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System Definition
Published in Douglas Brauer, John Cesarone, Total Manufacturing Assurance, 2022
Automated machining devices perform the same functions as traditional machine tools but are directed automatically with some sort of computer control, generally Computer Numerical Control (CNC). These machine tools can consist of traditional tools such as drill presses, vertical or horizontal milling machines, lathes, presses, and the like, or more modern devices, which combine several of these functions. The machines may operate upon a stationary workpiece positioned by the transfer mechanism or may have a built-in multiaxis positioning table to hold the work.
Parametric Study and Optimization of Parameters in Powder Mixed Wire-EDM Using Taguchi Analysis
Published in Satya Bir Singh, Prabhat Ranjan, Alexander V. Vakhrushev, A. K. Haghi, Mechatronic Systems Design and Solid Materials, 2021
Swarup S. Deshmukh, Arjyajyoti Goswami, Ramakant Shrivastava, Vijay S. Jadhav
Machining can be defined as the process of selective removal of work material to impart the desired shape and hence a desired functionality to the work material. Machining is a very useful process, which has been frequently utilized throughout the history of humans. Arguably, the earliest example of machining was when the primitive human picked up a stone and selectively chiseled away the edges to generate what was the first tool in the history of human civilization [1]. Soon our ancestors realized that by selective removal of material from a chosen substrate one can develop a particular tool for a specific purpose, which can reduce the effort and increase the benefit of a process.
Sustainability Through Green Manufacturing Systems
Published in Anil Kumar, Jose Arturo Garza-Reyes, Syed Abdul Rehman Khan, Circular Economy for the Management of Operations, 2020
Mahender Singh Kaswan, Rajeev Rathi, Ammar Vakharia
The cutting fluids are used in the machining process to carry chips, increase tool life and reduce the temperature of the cutting zone. But the disposal of the cutting fluid is the primary concern as it leads to skin diseases, eye rashes, cardiovascular diseases, etc. The cutting fluid is termed as the necessary evil because it leads to harm to human health, but it is essential for the machining process. The dry machining leads to cleaner parts, no waste, reduced machining cost and reduced recycling cost. But dry machining demands a considerable investment. The machines and tools that are adaptable with cutting fluids cannot be used for dry machining. DM requires high capacity and power machines and specially designed tools and fixtures that can withstand high temperatures. The distortion results in the machined parts due to the high cutting force and thermal expansion. Furthermore, handling and gauging of the parts produced by dry machining pose severe problems as the manufactured parts are quite hot. So, these disadvantages associated with DM lead to subsequent research and development in the field of machining, and consequently, NDM comes into the picture. NDM reduces tool wear, cutting zone temperatures, friction coefficients, as well as improves surface finish as compared to dry machining (Sharma et al., 2016). Figure 4.10 depicts near dry machining.
Digitalisation and servitisation of machine tools in the era of Industry 4.0: a review
Published in International Journal of Production Research, 2023
To better understand the research focuses represented by the various keywords, we grouped the keywords listed in Table 1 into nine categories and ranked the keywords in each category based on their occurrences in the publications (Figure 7). Modelling, simulation, compensation, and optimisation are closely coupled topics that have been most frequently studied. Specific research focuses include the thermal error, geometric error, dynamics, and stability of machine tools. FEA has been extensively used as the modelling and simulation method. Process monitoring has been a hot topic of machine tool research. Chatter, vibration, and cutting force are the most frequently monitored objectives. Process planning and control has also been a research focus that covers topics such as CNC, tool path, and CAPP. Measurement and calibration have been widely studied. Surface roughness and tool wear are among the top measurands which are also frequently used as the targets for prediction. Energy efficiency of machine tools has also been a hot topic in the last decade in association with the sustainable manufacturing concept. The most studied types of machining process include milling, 5-axis machining, and turning. Spindle has been the most studied machine tool component, followed by rotary axis, feed drive, ball screw, and cutting tool. Data analytics methods that have been frequently used include genetic algorithm, sensitivity analysis, and neural networks. The manufacturing paradigms that have been frequently discussed with machine tools include sustainable manufacturing, Industry 4.0, and RMS.
Cutting fluid behavior under consideration of chip formation during micro single-lip deep hole drilling of Inconel 718
Published in International Journal of Modelling and Simulation, 2023
Ekrem Oezkaya, Andreas Baumann, Sebastian Michel, Dirk Schnabel, Peter Eberhard, Dirk Biermann
Cutting fluids are used in many machining processes to reduce the high mechanical and thermal loads on the tool to increase component quality and process reliability [5]. It has already been shown in some studies that the stability and reproducibility of machining processes can only be guaranteed if the cutting fluid is matched to the other process variables [12–14]. Furthermore, it has to be taken into account that the transport of the chips leads to a highly turbulent flow field. Thus, fluid distribution and flow velocities are influenced by the chip transport, which has thereby an impact on the lubrication of the tool and heat transport in the drilling process. Although the actual heat transport through the cutting fluid is not considered in this work, the results for fluid distribution and flow velocities allow to draw conclusions about the heat transport in general. Therefore, the influence of the chips cannot be neglected and consequently, the chips need to be considered within the simulations of the cutting fluid supply. In addition, the chip shapes need to be part of the simulation to analyze the chip transport itself. The transient transport cannot be correctly predicted by static simulations of certain points in time alone, consequently, a transient simulation is required.
A surrogate model-assisted robustness-oriented tolerance design method based on ‘reverse model’
Published in Journal of Engineering Design, 2022
Linjun Zhong, Yang Yang, Leshi Shu, Ping Jiang, Hua Wei
Practical engineering problems often contain uncertainties of parameters, such as material heterogeneity, geometric errors caused by machining (Lee and Park 2001; Huang and Zhang 2010; Tang et al. 2019). Tolerance is introduced to specify the allowable variation of uncertain parameters, which usually contains assembly tolerances and machining tolerances (Zhang and Wang 1998). The assembly tolerance is to ensure the interchangeability or assemblability of the product (Manarvi and Juster 2004), whereas the machining tolerance is specified in the process plan for manufacturing (Plante 2002). For some general machine parts, there are national or international standards to regulate the tolerances (Natarajan, Sivasankaran, and Kanagaraj 2018), but for some special or customised products, especially those with high-dimensional parameters and high-precision requirements, their parameter uncertainties may deteriorate the product performance or even lead to the preexisting alternative infeasible (Kang et al. 2019; Wei et al. 2021). Generally, larger tolerances will reduce manufacturing costs, but they can also result in greater deviation between actual performance and design objectives (Ledoux, Teissandier, and Sebastian 2016). Tolerance design allocates appropriate tolerances to different parameters through the connection between quality, cost and tolerance, achieving a balance between product quality and manufacturing cost (Jeang 1994; Luo et al. 2015).