Sharif Digital Repository

The application of sensor system is becoming more commonplace in improving productivity and reliability. Although measuring force signal have been widely used for monitoring of metal machining process that their application to stone cutting has not been well investigated. In this paper, the effect of machining parameter on force signal and tool wear was investigated. The result indicate that increasing of the depth of cut and spindle speed will increase the force and tool wear while increasing feed rate will increase force and decrease tool wear  

Different real-world processes can be described by a linear model parameterised with respect to the processoperating point, as an uncertain parameter. The family of transport processes with long memory is a kind of these processeswhich are characterised by the parameterised time-fractional diffusion equations. This study proposes a generalised isodamping feature for achieving the phase margin invariance regardless of the uncertain parameter variations in control of timefractional diffusion processes. Also, the study suggests an analytical method to tune stabilising fractional-order proportional-integral/proportional-derivative controllers for adjusting a desired value for the phase margin at... 

This paper presents an investigation of the effects of tool rake angle and nose radius on the surface quality of ultraprecision diamond-turned porous silicon. The results showed that as rake angle decreases, the high-stress field induced by the tool edge increases, causing microcracks to propagate extensively near the pore walls. As a result, the ductile-machined areas shrank under a negative tool rake angle. On the other hand, brittle fracture occurred around pores released cutting pressure significantly. These trends of rake angle effects are distinctly different from those in the cutting of non-porous silicon. Finite element simulation of stress in the cutting area agreed with the... 

In this paper, a new relation is introduced that simplifies the determination of the Muskhelishvili's potential function in plane contact problems. The relation is Φ (z) = 1 / 2 [p (z) - i q (z)], which is correct for all uncoupled contact problems. The new relation is proved in a mathematical way and utilized to obtain the potential function in several contact problems. A complete agreement has been observed between our results and the potential functions that have been obtained from complicated methods in the past. Utilization of the new relation simplifies the solution of contact problems and analytical calculation of the stress and displacement fields, which may lead to the design of... 

In this paper, bifurcation analysis is performed for the nonlinear milling process under sub-harmonic resonance and regenerative chatter, with tool wear and process damping effects. Multiple-scales approach is used to construct analytical approximate solutions for non-autonomous parametrically excited equations of the system with time delay terms. The new bifurcation parameters are the detuning parameter (deviation of the tooth passing frequency from three times of the chatter frequency), damping ratio (affected by process damping) and tool wear width. Jump phenomenon and multi-values responses are observed in the first order solution under sub-harmonic resonance condition. Periodic,... 

Generally in the drilling of modern aviation materials such as nickel and titanium base super alloys, problems frequently occur in terms of burr formation at the cutter exit, tool stress, high heat generation on tool surface as well as low process reliability. A recent and promising method to overcome these technological constraints is the use of ultrasonic assistance, where high-frequency and low-amplitude vibrations are superimposed on the movement of cutting tools. This paper presents the design of an ultrasonically vibrated tool holder and the experimental investigation of ultrasonically assisted drilling of Inconel 738-LC. The circularity, cylindricity, surface roughness and hole... 

Free, forced, and self-excited vibrations are the three main types of machine tool vibrations. Self-excited vibration is the most important type of destructive vibration in machining. The most important factor in increasing the chipping rate, stability, and tool life is decreasing this type of destructive vibration. In this paper, we aim to introduce a method to control the self-excited vibrations by the means of the combining a vibration absorber as a passive controlling method and a classical active controller such as PID or compensator or the other classical methods. Utilizing the SIMULINK toolbox of MATLAB software, first, we designed and added the vibration absorber to the model... 

Ultrasonic-assisted machining is an advanced method which could improve the process of machining. Besides, simulation modeling process is a method to help the researchers analyze different aspects of the process with more details in a shorter time. Simulation of ultrasonic-assisted machining is also a field of research that is of interest to researchers working in the field of machining processes. In recent years, a variety of papers have been published where cutting forces, chip formation, tool wear and temperature, and microstructure changes were simulated. That being the case, a review paper is required to represent the advances implemented by researchers in the simulation of... 

The process of laser assisted machining (LAM) of metal matrix composites (MMC) is experimentally studied. The effects of process parameters (cutting speed, feed rate and depth of cut), laser parameters (laser power, laser frequency and laser beam angle), and the percentage of reinforcing particles on the tool wear and the surface roughness are investigated. Furthermore, the effects of the mentioned parameters on the built-up edge (BUE), chip shape, and workpiece temperature are explored. The experiments were performed using uncoated tungsten carbide and PCD tools under dry conditions. In order to analyze the sensitivity of the process parameters, the Plackett-Burman method was used for... 

This paper presents an investigation of the effects of tool rake angle and nose radius on the surface quality of ultraprecision diamond-turned porous silicon. The results showed that as rake angle decreases, the high-stress field induced by the tool edge increases, causing microcracks to propagate extensively near the pore walls. As a result, the ductile-machined areas shrank under a negative tool rake angle. On the other hand, brittle fracture occurred around pores released cutting pressure significantly. These trends of rake angle effects are distinctly different from those in the cutting of non-porous silicon. Finite element simulation of stress in the cutting area agreed with the... 

Inaccuracies in workpiece location lead to errors in position and orientation of machined features on the workpiece, and strongly affect the assemblability and the quality of the product. The accurate positioning of workpiece on a fixture is influenced by rigid body displacements and rotations of the workpiece due to several errors (e.g. geometric radial and position errors in locators and manufacturing tolerances of the workpiece). In this paper, an efficient approach is introduced for analysis and compensation errors in the workpiece-fixture-cutting tool system. A new mathematical formulation of workpiece-fixture modelling is proposed to establish the relationship between the locating... 

Two-dimensional elastic contact problem of an asymmetrical rounded apex wedge with a half plane is considered and an analytical solution is presented for vertical and horizontal external loading in the presence of coulomb friction. The pressure and shear distribution functions are found in closed form under partial slip condition. Further by utilizing a new relation Muskhelishvili's potential function is obtained and results are analyzed. Designing better cutting tools, selecting fretting fatigue test pads and deeper lap joint analyzing are several practical applications of the outcomes  

In this paper, the fractionalized differentiating method is implemented to reduce commensurate fractional order models complexity. The prominent properties of this method are its simplicity and guarantee of preserving the stability of a specific class of fractional order models in their reduced counterparts. The presented reduction method is employed in simplifying complicated fractional order controllers to a fractional order PID (FOPID) controller and proposing tuning rules for its parameters adjustment. Finally, the efficiency of the FOPID tuning rule obtained based on the proposed reduction method is shown in the temperature control of a cutting process  

In this research work, an ultrasonic assisted drilling system is employed to apply both rotation and vibration to drill bits. The transducer horn transfers power very efficiently and changes tools effortlessly. The setup used to conduct drilling tests is Inconel 738LC with depth-to-diameter ratios from 2 to 10 by conventional drilling (CD), ultrasonic assisted drilling (UAD), and electro discharge drilling (EDD). The effects of ultrasonic vibration amplitude, spindle speed, and number of steps to drill each hole on machining force and surface roughness in UAD are investigated. The results demonstrate not only a significant improvement in tool life (by applying ultrasonic vibration to the... 

Laser assisted machining (LAM) is a promising technology for machining hard to cut materials. In most experimental cases, LAM is undergone in two stages; first, the temperature at the material removal point (Tmr) is tuned by adjusting laser parameters and next, the cutting tool is engaged. Introduction of highly localized heat energy to the workpiece makes the modeling of this process very complicated. Hence, an analytical model for the first stage of the process - rather than multiple experiments or FE modelling - would be beneficial. This article presents an analytical solution to the transient, temperature field in a rotating cylinder subject to a localized laser heat source. The... 

Ultra-high precision machining is proposed by externally actuating the work piece in linear motions in the X-Y plane and linear motion in the Z-axis. To solve the problems in the machining process such as nonlinearity and low repeatability positioning accuracy of machining tools in a larger scale, a novel platform for cutting tools in micro machining based on electrostatic linear micromotors and piezoelectric stack actuator system is presented. © 2017 IEEE  

In the present work, friction stir welding technique was applied on 2 mm thick ferrite-martensite DP700 steel sheets at rotational speeds of 600, 800 and 1000 rpm. The microstructure and mechanical properties of the welds were evaluated. It was found that Zener-Hollomon parameter decreased with increasing rotational speed that leads to grain coarsening in the stir zone. It was also found that increment of rotational speed increased softening phenomenon in sub-critical heat affected zone. The results also showed that the presence of WC particles in the stir zone, which was due to the tool wear, as well as formation of a soft ferrite band degrade the tensile properties at rotational speed of... 

In the machining processes, vibration suppression is crucial in order to achieve the high precision as well as high-quality surface and increase of the material removal rate. In this paper, an adaptive sliding mode control approach is presented to supress the chattering phenomenon in the boring process in the presence of model uncertainties and unmodeled dynamics. The boring bar is modeled as a cantilever Euler–Bernoulli beam, which is actuated by a piezo-actuator located at the bar's end. As a more realistic model, the cutting tool is modeled as an added mass at the bar's end. In order to derive the equations of motion, mode summation method with inclusion the first three modes of vibration... 

Chatter suppression is an important topic in any type of machining process. In this paper, orthogonal cutting process is modeled as a single degree of freedom dynamic system. A nonlinear delay differential equation is presented that models flank wear of the tool. Uncertainties in cutting velocity, tool wear size and parameters of the dynamic model are included in the model of cutting process. The force provided by a piezo-actuator is taken as the control input of the system. A sliding mode control scheme is used and an effective control law is derived which suppresses the chatter vibration. Results for two distinct cases of a sharp tool and a worn tool are presented and compared which shows...