Advanced Materials Research Vol. 498

Abstract: The current requirements for an efficient dimensional inspection of manufactured parts have lead to development of different in process and on-machine measurement (OMM) techniques. Touch trigger probes (TTP) are the most common technologies utilized, inspired on contact probes used on coordinate measuring machines (CMMs). The on-machine accuracy of TTPs depends upon precision of the tool-machine control as well as upon the procedure for TTP presetting. Taking this into account, a different OMM technique is considered in this work, which consists on a laser micrometer (LM) that is commonly used for in-process measurement of continuous products. The behaviour of TTP and LM is analysed and discussed in terms of repeatability and reproducibility. Results obtained by both techniques are compared each other by measuring a cylindrical workpiece and by checking the results with those obtained on a CMM.

Abstract: A very current technique in the research field of machining by material removal is the use of simulations using the Finite Element Method (FEM). Nevertheless, and although is widely used in processes that allows approximations to orthogonal cutting, such as shaping, is scarcely used in more complexes processes, such as milling. This fact is due principally to the complex geometry of the cutting tools in these processes, and the need to realize the studi es in an oblique cutting configuration. This paper shows a methodology for the geometrical characterization of commercial end-mill cutting tools, by the extraction of the cutting tool contour, making use of optical metrology, and using this geometry to model the active cutting zone with a 3D CAD software. This model is easily exportable to different CAD formats, such as IGES or STEP, and importable from FEM software, where is possible to study the behavior in service of the same ones.

Abstract: At the present time, in the automotive competitive industry, new materials are investigated for to satisfy relative requirements to the design and manufacturing of structures more slight and resistant that allows bigger speed with smaller energy consumption (compound materials, aluminum alloys, etc.). Structural adhesives can use for joint compounds materials with aluminum and they will provide, front traditional methods and among other advantages, a smaller weight, uniform distribution of stress, tightness and elimination of the galvanic corrosion. Present work analyzes viable technically structural adhesives and, by means the application of Value Analysis, to select the adhesive and surface treatment that have the best mechanical benefits/cost ratio.

Abstract: In the present paper the influence of the reference system with regard to the characterization of the surface finishing is analyzed. The effect of the reference systems choice on the most representative surface finishing parameters (e.g. roughness average Ra and root mean square values Rq) is studied. The study can also be applied to their equivalent parameters in waviness and primary profiles. Based on ISO and ASME standards, three different types of regression lines (center, mean and orthogonal) are theoretically and experimentally analyzed, identifying the validity and applicability fields of each one depending on profiles geometry.

Abstract: The effect of speed on the flank wear of the cutting tool when a nickel alloy is milled is studied. From the analysis of the measured forces, a dynamic semi-experimental model is developed based on the parallelism between the curve of the thrust forces of the unworn tool and the curves when the flank of the tool is worn. Based on the change in the geometry of the contact in the flank worn face, a theory of indentation of the tool on the workpiece is formulated in such a way that upon applying equations of contact mechanics, a good approximation of the experimental results is obtained.

Abstract: The cutting forces, mechanical vibration and acoustic emission signals obtained using dynamometer, accelerometer, and acoustic emissions sensors have been extensively used to monitor several aspects of the cutting processes in automated machining operations. This study assesses the significance of these on-line signals for the real-time monitoring and diagnosis of the roundness error in automated cylindrical turning processes. The system developed is based on predictive models obtained by regression techniques employing the orthogonal components of the cutting forces, mechanical vibration and acoustic emissions, and combines all three types of sensors into one system. This monitoring system enables the on-line monitoring and diagnosis of roundness error by registering, visualizing, and characterizing the signals obtained during the machining process.

Abstract: The use of conventional machining processes has been subject to important decline probably due to the increment in the use of emerging technologies. Therefore, the main applications of these traditional processes, such as automotive industry, are in crisis. In order to have a chance to compete successfully in the new trends, the machining industry must meet the needs of alternative sectors such as biomedical field. The aim of this study is to prove the capacity of micro-milling, by machining complex micro-cavities on aluminum workpiece using a conventional milling machine. Results are obtained by evaluating accuracy and geometric features. This study finds that the feed per tooth is a significant factor in order to obtain better results. The use of coolant increases the tool wear and therefore dimensional errors. This scope is a potential opportunity to reutilize the conventional machines from a new approach.

Abstract: Necking process stress and strain analysis, which is key to determine the plastic flow evolution in finite deformation, has been widely studied and applied to a number of materials based on the theories established by Davidenkov-Spiridnova and Bridgman in the 40s decade. These theories envolve from the study of necking geometry in fracture. In this paper, we develop an exhaustive experimental analysis of the stress and strain field in the necking process, applied to concrete bars and mechanized samples with similar features, in order to compare the results with the ones given by the theories listed above and to look for the corrugation influence in the materials plastic behavior.

Abstract: The present paper studies the technical feasibility of Photogrammetry and Coordinate Measuring Arms (AACMM or CMA) for the geometrical inspection of welded pins used for the assembly of medium-sized sheetmetal structures. As a result of this evaluation it was found that the deviations (measurement recorded by the device minus the nominal value of the measurement) obtained by means of Photogrammetry and the CMA were equivalent. Moreover, the number of measurements found to be out of tolerance by both methods was statistically equivalent. According to our results both methods are feasible for performing the dimensional inspection of the position of the welded cylinders of the structure as they are able to distinguish measurements inside and outside of tolerance and are equally capable of detecting the data variance.

Abstract: The aim of this paper is to introduce a method to reduce the weight in structures which are subjected to multiple restrictions like deformation, max allowable stress, natural frequency, etc. The method is shown through the analysis of an aluminum bracket, whose maximum stress and deformation is well defined. The analysis is done using the Structural and Design of Experiments modules of Ansys Workbench v12.1. As result of the method a weight reduction of 50,2% is achieved.