A novel dual point clamper for low-rigidity plate milling with deformation co...eSAT Journals
Abstract
The surface profile accuracy plays a significant role in achieving the overall product’s functional performance, which is seriously impacted by the cutting forces, clamping forces, and residual stresses. Conventionally, many researches about deformation compensation focus on cutting forces and fixture layout and do not consider clamping forces. Actually, clamping forces, which would dynamically change along with the movements of cutting tools, are essential in precision machining process. In this paper, a novel dual-point clamper method with adaptive deformation compensation is proposed to improve the workpieces milling precision. Based on the Generalized Principle of Superposition Method, a mathematical model considering the deflection from both cutting forces and clamping forces has been estimated and compared with the traditional clamping scheme. Both 3D finite element model (FEM) based simulation experiments and experimental case studies are carried out, and their results show good agreement with each other. The deflection computation and prediction from numerical studies indicates the efficiency and correctness of the proposed approach.
Keywords: Compensation; Deformation; Fixture; Milling
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Size effect of plain concrete beams–an experimental studyeSAT Journals
Abstract
The paper analyses the size dependency of the fracture energy (GF) and the effective length of fracture process zone (Cf) of concrete
determined as per the Bazant’s Size effect method and RILEM Work-of-fracture methods. The fracture parameters (GF,Cf) are
determined by measuring the maximum loads of geometrically similar notched plain concrete (M25) specimens of different sizes in a
size ratio of 1:5 with different pre-cast notch depths (a/d=0.15, 0.30 and 0.45) under three point bending through load-deflection
curves. In each notch depth ratio, 15 beams are cast and tested with 03 similar specimens in each size of the beams. Total beams
tested are 45.The variation of both the fracture energy and the effective length of fracture process zone as a function of the specimen
size and notch depth is determined using Bazant’s Size effect method and RILEM Work-of-fracture method. Fracture energy and
Fracture process zone length determined by Size effect method are found to be decreasing with the increasing notch depth ratios.
Fracture energy calculated using Work-of-fracture method is increasing with the increase in size of specimen and decreasing with the
increasing notch depth ratios.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
A novel dual point clamper for low-rigidity plate milling with deformation co...eSAT Journals
Abstract
The surface profile accuracy plays a significant role in achieving the overall product’s functional performance, which is seriously impacted by the cutting forces, clamping forces, and residual stresses. Conventionally, many researches about deformation compensation focus on cutting forces and fixture layout and do not consider clamping forces. Actually, clamping forces, which would dynamically change along with the movements of cutting tools, are essential in precision machining process. In this paper, a novel dual-point clamper method with adaptive deformation compensation is proposed to improve the workpieces milling precision. Based on the Generalized Principle of Superposition Method, a mathematical model considering the deflection from both cutting forces and clamping forces has been estimated and compared with the traditional clamping scheme. Both 3D finite element model (FEM) based simulation experiments and experimental case studies are carried out, and their results show good agreement with each other. The deflection computation and prediction from numerical studies indicates the efficiency and correctness of the proposed approach.
Keywords: Compensation; Deformation; Fixture; Milling
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Size effect of plain concrete beams–an experimental studyeSAT Journals
Abstract
The paper analyses the size dependency of the fracture energy (GF) and the effective length of fracture process zone (Cf) of concrete
determined as per the Bazant’s Size effect method and RILEM Work-of-fracture methods. The fracture parameters (GF,Cf) are
determined by measuring the maximum loads of geometrically similar notched plain concrete (M25) specimens of different sizes in a
size ratio of 1:5 with different pre-cast notch depths (a/d=0.15, 0.30 and 0.45) under three point bending through load-deflection
curves. In each notch depth ratio, 15 beams are cast and tested with 03 similar specimens in each size of the beams. Total beams
tested are 45.The variation of both the fracture energy and the effective length of fracture process zone as a function of the specimen
size and notch depth is determined using Bazant’s Size effect method and RILEM Work-of-fracture method. Fracture energy and
Fracture process zone length determined by Size effect method are found to be decreasing with the increasing notch depth ratios.
Fracture energy calculated using Work-of-fracture method is increasing with the increase in size of specimen and decreasing with the
increasing notch depth ratios.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
ER Publication,
IJETR, IJMCTR,
Journals,
International Journals,
High Impact Journals,
Monthly Journal,
Good quality Journals,
Research,
Research Papers,
Research Article,
Free Journals, Open access Journals,
erpublication.org,
Engineering Journal,
Science Journals,
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Probabilistic Design Hollow of Airfoil Wing by Using Finite Element MethodIJERA Editor
This study represents simulation of Airfoil composite beam by using Monte Carlomethod. A three dimensional static analysis of large displacement type has been carried out. Finite element analysis of NACA0012 airfoil composite structure has been carried out and uncertainty in bending stress is analyzed. Bending stress was objective function. Chord length , beam length ,elastic modulus in XY,YZ,XZ,shear modulus of epoxy graphite in in XY,YZ,XZ, ply angle and ply thickness of airfoil section, force are varied within effective range and their effect on bending stress has been analyzed. In order to validate the results, one loop of simulation is benchmarked from results in literature. Ultimately, best set of probabilistic design variable is proposed to reduce bending stress under static loading condition.
Probabilistic Design of Hollow Circular Composite Structure by using Finite E...IJERA Editor
This study represents simulation of hollow circular composite beam by using Monte Carlo method .A three
dimensional static analysis of large displacement type has been carried out. Finite element analysis of hollow
circular composite structure has been carried out and uncertainty in bending stress is analyzed. Bending stress
was objective function. Beam length, beam radius, elastic modulus, shear modulus and Poisson ratio of epoxy
graphite, ply angles of hollow circular section, radius and force are randomly varied within effective range and
their effect on bending stress has been analyzed. In order to validate the results, one loop of simulation is
benchmarked from results in literature. Ultimately, best set of probabilistic design variable is proposed to reduce
bending stress under static loading condition.
Empirical relation to estimate the reduction of root fillet stress in spur ge...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Stepped or non-prismatic beams are widely used in many engineering applications
and the calculation of their natural frequency is one of the most important problem.
Several methods were used to calculate the natural frequency of stepped beam. In this
work, the Rayleigh methods (Classical and Modified) and finite element method using
ANSYS software were used for calculating the natural frequency of Hollow stepped
cantilever beam with circular and square cross section area. The comparison between
the results of natural frequency and frequency ratio due to the increasing the length of
the small part for these types of beams and for these three methods were made. The
agreement between ANSYS the classical Rayleigh results was better than the agreement
between ANSYS the Modified Rayleigh results for the two types of cross section area. The
maximum error of MRM was greater than that of CRM and the maximum error of circular
C.S.A. Was greater than that of square C.S.A. At the same dimensions. The natural
frequency of circular C.S.A was smaller than that of square C.S.A. for the same
dimensions
Deformation Analysis of a Triangular Mild Steel Plate Using CST as Finite Ele...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted
ER Publication,
IJETR, IJMCTR,
Journals,
International Journals,
High Impact Journals,
Monthly Journal,
Good quality Journals,
Research,
Research Papers,
Research Article,
Free Journals, Open access Journals,
erpublication.org,
Engineering Journal,
Science Journals,
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Probabilistic Design Hollow of Airfoil Wing by Using Finite Element MethodIJERA Editor
This study represents simulation of Airfoil composite beam by using Monte Carlomethod. A three dimensional static analysis of large displacement type has been carried out. Finite element analysis of NACA0012 airfoil composite structure has been carried out and uncertainty in bending stress is analyzed. Bending stress was objective function. Chord length , beam length ,elastic modulus in XY,YZ,XZ,shear modulus of epoxy graphite in in XY,YZ,XZ, ply angle and ply thickness of airfoil section, force are varied within effective range and their effect on bending stress has been analyzed. In order to validate the results, one loop of simulation is benchmarked from results in literature. Ultimately, best set of probabilistic design variable is proposed to reduce bending stress under static loading condition.
Probabilistic Design of Hollow Circular Composite Structure by using Finite E...IJERA Editor
This study represents simulation of hollow circular composite beam by using Monte Carlo method .A three
dimensional static analysis of large displacement type has been carried out. Finite element analysis of hollow
circular composite structure has been carried out and uncertainty in bending stress is analyzed. Bending stress
was objective function. Beam length, beam radius, elastic modulus, shear modulus and Poisson ratio of epoxy
graphite, ply angles of hollow circular section, radius and force are randomly varied within effective range and
their effect on bending stress has been analyzed. In order to validate the results, one loop of simulation is
benchmarked from results in literature. Ultimately, best set of probabilistic design variable is proposed to reduce
bending stress under static loading condition.
Empirical relation to estimate the reduction of root fillet stress in spur ge...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Stepped or non-prismatic beams are widely used in many engineering applications
and the calculation of their natural frequency is one of the most important problem.
Several methods were used to calculate the natural frequency of stepped beam. In this
work, the Rayleigh methods (Classical and Modified) and finite element method using
ANSYS software were used for calculating the natural frequency of Hollow stepped
cantilever beam with circular and square cross section area. The comparison between
the results of natural frequency and frequency ratio due to the increasing the length of
the small part for these types of beams and for these three methods were made. The
agreement between ANSYS the classical Rayleigh results was better than the agreement
between ANSYS the Modified Rayleigh results for the two types of cross section area. The
maximum error of MRM was greater than that of CRM and the maximum error of circular
C.S.A. Was greater than that of square C.S.A. At the same dimensions. The natural
frequency of circular C.S.A was smaller than that of square C.S.A. for the same
dimensions
Deformation Analysis of a Triangular Mild Steel Plate Using CST as Finite Ele...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted
Finite Element Analysis of Single Point Cutting ToolIJMER
In this project, temperature at tool-tip interface is determined, generated in high-speed machining operations. Specifically, three different analyses are comparing to an experimental measurement of temperature in a machining process at slow speed, medium speed and at high speed. In addition, three analyses are done of a High Speed Steel and of a Carbide Tip Tool machining process at three different cutting speeds, in order to compare to experimental results produced as part of this study. An investigation of heat generation in cutting tool is performed by varying cutting parameters at the suitable cutting tool geometry. The experimental results reveal that the main factors responsible for increasing cutting temperature are cutting speed (v), feed rate (f), and depth of cut (d), respectively. It is also determined that change in cutting speed and depth of cut has the maximum effect on increasing cutting temperature. Various researches have been undertaken in measuring the temperatures generated during cutting operations. Investigators made attempt to measure these cutting temperatures with various techniques during machining.
In this project, “Fluke 62 max IR thermometer” (Range -40 0C to 650 0C) is used for measuring temperature at tool-tip interface. Single point cutting tool has been solid modeled by using CAD Modeler Pro/E and FEA carried out by using ANSYS Workbench 14.5. Experimental work is done at “Khushi Engineering”, Nagpur.
By varying various parameters the effect of those on temperature are compared with the experimental results and FEA results. After comparison nearly 4% variation is found in between the results.
Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation u...IJMER
Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchi’s L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Titanium is named after the Titans, the
powerful sons of the earth in Greek mythology.
• Titanium is the forth abundant metal on
earth crust (~ 0.86%) after aluminium, iron and
magnesium.
Titans
homepage.mac.com
Rutile (TiO2)
mineral.galleries.com
Ilmenite (FeTiO3)
• Not found in its free, pure metal form in
nature but as oxides, i.e., ilmenite (FeTiO3)
and rutile (TiO2).
• Found only in small amount in Thailand...
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
Modeling and Optimization of Surface roughness and Machining Induced Vibratio...theijes
This paper presents the machining induced vibration and surface roughness modeled, predicted and optimized as functions of the cutting tool overhang, feed rate and cutting speed during hard and high speed turning of 41Cr4 alloy structural steel on an engine lathe machine with a carbide tool. The response surface methodology, based on central composite design of experiment was adopted, and analysis facilitated by using the Design Expert 9 software to generate and validate the models, predict the effect of the process variables on the response variables as well as obtain the optimum setting of the process variables that would minimize the response variables. Quadratic regression models were suggested as best fit for the measured machining induced vibration and surface roughness data. All the model terms of the machining induced vibration are significant with exception of the square term of the tool overhang. Whereas, all those of the surface roughness are significant with exception of the linear term of the tool overhang. The optimum setting of the cutting tool overhang at 57.8784 mm, feed rate at 0.15 mm/rev and the cutting speed at 328.507 rev/min minimized the machining induced vibration to a value of 0.18 mm/s2 , and the surface roughness to a value of 4.399 µmm with desirability of 0.822. Within the selected experimental design limits, the obtained response surface models can be used to accurately predict and optimize the machining induced vibration and surface roughness as functions of the tool overhang, feed rate and cutting speed during hard turning of 41Cr4 alloy structural steel.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This paper focus on monitoring of surface roughness and cutting forces while
machining on two different grade stainless steels under dry and mist conditions.
Stainless steels like AISI 304 and AISI 316L are considered for study. Process
variables like workpiece speed, tool feed and depth of cut are taken for
experimentation on CNC lathe. Responses like surface roughness, power consumption
and cutting forces are predicted while machining on the two different stainless grades
under dry and mist. Taguchi design of experiments is considered for experimental
design. Signal-to-noise ratio of the responses are used for determining individual
optimization, while Analysis of Variance is used for knowing significant effect of
process variables over the generated responses. This paper shows novelty of using
power consumption for calculating cutting forces and also comparisons of two
different stainless steel grades simultaneously under dry and mist conditions. In
addition, comparison of AISI 304 material with two different diameters is also studied
Finite Element Modelling of Chip Formation in Orthogonal Machining for AISI 1050paperpublications3
Abstract: Finite element method has gained immense popularity in the area of metal cutting for providing detailed insight in to the chip formation process. This report presents an overview of the application of finite element method in the study of metal cutting process. The basics of both metal cutting and finite element methods, being the foremost in understanding the applicability of finite element method in metal cutting, have been discussed in brief. In this project, thermo mechanical simulation of turning process has been developed using commercially available finite element analysis software, ABAQUS 6.10. A 2-D orthogonal cutting has been modelled using an Arbitrary Lagrangian - Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. Adaptive meshing dynamic explicit is also employed in this model to avoid the severe deformation. This study is aimed at temperature and stresses distributions during machining of AISI 1050 steel with three different speed 120m/min, feed 0.1 mm/rev. and depth of cut 1.5 mm. The results showed for speed 120 m/min, feed 0.1 and depth of cut 1.5 that the maximum stress for -7oC rake angle is 1.35 GPa while the maximum temperature results shown that 699°C.
ANALYSIS OF CNC LATHE SPINDLE FOR MAXIMUM CUTTING FORCE CONDITION AND BEARING...AM Publications
The present CNC machine structures consist of spindle system which plays a relating to the quality of the
final product and the overall productivity and efficiency of the machine tool itself. The spindle of a CNC lathe
machine, which is rotated by the main motor, holds the cutting tool, which cuts the work piece, so that the cutting
forces are generated which effects the spindle accuracy directly. The forces which are affecting the CNC machine tool
spindle are tangential force (Ft), feed force (Fc), radial force (Fr) and will be estimated. Based on maximum cutting
force incurred the analysis will be carried out. The main objective is to find the static, fatigue analysis of spindle
structure for maximum cutting force condition and predicting life of bearings. From static analysis stress and
deformation of the spindle can be found. Stress obtained from the stress analysis is less than the yield strength of the
material and deformation of the spindle is very less which can be neglected. Equivalent alternating stress, factor of
safety and life of the spindle is found by fatigue analysis and which results are closely matches with the analytical
value
Surface residual stresses in machined austenitic stainless steelLepuufu
Surface residual stresses due to turning operations in AISI 304 type stainless steel were studied as a function of machining speed, feed rate,
depth of cut, and tool geometry and coating. Residual stress tensors were determined using X-ray diffraction technique. The effects of turning
conditions and tool on the residual stresses were discussed in terms of mechanically and thermally induced non-homogeneous plastic
deformation of the surface layers of the workpiece.
This is my master degree paper under title experimental analysis of surface roughness and material removal rate in turning operation using response surface methodology
Similar to Determination of proportionality constants from cutting force (20)
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Cosmetic shop management system project report.pdfKamal Acharya
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Determination of proportionality constants from cutting force
1. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351
Maejo International
Journal of Science and Technology
ISSN 1905-7873
Available online at www.mijst.mju.ac.th
Full Paper
Determination of proportionality constants from cutting force
modelling experiments during broaching operation
Raghavendra C. Kamath 1,*
and Appu K. K. Kuttan 2
1
Department of Mechanical Engineering, Manipal Institute of Technology (MIT), Manipal, India
2
Department of Mechanical Engineering, National Institute of Technology Karnataka (NITK),
Surathkal, India
*
Corresponding author, e-mail: mitian99@rediffmail.com
Received: 14 March 2009 / Accepted: 13 August 2009 / Published: 17 August 2009
Abstract: Mechanistic model assumes that the types of cutting force acting on the broach
teeth, namely axial force, normal force and lateral force, are proportional to chip-thickness
area. In this paper, the proportionality constants related to the cutting force and chip-
thickness area were obtained through experimentation. The shaping process was used to
determine the proportionality constants in terms of specific cutting energy constants. The
paper also includes static force modelling for broaching operation and graphical presentation
of the experimental and simulated results.
Keywords: metal cutting, cutting force, broaching operation
Introduction
Metal cutting is one of the basic operations in manufacturing industries to produce the parts of
desired dimensions and shape. Metal cutting constitutes a complex process involving the diversity of
physical phenomena such as large plastic deformation, frictional contact, thermo-chemical coupling, and
chip and burr formation mechanisms. A great deal of research [1-9] has been devoted to understanding
the mechanism of machining with the objective of obtaining more effective tools and manufacturing
operations.
Over the last several years, research has been carried out to develop mechanistic force models
for a variety of machining processes, including end milling, face milling, boring, turning and broaching.
These models have been employed in a number of designs, operation plannings and process control
settings to predict both the cutting force and the resulting machine surface error.
2. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351 344
In the literature, two different approaches have been adopted for the prediction of the cutting
force system. The first method is based on the work done by Merchant [1] and involves a study of the
cutting mechanics and the prediction of the shear angle in metal cutting. Both analytical and empirical
models for shear angle prediction have been attempted. Lee and Shaffer [6] applied slip line theory to
machining to develop the equation for predicting the shear angle. Usui et al. [10] developed a model
that was based on the minimum energy criterion for predicting the chip flow angle and empirical models
were used for predicting both the friction angle and the shear angle. This approach generally requires
experimentation of a more fundamental nature of cutting mechanics to achieve the measurement and
prediction of the shear angle.
In this paper, an attempt has been made to determine the specific energy constants
experimentally for mild steel, aluminium and cast iron. Shaping process was used for the experimental
purpose of determining specific energy constants and proportionality constants which are used in
mechanistic modelling during broaching operation. A mechanistic model has been developed to compute
static forces. The experimental results and simulated results by mechanistic modelling are presented
graphically.
Methods
Computation of specific cutting energy constant for predicting the cutting forces__
mechanistic
modelling approach
In the mechanistic modelling approach, for any machining process the basic equations that relate
the axial force Fa, normal force Fn and lateral force Ft to the chip-thickness area are given by [10]:
Fa = Ka Ac
Fn = Kn Ac (1)
Ft = Kt Ac
where Fa, Fn and Ft are the three-dimensional forces acting on the tool tip. Ac is the chip-thickness area
and Ka, Kn and Kt are the proportionality constants corresponding to three-directional cutting forces.
The proportionality constants depend on the chip thickness tc, cutting velocity vc and rake angle
a of the cutting tool. Mathematically [10],
0 31 2 4
0 31 2 4
0 31 2 4
logt logv logt logv logγa + aa + a + a+ c c c c aΚ = ea
logt logv logt logv logγb + b+ b + b + bc c c c aΚ = en
logt logv logt logv logγc + c+ c + c + cc c c c aΚ = et
(2)
The coefficients ai , bi and ci (i = 1, 2, 3, 4) are called the specific cutting energy constants.
These constants depend upon the tool, work piece material, range of cutting speed and chip thickness.
They are independent of the machining process. These constants are determined from calibration test for
a given tool and work piece combination and a given range of cutting conditions.
Keeping the rake angle and the velocity of the tool movement constant corresponding to the
broaching tool, the equations (2) reduce to:
3. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351 345
+ logt
+ logt
+ logt
a a
Κ = ea
b b
Κ = en
c c
Κ = et
0 1
0 1
0 1
c
c
c
(3)
The values of specific cutting energy constants can be determined using a simple calibration
experiment. The experiment was conducted on a shaping machine and the specific cutting energy
constants were determined.
Experimental investigation
Several sets of shaping operation experiments were conducted in order to determine the specific
cutting energy constants. Three sets of experiments were conducted on each set of processes. The first
set of experiments was used to ascertain which tool and cutter geometry variables affected the
proportionality constants. The second set of experiments was used to develop an adequate model for
proportionality constants based on important tool and cutter geometry variables determined from the
first set of experiments. The third set of experiments was used to determine the specific cutting energy
constants. Experiments were repeated for aluminum, cast iron and mild steel at different depths of cut.
Chip-thickness area for calibration purpose was measured from the chip curl. The volume of the chip
was measured using water displacement method. After that the chip curl was heated and elongated.
The chip width (b) and length ( ) were measured using a micrometer and vernier calliper respectively.
Then the actual chip thickness (tc) was obtained by dividing the volume by the product of length and
width, i.e. tc = v / b , where v is the volume of chip curl. Knowing the chip thickness and width, the
chip-thickness area could be computed as the product of tc and b.
Static model
Figure 1 illustrates the static force measurement set-up during the broaching operation. The
cutting forces in three directions were measured using an accelerometre and the root mean square
(RMS) value was taken as the static cutting force. A static analysis calculated the effects of steady
loading conditions on a structure while ignoring inertia and damping effects such as those caused by
time-varying loads. A static analysis can, however, include steady inertia loads (such as gravity and
rotational velocity) and time-varying loads that can be approximated as static equivalent loads.
Chip-thickness area measurement
A tool-maker’s microscope was used to obtain the coordinates of the tooth profile of a
broaching tool. AutoCAD drawing of the broaching tool was drawn to procure the chip load area and
the dimensions of the tooth profile. Figure 2 shows the coordinates of a single tooth of the broach
obtained through the tool-maker’s microscope and AutoCAD drawing. Figure 3 shows three planar
angles of the cutting edge of a broach tooth where R is the rake angle and L is the release angle.
Figure 4 shows the coordinates of the full broach, which gives pitch = 6.78 mm, rake angle = 300
, rise
per tooth = 0.05 mm and width = 8 mm; hence, chip-thickness area = width x rise/tooth = 0.4 mm2
.
4. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351 346
Figure 1. Experimental set-up to obtain the force pattern during the broaching process
Figure 2. Broach tooth profile as obtained by tool maker’s microscope
a) Normal b) Rotated c) Rotated d) Rotated
position. about z axis. about y axis about x axis
Figure 3. Planar angles of the cutting edge of broach tooth
(3.26, 5.20)
(4.97, 6.52)
(6.78, 8.52)
(8.02, 8.56)
(7.52, 6.00)
(8.39, 505)
Broach
Work material
Accelerometre
Fixture
5. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351 347
Figure.4. AutoCAD drawing of a broach tool
Results
Figures 5, 6 and 7 illustrate the cutting force versus chip thickness during shaping operation for
mild steel, aluminium and cast iron respectively. In the plot, the x-axis is the logarithm of chip thickness
(marked as d) and y-axis is the logarithm of the cutting forces in Newton (marked as Kx, Ky and Kz)
along x, y and z directions respectively. Chip thickness corresponds to depth of cut which varied from
0.04 mm to 0.16 mm. The calibration test was performed for a small depth of cut to avoid error due to
impulsive cutting force coming on the work piece at greater depth of cut. A linear curve fitting was
made using Matlab software to determine the specific energy constants. Negative-slope linear curves
were obtained and the coefficients of the linear curve fitting gave the specific energy constants. The
proportionality constants Ka, Kn and Kt were determined using equation (3). Tables 1 and 2 give the
values of specific cutting energy constants and proportionality constants respectively.
Figure 5. Specific cutting energy constants for mild steel work material during shaping operation
6. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351 348
-3.4 -3.2 -3 -2.8 -2.6 -2.4 -2.2 -2 -1.8
-1
0
1
2
3
4
5
6
y = - 1. 2*x + 2. 1
log(d)
log(Kz)
Wo rk : Alu min ium
c) Plot for determining c0 and c1
Figure 6. Specific cutting energy constants for aluminium work material during shaping operation
7. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351 349
Figure 7. Specific cutting energy constants for cast iron work material during shaping operation
Table 1. Specific cutting energy constants obtained during shaping operation
Table 2. Proportionality constants determined from specific cutting energy constants
Material ao a1 bo b1 c0 c1
Mild steel 7.3 -0.46 7.2 -0.037 3.6 -0.71
Aluminium 7.4 -0.39 5.0 -0.68 2.1 -1.2
Cast iron 7.3 -0.29 5.9 -0.31 2.3 -1.0
Material Ka
(N/mm2
)
Kn
(N/mm2
)
Kt
(N/mm2
)
Mild steel 5732.3 1654.0 307.1
Aluminium 5370.0 1088.0 279.4
Cast iron 3562.0 924.4 199.5
8. Maejo Int. J. Sci. Technol. 2009, 3(02), 343-351 350
0 20 40 60 80 100 120
0
2000
4000
6000
8000
10000
12000
Length (m m )
AxialForce(N)
Work : Mild steel
Depth : 40 mm
0 20 40 60 80 100 120
0
500
1000
1500
2000
2500
3000
3500
Length (mm)
NormalForce(N)
Work : Mild steel
Depth : 40 mm
0 20 40 60 80 100 120
0
100
200
300
400
500
600
700
Length (mm)
LateralForce(N)
Work : Mild steel
Depth : 4 0 mm
Static forces during broaching operation
A MatLab program was written to simulate the static forces during broaching for different
materials at different depths. The simulation results were plotted as shown in Figure 8 for mild steel
work material at 40-mm depth. The cutting force progressively increased to a steady-state force when
all the teeth were engaged in the work piece.
a) Axial force acting on the broach
b) Normal force acting on the broach
c) Lateral force acting on the broach
Figure 8. Comparison of measured and simulated static forces for mild-steel work material at 40-
mm depth
Simulated
Measured
Simulated
Measured
Simulated
Measured