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Designing the Product
Published in David M. Anderson, Design for Manufacturability, 2020
If bar stock can be standardized on one type, then machine tools could be more efficient by avoiding setup delays and costs to change bar stock. A proliferation of types of stock can incur large inventory carrying costs and waste valuable space. Many different remnants are hard to keep track of in inventory management, which can result in perceived shortages, unnecessary ordering of excess materials, and expensive expediting. In addition, remnants may not retain identifying grade marks (usually at the end of bar stock) which would either discourage use or risk using the wrong material.
High-speed machining of additively manufactured Inconel 718 using hybrid cryogenic cooling methods
Published in Virtual and Physical Prototyping, 2022
Amin Bagherzadeh, Bahattin Koc, Erhan Budak, Murat Isik
The energy consumed during conventional production such as casting was also reported. Wilson et al. reported the energy for producing a metal in a bar stock form to fabricate a turbine blade was found to be 4586.7 MJ (Wilson et al. 2014). Almost 286.7 MJ of energy was reported to be consumed for remelting during the investment casting process (Morrow et al. 2007). Subsequently, 133.2 MJ (calculated by Wilson et al. (2014)) and 16.5 MJ (Margolis, Jamison, and Dove 1999) energy values was reported to be used for heat treatment and cleaning–finishing process of the nickel-based alloy made turbine blade, respectively. All of these steps foresee almost a 5023.1 MJ energy consumption for production of a turbine blade by means of using casting. The energy consumed during casting fabrication is almost 322 MJ per kg of a part meaning 1.5 times greater energy consumption than L-PBF fabrication but 6.4 times less than DED process.
Integrated energy-efficient machining of rotary impellers and multi-objective optimization
Published in Materials and Manufacturing Processes, 2020
Gokberk Serin, Murat Ozbayoglu, Hakki Ozgur Unver
Figure 4 depicts all the stages of impeller machining using the turn-mill machine tool. Steps 1–3 involved performing rough and finish bar stock OD turning to efficiently remove the unnecessary volume prior to the impeller-blade milling operations. After completion of the turning operations, rough-cut milling was performed to generate the main cavity between adjacent blades. Subsequently, the semi-finish milling operation was performed in two stages to reduce the finish-cut machining time and ensure the high surface-finish quality of the manufactured part by leaving a uniform uncut chip thickness for the final finish milling. The first-stage milling operation was performed using a 6-mm end mill, which reduced the staircase and rough-cut residue to a minimum. Subsequently, the second-stage ball end-milling operation further reduced the uncut thickness to approximately 0.25 mm, ensuring a smooth final finish on the impeller-blade surfaces. Additionally, the chip thickness of the inner fillets was reduced to 0.3 mm after the semi-finish operation.
Automated process planning for turning: a feature-free approach
Published in Production & Manufacturing Research, 2019
Morad Behandish, Saigopal Nelaturi, Chaman Singh Verma, Mats Allard
The 3D sweep of the tool insert along this maximal set of motions yields the maximal volume in the 3D space that does not result in undesirable collisions. This is obtained as a Minkowski sum of the maximal set of motions with the tool insert (Nelaturi et al., 2015), followed by an additional revolution (i.e., rotational sweep). The latter converts the maximal volume swept by the tool to the maximal volume removed from the bar stock due to rapid turning: