Sharif Digital Repository

Titanium alloys, in particular Ti6Al4V, are increasingly used recently due to high strength-to-weight ratio, biocompatibility and robust mechanical-properties at high temperatures. However, Ti6Al4V have poor machinability because of their poor thermal conductivity and high reactivity. Usually in conventional grinding (CG) of these alloys, surface burning is unavoidable. Ultrasonic assisted grinding (UAG) is an efficient method for overcoming the poor machinability of such materials. In this research, effect of imposed vibration on grinding of Ti6Al4V is studied. Obtained results show forces and surface roughness are reduced 18% and 12% by UAG comparing to CG respectively. It also results in... 

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... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, a single degree of freedom model of orthogonal turning process is used to set up the delay differential equation of motion with considering the tool wear effect as a contact force between the workpiece and tool flank surfaces. Sinusoidal spindle speed variations with different frequencies around the mean speed are modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. Results of the stability analysis and the... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, two control strategies are developed to suppress chatter vibration in the turning process including a worn tool. In the first stage, a sinusoidal spindle speed variation around the mean speed is modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. In the second stage, to improve the response of the system which is associated with small ripples under the steady state condition, an adaptive controller is designed. In... 

LM13 alloy is widely used in piston industry, due to its low coefficient of thermal expansion, excellent castability and hot tear resistance. In this research effect of casting process on wear behavior of LM13 alloy was investigated. First, samples were produced using two casting processes and heat treated. Then wear behavior of these samples under dry sliding condition was examined. Results of hardness and strength tests indicated that squeeze cast specimens exhibited higher mechanical properties. Wear experiment results showed that in both squeeze and gravity cast specimens, amount of weight loss increases with increase in sliding distance which is accompanied by reduction in wear rate and... 

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The... 

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... 

Chatter suppression is of great importance for achieving high precision and surface quality in machining processes. A single degree of freedom model of orthogonal turning process is used to set up the nonlinear delay differential equation of motion. Tool wear effect is considered as the contact force between the workpiece and tool flank surfaces. Uncertainties in parameters of dynamic model and machining conditions are included in the model. An adaptive control strategy is applied for chatter suppression in cutting process. The force provided by a piezoactuator is the control input of the system. Results of stability analysis and adaptive control for two distinct cases of sharp and worn... 

Chatter suppression is of great importance for achieving high precision and surface quality in machining processes. A single degree of freedom model of orthogonal turning process is used to set up the nonlinear delay differential equation of motion. Tool wear effect is considered as the contact force between the workpiece and tool flank surfaces. Uncertainties in parameters of dynamic model and machining conditions are included in the model. An adaptive control strategy is applied for chatter suppression in cutting process. The force provided by a piezoactuator is the control input of the system. Results of stability analysis and adaptive control for two distinct cases of sharp and worn...