Papers by Keyword: CNC

Abstract: Traditional sheet metal forming processes necessitate specialized tooling and costly dies to manufacture sheet metal components, leading to time-consuming and uneconomical procedures that are particularly unsuitable for batch production. However, Single Point Incremental Forming (SPIF) has emerged as a cost-effective solution for rapid prototyping, customization, and batch production. To achieve this, precise estimation of the incremental sheet forming force is essential, necessitating the design of dedicated equipment and the adaptation of machinery. This study explores the impact of several process parameters on the forces involved in SPIF to investigate their effects. Specifically, the focus is on analyzing the influence of step size, forming angle, and spindle speed on axial peak forces for Cp-Ti grade sheets. The results reveal that the maximum forming force increases with larger step downs, while a decrease in forming force is observed for smaller step sizes. Additionally, higher forming angles result in increased friction between the tool and the blank, leading to elevated forming temperatures. The evolution of forming force, which varies under different bending conditions, could serve as an indicator to prevent sheet failure. The current provides valuable insights into optimizing SPIF processes by understanding the relationship between process parameters and forming forces, facilitating more efficient and reliable production of sheet metal components.

Abstract: Single point incremental forming process, which is also known as SPIF, that forms from one direction. SPIF process was used for milling an aluminum metallic sheet. In this paper, an aluminum (A5052) sheet was formed in a conical shape by the SPIF process. The A5052 sheet was deformed by the computer numerical control (CNC) technology in the T60 series milling machine. The conical shape was deformed by the spiral toolpath in the T60 series milling machine. At the surface of the A5052, lubricant grease was continuously applied manually for reducing the friction generated due to milling. Also, for decreasing the tool rotational force friction on the A5052 sheet there was the use of lubricant. Moreover, 0.1mm step-down is used for the tool path because it takes more time for forming a metallic sheet, however, it deformed the sheet smoothly. The 0.5mm step-down g-code was extracted from fusion 360. Then the metallic sheet A5052 surface was compared before and after deformation. For testing a metallic sheet A5052 the formability parameter was analyzed in the experiment part. The experiment was performed to find the optimal smooth surface from the CNC milling machine. The initial roughness value and the microscopic image were presented in the investigational part. Likewise, the comparison of points for the highest and lowest rough point was further discussed and compared throughout the experiment.

Abstract: This research work is based on the machinability of an Inconel 800 alloy using TiAlN-coating and TiAlN-TiN-coating tools. In the CNC VMC Face milling process feed, depth of cut (DoC), and cutting speed consider input variables and surface roughness, Tool wear is measured for all machining conditions. To enhance the machining conditions a Taguchi L9 Design of Experiment was created. ANOVA analysis was used to identify the important variables influencing Flank wear (tool wear) and surface roughness. The signal-to-noise ratio for the ideal cutting combination was identified by evaluating the optimum surface roughness and tool wear. for the effect of coating, a comparison was done between the findings obtained using both TiAlN-coated and TiAlN-TiN tungsten carbide-coated tools. The best optimum surface roughness and tool wear of the experiment conducted under machining with TiAlN-TiN coated carbide tool resulted in .3433 µm and 128 µm respectively.

Abstract: The single point incremental forming (SPIF) process is a high-trend method for forming a metal in a desirable shape. Forming parameters is an important part of deforming metal sheets. So, while reshaping a metal sheet parameters like tools, toolpath, material properties, sheet thickness, and lubricant were considered. Since the Aluminum sheet is used world widely for the body parts of machines for manufacturing parts. So, an A5052 metallic sheet was formed for the improvement of the depth deforming through the SPIF process. While forming an A5052 sheet lubricant was used constantly. After deforming through the SPIF process, further evaluations of the formed part were examined with the nanoprofiling machine to evaluate the deformed areas. Moreover, the deformed part was analyzed for the nana profiling for the deformation occurs on the surface. Likewise, before forming a part, the A5052 design was computer analysis. The simulation part was studied for fixing the maximum depth.

Abstract: Forming a metallic sheet along with the consideration of computer simulation and experiment had benefited the milling industry for a long time. The ideal forming, without an error, is a concerning topic. So, the computer simulation had the advantage then direct forming. To observe the results before doing the real experiments simulation comes handy. Which helped to set the parameters for the milling process for the single point incremental forming (SPIF) process. For milling, a CAD design was converted into a 3D model. For this, a conical shape of 3D modeling was made in fusion 360. After onwards, it was simulated for finding the maximum depth for the cracking point. Next for the experimental part, the maximum forming depth was considered, and used lubricant grease for reducing friction. While forming with the grease, the impact of parameters was also changed. Throughout the process, an optimization approach was set to reduce the cracking areas for the G-code. Along with the lubricant use, smooth milling finished surface was observed. To reducing the depth forming errors, an optimization approach was introduced in this research.

Abstract: In this paper the issues of modeling the process of forming sheet materials using method of incremental forming for the manufacture of thin-walled non-axisymmetric parts. The proposed method of forming implemented by deformation of sheet material by providing the required trajectory of movement of the working tool in order to obtain the surface of a product of a given shape. Simulation and analysis of all experiment results are carried out.

Abstract: Cam mechanisms are used as the control system in several industrial fields such as filling and canning, textiles, automotive. This paper introduces the development of a software for designing planar cam mechanism adapting the dynamic and kinematic requirements. The designed cam profile is then changed into numerical data used to generate the machine codes served for CNC-based fabrication. Traditional cam design is very complicated and has accumulated errors. The envelope theory and inverse method are utilized to perform constraint in pressure angle and motion. The smallest cam radius is then determined in a non-linear optimization adapting the constraints. The paper also presents the design of a CNC machine for cam profile fabrication. The design includes the control system and the circuit board. The CNC control program is built to receive numerical data from cam design section, to simulate the cam profile fabrication and then to fabricate. The optimal design and fabrication are applied to the cam mechanisms with knife-edge/roller reciprocating/oscilating followers. The verification shows that the designed and fabricated cam adapts the requirement of accuracy.

Abstract: Computer numerical control (CNC) machine has greater utility in the modern advanced industrial field. This paper deals with the parametric effects such as spindle speed (1500-2100 rpm) (N) (X1), depth of cut (DOC) (0.15-0.55 mm) (X2) and feed rate (f) (30-50 mm/min) (X3) on machining characteristics like tool wear rate (TWR) and surface roughness (Ra) during fabrication of IS-617 Aluminum miniature component by advanced CNC lathe using Tungsten-carbide tool. The article analyzes the second-order mathematical model development with co-relation of co-efficient of regression (COR) and analysis of variances (ANOVA) using desirability function analysis during the production of the miniature segment. The paper also consists of multi-criteria optimization for achieving the optimal parametric combination for minimum surface roughness and tool wear rate for this manufacturing operation. The paper also shows the fabricated micro-product of Aluminum at the optimal parametric conditions using CNC programming. It is found that spindle speed has a greater effect on the tool wear rate and depth of cut has dominating effects on surface roughness of job specimen. Desirability parametric combination for minimized surface roughness as well as tool wear rate has been found 1523 rpm/0.15mm/30mmmin-1.

Abstract: Recently, drug nanoparticles formulation using Poly Lactic Acid-Cellulose nanocrystal (PLA-CNC) have been introduced. PLA-CNC were prepared by emulsion method for antidiabetic drug delivery applications. PLA is one of polymer which potentially used as raw material of drug delivery because it has the ability to bind and carry drugs into cell target, but the hydrophilic character of PLA can cause the degradation of PLA in the body run slowly, so it is necessary combining PLA with CNC to improve its property. In this study, special attention has been given to the modification of PLA-CNC as a drug delivery matrix to obtain the optimum drug release of antidiabetic drugs. In this study drug release analysis was conducted at 35-39 °C and pH range 3 to 9 with varied of time dissolution 0 to 180 min. PLA-CNC matrixs were characterized using FTIR and SEM, its drug loading capacity, encapsulation efficiency and in vitro drug release behavior was determined by using UV spectrophotometer. It gave the initial burst release at the first hour at 37 °C pH 3.

Abstract: A method for creating a control program has been developed, which ensures the manufacturing of the details-cladding of the required accuracy and quality in the automated mode. The method is based on the choice of the optimal loading scheme, under which the deformation program is created, the values of the control coordinates of the press are calculated in accordance with the kinematic model of the press. As a result, a control program is obtained, which ensures a more accurate manufacturing of the part, with a minimum amount of finishing work. The presented method of calculation of the tightening process allows, on the basis of the details of the part, to determine the shape of the tightening punch, and also, if necessary, to adjust the existing tightening punch in order to ensure a more precise manufacturing of the part.