vol. 15 no. 3 march 2016 editorial board contents ... mar_ 2016.pdf · contents technical papers...

Vol. 15 No. 3 March 2016

ContentsTechnical Papers

• Parametric analysis of optimum cutting parameters for AISI1042 using PVD tool in turning operation using grey relation analysisHemantha Kumar A, Subba Rao G, Rajmohan T and Krishnaiah G 3

• Developing empirical relationship to predict the strength of friction stir lap welded joints of AA2014-T6 aluminum alloyRajendran C, Srinivasan K, Balasubramanian V, Balaji H and

Selvaraj P 12

• An experimental study on influence of coolants in down milling of AMMC using Ti-N coated HSS cutterDadakhalandar S, Bhanodaya Reddy G, Venkataramaiah P, Sukumar MS 24

Photo Gallery: Vintage Machine: Metal Turning Machine 31

Calendar of Events 32

Manufacturing Technology Abstracts 36

Select Bibliography of Standards: Carbide Inserts 45

Select Bibliography: Carbide Inserts 46

Technology Trends 47

Patent Abstracts: Cutting Inserts 49

Product Information: Ceramic & Carbide Inserts 55

IPR News: A - Z Definitions of Intellectual Property Terminology 57

Annual Subscription* Inland ₨1000.00 + Service Tax (ST) @14.5% Single Copy ₨100.00 + [email protected]% Foreign USD 100

CMTI members will receive the journal against their membership

Editorial Board

*All payments are to be made by demand draft drawn in favour of ‘Central Manufacturing Technology Institute, Bengaluru'

Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same.

ChairmanS Satish Kumar

Technical Paper Review PanelS UshaN BalashanmugamDr. C K SrinivasaK K RajagopalB R Mohanraj

EditorMallikarjun G

Editorial Assistants

Shashi Rekha NMala RC

Events

Manufacturing Technology Today, March 201632

NATIONAL

10 Apr 2016ITR-International Conference on Mechanical And Production Engineering ICMPE-2016RourkelaContact: Institute of Technology and ResearchPlot No-200, Dharmavihar, Jagmara, Khandagiri,Bhubaneswar, IndiaTel: +91-8984829561 Email: [email protected] Web: http://www.allconferencealerts.com

10 Apr 2016IRAJ-International Conference on Computer Science and Mechanical Engineering (ICCSME)Hotel Sunday Inn, 8,New Atish Market, Gopalpura Bypass Road, Mansarovar, Jaipur, Rajasthan Contact: Institute of Research and Journals Plot No. 161 (Ground Floor), Dharma Vihar, Jagmara, Bhubaneswar, 751030, OdishaEmail: [email protected] Web: http://iraj.in/Conference/2016/Jaipur

17 Apr 2016IRAJ-International Conference on Computer Science and Mechanical Engineering (ICCSME)Hotel Madhav International, 6A, Ramabai Ambedkar Road, Before Hotel Le-Meridien, Behind Pune Railway Station, Pune Contact: Institute of Research and Journals Plot No. 161 (Ground Floor), Dharma Vihar, Jagmara, Bhubaneswar, 751030, Odisha, IndiaTel: +91-8984829561 Email: [email protected] Web: http://iraj.in

17 Apr 2016ITR-International Conference on Mechanical And Production Engineering ICMPE-2016The Oberoi, 37-39, Mahatma Gandhi RdBengaluruContact: Institute of Technology and ResearchPlot No-200, Dharmavihar, Jagmara, Khandagiri,Bhubaneswar, India, Pin-751030Tel: +91-8984829561 Email: [email protected] Web: http://itresearch.org.in

10 - 12 Aug 2016International Exhibition on Engineering and ManufacturingPragati Maidan Exhibition Center,Mathura Road, New DelhiContact: International Trade and Exhibitions India Pvt. Ltd.11th Floor, Kailash Building Kasturba Gandhi Marg110001 New DelhiEmail: [email protected] Web: http://www.tradefairdates.com

10 - 12 Aug 2016International exhibition for minerals, metals and metallurgy materialsPragati Maidan Exhibition Center,Mathura Road, 110002 New DelhiContact: International Trade and Exhibitions India Pvt. Ltd.11th Floor, Kailash BuildingKasturba Gandhi Marg, 110001 New DelhiEmail: [email protected] Web: http://www.tradefairdates.com

05 - 07 Oct 2016International trade fair for joining and separating and coatingBombay Convention & Exhibition Centre BCEC,Western Express HighwayMumbai, MaharashtraContact: Messe Essen GmbHNorbertstr., 45131 Essen, GermanyTel: +49 (0)201 72440 Fax: +49 (0)201 7244248Email: [email protected] Web: www.messe-essen.de

19 - 21 Oct 2016Intl exhibition for solar technology and energyBombay Convention & Exhibition Centre BCEC,Western Express Highway, 400063 Mumbai, MaharashtraContact: Freiburg Wirtschaft Touristik und Messe GmbHEuropaplatz 1, 79108 Freiburg im Breisgau, GermanyTel: +49 (0)761 388102 Fax: +49 (0)761 38813006Email: [email protected] Web: www.tradefairdates.com

16 - 19 Nov 2016International Mining and Machinery ExhibitionEco Tourism Park, Major Arterial Rd, Action Area II, 700156 Kolkata, West BengalContact:

Events

Manufacturing Technology Today, March 2016 33

INTERNATIONALConfederation of Indian Industry23, Institutional Area, Lodi Road110003, New DelhiTel: +91 (1)1 45771000 Fax: +91 (1) 24626149Email: [email protected] Web: www.cii.in

23 - 26 Nov 2016International trade fair for engineering, machine tools, automation & automotive technologyRace Course Ground,Race Course Road, Sadar, Rajkot, GujaratContact: K & D Communication Ltd.4th Floor, Chinubhai House, 7-B Amrutbaug Society380014 AhmedabadTel: +91 (0)79 26469725 Fax: +91 (0)79 26403087Email: [email protected] Web:http://www.tradefairdates.com

01 - 03 Dec 2016International trade fair for surface technologyBandra Kurla Complex, Maharashtra, 400051 Mumbai, MaharashtraContact: Hannover Milano Fairs India Pvt Ltd.No 13/16, Vatika Business Centre Wing B400076 MumbaiTel: +91 (0)22 42369710 Fax: +91 (0)22 42019191Email: [email protected] Web:http://www.tradefairdates.com

01 - 03 Dec 2016International exhibition for materials handling, intralogistics, storage and logisticsBandra Kurla Complex,Maharashtra, 400051 Mumbai, MaharashtraContact: Hannover Milano Fairs India Pvt Ltd.No 13/16, Vatika Business Centre Wing B400076 MumbaiTel: +91 (0)22 42369710 Fax: +91 (0)22 42019191Email: [email protected] Web:http://www.tradefairdates.com

12 - 15 Dec 2016International trade fair for construction machinery, building material machines, mining machines and construction vehiclesNSIC Exhibition Ground,Okhla Industrial Estate, 110020 New DelhiContact: MMI India Pvt. Ltd., 5th Floor, Cardinal Gracias Road, 400 052 MumbaiTel: +91 (2)2 42554700 Fax: +91 (2)2 42554719Email: [email protected] Web:http://www.tradefairdates.com

25 - 28 May 2016ASsean International Machine Tools & Metalworking Technology ExhibitionPutra World Trade Center,41, Jalan Tun Ismail, 50480 Kuala Lumpur, Kuala Lumpur, MalaysiaContact: Trade Link ITE Sdn BhdF-1-48, Jalan PJU 1A/347301 Petaling Jaya, MalaysiaEmail: [email protected] Web:http://www.tradefairdates.com

31 May -02 Jun 2016Trade fair for automotive test, evaluation and quality engineeringMesse Stuttgart,Messepiazza 1, 70629 Stuttgart, Baden-Wurttemberg, GermanyContact: UKIP Media & Events Ltd.Abinger House Church StreetRH41DF Dorking, United Kingdom of Great Britain and Northern IrelandTel: +44 (0)1306 743744 Fax: +44 (0)1306 742525Email: [email protected] Web: http://www.tradefairdates.com

01 - 04 Jun 2016Fair of the metalworking industryRomexpo Exhibition Center,65-67 Marasti Boulevard, 011465 Bucharest, Bucharest, RomaniaContact: EuroexpoGarlei Street, Intact Building, 2nd floorBucharest, RomaniaTel: +40 (0)21 4091849 Fax: +40 (0)21 4091854Email: [email protected] Web: http://www.tradefairdates.com

07 - 10 Jun 2016Mach Tool: Machines and Tools ExhibitionPoznan International Fair LtdGlogowska street 14, 60-734 Poznan, PolandContact: Tel: +48 61 869 2000 Fax: +48 61 869 2999Email: [email protected] Web: http://machtool.mtp.pl/en/

Events


07 - 10 Jun 2016Hydraulics, pneumatics and drives exhibitionPoznan International Fair Grounds, Glogowska Street 14, 60734 Poznan, Greater Poland, PolandContact: Poznan International Fair Ltd.ul. Glogowska 14, 60734 Poznan, PolandTel: +48 (0)61 8692000 Fax: +48 (0)61 8692999Email: [email protected] Web: http://www.tradefairdates.com

07 - 10 Jun 2016Trade fair for metallurgy, metal processing and foundry technologyPoznan International Fair Grounds, Glogowska Street 14, 60734 Poznan, Greater Poland, PolandContact: Poznan International Fair Ltd.ul. Glogowska 14, 60734 Poznan, PolandTel: +48 (0)61 8692000 Fax: +48 (0)61 8692999Email: [email protected] Web: http://www.tradefairdates.com

12 - 14 Jun 2016International Sheet metal machinery, Forging, Stamping and Setting Equipment ExhibitionChina Import & Export Fair Pazhou Complex,No. 380, Yuejiang Zhong Road, 510000 Guangzhou, Guangdong, ChinaContact: Julang Exhibition Co. Ltd.Huaming Road 29, Pearl River New City, Tianhe District, Guangzhou, ChinaTel: +86 (0)20 38621071 Fax: +86 (0)20 38620781Email: [email protected] Web: http://www.tradefairdates.com

12 - 14 Jun 2016International trade fair for metal and metallurgyChina Import & Export Fair Pazhou Complex,No. 380, Yuejiang Zhong Road, Guangdong, ChinaContact: Julang Exhibition Co. Ltd.Huaming Road 29, Pearl River New City, Tianhe District, Guangzhou, ChinaTel: +86 (0)20 38621071 Fax: +86 (0)20 38620781Email: [email protected] Web: http://www.tradefairdates.com

15 - 16 Jun 2016International trade fair for moldmaking and

tooling, design and application developmentSuburban Collection Showplace, 46100 Grand River Avenue, 48374 Novi, Michigan, USAContact: Demat GmbH, Carl-von-Noorden-Platz 560041 Frankfurt, GermanyTel: +49 (0)69 2740030 Fax: +49 (0)69 27400340Email: [email protected] Web: http://www.tradefairdates.com

15 - 18 Jun 2016Trade fair for laboratory, test, measurement and quality control equipmentBITEC - Bangkok International Trade & Exhibition Center, 88 Bangna-Trad Road, Bang Na, Bangkok, ThailandContact: Allworld Exhibitions12th Floor, Westminster TowerSE1 7SP London, United Kingdom of Great Britain and Northern IrelandTel: +44 (0)20 78402100 Fax: +44 (0)20 78402111Email: [email protected] Web: http://www.tradefairdates.com

22 - 24 Jun 2016Trade fair for mechanical components and materials technologyTokyo Big Sight, 3-21-1 Ariake Kotu-ku, Tokyo, JapanContact: Reed Exhibitions Japan Ltd.1-26-2 Nishishinjuku163-0570 Tokyo, JapanTel: + 81 (3) 33498501 Fax: + 81 (3) 33498599Email: [email protected] Web: http://www.tradefairdates.com

22 - 25 Jun 2016Manufacturing Expo Bangkok: Thailand's largest manufacturing and supporting industries eventBITEC - Bangkok International Trade & Exhibition Center, 88 Bangna-Trad Road, Bang Na, 10260 Bangkok, ThailandContact: Reed Tradex32nd fl., Sathorn Nakorn Tower, 100/68-69 North Sathon Road Silom, 10500 Bangkok, ThailandTel: +66 (0)2 6867299 Fax: +66 (0)2 6867288Email: [email protected] Web: http://www.tradefairdates.com ◘

Events


CMTI 'TECHNOLOGY UPGRADATION' TRAINING PROGRAMMES DURING APRIL 2016

Course Code Course Title Duration

(Days)Date of

Commencement

Course Fee (Rs.) Exclusive of *Service Tax

@ 14.5%. (* As applicable at the

time of billing)

0860

Measurement Uncertainty for Chemical & Mechanical Parameters by Guide for Uncertainty Measurement (GUM) Method

2 days 04th April 2016 7,000

0470 Advanced Course on Development of Ultra-Precision Machines 3 days 05th April 2016 10,500

550 NEw

Microstereolithography-Concepts & Applications 2 days 21ST April 2016 7,000

0410 Laboratory Management & Internal Audit as per ISO / IEC 17025 4 days 25th April 2016 14,000

560 NEw

Basic Course on Single Point Diamond Turning (SPDT) 3 days 27th April 2016 10,500

Please send confirmation/enrolements to Shri. V A P Sarma, Scientist-E – AEAMT, Central Manufacturing Technology Institute, Tumkur Road, Bengaluru - 560 022

Cell No. 09449842686 / 09449842678, E-mail: [email protected], [email protected], website: www.cmti-india.net

Evening Course on "CNC Programming through Mastercamx7"

Abstracts


Manufacturing technology abstracts

NANO TECHNOLOGY 37

PRECISION ENGINEERING 37

PRODUCT DESIGN & MANUFACTURE 38

QUALITY MANAGEMENT 41

RAPID PROTOTYPING 42

ARTIFICIAL INTELLIGENCE & ROBOTICS 43

TOOLS & TOOLING 43

TRIBOLOGY 44

The topics on various aspects of manufacturing technology can be discussed in term of concepts, state of the art, research, standards, implementations, running experiments, applications, and industrial case studies.

Authors from both research and industry contributions are invited to submit complete unpublished papers, which are not under review in any other conference or journal.

Contact: Central Manufacturing Technology Institute (CMTI) Tumkur Road, Bengaluru – 560 022, Karnataka, IndiaEmail: [email protected]

Abstracts


Manufacturing technology abstracts

NANO TECHNOLOGY

110635 Investigation of plasma produced by intense nanosecond laser ablation in vacuum under external magnetic field using a two-stage model

Tao, Sha; Wu, Benxin; Zhou, Yun; Cheng, Gary J [J of Manufacturing Sci & Engg:ASME Trans, v 135, n 6, Dec 2013, Starting

Page 061009, Pages 6] In this paper a two-stage physics-based model has been applied to study the evolution of plasma produced by high-intensity nanosecond laser ablation in vacuum under external magnetic field. In the early stage (Stage I), the laser-induced plasma generation and its short-term evolution are described through one-dimensional (1D) hydrodynamic equations. An equation of state (EOS) that can cover the density and temperature range in the whole physical domain has been applied to supplement the hydrodynamic equations. In the later stage (Stage II), the plasma long-term evolution is simulated by solving 2D gas dynamic equations. The two-stage model can predict the spatial distributions and temporal evolutions of plasma temperature, density, velocity, and other parameters. The model is used to study and discuss the effects of external magnetic field on the plasma evolution. It provides a useful tool for related fundamental studies and practical applications. (46 refs, 5 figs) (AA)

PRECISION ENGINEERING

110636 Characterizing the effect of laser power density on microstructure, microhardness, and surface finish of laser deposited titanium alloy

Mahamood, Rasheedat M; Akinlabi, Esther T;

Shukla, Mukul; Pityana, Sisa [J of Manufacturing Sci & Engg:ASME Trans, v 135, n 6, Dec 2013, Starting Page 064502, Pages 4] This paper reports the effect of laser power density on the evolving properties of laser metal deposited titanium alloy. A total of sixteen experiments were performed, and the microstructure, microhardness and surface roughness of the samples were studied using the optical microscope (OP), microhardness indenter and stylus surface analyzer, respectively. The microstructure changed from finer martensitic alpha grain to coarser Widmastätten alpha grain structure as the laser power density was increased. The results show that the higher the laser power density employed, the smoother the obtained surface. The microhardness initially increased as the laser power density was increased and then decreased as the power density was further increased. The result obtained in this study is important for the selection of proper laser power density for the desired microstructure, microhardness and surface finish of part made from Ti6Al4V. (20 refs, 3 figs, 1 table) (AA)

110637 Development of sleeve and spool assembly of hydraulic Spool valve by precision engineeringRaghavendra Bhat A, Navatha A, Apratim Talukdar and Karunanidhi S [Manufacturing Technology Today, v 13, n 10, Oct 2014, Starting Page 3, Pages 8] This paper deals with the techniques and sequence of operations required for precision machining and metrological inspection of the components in the second- stage of a Hydraulic Spool Valve. The requirements of high accuracies in dimensions, form and surface quality are the prime requirements to meet the stringent valve specifications such as leakage, threshold, pressure gain, hysteresis, linearity etc. The sleeve and spool assembly of the spool valve forms the second stage of the valve. The sleeve is incorporated to meet higher flow requirements. It has many rectangular slots or flow openings. These slots are machined by Wire Cut Electrical Discharge Machining (WEDM) process. The spool has to be then machined to the dimensions obtained from the sleeve, in order to meet the required valve performance. This assembly has very critical clearance (between sleeve and spool), cylindricity and finish requirements. The paper presents the various precision machining techniques such as WEDM,

Abstracts


cylindrical grinding, honing, and lapping used in achieving these requirements. These components have been assembled in the valve. The metrological and the valve performance results obtained have been given. (11 refs, 17 figs, 1 tables) (GM)

PRODUCT DESIGN & MANUFACTURE

110638 Optimal Design of Solenoid Actuators Driving Butterfly ValvesMousavi, Peiman N; Nataraj, C [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 094501, Pages 5] Smart valves are used in cooling applications and are responsible for regulating and supplying the coolant, which is critical for safe and effective operation of many components on naval and commercial ships. In order to be operated under local power (for various mission-critical reasons) they need to consume as little energy as possible in order to ensure continued operability. This paper focuses on optimized design of a typical system using high fidelity nonlinear dynamic models for all the subsystems with full consideration of stability constraints. A simulated annealing algorithm is applied to explore optimal design using two sets of design variables. The results indicate that substantial amount of energy can be saved by an intelligent design that helps select parameters carefully, but also uses hydrodynamic loads to augment the closing effort. (11 refs, 4 figs, 1 table) (AA)

110639 Comparison of two similar mathematical models for tolerance analysis: T-map and deviation domain

Mansuy, Mathieu; Giordano, Max; Davidson, Joseph K [J of Mechanical Design, v 135, n 10, Oct 2013, Starting Page 101008, Pages 7] The major part of production cost of a

manufacturing product is set during the design stage and especially by the tolerancing choice. Therefore, a lot of work involves trying to simulate the impact of these choices and provide an automatic optimization. For integrating this modeling in computer aided design (cad) software, the tolerancing must be modeled by a mathematical tool. Numerous models have been developed but few of them are really efficient. Two advanced models are “T-map” model developed by Joseph K. Davidson and “deviation domain” developed by

Max Giordano. Despite the graphical representation of these two models seems to be similar, they have significant differences in their construction and their resolution method. These similarities and differences highlight the needs of tolerancing modeling tool in each kind of problems, especially in case of assembly with parallel links. (27 refs, 12 figs, 1 table) (AA)

110640 Design optimization of complex hydromechanical transmissionsPettersson, Karl; Krus, Petter [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 091005, Pages 9] Demands for higher fuel efficiency for off-highway applications motivate manufacturers to replace existing drive transmissions with more complex, high-efficiency transmissions. Increased intelligence and more advanced architectures are, however, more difficult to design and prototype. This leads to longer product development processes and a greater need for early product evaluation. The great variety of existing concepts also requires a methodology to support the choice of architecture. This paper proposes a design methodology for complex hydromechanical transmissions based on optimization. The main objective is to maximize energy efficiency and adapt the design to suit the typical operating behavior of the application. The methodology is also implemented on a multiple mode transmission concept sui for a heavy wheel loader application. It is shown that the design of the gearbox heavily influences the energy consumption and the necessity to use optimization when designing the gearbox. (17 refs, 15 figs, 3 tables) (AA)

110641 Design of crashworthy structures with controlled energy absorption in the hybrid cellular automaton framework

Bandi, Punit; Schmiedeler, James P; Tovar, Andrés [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 091002, Pages 11] This work presents a novel

method for designing crashworthy structures with controlled energy absorption based on the use of compliant mechanisms. This method helps in introducing flexibility at desired locations within the structure, which in turn reduces the peak force at the expense of a reasonable increase in intrusion. For this purpose, the given design domain is divided into two subdomains: flexible (FSD) and stiff (SSD) subdomains. The design in the

Abstracts


flexible subdomain is governed by the compliant mechanism synthesis approach for which output ports are defined at the interface between the two subdomains. These output ports aid in defining potential load paths and help the user make better use of a given design space. The design in the stiff subdomain is governed by the principle of a fully stressed design for which material is distributed to achieve uniform energy distribution within the design space. Together, FSD and SSD provide for a combination of flexibility and stiffness in the structure, which is desirable for most crash applications. (30 refs, 16 figs, 2 tables) (AA)

110642 Conservative surrogate model using weighted Kriging variance for sampling-based RBDOZhao, Liang; Choi, KK; Lee, Ikjin; Gorsich, David [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 091003, Pages 10] In sampling-based reliability-based design optimization (RBDO) of large-scale engineering applications, the Monte Carlo simulation (MCS) is often used for the probability of failure calculation and probabilistic sensitivity analysis using the prediction from the surrogate model for the performance function evaluations. When the number of samples used to construct the surrogate model is not enough, the prediction from the surrogate model becomes inaccurate and thus the Monte Carlo simulation results as well. Therefore, to count in the prediction error from the surrogate model and assure the obtained optimum design from sampling-based RBDO satisfies the probabilistic constraints, a conservative surrogate model, which is not overly conservative, needs to be developed. In this paper, a conservative surrogate model is constructed using the weighted Kriging variance where the weight is determined by the relative change in the corrected Akaike Information Criterion (AICc) of the dynamic Kriging model. The proposed conservative surrogate model performs better than the traditional Kriging prediction interval approach because it reduces fluctuation in the Kriging prediction bound and it performs better than the constant safety margin approach because it adaptively accounts large uncertainty of the surrogate model in the region where samples are sparse. Numerical examples show that using the proposed conservative surrogate model for sampling-based RBDO is necessary to have confidence that the optimum design satisfies the probabilistic constraints when the number of samples is limited, while it does not lead to overly conservative designs like the constant safety margin approach. (38 refs, 6 figs, 7 tables) (AA)

110643 Knowledge-based model for constructing master assembly sequenceKashkoush, Mohamed; ElMaraghy, Hoda [J of Manufacturing Systems, v 34, Jan 2015, Starting Page 43, Pages 10] A novel knowledge-based mixed-integer programming (MIP) model is presented for generating the assembly sequence of a given product based on available assembly sequence data of similar products. The proposed mathematical model finds the optimal consensus assembly sequence tree for an existing product family based on the assembly sequence trees of individual product family members. The proposed model is inspired by problems studied in biology and phylogenetics where a consensus species classification for a set of conflicting classifications is sought. The generated consensus tree serves as a master assembly sequence tree and is used to generate the assembly sequence for new product variants that falls within, or significantly overlaps with, the boundary of the considered family of products. The developed model is demonstrated using a family of pilot valves. The knowledge-based MIP model supports automatic assembly sequence generation, hence, reduces assembly planning effort and cost and improves productivity. (36 refs, 15 figs, 1 table) (AA)

110644 Formalizing and exploring the transferability of inclusive design rulesSangelkar, Shraddha; McAdams, Daniel A [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 091004, Pages 12] Inclusive products intend to equally serve people with and without a disability. This paper focuses on creating guidelines that are applicable during the early stages of designing inclusive products. Actionfunction diagrams are used to formally compare existing inclusive products to their typical counterparts to study the design similarities and differences in the context of accessibility. A data mining technique, association rule learning, generates rules through comparison of inclusive and typical product data. In prior work, generation of function-based association rules for inclusive design has been performed on a smaller scale using this method; this research seeks to extend and formalize the same method, by studying a larger set of inclusive products. Trends in the generation of rules are analyzed indicating that a finite set of rules should be applicable to an arbitrarily large set of products. Further, the rules are analyzed in detail to evaluate their potential for transferability and reuse from one product to another. Of particular interest is the transferability of the rules across apparently disparate product domains

Abstracts


such as garden tools and residential furniture. The conceptual and physical similarity of the rules is discussed in the context of creating inclusive product families based on a platform of inclusive elements. (33 refs, 13 figs, 4 tables) (AA)

110645 Reliability Based Design Optimization Modeling Future Redesign with Different Epistemic Uncertainty TreatmentsMatsumura, Taiki; Haftka, Raphael T [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 091006, Pages 9] Design under uncertainty needs to account for aleatory uncertainty, such as variability in material properties, and epistemic uncertainty including errors due to imperfect analysis tools.While there is a consensus that aleatory uncertainty be described by probability distributions, for epistemic uncertainty there is a tendency to be more conservative by taking worst case scenarios or 95th percentiles. This conservativeness may result in substantial performance penalties.Epistemic uncertainty, however, is usually reduced by additional knowledge typically provided by tests. Then, redesign may take place if tests show that the design is not acceptable. This paper proposes a reliability based design optimization (RBDO) method that takes into account the effects of future tests possibly followed by redesign. We consider each realization of epistemic uncertainty to correspond to a different design outcome.Then, the future scenario, i.e., test and redesign, of each possible design outcome is simulated. For an integrated thermal protection system (ITPS) design, we show that the proposed method reduces the mass penalty associated with a 95th percentile of the epistemic uncertainty from 2.7% to 1.2% compared to standard RBDO, which does not account for the future. We also show that the proposed approach allows trading off mass against development costs as measured by probability of needing redesign. Finally, we demonstrate that the tradeoff can be achieved even with the traditional safety factor based design. (27 refs, 12 figs, 4 tables) (AA)

110646 Design and analysis of electro-thermal grippers for holding micro-componentsVidyaa V, Gladys Sheba Chandrakumari A, Hosimin Thilagar S, Kanthababu M, Balasubramanian R, Suri VK [Manufacturing Technology Today, v 13, n 12, Dec 2014, Starting Page 20, Pages 4] Grippers are used to pick, hold and place macro/micro-components, which are widely used in the field of assembly. In this work, for the first time an electro-thermal gripper (collet) is designed and analysed using two thermal actuator structures

with reverse currents in order to reduce the out-of-plane actuation for holding micro-components in a narrow range of sizes between 100 μm to 1000 μm. The electro-thermal gripper is designed and analyzed using Comsol Multiphysics Design and Analysis Software. The materials considered for the electro-thermal gripper are alluminium and steel. From the analysis, it is observed that in the case of alluminium electro-thermal gripper at 0.1 V, the in-plane displacement is found to be 22 μm and the out-of-plane displacement is found to be 0.1 μm. In the case of steel electro-thermal gripper at 0.1V, the in-plane displacement is found to be 0.1 μm and out-of-plane displacement is found to be 0.00005 μm. It is observed that alluminium results in better displacement compared to steel. (11 refs, 7 figs, 1 tables) (AA)

110647 Updating Kriging Surrogate Models Based on the Hypervolume Indicator in Multi-Objective Optimization

Shimoyama, Koji; Sato, Koma; Jeong, Shinkyu; Obayashi, Shigeru [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 094503, Pages 7] This paper presents a comparison of the criteria for updating the Kriging surrogate models in

multi-objective optimization: expected improvement (EI), expected hypervolume improvement (EHVI), estimation (EST), and those in combination (EHVI + EST). EI has been conventionally used as the criterion considering the stochastic improvement of each objective function value individually, while EHVI has recently been proposed as the criterion considering the stochastic improvement of the front of nondominated solutions in multi-objective optimization. EST is the value of each objective function estimated nonstochastically by the Kriging model without considering its uncertainties. Numerical experiments were implemented in the welded beam design problem, and empirically showed that, in an unconstrained case, EHVI maintains a balance between accuracy, spread, and uniformity in nondominated solutions for Kriging-model-based multiobjective optimization. In addition, the present experiments suggested future investigation into techniques for handling constraints with uncertainties to enhance the capability of EHVI in constrained cases. (24 refs, 6 figs, 2 tables) (AA)

Abstracts


110648 Studies about the use of semicircular beams as hinges in large deflection planar compliant mechanisms

A h u e t t - G a r z a , Horacio; Chaides, Oscar; Garcia, Pedro N; Urbina, Pedro [Precision Engg, v 38, n 4, Oct 2014, Starting Page 711, Pages 17] Conventional hinge designs in planar c o m p l i a n t mechanisms have a limited deformation range because of the

high stresses induced during deflection. To improve the range of motion of these mechanisms, hinges that allow for large displacement are highly desirable. This paper explores the use of curved beams as large displacement hinges in planar compliant mechanisms. To facilitate design, analytic expressions that predict deflections under different types of loads are introduced. These expressions are used in pseudo rigid link models of compliant mechanism designs. Predictions made by the analytic expressions are compared with the results of FEA simulations. To validate the proposed models, two planar compliant mechanism designs were prepared and experimental measurements of deflections under loads were made. Overall, results showed that analytic models and FEA predictions lie within 10% of experimental data for the planar mechanism geometry in which pseudo rigid motion models apply. FEA models of the second case, a more complex mechanism, make predictions that lie within 15% of experimental measurements. Results and ways to improve accuracy of models and designs are discussed at the end of the article. (27 refs, 23 figs, 10 tables) (AA)

110649 Impact of Product Design Representation on Customer Judgment

Reid, Tahira N; MacDonald, Erin F; Du, Ping [J of Mechanical Design, v 135, n 9, Sep 2013, Starting Page 091008, Pages 12] When researchers ask

customers to judge product form during the design process, they often manipulate simplified product representations, such as silhouettes and sketches, to gather information on which designs customers prefer. Using simplified forms, as opposed to detailed realistic models, make the analysis of gathered information tractable and also allows the researcher to guide customer focus. The theory of constructed preferences from psychology suggests that the product form presented will influence customer judgments. This paper presents a study in which subjects were shown computer sketches, front/side view silhouettes, simplified renderings, and realistic renderings to test the extent to which a variety of judgments including opinions, objective evaluations, and inferences are affected by form presentation. Results show a variety of phenomena including preference inconsistencies and ordering effects that differed across type of judgment. For example, while inferences were consistent across form, opinions were not. An eye tracker identified differences in viewing strategies while making decisions. Associated data, such as fixation times and fixation counts, provide additional insight into findings. (57 refs, 11 figs, 10 tables) (AA)

QUALITY MANAGEMENT

110650 Manufacturing setup cost reduction and quality improvement for the distribution free continuous-review inventory model with a service level constraintSarkar, Biswajit; Chaudhuri, Kripasindhu; Moon, Ilkyeong [J of Manufacturing Systems, v 34, Jan 2015, Starting Page 74, Pages 9] Over several decades, the continuous-review inventory model has been widely studied based on various assumptions and restrictions such as those related with quality improvement, service level constraint, and setup cost reduction. We extend Moon and Choi’s [1] model by assuming setup cost reduction and quality improvement. A distribution free approach is employed such that only mean and standard deviation need to be known. The total system cost is minimized with respect to decision variables against the worst possible distribution scenario. The benefit of using quality improvement and setup cost reduction in this model is shown. Numerical examples show that this model offers significant improvements over existing models. Finally, sensitivity analysis of the key parameters is also presented. (31 refs, 5 figs, 6 tables) (AA)

Abstracts


RAPID PROTOTYPING

110651 Electron beam additive manufacturing of titanium components: Properties and performance

Edwards, P; O’Conner, A; Ramulu, M [J of Manufacturing Sci & Engg: ASME Trans, v 135, n 6, Dec 2013, Starting Page 061016, Pages 7] This research evaluates the fatigue properties of Ti-6Al-4V specimens and c o m p o n e n t s produced by Electron Beam additive manufacturing. It was

found that the fatigue performance of specimens produced by additive manufacturing is significantly lower than that of wrought material due to defects such as porosity and surface roughness. However, evaluation of an actual component subjected to design fatigue loads did not result in premature failure as anticipated by specimen testing. Metallography, residual stress, static strength and elongation, fracture toughness, crack growth, and the effect of post processing operations such as machining and peening on fatigue performance were also evaluated. (27 refs, 12 figs, 2 tables) (AA)

110652 Height Dependent Laser Metal Deposition Process Modeling

S a m m o n s , Patrick M; Bristow, Douglas A; Landers, Robert G [J of Manufacturing Sci & Engg:ASME Trans, v 135, n 5,

Oct 2013, Starting Page 054501, Pages 7] Laser metal deposition (LMD) is used to construct functional parts in a layer-by-layer fashion. The heat transfer from the melt region to the solid region plays a critical role in the resulting material properties and part geometry. The heat transfer dynamics can change significantly as the number of layers increase, depending on the geometry of the sub layers. However, this effect is not taken into account in previous analytical models, which are only valid for a single layer. This paper develops a layer

dependent model of the LMD process for the purpose of designing advanced layer-to-layer controllers. A lumped-parameter model of the melt pool is introduced and then extended to include elements that capture height dependent effects on the melt pool dimensions and temperature. The model dynamically relates the process inputs (laser power, material mass flow rate, and scan speed) to the melt pool dimensions and temperature. A finite element analysis (FEA) is then conducted to determine the effect of scan speed and part height on the solid region temperature gradient at the melt pool solidification boundary. Finally, experimental results demonstrate that the model successfully predicts multilayer phenomenon for two deposits on two different substrates. (20 refs, 12 figs, 4 tables) (AA)

110653 Surface oxidation behavior of Ti–6Al–4V manufactured by Electron Beam Melting (EBM®)

K a r l s s o n , J o a k i m ; N o r e l l , M a t s ; Ackelid, Ulf; E n g q v i s t , H å k a n ; L a u s m a a ,

Jukka [J of Manufacturing Processes, v 17, Jan 2015, Starting 0, Pages 7] Additive manufacturing is an emerging manufacturing technology that enables production of patient specific implants, today primarily out of titanium. For optimal functionality and proper integration between the titanium implant and the body tissues surface properties, such as surface oxide thickness is of particular importance, as it is primarily the surface of the material which interacts with the body. Hence, in this study the surface oxidation behavior of titanium parts manufactured by Electron Beam Melting (EBM®) is investigated using the surface sensitive techniques ToF-SIMS and AES. Oxide thicknesses comparable to those found on conventionally machined surfaces are found by both analysis techniques. However, a build height dependency is discovered for different locations of the EBM® manufactured parts due to the presence of trapped moisture in the machine and temperature gradients in the build. (47 refs, 6 figs) (AA)

110654 Indirect additive manufacturing based casting of a periodic 3D cellular metal – Flow simulation of molten aluminum alloyMun, Jiwon; Yun, Byoung-Gwan; Ju, Jaehyung; Chang, Byung-Moon [J of Manufacturing Processes,

Abstracts


v 17, Jan 2015, Starting Page 28, Pages 13] Direct-metal additive manufacturing (AM) processes such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM) methods are being

used to fabricate three dimensional (3D) metallic mesostructures with a laser or electron beam over metal powder beds. In spite of their good manufacturability on 3D network structures, the direct AM processes still appear to have disadvantages – limited selection of materials, high thermal stress traced to the high local energy source, poor surface finish, anisotropic properties, and high cost on powder materials and manufacturing with high power beams. As an alternative method to manufacture 3D network cellular metals, we suggest and implement an indirect AM method combining an inkjet 3D printing of wax and metal casting – Indirect AM based Casting (I·AM Casting). The objective of this study is to test the hypothesis that casting of a molten metal into a cellular structural mold is highly sensitive to temperature that temperature-dependent viscosity, density, and thermal conductivity should be implemented for the simulations on flow and solidification of a molten metal. We found that solidification is sensitive to viscosity and thermal conductivity of AC4C and the zircon mold, which are a strong function of temperature. The simulation with constant thermal and physical properties of AC4C and the zircon mold overestimates the solidification time with an error of 20% compared to the one with the temperature dependent properties. (49 refs, 14 figs, 7 tables) (AA)

ARTIFICIAL INTELLIGENCE & ROBOTICS

110655 Design and kinematics modeling of a Novel 3-DOF Monolithic Manipulator featuring improved Scott-Russell mechanismsQin, Yanding; Shirinzadeh, Bijan; Zhang, Dawei; Tian, Yanling [J of Mechanical Design, v 135, n 10, Oct 2013, Starting Page 101004, Pages 9] This paper proposes the design of a novel 3-DOF monolithic manipulator. This manipulator is capable of performing planar manipulations with three kinematically coupled DOFs, i.e., the translations in the X and Y axes and the rotation about the Z axis. An improved Scott-Russell (ISR) mechanism is utilized to magnify the displacement

of the piezoelectric actuator (PEA). Unlike the SR mechanism, a set of leaf parallelograms is incorporated into the drive point of the ISR mechanism as a prismatic joint. As a result, the linearity of motion and stability are improved. With circular flexure hinges being treated as revolute joints, the forward kinematics and inverse kinematics of the 3-DOF manipulator are analytically derived. Computational analyses are performed to validate the established kinematics models. Due to the unwanted compliance of the flexure hinges, the actual displacement amplification ratio of the ISR mechanism is smaller than its theoretical value. This is the main cause of the discrepancies between the analytical and computational results. The reachable workspace and the static/dynamic characteristics of the 3-DOF manipulator are also analyzed. (33 refs, 9 figs, 3 tables) (AA)

TOOLS & TOOLING

110656 Characterisation of tool shape and rotational speed for increased speed during friction stir welding of AA2024-T3

Trimble, D; O’Donnell, GE; Monaghan, J [J of M a n u f a c t u r i n g Processes, v 17, Jan 2015, Starting Page 141, Pages 10] A combination of tool

force monitoring and post weld assessment has been used to determine effective welding parameters for the production of good quality friction stir welds at the highest possible welding speeds. Results indicate that it is possible to achieve good weld quality at speeds up to 355 mm/min by welding with a scroll shoulder and triflute pin at a rotational speed of 450 rpm. Welds produced at this speed achieved a tensile strength of 93.9% of that of the parent material with relatively good ductility (8.5% tensile elongation) and the presence of no internal or surface defects. (31 refs, 12 figs, 4 tables) (AA)

110657 Tool wear in cutting operations: Experimental analysis and analytical models

Attanasio, A; Ceretti, E; Giardini, C; Cappellini, C [J of Manufacturing Sci & Engg: ASME Trans, v 135, n 5, Oct 2013, Starting Page 051012, Pages 11] The possibility of predicting the amount of the tool wear in machining processes is an

Abstracts


interesting topic for industries, since tool wear affects surface integrity of the final parts and tool life is strictly connected with substitution policy and production costs. The definition of models able to correctly forecast the tool wear development is an important topic in the research field. For this reason in the present work, a comparison between response surface methodology (RSM) and artificial neural networks (ANNs) fitting techniques in tool wear forecasting was performed. For developing these predictive models, experimental values of tool wear, obtained by longitudinal turning operations with variable cutting parameters, were collected. The results showed that the developed models are able to predict the amount of wear. The comparison demonstrated that ANNs give better approximation than RSM in the prediction of the amount of the flank wear (VB) and of the crater wear (KT) depth. The obtained results are interesting not only from a scientific point of view but also for industries. In fact, it should be possible to implement the best model into a production manager software in order to correctly define the tool change during the lot production. (24 refs, 11 figs, 6 tables) (AA)

110658 Experimental investigation of hard turning process using PCBN insert and optimization of cutting parametersPrashant A Patil and MR Dhanvijay [Manufacturing Technology Today, v 13, n 9, Sep 2014, Starting Page 3, Pages 10] Hard turning is becoming more popular for machining hardened steels as it has several benefits over grinding. It is defined as machining steel with hardness greater than 45 HRC. PCBN is the widely used tool material for hard turning applications due to its high hardness, high wear resistance, and high thermal stability. There are several issues, which should be understood and dealt with, to achieve successful performance of hard turning process. The objective of present work is to establish a correlation between cutting parameters such as cutting speed, feed rate and depth of cut with cutting force and surface roughness on work piece. Optimization of cutting parameters for minimising cutting forces and surface roughness while turning 42CrMoS4 steel of 55±2 HRC. It is observed that, the use of lower feed (0.05mm/rev), lower depth of cut (0.2mm) and limiting the cutting speed to medium value (180 m/min) ensures minimum cutting forces (100N to 150 N) and surface roughness (0.467 μ). (15 refs, 9 figs, 7 tables) (AA)

110659 Effect of different features to drill-wear

prediction with back propagation neural networkXu, Jie; Yamada, Keiji; Seikiya, Katsuhiko; Tanaka, Ryutaro; Yamane, Yasuo [Precision Engg, v 38, n 4, Oct 2014, Starting Page 791, Pages 8] In this paper, a back propagation neural network (BPNN) has been applied to predict the corner wear of a high speed steel (HSS) drill bit for drilling on different workpiece materials. Specially defined static and dynamic features extracted by a wavelet packet transform (WPT) from the resultant force converted from thrust and torque together with the cutting conditions (workpiece material, spindle speed, drill diameter, feed rate) are used as inputs to train the network to obtain a better output, drill corner wear. Drilling experiments have been carried out over a wide range and, features newly defined and conventional ones, features extracted from different frequency bands are compared. (12 refs, 15 figs, 7 tables) (AA)

TRIBOLOGY

110660 Lubrication of tube in cold pilgering

Abe, Hideaki; Nomura, Takashi; Kubota, Yuuya [J of Materials Processing Technology, v 214, n 8, Aug 2014, Starting Page 1627, Pages 11] A new method of evaluating the lubrication state of a tube in cold pilgering has been studied. A method of calculating the oil film thickness in a bite area on both the outer and inner sides of a tube using the Reynolds equation was proposed. The calculation results revealed that the effects of the tool design, rolling speed, and feed rate on the oil film thickness were significant. Cold pilgering tests were performed on zirconium alloy tubes, including measurement of the oil film thickness using laser equipment and observation of the surface characteristics of tubes. The test results proved the validity of the proposed method. The method is expected to assist the selection of appropriate operation conditions in cold pilgering. (12 refs, 25 figs, 5 tables) (AA) ◘

Bibliography


SELECT BIBLIOGRAPHY: CARBIDE INSERTS

Cemented carbide is a hard material used extensively in cutting for machining, as well as other industrial applications. It consists of fine particles of carbide cemented into a composite by a binder metal. Cemented carbides commonly use tungsten carbide (WC), titanium carbide (TiC), or tantalum carbide (TaC) as the aggregate. Mentions of “carbide” or “tungsten carbide” in industrial contexts usually refer to these cemented composites.

Most of the time, carbide cutters will leave a better surface finish on the part, and allow faster machining, than high-speed steel or other tool steels. Carbide tools can withstand higher temperatures at the cutter-workpiece interface than standard high-speed steel tools (which is a principal reason for the faster machining). Carbide is usually superior for the cutting of tough materials such as carbon steel or stainless steel, as well as in situations where other cutting tools would wear away faster, such as high-quantity production runs.

1. Brittleness and fatigue effect of mono- and multi-layer PVD films on the cutting performance of coated cemented carbide inserts

Skordaris, G; Bouzakis, KD; Charalampous, P; Bouzakis, E; Paraskevopoulou, R; Lemmer, O; Bolz, S [CIRP Annals, V 63, N 1, 2014, Starting page 93, 4 Pages] Rec. No: 110094

2. Machinability and surface integrity issues in finish turning of hardened steel with coated carbide, deep cryogenically treated uncoated/coated carbide inserts.

Manu Dogra; Sharma, VS [International Journal of Precision Technology, V 2, N 4, 2011, Starting page 355, 20 Pages] Rec. No: 108402

3. Effect of substrate pretreatments and HPPMS deposited adhesive interlayers’ materials on the cutting performance of coated cemented carbide inserts

Bouzakis, K-D; Skordaris, G; Gerardis, S; Katirtzoglou, G; Makrimallakis, S; Pappa, M; Bolz, S; Koelker, W [CIRP Annals, V 59, N 1, 2010, Starting page 73, 4 Pages] Rec. No: 105601

4. Investigations on the effects of multi-layered coated inserts in machining Ti-6Al-4V alloy with experiments and finite element simulations.

Oezel, T; Sima, M; Srivastava, AK; Kaftanoglu,B [CIRP Annals, V 59, N 1, 2010, Starting page 77, 6 Pages] Rec. No: 105653

5. Performance evaluation of carbide inserts on surface roughens in hard turning.

Srinivasa Rao, G; Neelakanteswara Rao, A; Sudheer, NVVS [3rd Int. & 24th AIMTDR Conf, Visakhapatnam, V 2, 13-15 Dec, 2010, Starting page 647, 5 Pages] Rec. No: 108238

6. wear characterisation and tool performance of sintered carbide inserts during automatic machining of AISI 1045 steel.

Rogante, M [J of Materials Processing Tech,

V 209, N 10, 2009, Starting page 4776, 8 Pages] Rec. No: 106312

7. Nucleation and growth of diamond by different seeding materials on cemented carbide inserts by HFCVD method.

Sarangi, SK; Chattopadhyay, A; Chattopadhyay, AK [Competitive Mfg- Proc.of 2nd Intl. & 23rd AIMTDR Conf, V 1, 2008, Starting page 171, 6 Pages] Rec. No: 104740

8. Development of coated grades of carbide tools.

Palsson, M; Richt, C [American Machinist, V 151, N 12, 2007, Starting page 11, 4 Pages] Rec. No: 103806

9. Crater wear evolution in multilayer coated carbides during machining using confocal microscopy.

Olortegui-Yume, JA; Kwon, PY [J of Manufacturing Processes, V 9, N 1, 2007, Starting page 47, 14 Pages] Rec. No: 103391

10. Turning a tiger into a piggy bank. - [Tooling & Production, V 71, N 3, 2005,

Starting page 46, 3 Pages] Rec. No: 10255711. Role of soluble oil and liquid nitrogen jets on

machining of inconel 718 by uncoated and coated carbide inserts.

Adhikari, SS; Kumar, S and Chattopadhyay, AB [COPEN-2005- Proc of the 4th National Conf on Precision Engg, 2005, Starting page 133, 6 Pages] Rec. No: 102071

12. Gradual wear monitoring of turning inserts using wavelet analysis of ultrasound waves.

Abu-Zahra, NH; Yu, G [V 43, N 4, 2003, Starting page 337, 7 Pages] Rec. No: 100365

13. Influence of radial and axial runouts on surface roughness in face milling with round insert cutting tools.

Franco, P; Estrems, M; Faura, F [Int J of Machine Tools & Manufacture, V 44, N 15, 2004, Starting page 1555, 11 Pages] Rec. No: 99706 ◘

vol. 15 no. 3 march 2016 editorial board contents ... mar_ 2016.pdf · contents technical papers...

Documents