Papers by Keyword: Machining

Abstract: This study presents a static finite element analysis of the milling of a flexible unidirectional glass fiber–reinforced polymer (UD-GFRP) plate. The workpiece is modeled as a clamped–free cantilever, with cutting forces evaluated independently of structural deflections and applied along the machined edge. SC8R continuum shell elements are employed to accurately represent through-thickness loading and bending behavior. A mesh sensitivity analysis is conducted to determine a suitable discretization, leading to a 64 × 56 × 8 element mesh. For the investigated configuration (, mm/tooth), the out-of-plane displacement reaches approximately 120 µm near the free end of the plate, whereas in-plane displacements reach up to-75 µm. These in-plane displacements are greater than or equal to the nominal feed per tooth, indicating a highly significant influence on chip formation. This work provides a basis for understanding the structural response of flexible composite plates during trimming and emphasizes the need for coupled force–deformation formulations.

Abstract: Sectors such as energy, aerospace, and heavy machinery increasingly rely on the machining of large components, where boring bars can easily exceed 200 mm in diameter and reach length-to-diameter ratios of up to 14. In these operations, chatter remains the dominant limitation due to the inherently low dynamic stiffness of such long tools. While Tuned Mass Dampers (TMDs) are widely applied in small and medium-sized boring bars, but transferring this technology to large-scale tools introduces significant challenges, particularly in the selection and tuning of damper components and the difficulty of evaluating performance prior to manufacturing. Because producing large boring bars is costly, a structured and predictive design strategy is essential to avoid trial-and-error iterations. This work introduces a scaling methodology that adapts TMD-integrated boring bar designs to large dimensions, providing a systematic approach to predict dynamic behavior across different tool sizes. The methodology is demonstrated through a case study involving Ø200 mm boring bar with length of 14 times the diameter. Experimental validation with the manufactured prototype confirms that the proposed scaling strategy enables effective chatter suppression and offers a practical path for extending TMD technology to large-scale boring applications.

Abstract: This paper describes a development of Electrical Discharge Machining (EDM) system for biomedical application. In general, the mechanism of EDM comprises of mechanical structure and electronic control system. This laboratory scale of the EDM system has a capability to accommodate the machining of hip implant which employs low power generator. The holder for the workpiece is created to accurately position the hip implant, ensuring that the machining angle of the implant directs the micro-pits precisely toward the workpiece. A traditional linear x-y-z axis setup (Cartesian coordinate system) is utilized, along with two types of spherical coordinates (swing-swing and swing-rotate configurations). By the results of performance test, the Swing Motor behaves differently to the common servo motor. The Swing Motor is affected by unbalanced load and gravity in which the Ziegler-Nichols PID optimization method has been altered from the conventional model. The average of absolute error is 0.2308 degrees. However, optimized PI controller by Ziegler-Nichols method is able to eliminate the effect in term of final achieved position (steady state condition) and fulfil the objectives.

Abstract: The longitudinal turning of 304 austenitic stainless steel (ASTSTS) occurred on a lathe using a Tungaloy-made carbide insert (SNMG 12 04 08). The machining parameters were the cutting velocity, feed rate, and depth of cut (DOC). The machining occurs according to the L27 Taguchi design. The strain hardening index (n) and strength coefficient (K) were available by tensile test on the specimen. The chip reduction coefficients (CRC) and von Mises stresses (VMS) were experimentally available. The maximum CRC and the maximum von Mises stresses were for moderate speed, moderate feed, and moderate depth of cut. The SEM observation on chip surfaces at different experimental conditions revealed hardening behaviour for most of the experimental conditions. However, under the specific condition, extensive ductile behaviour was significant, which resulted in maximum von Mises stress generation. The application of design of experiment (DOE) methodology yielded the theoretical model. The trend of CRC found through the theoretical model showed a similarity with the curve-fitting trend from experimental data. However, a fuzzy inference system (FIS) model showed better adequacy in comparison to the other models in the present study.

Abstract: During metal machining, under certain conditions, vibrations occur, both at the cutting tool, at the workpiece and at the machine tool. The appearance of vibrations during the cutting process is troublesome, because vibrations reduce the durability of cutting tools (especially in tools with inserts). It also increases machine tool wear and worsens the quality of the machined surface (roughness). The problem of vibration is vast and will represent a permanent research topic for tool makers, machine tool builders and process engineers. This paper presents the study and finite element analysis of the vibrations of a cutting tool, a tool used in the longitudinal turning process, both for deburring and finishing operations. The behavior of the tool, the natural frequencies and the elastic deformations that lead to the impairment of the processing precision and the quality of the surface obtained after processing were demined by calculation. We believe that this study is useful both to the manufacturers of cutting tools, but especially to the technological engineers, for the optimization of the process, by avoiding the cutting parameters that lead to resonance with the tool's own frequencies.

Abstract: In machining process, surface roughness and material removal rate have a vital importance since they affect mass production, consumption of energy, force, and tool life and product quality. In this study, Taguchi-Grey Relation Method (TGRM) is applied to AISI 1040 mild steels in the hardened form when machined with ceramic inserts using response surface methodology for multi-objective optimization. Grey-Relation Method and Pareto chart reveal that feed rate, depth of cut, speed besides square effect of speed/feed rate are effective parameters on the response. Among all eighteen experiments, trial twelfth provides the best multi-performance characteristics while the first experiment shows the worst performance. Optimal levels are determined at higher speed, higher feed rate associated with higher depth of cut. It is concluded that quadratic regression model and reduced quadratic regression model are developed. The correlation coefficients range from 98.3% to 96.89%, respectively. As a result, TGRM has an efficient to provide a good modelling in combination of surface roughness and metal removal rate.

Abstract: This study details the design, assembly, and measurement processes of a modified test bench for examining sliding ring seals. We designed a test bench suitable for measuring mechanical seals, during which we first developed the concept and the design of the bench, defined the parameters to be measured and the measurement methods, and then implemented these objectives using an existing test bench. After procuring raw materials, I manufactured and assembled the necessary components, including acid-resistant and corrosion-resistant steel parts. Key machining operations were performed, such as drilling and threading, to accommodate the mechanical seals and ensure proper alignment. Following assembly, I conducted three reference measurements with varying compressive spring forces. The system's torque was measured at a consistent rotational speed of 200 RPM. Results from the frictional torque measurements revealed that the seals displayed sensitivity to compressive forces, confirming the effectiveness of the modified test bench for future seal evaluations.

Abstract: In this paper, the effect of the constant number of simultaneous cutting edges was verified for high-precision machining of a corner radius. To verify the effect of the constant number of simultaneous cutting edges, we measured the size of corner radius at several locations using a coordinate measuring machine which can measure 3D. As a result, it was found that percentage of remaining cutting volume was reduced by keeping the constant number of simultaneous cutting edges. Furthermore, surface photograph was also measured to investigate the influence of number of cutting flutes.

Abstract: This study investigates the careful investigation of cutting parameters to improve machining effectiveness and increase tool life while milling Nickel-Titanium Shape Memory alloy (NiTiNOL). The NiTiNOL material is employed to manufacture components such as, dental braces, seismic dampers and medical implants. Using Finite Element (FE) simulation, the research closely examines the intricate interactions among parameters, such as feed rate (f_r), depth of cut (D), and cutting speed (V_c). The use of Response Surface Methodology (RSM) and Taguchi has been used to determine the most optimal settings for tool longevity and machining efficiency. The FE simulation model provides a strong framework to investigate how cutting parameters affect necessary reactions. The present study examines interactions among parameters like cutting speed, depth of cut, and feed rate. Moderate cutting speed, lower depth of cut, and the highest feed rate has induced lower stress in the workpiece. This study adds to understanding NiTiNOL alloy machining fundamentals and offers useful information for industry applications. To attain better machining results while milling NiTiNOL alloy, the results are intended to guide an optimization technique

Abstract: Cutting down on energy usage while keeping the material removal rate (MRR) as high as possible is widely acknowledged to be one of the most important goals in the machining industry for a considerable amount of time. So that we can create a forecast model for side-milling machining that makes the most efficient use of the feasible amount of power, the response surface method was utilized. After that, this model was used to establish which parameters should be optimized for the machining process. The response surface approach was applied to investigate the effect that several distinct cutting elements, factors like radial slicing depth, feeding rate, and spindle rpm, all examples (RSM), had on the total power needed throughout the cutting process. The data indicate that the variable known as the feeding rate is the most important factor in the amount of energy consumed. Reduced power consumption is an unavoidable natural byproduct of accelerating cycle durations and increasing feed rates. A radial how deep the wound is in 0.3 millimetres, a feed rate of 6,000 millimetres per inch, and a spindle speed of 12,000 revolutions per minute can produce a minimum power usage of 82.38 kilowatts, as the optimization model indicates. Keywords: Material removal rate, Machining, Power consumption