Advanced Materials Research Vol. 845

Abstract: This review paper describes the implementation process for STEPNCFBUoA. Its software environment is first explained. ST-Developer is the central software tool that is responsible for converting EXPRESS schema to Java classes. FBDK is the tool used for developing the function blocks editor, raw material user interface, machining set-up data interface, and machine tool database. The two examples in the ISO 14649-11 standard are used as the main test parts. The paper provides a detailed account of STEP-NC data processing, Graphic user interface (GUI) and local manufacturing databases, for example, raw material, set-up, machine tool, and cutting tool databases. Machining simulation is validated through physical machining. This is done through machining a number of parts with varying data. The simulation graphic user interface is simple and wire-frame based, but sufficiently illustrates the tool-path information as well as showing the machine tools limits, and set-up orientations.

Abstract: Minimizing the power demand through machining of aluminum alloy can significantly develop the environmental performance of manufacturing systems. To accomplish this, calculation of power demand in turning processes is necessary. This paper presents the calculation of power demand based on cutting force and material removal rate, taking case study on machining of Al-11%Si alloy at various cutting speeds and feeds. The results showed that both approaches can calculate power demand with similar results. The power demand for the particular turning process was found to be proportional to feed and cutting speed.

Abstract: Oxyacetylene flame heights which were obtained through representation from a number of camera shots were compared from those estimated from empirical correlations for determining the flame height based on the heat release rate (Q) and flame base diameter (D). Pressure of gas mixtures are purposely changed to obtained a varying flow rate with the flame set to neutral during each routine. It is found that operating conditions like Reynolds number and flow rate influences the profile of the combustion flame.

Abstract: The current paper aims to study on synthesis of polyaniline (PANI)-polypyrrole (PPY) composite through simple interfacial polymerization method using chloroform as organic solvent, ammonium persulphate as an oxidant agent and sulphuric acid as a dopant. The composite was characterized by using Field Emission Scanning Electron Microscopy (FESEM), Fourier Transform Infrared Spectroscopy (FTIR), X-Ray Diffraction (XRD) and four pint probe methods. FESEM results showed the formation of fibrous PANI-PPY composite. FTIR and XRD results confirmed the successful formation of PANI-PPY composite. Four-point probe results showed the low electrical conductivity of the product. This study gives the better understanding on synthesis and characterization of the PANI-PPY through simple interfacial polymerization method.

Abstract: Machining process should also consider environmental aspect, with power consumption as one of the criteria. Cutting parameters can be optimized to minimize power consumption. This paper takes a study on turning of nickel-based hastelloy under dry condition (no cutting fluid) which varies cutting speed (150, 200, and 250 m/min) and depth of cut (0.5, 1.0, and 1.5 mm). Power consumption of particular machining process at various cutting parameters was derived and calculated. It was found that minimum power consumption was shown when the turning process was performed at the lowest cutting speed and depth of cut.

Abstract: In this paper the explosive mass for forming a circular plate to a cone is determined using the energy method. To achieve this goal, the strain energy which is necessary to form a circular plate to a cone is calculated at first. Later the transmitted energy due to the detonation of an explosive material which is placed in a constant stand-off distance to a circular plate is specified. Equaling the strain energy and the transmitted energy, the explosive mass is figured out. Comparing the obtained results with the experiments shows the relatively acceptable compatibility.

Abstract: Increased attention on environmental and health impacts by industrial activities forces the manufacturing industry to reduce the mineral oil-based metalworking fluids as a cutting fluid. The advantages of using vegetable oil-based cutting fluids on tool wear and the cutting force have been reported in the literature, but those reporting the effects of their use on the surface finish of the workpiece are still lacking. This mini-review gives an overview of the influence of vegetable oil-based cutting fluids on surface integrity of steel during drilling process. Effect of the different cooling strategies on surface integrity is also presented.

Abstract: Sustainability assessment of concrete manufacturing processes has recently received great attention among scholars and practitioners. While most of the studies on sustainability assessment of concrete manufacturing processes focus on economic and environmental issues, those which consider all three dimensions of sustainability (social, economic, and environmental) simultaneously are rather limited. In this study, a hybrid approach of fuzzy inference system and analytical hierarchy process (AHP) is proposed in order to evaluate the sustainability level of concrete manufacturing processes based on Life Cycle Assessment (LCA) principals. AHP is applied to weight the selected sustainability elements and sub elements. Afterward, fuzzy inference system is used to evaluate the sustainability level of concrete manufacturing processes. The practicality and applicability of the proposed approach are examined by conducting sustainability assessments of four different concrete manufacturing processes: (1) 100% of Portland cement (2) 35 % slag cement and 65% Portland cement (3) 50% slag cement and 50% Portland cement (4) 20% fly ash and 80% Portland cement. The results disclose the more sustainable concrete manufacturing process which is 50 % of Slag cement and 50% Portland cement.

Abstract: The purpose of this study was to find experimentally the effects of concave and convex major cutting edge (Helical & Recon point) and chisel point on the drilling composite. Due to composite materials are natural orthotropic, so gradually these materials are substituted by some metals such as steel that are used in manufacturing automobile and aerospace and other industris. Because of increasing composites utilization in industries, it is necessary to stabilize and set standards of machining parameters. Drilling is the main machining operation in producing process for assembled the composite work piece. So the quality of drilling hole should be considered to avoid snapping mechanical structure. Tool geometry is one of the most important factors in the drilling process. If it is neglected, the thrust forced increase, and it causes damage around the hole such as delamination, large entrance and exit burr, and induced cracks. The most damaging in drilling FRP is delamination of the composites lamina that occurs when drill bit is entered and exited. In the other hand, this study used ANSYS finite element software to determine the value of stress in composite plate and use to analyze for designing the jig & fixture in this drilling process. In conclusion, with comparing delamination, the best geometry tool introduced for the lowest amount of damage.

Abstract: The trend in machine tools and positioning systems nowadays are demanding for accuracy, precision and robustness attributes. In addition to those characteristics, a low-cost and adaptive control systems towards various disturbance forces also add a significant advantage to control engineers who can fulfill those needs. The objective of this paper is to introduce a newly improved control strategy named as Nonlinear Cascade Feedforward. It is basically, a cascade control structure with the additional of two add on modules called Nonlinear function plus independent feedforward function. Secondly, the aim of this article is to focus on the fundamental aspect on how to analyze the open loop and closed loop behavior for both velocity and position loop in the control structure by extracting the mathematical formulation of the controller. The outcome from this paper which is in the form of mathematical formula is beneficial and exceptionally significant during the validation and verification stage. The theoretical analysis involved are analysis on gain and phase margin, bandwidth frequency, sensitivity function, position error and finally analysis on dynamic stiffness of the system which is in this case the XY Table Ballscrew drive system. The strength of this controller is the self-adjusting mechanism towards variable disturbance cutting forces. Based on mathematical formulation, it is observed that the designed nonlinear cascade feedforward offer more flexibility and robustness in terms of the ability to compensate the tracking errors at variable disturbances.