composite and orthogonal array designs for cutting force and surface roughness prediction modelling in turning

Srinivasa Rao, G; Neelakanteswara Rao, A [International Journal of Material & Product Technology, V 43, N 1/2/3, 2012, Starting page 144, 21 Pages] Rec. No: 108907

24.Performance and wear of coated carbide drill in machining of carbon fibre reinforced composite/titanium stack

Ghassemieh, Elaheh [International Journal

of Material & Product Technology, V 43, N 1/2/3, 2012, Starting page 165, 19 Pages] Rec. No: 108901

25. Influence of cryogenic cooling in turning of AISI 304 stainless steel

Dhananchezian, M; Pradeep Kumar, M [COPEN 6 2009 - Proceedings 6th Int Conf. on Precision Engg., 2009, Starting page A1, 4 Pages] Rec. No: 108900

26.Parametric study for surface roughness during abrasive flow finishing of AL/SiCp-MMC

H.S.Mali, A.Manna [COPEN 6 2009 - Proceedings 6th Int Conf. on Precision Engg., 2009, Starting page B-42, 6 Pages] Rec. No: 108892

27.Prediction and optimal parameter selection for surface roughness and cutting forces in CNC End Milling of Al/ SiCp MMC

K.Jayakumar, Jose Mathew, M.A. Joseph [COPEN 6 2009 - Proceedings 6th Int Conf. on Precision Engg. , 2009, Starting page J-7, 5 Pages] Rec. No: 108891

28.Development of surface roughness prediction model for titanium alloys in milling.

Enomoto, T; Satake, U; Miyake, T; Tabata, N [Manufacturing Technology Today, V 11, N 8, 2012, Starting page 5, 9 Pages] Rec. No: 108863

29.Analysis and optimisation of cutting parameters for surface roughness in machining Al/SiC particulate composites by PCD tool.

Palanikumar, K; Shanmugam, K; Davim, J Paulo [Int J of Materials & Production Tech, V 37, N 1/2, 2010, Starting page 117, 12 Pages] Rec. No: 108637

30.Determination of optimum amount lubricant in drilling using soft-computing tools: desired surface roughness.

Nandi, Arup Kumar; Davim, J Paulo [Int J of Materials & Production Tech, V 37, N 1/2, 2010, Starting page 102, 15 Pages] Rec. No: 108563

31.Surface roughness analysis in turning of polyamide PA-6 using statistical techniques.

Mata, F; Petropoulos, G; Ntziantzias, I; Davim, J Paulo [Int J of Materials & Production Tech, V 37, N 1/2, 2010, Starting page 173, 15 Pages] Rec. No: 108559

32.Surface preparation of crystal and characterization of surface roughness using power spectral density analysis

Paliwal, Nidhi; Sharma, Rina; Chand, Mahesh; Ojha, VN [Manufacturing Technology Today, V 11, N 3, 2012, Starting page 5, 6 Pages] Rec. No: 108539 ◘

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

SHEET METAL WORKING 32

HYDRAULICS & PNEUMATICS 33

INDUSTRIAL ENGINEERING 33

JOINING & ASSEMBLY 34

LASERS 41

MACHINE TOOLS 42

MACHINING 43

NON TRADITIONAL MACHINING 48

CNC MACHINING 50

DIAMOND TURNING 50

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

SHEET METAL WORKING

111078 Research on sheet-metal flexible-die forming using a magnetorheological fluid

Wang, Zhong-jin; Wang, Peng-yi; Song, Hui [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2200, Pages 12] Related studies showed that viscosity has a great effect on the formability of sheet metal in viscous

pressure forming. However, the viscosity of viscous medium keeps constant in VPF. In this paper, a new flexible-die forming method for sheet metal using magnetorheological (MR) fluids, magnetorheological pressure forming (MRPF), is proposed, which enables the viscosity of flexible-die medium adjustable by changing the magnetic fields during the forming process. Squeezing tests of MR fluid show that its rheological behavior can be changed greatly under different magnetic fields. Magnetorheological pressure bulging tests of Al1060 sheet are conducted on the self-designed experimental apparatus. Experimental results show that MR fluids can be used effectively as a flexible-die medium to form the parts and its rheological behavior can be adjusted during bulging process. Variation of MR fluid’s rheological behavior can lead to different forming pressure load paths and have an effect on sheet metal formability. For the same piston stroke of 8.0 mm, when the magnetic flux density is 0.180 T and 0.318 T, average dome height of bulging specimen is 8.71 mm and 10.61 mm, respectively. The value increases significantly by 21.8%. At the same time, the maximum thickness strain increases from -9.2% to -23.0%.

111079 Electrically assisted solid-state pressure welding process of SS 316 sheet metalsXu, Zhutian; Peng, Linfa; Lai, Xinmin [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2212, Pages 8] Physical experiments were conducted to study the effect of electric current on the shear strength of pressure-welded SS 316 sheet metals. Through experiments, it is found the shear strength first increases with the welding pressure, then decreases due to the excessive thinning. Higher current density leads

to larger maximum shear strength. The numerical simulations of welding process were also carried out to explore the influence of current density on the bond formation: using the critical stress as the indicator of joining, the bond area is found to increase significantly with the current density from 5 Å/mm2 to 20 Å/mm2 when the thickness

reduction is below 80%. The welding force required for successful joining also decreases with the increase of current density. Based on the simulations, the shear strength is further predicted by modeling the joining behavior and the results are corroborated and verified by experiments.

111080 Thermal loads of working coils in electromagnetic sheet metal formingGies, S; Löbbe, C; Weddeling, C; Tekkaya, AE [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2553, Pages 13] One basic problem of electromagnetic forming is the limited tool life. Besides the mechanical loads especially thermal loads acting on the tool coil affect its lifetime. In electromagnetic forming, about 50% of the deployed electrical energy is lost because of joule heating in the working coil. In case of high volume production, an accumulation of this heat promotes failure of the coil and reduces the coil lifetime. Despite this importance of the thermal loads only insufficient information about the coil temperature and its influencing parameters is available. Focus of this paper is on the determination of the temperature distribution in case of long-term discharge sequences. Experimental investigations using an infrared camera were performed to measure the coil surface temperature. Numerical process simulation is used to gather information about the temperature inside the working coil. The results prove that the coil reaches an equilibrium temperature after several discharges. For the analyzed range of input power the maximum coil surface temperature and the maximum coil winding temperature reached values of 92 °C and 178 °C, respectively. These temperatures exceed the weakening temperature of most reinforcement and insulation materials. The derived knowledge

Abstracts


about the parameters influencing the coil temperature can be used for an improved process design to avoid thermal overstressing of the coil. A comparison of experiments with and without workpiece deformation revealed that the temperature in case of prevented deformation is always higher, and thus, represents an upper bound for the coil temperature.

HYDRAULICS & PNEUMATICS

111081 Design of High Speed Rotary Valves for Pneumatic Applications

Brown, Travis L; Atluri, Prasad; Schmiedeler, James P [J of Mechanical Design, v 136, n 1, Jan 2014, Starting Page 015001, Pages 7] Valves based on rotating geometry have long been sought by designers for their simplicity,

compactness, and desirable dynamic properties. Unfortunately, they generally involve tight sealing surfaces with significant relative motion, making them particularly prone to problems of wear, leakage, and seizure. These inherent weaknesses are easily overcome in applications involving low pressures or low actuation speeds but become more significant in applications with high pressures and/or high speeds. In this paper, a new high speed, high pressure rotary valve design for an experimental reciprocating compressor-expander is presented. A physical prototype is created, and leakage and valving experiments are performed. Sealing performance is verified and shown to be on the order of piston ring leakage, making it suitable for compressor use. Although not intended for combustion applications, it is possible that a modified version of this design could function in that capacity. As shown, this design is useful in pneumatic applications in which temperatures are lower and oil leakage is tolerable.

111082 Investigation of Flux Decline in Tortuous Pore Structures via Three-Dimensional Simulation of Cross-Flow Microfilter FoulingYu, Bingyi; Kapoor, Shiv G; DeVor, Richard E; Wentz, John E [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 031001, Pages 8] This paper presents a fluid dynamic-based approach to the prediction of the flux decline due to partial and complete

pore blocking in the microfiltration process. The electrostatic force model includes both particle–particle (PP) and particle–membrane (PM) electrostatic forces. The addition of such forces was shown to affect particle trajectories in a tortuous three-dimensional microfilter membrane geometry. The model was validated by comparing experimental flux decline data with simulation flux decline data. A design of experiments was conducted to investigate the effects of transmembrane pressure, PM- and PP-zeta potential on flux decline. The simulation experiments revealed that low flux decline was associated with relatively low transmembrane pressures and near-zero values of PP- and PM-zeta potential; and relatively high transmembrane pressures and more-negative values of PP- and PM-zeta potential. The amount of flux decline was shown to be correlated to the specific nature of partial and complete pore blocking in the pore structure.

INDUSTRIAL ENGINEERING

111083 3D numerical simulation of electrical arc furnaces for the MgO production

Wang, Zhen; Fu, You; Wang, Ninghui; Feng, Lin [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2284, Pages 8] Targeted at the 3000 kVA and 1500 kVA electric arc furnaces for MgO production, 3D models are developed to characterize the thermal behavior in the

furnaces. The electromagnetic stirring effect of the molten bath is studied respectively with a rated current, and its influence on the temperature field is predicted by the model in FLUENT. Some calculated results are proved reliable by comparison with the measurements. It can be seen that a stronger stirring effect leads to a higher average flow velocity in the 3000 kVA furnace, and the size of its molten bath is much larger than that in the 1500 kVA furnace. The appropriate location of the three electrodes can help to maintain a homogenous bath temperature distribution. The comparison between the calculated results and the measurements proves that the dimensional designs of the two furnaces are acceptable for the prevention of the local overheating or overcooling. Large-capacity electric

Abstracts


arc furnaces are qualified with significant advantages in energy conserving and increase of productivity.

JOINING & ASSEMBLY

111084 Molten pool behavior in the tandem submerged arc welding processCho, Dae-Won; Kiran, Degala Venkata; Song, Woo-Hyun; Na, Suck-Joo [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2233, Pages 15] A three-dimensional numerical heat transfer and fluid flow model is developed to examine the temperature profiles, velocity fields, weld pool shape and size in a two-wire tandem submerged arc welding process. The model solves the equations of the conservation of mass, momentum, and energy along with the volume of fluid method. The volume of fluid method is used to track the shape of the free surface. Further, a novel scheme is proposed to handle the arc interaction and its influence on the molten droplet transfer direction. Using the computational fluid dynamics simulations, it is found that the droplet movement and arc forces from the leading electrode heavily affect the molten pool flow patterns and the resultant bead shapes, even though the same heat inputs are applied. The computed weld width and penetration are in fair agreement with the corresponding experimental results.

111085 Resistance spot welding and the effects of welding time and current on residual stresses

M o s h aye d i , Hessamoddin; S a t t a r i - F a r, Iradj [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 2545, Pages 8] A 2-D finite element model is developed based on fully coupled electrical-thermal and incrementally coupled thermal-mechanical analysis. The growth rate of the weld nugget as a function of welding time and current is studied. Comparison of the predicted results with the experimental data shows good agreement. Contact area variations and pressure distribution between the sheets’ faying surface and electrode-sheet interfaces during the welding process are studied. Compressive radial residual stress on the surface of the specimen obtained in the center region of the nugget while it becomes tensile and rises

toward the nugget edge. The maximum tensile residual stress occurs outside of the nugget, near the edge region. The effects of welding time and current on distribution and magnitude of welding residual stresses are also investigated. The magnitudes of radial residual stresses in the inner and outer areas of the weld nugget grow with increasing the welding time and current while they decrease slightly in the edge regions of the weld nugget. The growth rate of the maximum residual stress reduces with increase in the welding time and current. This fact is more tangible for welding time.

111086 Optical investigation of the behavior of the electric arc and the metal transfer during vacuum remelting of a Ti alloy

Chapelle, P; Noël, C; Risacher, A; Jourdan, J; Jardy, A; Jourdan, J [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2268, Pages 8] High-speed camera imaging and optical emission spectroscopy have been used for investigating the structure of the electric arc and the transfer mechanisms of the liquid metal during vacuum arc remelting (VAR) of Ti alloys. The arc exhibited a similar operating regime to that described in the previous literature for the case of Inconel 718 and zirconium alloy electrodes. The arc behaved in a diffuse mode with many separate and rapidly moving cathode spots. Several parameters of the cathode spots, including their current, size and apparent velocity were evaluated. The application of an external axial magnetic field tended to encourage the cathode spots to locate themselves on the base of the electrode. A large density ratio of Ti+ ions and Ti atoms in the interelectrode plasma was evaluated, suggesting that the plasma was strongly ionized. The calculated excitation temperature of Ti+ ions (1–1.2 eV) was about 1.5–2 times greater than that obtained for Ti atoms. The transfer mechanisms of the drops of liquid metal might be classified into three main modes depending on the gap length: drop falling, drip short and drop erosion induced

Abstracts


by the cathode spots. The importance of the influence of the arc on the metal transfer mechanisms was inversely related to the gap length.

111087 The influence of deformation conditions in solid-state aluminium welding processes on the resulting weld strength

Cooper, Daniel R; Allwood, Julian M [J of M a t e r i a l s P r o c e s s i n g Te c h n o l o g y, v 214, n 11, Nov 2014, Starting Page

2576, Pages 17] Solid bonding of aluminium is an important joining technology with applications in fabrication, forming and new low-carbon recycling routes. The influence of deformation conditions on the strength of the resulting weld has yet to be fully assessed, preventing optimization of current processes and development of new ones. In this work, an extensive literature review identifies the deformation parameters important to weld strength: interface strain, strain rate, normal contact stress, temperature and shear. The film theory of bonding is used to derive a model that quantifies the relevance of these parameters to the weld strength. This model is then evaluated using an experiment in which the interface strain and normal contact stress are decoupled, and the friction hills between both the tooling and the samples and between the samples themselves minimized. Neither the model nor the experiments deal with samples that have undergone mechanical surface preparation (for example, scratch brushing) prior to bonding. The experiments show that a minimum strain is required for bonding. Increasing the temperature, normal contact stress or shear stress can reduce this minimum strain. A normal contact stress above the materials’ uniaxial yield stress is necessary to produce a strong bond. Increasing the strain rate has little affect on the weld strength for bonds created at low temperatures, but can significantly reduce the strength of bonds created at higher temperatures. The proposed model correctly predicts these trends; however, for higher temperatures it underestimates bond strengths and the influence of strain rate, suggesting that diffusion mechanisms increase the strength of bonds created at higher temperatures.

111088 Cold hole expansion effect on the fatigue crack growth in welds of a 6061-T6 aluminum alloyViveros, KC; Ambriz, RR; Amrouche, A; Talha, A; García, C; Jaramillo, D [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2606, Pages 11] Compact test specimens were extracted from a 6061-T6 aluminum alloy welded plate with a thickness of 9 mm to analyze the cold hole expansion effect on fatigue crack growth tests conducted in mode I cyclic loading. At R = 0.1, a sharp crack in base metal, weld metal and heat affected zone was propagated from 17 to 24 mm. The fatigue crack growth at 24 mm (a = a/W = 0.3) was delayed by drilling a hole at the crack tip and applying a cold hole expansion of 4.1%. The residual stress fields due to cold hole expansion were determined with the finite element method. The fatigue crack growth testing was continued up to a crack length of 35 mm (a ~ 0.43) at the same R, and crack opening displacements of the post-expansion crack were also determined with the finite element method. The results were expressed in terms of crack length versus number of cycles, as well as, fatigue crack growth rate as a function of applied and effective stress intensity factor range. The cold hole expansion contributed to delay the fatigue crack growth in base metal, and to a lesser extent in the weld metal and heat affected zone. A crack closure effect was determined by means of load versus crack opening displacement curves of the post-expansion crack, which was, completely or partially closed, in welded zones with compressive residual stress fields. The fracture surfaces of each welded zone were analyzed to elucidate the crack nucleation zone and its relation with the residual stress field. In all cases the crack was initiated at the surface of the specimen where the residual stresses were positive.

111089 Bilinear Model Predictive Control of Plasma Keyhole Pipe Welding Process

Qian, Kun; Zhang, YuMing [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 031002, Pages 10] C o n t r o l l e d q u a s i - k e y h o l e plasma arc welding

process adjusts the amperage of the peak current to establish a keyhole in a desired time. This keyhole establishment time is the major parameter

Abstracts


that controls the consistence of the weld penetration/quality and needs to be accurately controlled. This paper addresses the control of keyhole establishment time during pipe welding around the circumference, in which the gravitational force acting on the weld pool continuously changes. Because of this continuous change, the dynamic model of the controlled process, with the keyhole establishment time as the output and the amperage of the peak current as the input, varies around the circumference during welding. In addition, it is found that this dynamic model is nonlinear. To control this time varying nonlinear process, the authors propose an adaptive bilinear model predictive control (MPC) algorithm. A self-search algorithm is proposed to decouple the input and output in the model to apply the proposed MPC. Experiments confirmed the effectiveness of the developed control system including the adaptive bilinear MPC.

111090 Welding simulation of fillet-welded joint using shell elements with section integrationShen, Jichao; Chen, Zhen [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2529, Pages 8] For the purpose of reducing time cost of welding simulation, a FE approach combing shell elements for modeling the overall welded plates and solid elements for considering the contribution of detail materials at the local region of weld line was developed in this paper. The corresponding thermal and mechanical degrees of freedom were related between shell and solid elements by linear constraint equations. A typical fillet-welded joint of 9 and 12 mm was simulated by the method and the temperature history and distribution, welding distortion together with residual stress was compared with solid model and measured experiment data. The results show that very good agreement can be achieved and the computational time can save up to 40% compared with solid model for the joint.

111091 High speed TIG–MAG hybrid arc welding of mild steel plate

Meng, Xiangmeng; Qin, Guoliang; Zhang, Yuqi; Fu, Banglong; Zou, Zengda [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2417, Pages 8] A TIG–MAG hybrid arc welding process was proposed to achieve high speed welding. The influences of hybrid arc welding parameters on welding speed and weld appearance were studied through orthogonal experiment and the microstructures and mechanical properties of weld were tested and compared with that of the conventional MAG weld. The TIG–MAG hybrid arc welding speed could reach up to 3.5 m/min for bead-on-plate welding of 2.5 mm thick mild steel plate under the condition of high quality of weld appearance and 4.5 m/min for butt welding of 2 mm thick mild steel plate, respectively. The mechanical properties of hybrid arc weld were not lower than that of the conventional MAG weld. The assistant TIG arc could effectively stabilize the MAG welding current and MAG arc voltage in high speed TIG–MAG hybrid arc welding process. The stable hybridization obtained by balance between TIG and MAG welding current and proper wire-electrode distance was a key factor to stabilize the welding process.

111092 Interchangeable metal transfer phenomenon in GMA welding: Features, mechanisms, classification

Scotti, Américo; P o n o m a r e v , Vladimir; Lucas, William [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 2488, Pages

9] Metal transfer modes in arc welding processes have previously been classified as Natural or Controlled Metal Transfer. Modern laboratory techniques have helped to establish a new transfer classification mode in GMAW of carbon steels, which has been termed Interchangeable Metal Transfer. In order to characterize the new mode, a series of specimens was welded at different combinations of welding current (wire feed speed), arc voltage and gas composition. Laser backlighting techniques and high speed filming were employed to study metal transfer. The video was synchronized with the welding current and arc voltage signals to aid the understanding of the transfer behaviour. The results showed that this new interchangeable metal transfer class is distinguished from the Natural or Controlled

Abstracts


Metal Transfer class because of its unique characteristic of periodical changes in the transfer mode induced by changes in welding parameters (a self-sustained behaviour). The characteristic feature of the interchangeable metal transfer class was shown to comprise of two or more natural transfer modes occurring in a regular repetitive sequence. The metal transfer sequence occurs without interference from the operator or the adaptive control system of the power source. Phenomenological explanations based on arc physics are given to justify the main governing factors for the particular metal transfer characteristics.

111093 Assessment of resistance spot welding quality based on ultrasonic testing and tree-based techniques

Martín, Óscar; Pereda, María; Santos, José Ignacio; Galán, José Manuel [J of Materials P r o c e s s i n g Te c h n o l o g y, v 214, n 11,

Nov 2014, Starting Page 2478, Pages 10]Classification and regression tree (CART) and random forest techniques were proposed as pattern recognition tools for classification of ultrasonic oscillograms of resistance spot welding (RSW) joints. The results showed that CART models produced an acceptable error rate with high interpretability. These features may be used to understand and control the decision processes, instruct other human operators, compare margins of safety or modify them depending on the criticality of the industrial process. Compared with CART trees, random forests reduced the error rate at the cost of decreasing decision interpretability. The use of the agreement of the forest was proposed as a measure to reduce the workload of human operators, who would only have to focus on the analysis of ultrasonic oscillograms that are difficult to interpret.

111094 Effect of tool geometry on friction stir processing and fatigue strength of MIG T welds on Al alloysJesus, J S de; Loureiro, A; Costa, JM; Ferreira, JM [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2450, Pages 11] Several tool geometries were developed and their effect on weld morphology, material flow, microstructure and hardness of processed regions was analyzed. Their effect on fatigue strength of welds was

also examined for the most promising tools. The feasibility of FSP MIG T welds was proved. Quality of processed regions is very influenced by tool geometry. FSP removes defects in the MIG weld toe and increases its radius of curvature. Also promotes significant grain refinement in processed regions, reduces hardness in welds on AA 6082-T651 and hardens AA 5083-H111 welds. Only tools with concave and rounded edge shoulder and cylindrical threaded pin allow the improvement of fatigue strength of MIG welds on both alloys.

111095 Coupled thermal and metallurgical model for welding simulation of Ti–6Al–4V alloy

Mi, Gaoyang; Wei, Yanhong; Zhan, Xiaohong; Gu, Cheng; Yu, Fengyi [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2434, Pages 10] The accurate prediction of the mechanical behavior of welded components made of Ti–6Al–4V requires a particular material model considering the significant effects of the material behavior during welding.

Especially, phase transformations are assumed to have an influence on the temperature distribution. The flow curves of the material are changed during welding by complex mechanisms which might be describable using time-temperature history dependent flow curves. The following paper shows (as a step forward), how the influence of phase transformations on the transient heat conduction in components made of Ti–6Al–4V during tungsten inert gas (TIG) arc welding is investigated using a coupled thermal and metallurgical model. Kinetics of a+ß?ß phase transformation during heating and ß?a phase transformation during cooling are studied using the Johnson–Mehl–Avrami–Kolmogorov (JMAK) equation. A numerical heat transfer model is used to calculate the transient temperature field during welding. The thermal properties are calculated by a linear mixing rule based on the

Abstracts


phase fractions and the thermal properties of each pure phase. Using these obtained thermal properties, the welding process of Ti–6Al–4V alloy is modeled using finite-elements for the spatial discretization and finite-differences to predict the transient temperature field. Additional calculations neglecting the phase changes are carried out to compare the temperatures and visualize the effects of phase transformations on the cooling behavior. The comparison of these models with measurements shows that the model considering the influence of solid phase transformations describes the temperature profile during cooling accurately.

111096 Weld structure of joined aluminium foams with concentrated solar energy

Cambronero, LEG; Cañadas, I; Ruiz-Román, JM; Cisneros, M; Iglesias, FA Corpas [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2637, Pages 7] Concentrated solar energy was applied to welded foam plates in non-protective atmosphere. The filler was a pore-generating aluminium–silicon alloy placed between two commercial aluminium foam plates. The heating device provided enough energy to melt and foam the filler. The heat affected surfaces on foam plates and welding mechanisms were correlated with heating conditions. Test plate thickness controlled filler foaming, and two runs were necessary to complete foaming. Weld characterization through tensile tests and microstructural study was performed. The role of the oxide layer on the weld was analyzed and the main welding mechanisms identified: a mechanical form-fit and a metallurgical connection.

111097 The origin of weld seam defects related to metal flow in the hot extrusion of aluminium alloys EN AW-6060 and EN AW-6082

Bakker, A J den; Werkhoven, RJ; Sillekens, WH; Katgerman, L [J of Materials P r o c e s s i n g Technology, v 214, n 11, Nov 2014, Starting

Page 2349, Pages 10] Longitudinal weld seams are an intrinsic feature in hollow extrusions produced with porthole dies. As these joins occur along the entire extruded length, it is desirable that these weld seams have a minimal impact on the structural integrity of the extrudate. In particular, defects associated with weld seam formation should be avoided. In this research, the occurrence of defects related to material flow inside the extrusion tooling is studied. In lab-scale experiments, EN AW-6060 and EN AW-6082 aluminium alloy billets are formed into strips by means of the direct hot extrusion process. By utilising model dies with an internal obstruction similar to the supports present in porthole dies, a strip with a central longitudinal weld seam is formed. The effects of different geometries of the weld-chamber and the processing conditions on the quality of the weld seam are investigated. Characterisation is performed through mechanical testing, focusing on the ability of the weld seam area to accommodate plastic deformation, and microstructural analysis provides insight into the defects related to unsound metal flow. Through computer simulations, conditions related to weld seam formation are modelled and correlated with the experimental results. The experimental results demonstrate that metal flow controlled by the die geometry causes defects leading to inferior mechanical performance of the extrudate. It is further argued that current weld seam formation criteria utilised in finite element modelling need enhancement to incorporate these flow related defects.

111098 An investigation on microstructures and mechanical properties of explosive cladded C103 niobium alloy over C263 nimonic alloy

Mastanaiah, P; Madhusudhan Reddy, G; Satya Prasad, K; Murthy, CVS [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 2316, Pages 9] Futuristic aerospace applications such as advanced turbojet and scramjet engines used in subsonic, supersonic, and trans-atmospheric flights require materials with ever-increasing temperature and load bearing capabilities for improved performance. The materials C103 niobium alloy and C263 nimonic alloy are widely employed in the manufacturing of scramjet engine components. Efforts to join these two materials by fusion welding

Abstracts


process have revealed that they are metallurgically incompatible due to the extreme propensity to form brittle intermetallics. The possibility of interdicting interlayer is explored to overcome the formulation of intermetallics and the attempts have not yielded fruitful results. Explosive welding/cladding is one of the possible ways to join these materials, as it is a solid state joining process. The present work aims at studying structure–property correlations in an explosive weld of C103 niobium alloy and C263 nimonic alloy. Explosive welding was carried out taking both the materials in solution-annealed condition. Microstructural studies were carried out to evaluate the integrity of weld joint. Mechanical properties such as shear strength of weld interface was found to be superior and ram tensile strength was observed to be marginally inferior compared to the strength of weaker component of the weld joint. The micro-hardness was observed to be high at the bond interface on C263 nimonic alloy side. The three point bend tests were conducted on the weld joint in such a way that the cladding was subjected to tension, which has not shown any cracks at the interface.

111099 Numerical and experimental investigation of FSP of PA 6/MWCNT composite

Zinati, R F a r s h b a f ; Razfar, MR; Nazockdast, H [J of Materials P r o c e s s i n g Technology,

v 214, n 11, Nov 2014, Starting Page 2300, Pages 16] In the current study, a numerical model based on Lagrangian incremental formulation was developed for friction stir process of polyamide 6 and polyamide 6/multi-walled carbon nano-tube composite to investigate the thermo-mechanical behavior of them (e.g. temperature, effective plastic strain distribution, material flow, and material velocity). For this purpose, friction stir process was used to disperse the multi-walled carbon nano-tubes among the polymer matrix of PA 6, homogenously. The X-ray diffraction, scanning electron microscopy, and micro-indentation hardness were used to investigate the properties of fabricated nano-composite. The obtained results were then used to verify the objectives of numerical model. According to the results, the MWCNTs are separated from each other while passing the tool-pin due to high plastic strain applied on them and greater amount of the material accumulates in the AS of stirred zone after passing the tool-pin. Also, MWCNTs

were homogeneously and straightly dispersed throughout the PA 6. The straight and non-curved dispersion of MWCNTs results in growth of its reinforcement capability.

111100 Twin-wire indirect arc welding by modeling and experiment

Shi, Chuanwei; Zou, Yong; Zou, Zengda; Wu, Dongting [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2292, Pages 8] Argon-shielded twin-wire indirect arc (TWIA) welding is a method with a high

melting rate, high welding efficiency, low welding deformation and low penetration depth of the weld joint. In this paper, the arc behavior of the twin-wire indirect arc (TWIA) for current values of 100 A, 150 A and 200 A and their influence on the welding process were discussed, and the reasons of the previously mentioned advantages of this welding method were analyzed. The plasma temperature was measured to verify the correctness of the simulation. The results indicate that the arc behavior is mainly controlled by the welding current. With the increasing current, the arc parameters in the anode and cathode regions significantly increase, whereas those in the arc column region vary by a smaller degree. The rate of increase of the arc parameters in the entire arc region is smaller than that of the welding current. The isotherm shifts toward the anode side and the shift of the isotherm increases when the welding current increases. The advantaged of TWIA welding was discussed according to the calculated result.

111101 Physical simulation of longitudinal seam welding in micro channel tube extrusion

Tang, Ding; Zhang, Qingqing; Li, Dayong; Peng, Yinghong [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2777, Pages 7] Micro channel tube is a newly developed type of aluminum profiles with sub-millimeter-diameter ports in the cross-section designed for

Abstracts


heat transfer enhancement. Micro channel tube is formed with porthole extrusion die, and the longitudinal seam welding problem is the key issue related to both the design of the delicate mandrel in the extrusion die and the pressure bearing capacity of the tube. This paper proposes a novel method to evaluate the seam welding strength of the micro channel tube at the stage of extrusion die design. First, a finite element (FE) simulation of the tube extrusion process is performed for the seam welding conditions in the die chamber and effect of the welding chamber height on hydrostatic pressure. Then, a thermo-mechanical experiment is carried out for a quantitative relationship between the welding strength and the weld condition parameters. Combining this relationship to the numerical results, the welding strength under different die design can be evaluated. Pressure bearing tests on the tube prove the reliability of this evaluation method. This study quantitatively connects the seam welding strength of the profile to the extrusion die parameters, which is helpful for optimizing the design of the extrusion process.

111102 Modified Fowler–Milne method for monochromatic image analysis in multi-element arc plasma weldingXiao, Xiao; Hua, Xueming; Li, Fang; Wu, Yixiong [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2770, Pages 7] The monochromatic images of 794.8 nm Ar I and 487.98 nm Ar II spectrums are obtained by high speed camera, and these images are normalized with respect to their relative maximum emission coefficient in a pure argon (single element) arc. The relative maximum emission coefficient of 487.98 nm Ar II is calculated based on Olsen-Richter diagram. Unlike other spectroscopic methods, the presented method does not require spectra scan or the maximum emission coefficient of non-argon elements. This technique is applied to the measurement of radial profile of temperature and gas composition of argon–helium arc plasma in gas tungsten arc welding (GTAW), significant demixing occurs in the argon–helium arc plasma. Helium concentration in arc plasma is higher than that in original gas mixture, and it decreases as the point moves away from the axis along radial direction and increases as the point gets closer to the cathode. The calculated arc temperature and gas composition are compared with the data obtained using conventional method where a spectrometer is used for spectral line intensity measurement and two-line relative intensity method for calculation. Very good agreements have been observed. That means, the developed

technique measures arc temperature and gas composition as accurate as the conventional spectroscopic methods. With the usage of a high speed camera, the developed technique enables measurement of arc temperature and gas composition distribution in a dynamic arc such as arc ignition, pulsing arc.

111103 Real time monitoring of phase transformation and strain evolution in LTT weld filler material using EDXRD

Gibmeier, J; Held, E; Altenkirch, J; Kromm, A; Kannengiesser, Th; Buslaps, Th [J of Materials P r o c e s s i n g

Technology, v 214, n 11, Nov 2014, Starting Page 2739, Pages 9] For a newly developed 10% Cr and 10% Ni low transformation temperature (LTT) weld filler material, the local phase transformation kinetics and the strain evolution during gas tungsten arc welding (GTAW) under real welding conditions was studied. An experimental set-up and a measuring and evaluation strategy are presented to gain a real time insight into the welding process. The experiments were carried out at the beam line ID15@ESRF using a two detector EDXRD (energy dispersive X-ray diffraction) set-up and high energy synchrotron X-rays. The time-resolved diffraction analysis during welding was carried out locally throughout the weld in longitudinal as well as in transverse direction to the weld line to examine the interdependence of the strain state and the transformation kinetics. This comprehension is crucial for the optimization of the weld process, and thus for the tailoring of the resulting residual stress states, which is one of the main issues for the application of LTT alloys. Using the herein proposed approach EDXRD diffraction pattern can be monitored during real welding with a counting rate of 5 Hz. By means of the time resolved diffraction data the local transformation temperatures and times were determined and the local phasespecific strain evolutions are discussed with respect to the transformation rates and the time-delayed phase transformations.

111104 Modelling the effect of welding current on resistance spot welding of DP600 steelWan, Xiaodong; Wang, Yuanxun; Zhang, Peng [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2723, Pages 7] Experiments were made for welding current

Abstracts


variation between 6 kA and 12 kA. Microstructure and mechanical performance under tensile-shear tests were recorded and compared. Welding current effect on micro-properties was very slight while nugget size was highly dependent on welding current.

Expulsion phenomenon existed at 12 kA welding current and the unsatisfactory partial interfacial failure was detected. Nugget formation and temperature distribution were analysed numerically. Comparisons with experimental results showed that the nugget size deviation was within 10% and the nugget shape was well predicted.

111105 Direct glass-to-metal joining by simultaneous anodic bonding and soldering with activated liquid tin solder

Elrefaey, A; Janczak-Rusch, J; Koebel, MM [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2716, Pages 7] Anodically bonded glass/titanium and glass/steel were investigated for applications in a variety of industrial sectors. Residual stresses that build up during the

bonding or cooling down of a joint to room temperature represent the main challenge to the joining process since they drastically weaken the mechanical strength of the joint. A layer of liquid tin-based solder in between the glass and metal part of the joint is used to reduce the internal stresses and improve the contact between the surfaces. The microstructural characterization of glass/solder/titanium and glass/solder/steel joints formed from Ni coated metal substrates indicated that Ni3Sn4 was formed for both types of joint but with a different morphology and location depending on the type of metal substrate. The average shear strength of the joints was 24 MPa for glass–titanium and 21 MPa for glass–steel joints. For both types of joint, the fracture crack propagated along the glass–solder interface.

LASERS

111106 Laser transformation hardening of carbon

steel sheets using a heat sinkKi, Hyungson; So, Sangwoo; Kim, Sanseo [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 2693, Pages 13] A heat-sink assisted laser transformation hardening method is presented as a way to enhance the hardenability of carbon steel sheets. In this study, the thermal conductivity of the heat sink and the thermal contact resistance between the steel sheet and the heat sink were identified as the two primary parameters for the process. Using a process map approach, the heat-treatability of steel sheets was studied theoretically focusing on carbon diffusion and cooling time characteristics. For validation purposes, 2 mm thick DP 590 and boron steel sheets were laser-hardened using four types of heat sink: stainless steel, steel, copper, and no heat sink. Surface hardness, hardening width and depth were measured and analyzed over a wide range of process parameters. From this study, it was revealed that, when a heat sink is used, both cooling and carbon diffusion characteristics become roughly on par with those of the thick plate case, but the heat treatable region remains similar to that of the no heat sink case. The use of a heat sink was found to be an effective way of enhancing the hardenability of steel sheets and the amount of enhancement is largely proportional to the heat sink thermal conductivity.

111107 Effect of laser irradiation on failure mechanism of TiCp reinforced titanium composite coating produced by laser cladding

Candel, JJ; Jimenez, JA; Franconetti, P; Amigó, V [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2325, Pages 8] Laser cladding is an effective technique to coat a metallic substrate with a layer of a different nature. It has been widely reported that the most important combined parameters controlling the

quality of the coating are the specific energy (E) and the powder density (?). In the present work, clad deposits of Ti6Al4V + 60 wt.% TiC were prepared on a Ti6Al4V substrate using an optimum combination of Ec = 24 J/mm2 and ?c = 3 mg/mm2.

Abstracts


These experiments were performed using a laser power of 400 and 600 W, in order to study the effect of laser power on the properties of the clad. The microstructure, phase composition and nanohardness of the coatings were investigated by optical microscopy, scanning electron microscopy and X-ray diffraction. During laser processing, TiC can be partially converted to TiCX (X = 0.5) due mainly to the TiC dissolution into the laser-generated melting pool and subsequent precipitation during cooling. It was observed that the lower laser power limit reduces primary TiC dissolution but it also promotes secondary carbide alignment at the interface. On the other hand, the damage mechanism induced by high laser power is dominated by primary TiC particle cracking by the high stress concentration at the particle–matrix interface followed by ductile failure of the matrix. It is also remarkable that irradiance affects the TiC/TiCx ratio despite Ec and ?c are fixed and it determines hardness distribution inside the coating.

MACHINE TOOLS

111108 The effect of axis coupling on machine tool dynamics determined by tool deviation

Wang, Lei; Liu, Haitao; Yang, Lei; Zhang, Jun; Zhao, Wanhua; Lu, Bingheng [Int J of Machine Tools & M a n u f a c t u r e , v 88, Jan 2015, Starting Page 71,

Pages 11] High acceleration forces of machine tool with kinetic coupling as the dominating coupling forces may deform the machine structure and result in the tool deviation. In this paper, a dynamic model of a three-axis gantry milling machine tool considering axis coupling effects is proposed to model the varying dynamic behavior and evaluate the Tool Center Point (TCP) position deviations. The effect of axis coupling force on the stiffness changes of kinematic joints is analyzed. The variations of the frequencies and frequency response functions with respect to position parameters are calculated. And the TCP deviation affected by axial coupling in real-time motion state is discussed in detail. The results show that it is able to obtain an excellent match between the simulations and the measurements. The simulation and experimental results show that: (1) the natural frequencies and the receptance are greatly changed when the TCP is moving along the X-axis

or the Z-axis, where the maximum changing of natural frequencies is up to 10% and response magnitude up to 2 times; (2) the elastic deformation and vibration of machine tool are caused by the coupling forces in acceleration and braking, which detrimentally affect dynamic response of the TCP. Thus, the model proposed in this paper represents the important effects for comprehension of machine dynamic behavior and for further compensation in future.

111109 Development of an Integrated Approach to the Design of Reconfigurable Micro/Mesoscale CNC Machine ToolsPérez, Roberto; Molina, Arturo; Ramírez-Cadena, Miguel [J of Manufacturing Sci & Engg: ASME Trans, v 136, n 3, Jun 2014, Starting Page 031003, Pages 10] In the present, the technology related to the micro/meso manufacturing is promising as a key enabling technology for maximizing high value manufacturing. This paper addresses a new methodology to design reconfigurable micro/mesoscale CNC machine tools in the integrated product, process, and manufacturing system development context. This is followed by a description of the design of a reconfigurable two-axis first-generation test bed CNC micromachine tool that was developed to assess the feasibility of the new design method. The test bed utilizes a high-speed miniature spindle that is required to obtain appropriate cutting velocities for the efficient cutting of metals, use micro-actuators for the axis movements and open-architecture controllers, in order to guarantee the reconfigurability properties of the micromachine. Results indicate the new methodology enhances the design of reconfigurable micro/mesoscale CNC machine tools in the integrated product, process, and manufacturing system development context, following the prescriptive models of design.

111110 New error measurement method to identify all six error parameters of a rotational axis of a machine tool

He, Zhenya; Fu, Jianzhong; Zhang, Liangchi; Yao, Xinhua [Int J of Machine Tools & M a n u f a c t u r e , v 88, Jan 2015, Starting Page 1, Pages 8] This paper presents a new error measurement method, a Dual Optical

Path Measurement Method (DOPMM), to identify error parameters of the rotational axis of a

Abstracts


machine tool along its error sensitive directions. The method development was carried out on a motorized rotary stage equipped with a Doppler laser instrument. An error measurement experiment and a machining experiment were conducted on a five-axis machining center with a titling rotary table. It was found that the DOPMM can identify all of the six volumetric error parameters with the simple algebraic operations. Compared with the existing ball bar tests, which need a mathematical error modeling of machine tools to separate the error parameters, the identified process of DOPMM is more simple and easier to understand. And the operation of machine tools during the measurement is much easier than that of the existing ball bar tests. The experimental results showed that the part precision can have a significant improvement of 68% when the identified error parameters are used for error compensation. Hence, the measurement method established in this study is sensible and efficient, and could be used for the error compensation on a wide range of machine tools to improve their machining precision.

MACHINING

111111 New approach to contour error control in high speed machiningRahaman, Mostafizur; Seethaler, Rudolf; Yellowley, Ian [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 42, Pages 9] High speed machining technology attempts to maximize productivity through the use of high spindle speeds and axis traverse rates. The technology is dependent upon the development of suitable mechanical hardware, electrical drives and associated control software to ensure that all components are used to maximum advantage. The role of the control software is particularly demanding since one needs to maximize traverse rates while providing the necessary accuracy, and indeed providing a margin of safety to deal with unexpected changes in process, or system parameters. There have been relatively few improvements in commercial CAD or CAM systems that would help machine tool users to take maximum advantage of high speed machining; rather the majority of the approaches have been undertaken at the machine tool controller level. This paper uses circular interpolation and corner tracking to compare several such control techniques, (Cross Coupled Control (CCC), Zero Phase Error Tracking Control (ZPETC), and Realtime Frequency Modulated Interpolation (FMI)), each of which have been proposed in the literature order to improve

machining accuracy. None of these approaches are found to be universally successful when used alone and the authors, in this paper, examine the use of these systems in combination. Particular attention is focused upon an extension of a simplified version of cross coupled control together with Frequency Modulated Interpolation. It is shown that the combined system performs extremely well, and is easily actuated at high frequencies with conventional hardware. A custom built high speed x-y table is used to confirm system performance with multiple constraints present.

111112 Development of a hybrid rapid prototyping system using low-cost fused deposition modeling and five-axis machining

Lee, Wei-chen; Wei, Ching-chih; Chung, Shan-Chen [J of Materials Processing T e c h n o l o g y , v 214, n 11, Nov 2014, Starting Page 2366, Pages 9] Currently, two major processes

are being used to produce prototypes, namely machining and rapid prototyping. Machining is generally more accurate and precise, but it is difficult to produce objects with certain complicated features. In contrast, rapid prototyping can produce objects with complicated features, which allows materials to be used more efficiently. However, due to the uneven shrinkage and residual stresses within rapid prototyping products, their accuracy is usually uncertain. This study attempts to integrate these two manufacturing processes and develop a hybrid rapid prototyping system in order to overcome the disadvantages associated with each process and to develop new applications. Fused deposition modeling (FDM) was used as the rapid prototyping process in this work. A spindle and a low-cost FDM extruder were designed to be placed on each end of a rotary axis in a five-axis machine tool. The proposed design allows the rotation of the axis on the five-axis machine to switch between machining and FDM, thus achieving the advantage of reducing costs for extra actuators without sacrificing working space. The case studies demonstrated that the proposed hybrid system can build FDM objects without using support materials and produce FDM parts with metal embedded to increase the stiffness. The system can also conduct five-axis machining on a completed FDM part or trim the freeform surface fabricated by FDM to achieve more accurate

Abstracts


dimensions or better surface finish.

111113 Estimating the Cohesive Zone Model Parameters of Carbon Nanotube–Polymer Interface for Machining Simulations

Jiang, Lingyun; Chandra Nath; Samuel, Johnson; Kapoor, Shiv G [J of Manufacturing Sci & Engg: ASME Trans, v 136, n 3, Jun 2014, Starting

Page 031004, Pages 8] The failure mechanisms encountered during the machining of carbon nanotube (CNT) polymer composites are primarily governed by the strength of the CNT–polymer interface. Therefore, the interface should be explicitly modeled in microstructure-level machining simulations for these composites. One way of effectively capturing the behavior of this interface is by the use of a cohesive zone model (CZM) that is characterized by two parameters, viz., interfacial strength and interfacial fracture energy. The objective of this study is to estimate these two CZM parameters of the interface using an inverse iterative finite element (FE) approach. A microstructure-level 3D FE model for nanoindentation simulation has been developed where the composite microstructure is modeled using three distinct phases, viz., the CNT, the polymer, and the interface. The unknown CZM parameters of the interface are then determined by minimizing the root mean square (RMS) error between the simulated and the experimental nanoindentation load–displacement curves for a 2?wt. % CNT–polyvinyl alcohol (PVA) composite sample at room temperature and quasi-static strain state of up to 0.04?s-1, and then validated using the 1?wt. % and 4?wt. % CNT–PVA composites. The results indicate that for well-dispersed and aligned CNT–PVA composites, the CZM parameters of the interface are independent of the CNT loading in the weight fraction range of 1–4%.

111114 Fundamental investigation of ultra-precision ductile machining of tungsten carbide by applying elliptical vibration cutting with single crystal diamond

Zhang, Jianguo; Suzuki, Norikazu; Wang, Yilong; Shamoto, Eiji [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2644, Pages

16] This paper presents essential investigations on the feasibility of ductile mode machining of sintered tungsten carbide assisted by ultrasonic elliptical vibration cutting technology. It lays out the foundations toward efficient application of elliptical vibration cutting technology on tungsten carbide. Tungsten carbide is a crucial material for glass molding in the optics manufacturing industry. Its grain size and binder material have significant influence not only on the mechanical and chemical properties but also on the machining performance of tungsten carbide. In order to investigate the influence of material composition on tungsten carbide machining, a series of grooving and planing experiments were conducted utilizing single crystal diamond tools. The experimental results indicated that as compared to ordinary cutting where finished surface deteriorates seriously, ductile mode machining can be attained successfully by applying the elliptical vibration cutting technique. It was also clarified that the binder material, the grain size, cutting/vibration conditions as well as crystal orientation of the diamond tool have significant influence on the tool life and the machined surface quality. Based on these fundamental results, feasibility of micro/nano-scale fabrication on tungsten carbide is investigated. By applying amplitude control sculpturing method, where depth of cut is arbitrary changed by controlling the vibration amplitude while machining, ultra-precision textured grooves and a dimple pattern were successfully sculptured on tungsten carbide in ductile mode.

111115 Targeted suppression of vibration in deep hole drilling using magneto-rheological fluid damperKong, Lingfei; Chin, Jih-Hua; Li, Yan; Lu, Yanjun; Li, Pengyang [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2617, Pages 10] Under the concept of precision or targeted vibration suppression, a novel approach is developed to reduce the vibration of drilling tool system in deep-hole drilling process. The concept is to suppress the dominant vibration upon its emergence by variable damping or to force the harmful vibration morph into less harmful by different damper position. A magneto-rheological (MR) fluid damper is designed with adjustable damping capability to counteract emerging vibration. A series of experimental investigations are carried out on the BTA deep hole drilling process. The experimental results show that the adjustable MR damping brings down the vibration in all applications with different suppression effect. A relative optimal suppression can always be found. The suppressed vibration experiences a

Abstracts


frequency shift which sheds light on the possible avoidance of matching of unwelcome frequency. Different damper locations have different but consistent suppression results which foresee a possibility of forcing the mode of vibration into less harmful one. A potential precision or targeted suppression of vibration upon its emergence is thus possible.

111116 Straightness error compensation for large CNC gantry type milling centers based on B-spline curves modeling

Feng, WL; Yao, XD; Azamat, Arynov; Yang, JG [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 165, Pages 10] Fast and accurate modeling for the straightness errors of machine tools is significant important for the implementation of error compensation. To decrease the straightness errors which generally exist in gantry

type milling centers, a novel approach for real-time compensation of straightness errors is presented, including an accurate spatial straightness error model which based on B-Spline curves method and a real-time errors compensation system which can compensate multiple errors at the same time in real-time. An experiment is carried out to measure the straightness errors of a gantry type milling center by using a laser interferometer. There are two straightness errors for one direction movement of an axis. As a result, there are six straightness errors for a three-axis milling center. The straightness error model is established by the B-Spline curves method. According to these six straightness error models, a spatial straightness error model is obtained by superposition of these straightness error models. In addition, an external real-time errors compensation system is developed based on the function of external mechanical origin offset in Fanuc CNC systems. The compensation experiments are conducted to verify the accuracy of the spatial straightness error model and the effectiveness of the error compensation system. The experimental results show that the straightness errors of the machined work-pieces are proved to have been decreased over 90% compared with that of non compensations. The B-Spline curves modeling combining the errors compensation system can be utilized as an effective approach to improve the accuracy of the CNC gantry type milling centers.

111117 Study of an improved cutting mechanism of composite materials using novel design of

diamond micro-core drillsButler-Smith, PW; Axinte, DA; Daine, M; Kennedy, AR; Harper, LT; Bucourt, JF; Ragueneau, R [Int J of Machine Tools & Manufacture, v 88,

Jan 2015, Starting Page 175, Pages 9] Core drilling at small diameters in carbon composite materials is largely carried out using diamond electroplated tools consisting of hollow shafts and simplistic geometries that are likely to work in an abrasional/rubbing mode for material removal. The paper reports a step change in the performance of small diameter core drilling by facilitating a shearing mechanism of the composite workpiece through the utilisation of a novel tool design. This has been achieved by laser producing core drills from solid polycrystalline diamond, incorporating controlled cutting edges where the geometries are defined. To evaluate the efficiency of the shearing vs. abrasion/rubbing cutting mechanisms, a critical comparison between the novel (defined cutting edges) and the conventional electroplated tools (randomly distributed micro-grains) has been made with reference to thrust forces, tool wear mechanisms and their influences on the hole quality (e.g. delamination, fibre pullout). This work has been augmented by studies using high-speed thermal imaging of the two tool types in operation. The examinations have shown that, based on the concept of defined cutting edges in solid diamond, there is the possibility to make significant improvements in core drilling performance, (ca. 26% lower thrust force, minimal tool surface clogging, lower drilling temperatures) resulting in improved cleanliness of fibre fracture and a reduced tendency of material delamination.

111118 Machining of Carbon Fiber Reinforced Plastics/Polymers: A Literature Review

C h e , D e m e n g ; S a x e n a , Ishan; Han, P e i d o n g ;

Guo, Ping; Ehmann, Kornel F [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 034001, Pages 22] Carbon fiber reinforced plastics/polymers (CFRPs) offer excellent mechanical properties that lead to enhanced functional performance and, in turn, wide applications in numerous industrial fields. Post machining of CFRPs is an essential procedure that assures that the manufactured components meet

Abstracts


their dimensional tolerances, surface quality and other functional requirements, which is currently considered an extremely difficult process due to the highly nonlinear, inhomogeneous, and abrasive nature of CFRPs. In this paper, a comprehensive literature review on machining of CFRPs is given with a focus on five main issues including conventional and unconventional hybrid processes for CFRP machining, cutting theories and thermal mechanical response studies, numerical simulations, tool performance and tooling techniques, and economic impacts of CFRP machining. Given the similarities in the experimental and theoretical studies related to the machining of glass fiber reinforced polymers (GFRPs) and other FRPs parallel insights are drawn to CFRP machining to offer additional understanding of on-going and promising attempts in CFRP machining.

111119 Characterization of Surface Integrity Produced by Sequential Dry Hard Turning and Ball Burnishing Operations

Grzesik, Wit; Zak, Krzysztof [J of Manufactur ing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting

Page 031017, Pages 9] This paper presents the state of surface integrity produced on hardened-high strength 41Cr4 steel after hard machining and finish ball burnishing. Surfaces machined by sequential machining processes were characterized using 2D and 3D surface roughness parameters. Moreover, detailed functionality of the generated surfaces was performed using a set of 3D functional roughness parameters. Among the characteristics of the surface layer, its microstructure, the distribution of microhardness and the residual stresses were determined. This investigation confirms that ball burnishing allows producing surfaces with lower surface roughness and better service properties than those generated by cubic boron nitride (CBN) finish hard turning operations.

111120 On-machine dry electric discharge truing of diamond wheels for micro-structured surfaces grinding

Guo, Bing; Zhao, Qingliang [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 62, Pages 9] Precision grinding with diamond wheels

gives a promising alternative to achieve high quality micro-structured surfaces on optical molds. However, it is difficult to true these diamond wheels efficiently, because of the remarkable resistance property and the geometrical limitation of small wheel profile. In this paper, an on-machine dry-EDT method to precision shape and prepare diamond wheels with various profiles was proposed for micro-structured surface grinding. Firstly, the fundamental truing errors were analyzed based on the dry-EDT kinematics. And then the capabilities of dry-EDT truing for high abrasive concentration metal bonded diamond wheels were presented. Next, the effects of kinematic parameters variables on trued wheel profile accuracy were investigated. Finally, the micro-structured surfaces on SiC ceramic and tungsten carbide WC were ground by these trued diamond wheels. The experiments results showed that the arc-shaped diamond wheel (diameter of 200 mm) with 4 µm profile error (PV) and 1.0023 mm profile radius, and the V-shaped diamond wheel with 22.5 µm V-tip radius and 120.03° profile angle could be obtained by on-machine dry EDT. The kinematic parameters of dry-EDT have an important influence on truing profile accuracy of diamond wheels, especially for the tip of V-shaped wheel. The subsequent grinding show that the edge radius of V groove array on SiC is less than 2 µm, while the radius of included corner is around 55 µm. The PV error of ground arc groove array on WC is less than 5 µm. The surface roughness of ground micro-structured surface Ra is 142 nm and 97 nm for SiC and WC, respectively.

111121 Precise prediction of forces in milling circular cornersHan, Xiong; Tang, Limin [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 184, Pages 10] Pocket corner is the most typical characters of aerospace structure components. To achieve high-quality product and stable machining operation, manufacturer constantly seek to control the cutting forces in pocket corner milling process. This paper presents the cutting force in corner milling considering the precision instantaneous achievements of tool engagement angle and undeformed chip thickness. To achieve the actual milling tool engagement angle in corner milling process, the details of tool–corner engagement relationship are analyzed considering the elements of tool trajectory, tool radius, and corner radius. The actual undeformed chip thicknesses in up and down milling operations are approached on account of the trochoid paths of adjacent teeth by a presented iteration algorithm. Error analysis shows that the presented models of tool engagement angle and

Abstracts


undeformed chip thickness have higher precision comparing with the traditional models. Combined with the cutting force coefficients fitted by a series of slot milling tests, the predicted cutting force in milling titanium pocket with different corner structure and milling parameters are achieved, and the prediction accuracy of the model was validated experimentally and the obtained predict and the experiment results were found in good agreement.

111122 Theoretical and experimental study on rifling mark generating phenomena in BTA deep hole drilling process (generating mechanism and countermeasure)

M a t s u z a k i , Kenichiro; Ryu, Takahiro; Sueoka, Atsuo; Tsukamoto, Keizo [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting

Page 194, Pages 12] Boring and Trepanning Association (BTA) deep hole drilling is used for producing holes with high aspect ratios. In this process, chatter vibration sometimes occurs, and a rifling mark is formed on the bore surface. The rifling mark generating phenomenon is considered to be a result of self-excited vibration caused by time delay. An analytical model is proposed considering the supporting condition of the boring bar in detail. In a real machine for BTA drilling, the boring bar is supported at the oil pressure head and the supporting pad, as well as at the base. The stability of the self-excited vibration is analyzed numerically, and the result is compared with the experiment. The theoretical and experimental results agree well with each other. Furthermore, the effect of an additional guide pad proposed by the authors as a countermeasure is evaluated theoretically and experimentally.

111123 Corner rounding of linear five-axis tool path by dual PH curves blendingShi, Jing; Bi, Qing Zhen; Zhu, LiMin; Wang, YuHan [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 223, Pages 14] The widespread linear five-axis tool path (G01 blocks) is usually described by two trajectories. One trajectory describes the position of the tool tip point, and the other one describes the position of the second point on the tool axis. The inherent disadvantages of linear tool path are tangential and curvature discontinuities at the corners in five-axis tool path, which will result in feedrate fluctuation and decrease due to the kinematic constraints of the machine tools. In this paper, by using a pair of

quintic PH curves, a smoothing method is proposed to round the corners. There are two steps involved in our method. Firstly, according to the accuracy requirements of the tool tip contour and tool orientation tolerances, the corner is rounded with a pair of PH curves directly. Then, the control polygon lengths of PH curves are adjusted simply to guarantee the continuous variation of the tool orientation at the junctions between the transition curves and the remainder linear segments. Because the PH curves for corner rounding can be constructed without any iteration, and those two rounded trajectories are synchronized linearly in interpolation, which makes this smoothing method can be applied in a high efficiency way. Its high computational efficiency allows it to be implemented in real-time applications. This method has been integrated into a CNC system with an open architecture to implement on-line linear five-axis tool path smoothing. Simulations and experiments validate its practicability and reliability.

111124 Bayesian Inference for Milling Stability Using a Random Walk Approach

K a r a n d i k a r , Jaydeep; Traverso, Michael; Abbas, Ali; Schmitz, Tony [J of Manufacturing Sci & Engg: ASME Trans, v 136, n 3, Jun 2014, Starting Page 031015,

Pages 11] Unstable cutting conditions limit the profitability in milling. While analytical and numerical approaches for estimating the limiting axial depth of cut as a function of spindle speed are available, they are generally deterministic in nature. Because uncertainty inherently exists, a Bayesian approach that uses a random walk strategy for establishing a stability model is implemented in this work. The stability boundary is modeled using random walks. The probability of the random walk being the true stability limit is then updated using experimental results. The stability test points are identified using a value of information method. Bayesian inference offers several advantages including the incorporation of uncertainty in the model using a probability distribution (rather than deterministic value), updating the probability distribution using new experimental results, and selecting the experiments such that the expected value added by performing the experiment is maximized. Validation of the Bayesian approach is presented. The experimental

Abstracts


results show a convergence to the optimum machining parameters for milling a pocket without prior knowledge of the system dynamics.

NON TRADITIONAL MACHINING

111125 Additive manufactured porous titanium structures: Through-process quantification of pore and strut networks

Kim, Taek Bo; Yue, Sheng; Zhang, Ziyu; Jones, Eric; Jones, Julian R; Lee, Peter D [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting Page 2706, Pages 10] Titanium and its alloys are successfully used in aerospace through to marine applications. Selective laser melting (SLM) is an additive manufacturing technique, which promises to allow production of novel Ti structures. However, there is still a paucity of accepted methods for quantifying build quality. The viability of using X-ray microtomography (µCT) to quantify and track changes in morphology of SLM Ti porous structures at each stage of the post-laser melting production was tested, quantifying its quality through process. Quantification was achieved using an accessible volume tool to determine pore and strut sizes. Removal of partially sintered struts by cleaning was visualised and quantified. Eighty-eight percent of the struts broken by the cleaning process were found to have connecting neck diameters of less than 180 µm with a mean of 109 µm allowing build criteria to be set. Tracking particles removed during cleaning revealed other methods to improve build design, e.g. avoiding low angle struts that did not sinter well. Partially melted powder particles from strut surfaces were quantified by comparing surface roughness values at each cleaning step. The study demonstrates that µCT provides not only 3D quantification of structure quality, but also a feedback mechanism, such that improvements to the initial design can be made to create more stable and reliable titanium structures for a wide variety of applications.

111126 Abrasive waterjet micro-machining of channels in metals: Comparison between machining in air and submerged in water

Haghbin, Naser; Spelt, Jan K; Papini, Marcello [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 108, Pages 10] Abrasive water jet technology can be used for micro-milling using recently developed miniaturized nozzles. Abrasive water jet (AWJ) machining is often used with both the nozzle tip and workpiece submerged in water to reduce noise and contain debris. This paper compares the performance of submerged and unsubmerged abrasive water jet micro-milling of channels in 316L stainless steel and 6061-T6 aluminum at various nozzle angles and standoff distances. The effect of submergence on the diameter and effective footprint of AWJ erosion footprints was measured and compared. It was found that the centerline erosion rate decreased with channel depth due to the spreading of the jet as the effective standoff distance increased, and because of the growing effect of stagnation as the channel became deeper. The erosive jet spread over a larger effective footprint in air than in water, since particles on the jet periphery were slowed much more quickly in water due to increased drag. As a result, the width of a channel machined in air was wider than that in water. Moreover, it was observed that the instantaneous erosion rate decreased with channel depth, and that this decrease was a function only of the channel cross-sectional geometry, being independent of the type of metal, the jet angle, the standoff distance, and regardless of whether the jet was submerged or in air, in either the forward or backward directions. It is shown that submerged AWJM results in narrower features than those produced while machining in air, without a decrease in centerline etch rate.

111127 Effect of Thermal Deformation on Part Errors in Metal Powder Based Additive Manufacturing ProcessesPaul, Ratnadeep; Anand, Sam; Gerner, Frank [J of Manufacturing Sci & Engg: ASME Trans, v 136, n 3, Jun 2014, Starting Page 031009,

Abstracts


Pages 12] In metal additive manufacturing (AM) processes, parts are manufactured in layers by sintering or melting metal or metal alloy powder under the effect of a powerful laser or an electron beam. As the laser/electron beam scans the powder bed, it melts the powder in successive tracks which overlap each other. This overlap, called the hatch overlap, results in a continuous cycle of rapid melting and resolidification of the metal. The melting of the metal from powder to liquid and subsequent solidification causes anisotropic shrinkage in the layers. The thermal strains caused by the thermal gradients existing between the different layers and between the layers and the substrate leads to considerable thermal stresses in the part. As a result, stress gradients develop in the different directions of the part which lead to distortion and warpage in AM parts. The deformations due to shrinkage and thermal stresses have a significant effect on the dimensional inaccuracies of the final part. A three-dimensional thermomechanical finite element (FE) model has been developed in this paper which calculates the thermal deformation in AM parts based on slice thickness, part orientation, scanning speed, and material properties. The FE model has been validated and benchmarked with results already available in literature. The thermal deformation model is then superimposed with a geometric virtual manufacturing model of the AM process to calculate the form and runout errors in AM parts. Finally, the errors in the critical features of the AM parts calculated using the combined thermal deformation and geometric model are correlated with part orientation and slice thickness.

111128 Defect generation and propagation mechanism during additive manufacturing by selective beam meltingBauereiß, A; Scharowsky, T; Körner, C [J of Materials Processing Technology, v 214, n 11, Nov 2014, Starting 22, Pages 7] During powder bed based additive manufacturing processes a component is fabricated by locally melting of powder layers with a laser or an electron beam. The fast melting process of the stochastic powder bed induces vigorous melt pool movements which sometimes lead to faults acting as starting points for larger defects such as channels bridging many layers. Since the formation of these defects cannot be understood in the framework of a homogenized numerical approach we have developed a mesoscopic numerical model based on the Lattice Boltzmann Method for the local melting process which considers individual

powder particles. The model takes into account full hydrodynamics including capillary and wetting effects. It is shown that these effects combined with the stochastic powder layer are the origin of fault formation. The numerical results are compared with experiments in order to demonstrate the predictive value of our model.

111129 Model of Micro Electro-Discharge Machining Plasma Discharge in Deionized WaterMujumdar, Soham S; Curreli, Davide; Kapoor, Shiv G; Ruzic, David [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 3, Jun 2014, Starting Page 031011, Pages 12] For successful commercial adaptation of the µ-EDM (micro electro-discharge machining) process, there is a need to increase the process efficiency by understanding the process mechanism. This paper presents a model of the plasma discharge phase of a single discharge µ-EDM event in deionized water. The plasma discharge is modeled using global model approach in which the plasma is assumed to be spatially uniform, and equations of mass and energy conservation are solved simultaneously along with the dynamics of the plasma bubble growth. Given the input discharge voltage, current and the discharge gap, complete temporal description of the µ-EDM plasma during the discharge time is obtained in terms of the composition of the plasma, temperature of electrons and other species, radius of the plasma bubble and the plasma pressure. For input electric field in the range of 10–2000 MV/m and discharge gap in the range of 0.5–20 µm, time-averaged electron density of 3.88×1024m-3-30.33×1024m-3 and time averaged electron temperature of 11,013 29,864 K are predicted. Experimental conditions are simulated and validated against the spectroscopic data from the literature. The output from this model can be used to obtain the amount of heat flux transferred to the electrodes during the µ-EDM process.

111130 Batch-mode micropatterning of carbon nanotube forests using UV-LIGA assisted micro-electro-discharge machining

Sarwar, Mirza Saquib us; D a h m a r d e h , Masoud; Nojeh, Alireza; Takahata, Kenichi [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 ,

Abstracts


v 214, n 11, Nov 2014, Starting Page 2537, Pages 8] This paper reports batch-mode, three-dimensional micropatterning for arrays of vertically aligned carbon nanotubes, also known as CNT forests, based on dry micro-electro-discharge machining (µEDM). The process employs an array of copper electrodes microfabricated through an advanced UV-LIGA process enabled with a new photoresist system in combination with electroplating, providing a low-cost path to constructing high-density arrays of µEDM electrodes for high-throughput parallel processing. The fabricated arrays of 85-µm-tall electrodes are utilized to demonstrate and characterize planar dry µEDM for post-growth patterning of CNT forests in air. Die sinking and scanning processes are tested to show pattern transfers with a 4-µm tolerance and an average surface roughness of 230 nm. An elemental analysis suggests that contamination of the electrode material on the produced patterns is minimal. Key characteristics in the use of planar electrodes for batch processing of CNT forests are revealed through experimental analysis and discussed in detail. The results suggest that the investigated process is a promising approach toward offering a cost-effective manufacturing technology for future products functionalized with custom-designed microstructures of CNT forests.

CNC MACHINING

111131 Generalized on-line estimation and control of five-axis contouring errors of CNC machine toolsYang, Jixiang; Altintas, Yusuf [Int J of Machine Tools & Manufacture, v 88, Jan 2015, Starting Page 9, Pages 15] Nonlinear and configuration-dependent five-axis kinematics make contouring errors difficult to estimate and control in real time. This paper proposes a generalized method for the on-line estimation and control of five-axis contouring errors. First, a generalized Jacobian function is derived based on screw theory in order to synchronize the motions of linear and rotary drives. The contouring error components contributed by all active drives are estimated through interpolated position commands and the generalized Jacobian function. The estimated axis components of contouring errors are fed back to the position commands of each closed loop servo drive with a proportional gain. The proposed contouring error estimation and control methods are general, and applicable to arbitrary five-axis tool paths and any kinematically

admissible five-axis machine tools. The proposed algorithms are verified experimentally on a five-axis machine controlled by a modular research CNC system built in-house. The contouring errors are shown to be reduced by half with the proposed method, which is simple to implement in existing CNC systems.

DIAMOND TURNING

111132 Diamond machining of silicon: A review of advances in molecular dynamics simulation

Goel, Saurav; Luo, Xichun; Agrawal, Anupam; Reuben, Robert L [Int J of Machine Tools & M a n u f a c t u r e , v 88, Jan 2015, Starting Page 131, Pages 34] M o l e c u l a r dynamics (MD)

simulation has enhanced our understanding about ductile-regime machining of brittle materials such as silicon and germanium. In particular, MD simulation has helped understand the occurrence of brittle–ductile transition due to the high-pressure phase transformation (HPPT), which induces Herzfeld–Mott transition. In this paper, relevant MD simulation studies in conjunction with experimental studies are reviewed with a focus on (i) the importance of machining variables: undeformed chip thickness, feed rate, depth of cut, geometry of the cutting tool in influencing the state of the deviatoric stresses to cause HPPT in silicon, (ii) the influence of material properties: role of fracture toughness and hardness, crystal structure and anisotropy of the material, and (iii) phenomenological understanding of the wear of diamond cutting tools, which are all non-trivial for cost-effective manufacturing of silicon. The ongoing developmental work on potential energy functions is reviewed to identify opportunities for overcoming the current limitations of MD simulations. Potential research areas relating to how MD simulation might help improve existing manufacturing technologies are identified which may be of particular interest to early stage researchers ◘

Editorial Board Contents - CMTI-India · Bank: State Bank of India, Yeshwanthpur Branch, APMC Yard,...

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