...Project Team • University of Massachusetts • Springfield Technical Community College – Gary Masciadrelli – Megan Piccus – John Lafrancis – Zvi Rozen – Dave Cruise – Thomas Langevin – Tiefu Shao – Sundar Krishnamurty • PMRAP Why Cryogenic Machining? • Environmentally sound. • Higher production rates • Greater tool life • Hogouts What is Cryogenic Machining? • Using liquid nitrogen (ln2)as a coolant for tools. Liquid Nitrogen • Temperature -196 C -321 F • Colorless • Inert, doesn’t react with other materials • Non toxic • Readily vaporizes into gas. Keeping Tools Cool Hardness at Temperature Carbide tools at room temperature -1600 -1800 kg/mm^2 Carbide at 500 C – 1000 – 1100 kg/mm^2 Carbide at 900 C - 600 – 500 kg/mm^2 Tool wear at 70m/min @ feed of .20 mm/rev Project Icefly • Commercialized cryogenic process. – Collaboration between Air Products and Hardinge machine tool builder. In 2003. – Developed specifically for turning. – Team experimented with some milling. Summary • Tool life increases up to 40% in Titanium turning. • Tool life increases up to 130% in Hard turning. • Increase in MRR up to 290% in Hard turning. • Increase in MRR up to 60% in Titanium milling. • Tool life increases up to 260% in Titanium milling. Discussion Project Project deliverables 1, Design robust ln2 system to support milling processes. 2, Build prototype system. 3, Implement and debug system in STCC. 4, Optimize prototype to yield MRR of 25%. 5, Report out to industry. Project...
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...EXPERIMENTAL STUDY OF MICRO ULTRASONIC MACHINING PROCESS Sreenidhi Cherku, Murali M Sundaram, and K P Rajurkar Center for Nontraditional Manufacturing Research University of Nebraska-Lincoln Lincoln, Nebraska, USA INTRODUCTION Micro ultrasonic machining (micro USM), is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. The principle of micro USM is shown in Figure 1. In micro USM workpiece which is placed on the workpiece table vibrates at ultrasonic frequency (40 KHz). Abrasive slurry is injected on the top of the workpiece. There is a rotating tool which hits the abrasive particles in the slurry which in turn hit the workpiece and chip away the material from it. The vibrations given to the workpiece aid in refreshing the slurry so that fresh abrasive particles are in contact with the workpiece and also in removing the debris from the tool workpiece gap [1-4]. In many conventional machining processes like grinding, milling and broaching processes oil has been successfully used as cutting fluid. These oils can be used either as straight oils, which are pure petroleum based oils or emulsifiers which are water based oils. Use of straight oils have excellent lubricating properties and are used especially for machining process involving low speeds, low clearance requiring high quality surface finish. These oils have more viscosity and good lubricating properties than water...
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...From: Anis Mansuri <anis_im@ymail.com> Date: November 14, 2013 Subject: Manufacturing of C-Clamp report No. 2 The manufacturing of C-Clamp has progressed well during September 24 to November 12 periods. We are almost done with the all manufacturing processes as per schedule. The grinding process of C-Clamp will be done by the next week. We expect to finish our C-Clamp by November 26, 2103. The process started on September 24 by submitting layouts and engineering drawings of C-Clamp to our professor. We started machining process with bench work the week after. Drilling and trade calculations were done during the week of October 22. As drilling is very convenient and fast, we were one week ahead from our schedule. We started milling operation as it is a lengthy machining process and hard because we have to be very careful with our measurements, and it took two weeks to finish. We just finished turning and threading operation on the lathe machine last week. Three problems affected the manufacturing process during this period: 1. There was an accident with one student at milling machine, so the professor stopped all processes for a week. We did milling in the next week but on that week we did trade calculations so there was not a big problem. 2. During the turning process on the lathe machine, the diameter of the cylindrical bar was less than the threshold range and there was no extra bar in the warehouse, so it took two days to get a new one. Our professor explained...
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...NON TRADITIONAL MACHNING PROCESS SUBMITTED BY :-HARMOHAN SINGH11011102ROLL NO. A23 | TERM PAPER | TOPIC:- Micro ultrasonic machining and its application in MEMS | Ultrasonic machining Schematic of the ultrasonic machining operation Ultrasonic machining, also known as ultrasonic impact grinding,[1] is a machining operation in which a vibrating tool oscillating at ultrasonic frequencies is used to remove material from the workpiece, aided by an abrasive slurry that flows freely between the workpiece and the tool.[2] It differs from most other machining operations because very little heat is produced.[2] The tool never contacts the workpiece and as a result the grinding pressure is rarely more than 2 pounds,[1] which makes this operation perfect for machining extremely hard and brittle materials, such as glass, sapphire, ruby, diamond, and ceramics.[3] Contents [ * 1 Surface finish * 2 Machine time * 3 Mechanics of ultrasonic machining * 4 References | Surface finish The surface finish of ultrasonic machining depends upon the hardness of the workpiece/tool and the average diameter of the abrasive grain used. Up close, this process simply utilizes the plastic deformation of metal for the tool and the brittleness of the workpiece. As the tool vibrates, it pushes down on the abrasive slurry (containing many grains) until the grains impact the brittle workpiece. The workpiece is broken down while the tool bends very slightly. Commonly used tool material consist...
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...are widely used in aeronautical and automobile industries due to their excellent mechanical and physical properties. However machining this composites find difficult because of the reinforcement particles. Tools wear more quickly and reduce the life of the tool. This paper presents the experimental investigation on machining two different A356 matrix metal reinforced with 10 % and 20 % by weight of Silicon carbide (SiCp) particles is fabricated in house by stir casting method. Fabricated samples are turned on medium duty lathe with Poly crystalline Diamond (PCD) insert of 1600 grade at various cutting conditions. Parameters such as power consumed by main spindle, machined surface roughness and tool wear are studied and influence of SiC particles percentage on tool wear also discussed. Scanning Electron Microscope (SEM) images support the result. It is evident that, tool wear is strongly dependent on reinforcement percentage. Key words: A356 Alloy, PCD, Power consumed, Surface roughness, SiC percentage 1. Introduction Metallic matrix composites have found considerable applications in aerospace, automotive and electronic industries [1] because of their improved strength, stiffness and increased wear resistance over unreinforced alloys [2]. However, the final conversion of these composites in to engineering products is always associated with machining, either by turning or by milling. A...
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...SECTION 3 REPORT 3.1 CLASSIFICATION AND DESCRIPTION OF THE MANUFACTURING TECHNIQUES IN FNSS Following techniques of manufacturing are being used in FNSS; * Chip Removal * Joining * Metal Forming * Testing * Chemical Operations 3.1.1 CHIP REMOVAL PROCESSES Metal cutting, commonly called machininh, is the removal of unwanted portions from a block,plate of material in the from o chips so as to obtain a finished product of desired dimensions, finish.Most of the manufactured products require machining at some stage of their production, ranging from rough work to high precision work.Hence metal cutting is the most important of the basic manufacturing processes. In all metal cutting operations an edged tool driven in to the material to remove chips from the main body and reach the desired geometry.Other actions that occurs are related to that action. In cutting operations, there are three cutting conditions; namely speed, feed and depth of cut.Speed is the primary cutting motion, which relates the velocity of the tool relative to work.Feed is the amaount of material removed per revolution.The depth of cut is the depth of cutting edge engaged in the workpiece. The properties of the workpiece are important in chip formation.High strength materials require larger forces than do materials of lower strength, causing greater tool and work deflection, increased friction and heat generation and operating temperatures,and requiring greater work input.The...
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...Production and Tooling Design | Box Jig | Engr. Awais Ahmad | 1/21/2013 | Submitted by: Saba Noor (2009-IME-108) Misbah Niamat (2009-IME-116) Asma Aslam (2009-IME-127) Contents: * What are Jigs and Fixtures? * Why Jigs and Fixtures are used? * Elements of Jigs and Fixtures * Important Considerations while designing a Jig * Box Type Jig * Designing a Box Type Jig * Benefits of Jigs * Drawbacks of Jigs * Conclusion What are Jigs and Fixtures? * Anything used to hold a work piece in a desired location * Locate parts for precision * Repeating process on a series of parts * Holding parts for machining, painting, assembly Why Jigs and Fixtures are used? Holding cylindrical parts to be drilled is one of major problems faced by the manufacturing company, especially small medium company. Sometimes they need expensive equipment to holds the parts to be drill. Today, customers request in industries is increasing. So, the company must find new methods to improve their productivity. Jigs are important part using in any industry. Before this, jigs always have limited function like just one part can be support for one process. This makes the production process slow and cannot fulfill the customers demand. Now days, there are several methods available to improve design to increase the productivity. Jigs are simplified locating and clamping of the work-piece. Tool guiding elements to ensure correct positioning of the tools with...
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...for holding the workpiece directly on the table. With a combination of T-bolts and clamps workpieces with varying height can be held in a levelled position using the different steps on the step block. Figure 23 (Anon., n.d.) Drill jig When the production process requires the output to be in large numbers, drill jigs are used. It is a device that is designed to hold the work securely and makes sure that it guides to the tool at any desired position. In this the work can be fixed (with clamps) and removed with ease. Holes can be drilled at the same position on every other identical workpiece without the need to mark each workpiece individually. The workpiece is clamped below the jig and the holes are properly defined. To continue the machining process on the next workpiece the work is removed and the second work is clamped below the jig and the process is repeated. Figure 24 (Anon., n.d.) Clamps: These devices are small, portable vises or plates which bear against the work-piece and holding devices to steady job. These devices come with different shapes to meet the different operation. Common types of clamps are C-clamp, angle clamp, the bent tail machine clamp and the U-clamp. Figure 25 (Anon., n.d.) Geared drill chuck: In this devices drill with straight shanks are held in geared drill chuck which have three adjustable jaws to clamp onto the machine. The drill chuck come with standard two sizes 3/8 or ½ inches and this devices can be used for different...
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...Using of anisotropic bars with a specific orientation of stiffness axis relative to the cutting forces, result in a significance increase in dynamic stability. Another technique involves making solid bars with materials having high youngs modulus or high damping materials. Typical examples include sintered tungsten carbide and sintered tungsten carbide alloyed with copper and nickel. These materials are expensive but give stable machining for l/ratios up to...
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...Introduction (1) This career episode took four months, from June to October 2008. It was a machining process improvement project that I participated at XXXXXl. I was working as a Manufacturing Process Engineer with machining process, and in this particular case I made a validation of new cutting fluid for shaving process. Background (2) The main purpose of this project was validate a new kind of cutting fluid for shaving process of the gears for vehicle transmissions at Eaton (http://www.). These gears are the main parts of the transmission, which is manufactured in many machining steps, thermal treatment, assembly, and the project aim was improvement / cost reduction of cutting fluid usage. (3) Due to approval problems in the operation of shaving, the manufacturing team exchanged the current oil that time (integral oil plus chlorinated paraffin – usually used in shaving process) for new oil (soluble oil – called FLUCOR 405e) with thirty percent of concentration and seventy percent of water. There was no follow up for all costs involved and performance in the operation that could ensure that the usage of the new oil was advantageous for the company. (4) The facilitators were EHS department (Environment Health and Safety), Lubrication department, and Manufacturing department. As internal clients two areas of the company were considered the main departments with possible benefits, Manufacturing and Management tools. (5) Manager EHS Department ...
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...Expert system for the definition of the cutting parameters and machining strategies 1 L.Zaquini1, J.Charpy1, J-P. Bendit2, T.Voumard3, P-E Mathez3, L. Béguelin3 HE-ARC-Ingénierie LMO (Laboratoire de Machines-Outils), University of Applied Science, Le Locle, Switzerland, 2 Jurasoft SA, Porrentruy, Switzerland, 3 Haute Ecole ARC – Software Engineering, University of Applied Science, St-Imier, Switzerland, Switzerland, Abstract The definition of the cutting parameters (Vc, fz, ae, ap), and the definition of the machining strategies or the strategies to engage the tool in the material and to start the cutting process, are usually requested by the CAM systems as input information. These data are usually strongly influenced by the consolidated experience of the operators, by the specific previous similar machining cases and by several other factors depending on the machining practices. In a project, financed by the Swiss national organization for the industrial research, the authors have developed an expert system (ES) in order to get this information through software processes. The paper shows the structure of this expert system. The ES has been realized through the definition of ontology of components and elements of the machining. The ES includes a very large data base of cutting parameters, and is based on the establishment of rules for the competition between the machining strategies. The ES includes learning methods which are able to identify similar operations. The learning...
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...SEMINOR TOPIC ASSESSMENT ON EFFECT OF CUTTING FLUID ON MACHINING COURSE NAME GRADUATE SEMINOR COMPILED BY: TESFAYE KASSAHUN MSC/00017/03 SUBMITTED TO: Professor (Dr.) RANTAM UPPULA September, 2013 Abstract During machining operation, friction between workpiece-cutting tool and cutting tool-chip interfaces result high temperature on cutting tool. At such elevated temperature the cutting tool if not enough hot hard may lose their form or stability quickly, wear out rapidly, resulting in increased cutting forces, higher surface roughness, shorter tool life and lowers the dimensional sensitiveness of work material. Different methods have been reported to protect cutting tool from the generated heat during machining operations. The selection of coated cutting tools is an expensive alternative and generally it is a suitable approach for machining hard materials. Another alternative is to apply cutting fluids in machining operation. Cutting fluids used to provide lubrication and cooling effects between cutting tool and workpiece and cutting tool and chip during machining operation. As a result, important benefits would be achieved such longer tool life, easy chip flow and higher machining quality in the machining processes. The selection, method of application, storage and disposal of cutting fluids should be carefully carried out to obtain optimum result in machining processes. Metal cutting fluids change the performance of machining operations because of their lubrication, cooling,...
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...here was achieved without a chamfer machining process High Speed Precision Edge and Surface Finishing for Rotating Components INDEX TERMS: Deburring Edge Contour Isotropic surfacing Non-traditional Grinding Non-traditional Machining Super-Polishing Surface Finishing Loose Abrasive Edge Finishing Super-Finishing Turbo-Abrasive T U R BO - F I N I S H CORPORATION 25 Williamsville Road Barre MA 01005 Dr. Michael Massarsky President Phone: 978-355-9070 Fax: 978-355-2917 Email: Michael@turbofinish.com AFTER TURBO-FINISH BEFORE TURBO-FINISH This close up photo shows details on disk features and geometries prior to TAM Process- NOTE: Original sharp edge condition (this edge not modified by chamfer machining) NOTE: prior to TurboFinish processing surfaces exhibit positive skew and nonisotropic surface characteristics Tu r b o - F i n i s h C o r p o r a t i o n T E S T N o . 100906A T E S T D A T E: 2 0 O c t 0 6 TURBO-FINISH EDGE AND S U R FAC E T E S T PAGE 2 TURBO[TURBOTURBO-FINISH [TURBO-ABRASIVE MACHINING] is a loose abrasive machining method that can deburr and produce edge contour effects very rapidly. The method is especially useful for the final machining and finishing of larger complex rotating components. These types of parts often are not good candidates for other mass media finishing techniques and until now have required very tedious and expensive manual deburring. The Turbo-Abrasive Machining process can automate...
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...Reduction of Wrinkling Defect in Deep Drawing Process Abstract. The aim of this experiment is to obtain the best parameters for reducing wrinkle defect during deep drawing process. Deep drawing is a sheet metal forming process where a punch is utilized to force a flat sheet metal to flow into the gap between the punch and die surfaces. Due to that, the sheet metal will deformed into the desired shape. Some of the most common outcomes in deep drawing process are tearing and wrinkling or the formation of uneven height at the top rim of a drawn part due to the material anisotropy. Wrinkling as become a serious obstacle to forming quality and part functions and finally results in scraps. This defects are caused due to change in parameters like blank holder force, Die radius, punch radius, blank diameter, friction, and blank thickness. This project involves the experimental studies of the die design to investigate the formability of sheet metal. From the data documentation, the result were concluded to determine the effect of different parameters on wrinkling phenomenon during sheet metal forming process. Keywords: deep drawing, wrinkling defect, sheet metal, drawing punch, drawing die 1. Introduction In this experiment, 20 tonnage deep drawing machine was used to draw a sheet metal of 1mm thickness to produce a cup of diameter 50 mm. At first, sheet metal was cut into the required shape and placed on the die. Punch is fixed on the top of machine which give compressive force on the...
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...Beck’s Capacity Beck’s Capacity Name Candidate for Master of Business Administration May 6, 2013 Dr. Alvin Pexico Beck’s Capacity Beck Manufacturing has 5 Operational work stations. They are Milling, Grinding, Boring, Drilling and Assembly. The one work station that can easily be adjusted, according to the engineering department is the assembly station. The Milling station has 5 machines that can produce 2 pieces per minute. The Grinding department has 7 machines can produce 3 pieces per minute. The Boring department can produce 1 piece per minute. The Drilling department has 6 machines that can produce 2.5 pieces per minute. The following table shows each department and the total capacity per hour of each department. Table 1. |Machine Center |Capacity |pieces per hour | |Milling |(5 machines)(2 Pieces/min)(60min/hour)/(16 hours/day) = |37.5 p/hr | |Grinding |(7mach)(3 p/min)(60 min/hr)/(16 hr/day) = |78.75 p/hr | |Boring |(3 mach)(1 p/min)(60 min/hr) / (16 hr/day) = |11.25 p/hr | |Drilling |(6 mach)(2.5 p/min)(60 min/hr)/(16 hr/day) = ...
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