editorial board vol. 14 no. 5 may 2015 contents technical papers · 2015. 6. 5. · 12 pages] rec....

Vol. 14 No. 5 May 2015

Contents

Technical Papers

• Optimization techniques in turning- A Review by PuneetNP,SrinivasaPaiPandGrynalD’Mello 3

• Optimization of machining parameters in hard turningprocess using Taguchi orthogonal array by Awale AS andInamdarKH 22

Photo Gallery: Vintage Machine: OldTheodolite 31

Calendar of Events 32

Bibliography: HardTurning 35

Manufacturing Technology Abstracts 38

Patent Abstracts: HardTurning 52

IPR News: Cyber threats must be addressed withouttrade barriers, says us commerce secretarypennypritzker 58

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Editorial Advisory CommitteeProf.SMohanPJMohanRamVKSubramanya

ChairmanSSatishKumar

Technical Paper Review PanelSUshaNBalashanmugamDr.CKSrinivasaKKRajagopalBRMohanraj

EditorMallikarjunG

Editorial Assistants

ShashiRekhaNMalaRC

Events

Manufacturing Technology Today, May 201532

INDIA 07 Jun 2015IRAJ-Intl Research Conference on Computer Science & Mechanical Engineering (IRCCSME)Hotel Siddhartha Inn, 90, Central Avenue,Near Agrasen Square, Gandhibagh, Nagpur,MaharashtraContact: IRAJ,Tel:+91-8339923308 E-mail:[email protected]://iraj.in/Conference/2015/Nagpur.php

07 Jun 2015IRAJ-Intl Conference on Mechanical & Production Engineering (ICMPE)Hotel City Plaza, 17 S.C.O. 96-97, Near I.S.B.T. inMainShoppingCentre,Sector17-C,ChandigarhContact: IRAJ,Tel:+918598978459 E-mail:[email protected]:http://iraj.in/Conference/2015

07 Jun 2015IRAJ-Intl Conf on Electrical, Electronics, Computer Science & Mechanical Engg (ICEECSME)HotelRainbow,10,CVRamanRoad,SriramColony,Alwarpet,Chennai,TamilNadu600018Contact: IRAJ,Tel:+91-9040050453 E-mail:[email protected]:http://iraj.in/Conference/2015

14 Jun 2015IRAJ-Intl Conf on Electrical, Electronics, Computer Science & Mechanical Engg (ICEECSME)Hotel Trinity Isle, # 139, Subedar Chatram Road,SwastikCircle,Sheshadripuram,BangaloreContact: IRAJ,Tel:+918598978459 E-mail:[email protected]:http://iraj.in/Conference/2015

14 Jun 2015IRAJ-Intl Conf on Civil, Mechanical, Biological and Medical Engineering (ICMBME - 2015)HotelRainbow,10,CVRamanRoad,SriramColony,Alwarpet,Chennai,TamilNadu600018Contact: IRAJ,Tel:+918598978459 E-mail:[email protected]:http://www.iraj.in/Conference/2015

14 Jun 2015IRAJ-Intl Conf on Electrical, Electronics, Computer

Science & Mechanical Engg (ICEECSME)HotelRainbow,10,CVRamanRoad,SriramColony,Alwarpet,Chennai,TamilNadu600018Contact: IRAJ,Tel:+918598978459 E-mail:[email protected]:http://www.iraj.in/Conference/2015

14 Jun 2015IRAJ-Intl Conf on Computer Science and Mechanical Engineering (ICCSME)HOTEL Palacio de Goa, A Unit Of Sheikh HassonHotels,Dr.GamaPintoRoad,Panjim-GoaContact: IRAJ,Tel:+91-7735082562 E-mail:[email protected]:http://www.iraj.in/Conference/2015

14 Jun 2015IRAJ-Intl Conf on Computer Science and Mechanical Engineering (ICCSME)Hotel Lindsay, 8A & 8B, Lindsay Street, Kolkata,WestBengal700087Contact: IRAJ,Tel:+91-7735082562 E-mail:[email protected]:http://iraj.in/Conference/2015

14 Jun 2015IRAJ-Intl Conf on Recent Development in Mechanical and Industrial Engg (ICRDMIE 2015)HotelGrandRidge,KorramenuguntaTirupati,APContact: IRAJ,Tel:+91-7735082562E-mail:[email protected]:http://iraj.in/Conference/2015

21 Jun 2015IRAJ-Intl Research Conference on Computer Science & Mechanical Engineering (IRCCSME)Hotel Trinity Isle, # 139, Subedar Chatram Road,SwastikCircle,Sheshadripuram,BangaloreContact: IRAJ,Tel:+91-8339923308 E-mail:[email protected]:http://iraj.in/Conference/2015/Bangalore

21 Jun 2015IRAJ-International Conference on Computer Science and Mechanical Engineering (ICCSME)Hampshire Plaza Hotel, 679 & 80, Lakdikapul,HyderabadContact: IRAJ,Tel:+91-8339923308E-mail:[email protected]:http://www.iraj.in/Conference/2015

Events

Manufacturing Technology Today, May 2015 33

INTERNATIONAL 21 Jun 2015IRAJ-Intl Conf on Research in Electrical, Electronics & Mechanical Engg (ICREEME)PatelNagar,Niranjanpur,Opp.TelephoneExchange,(Near Lal Pul), Saharanpur road, DehradunUttarakhandContact: IRAJ,Tel:+91-9040050453 E-mail:[email protected]:http://iraj.in/Conference/2015

21 Jun 2015IRAJ-Intl Conf on Computer Science & Mechanical Engineering (ICCSME)HotelRainbow,10,CVRamanRoad,SriramColony,Alwarpet,Chennai,TamilNadu600018Contact: IRAJ,Tel:+918598978459 E-mail:[email protected]:http://www.iraj.in/Conference/2015

28 Jun 2015IRAJ-Intl Conf on Electrical, Electronics Computer Science, Management & Mechanical Engineering (ICEECSMME)HotelGrandplaza,(AUnitofM/S.M.S.GuestLineServices), 5-9-88/A/1, Beside Haj House, Opp.PublicGardens,Nampally,Hyderabad-01A.PContact: IRAJ,Tel:+91-9040050453 E-mail:[email protected]:http://iraj.in/Conference/2015

28 Jun 2015IRAJ-International Conference on Mechanical & Production Engineering (ICMPE)HotelPresidency,KCMMatherRd,AyyappankavuErnakulam,KLContact: IRAJ,Tel:+918598978459 E-mail:[email protected]:http://iraj.in/Conference/2015/COCHIN

28 Jun 2015IRAJ-International Conference on Computer Science & Mechanical Engineering (ICCSME)Hotel Trinity Isle, # 139, Subedar Chatram Road,SwastikCircle,Sheshadripuram,BangaloreContact: IRAJTel:+918598978459 E-mail:[email protected]:http://iraj.in/Conference/2015/Bangalore/ICCSME/contactus.php

09 - 12 Jun 2015International Machine Tools ExhibitionPoznan International Fair Grounds, GlogowskaStreet14,60734Poznan,GreaterPoland,PolandContact: PoznanInternationalFairLtd.,ul.Glogowska1460734Poznan,PolandTel:+48(0)618692000Fax:+48(0)618692999E-mail:[email protected]:http://www.tradefairdates.com

09 - 12 Jun 2015Trade fair for metallurgy, metal processing and foundry technologyPoznan International Fair Grounds, GlogowskaStreet14,60734Poznan,GreaterPoland,PolandContact: Poznan International Fair Ltd., ul. Glogowska 14,60734Poznan,PolandTel:+48(0)618692000Fax:+48(0)618692999E-mail:[email protected]:http://www.tradefairdates.com

10 - 13 Jun 2015Intl trade fair for machinery, equipment, materials and services for the manufacturing industryGrandCityExpo,JlGubengPojokDalamSurabayaSurabaya,EastJava,IndonesiaContact: PTPamerindoIndonesia,DeutscheBankBuilding,13thFloor,Jl.ImamBonjol80,Jakarta,IndonesiaTel:+62(0)213162001Fax:+62(0)2131619812E-mail:[email protected]:http://www.tradefairdates.com

10 - 13 Jun 2015International trade fair for machine tools, metalworking and allied industriesGrandCityExpo,JlGubengPojokDalamSurabayaSurabaya,EastJava,IndonesiaContact: PTPamerindoIndonesia,DeutscheBankBuilding,13thFloor,Jl.ImamBonjol8010310Jakarta,IndonesiaTel:+62(0)213162001Fax:+62(0)2131619812E-mail:[email protected]:http://www.tradefairdates.com

14 Jun 2015IIER First Intl Conf on Mechanical and Industrial Engineering (ICMIE-2015)Bayview Hotel Singapore, 30 Bencoolen Street,Singapore

Events


Contact: TheIIER,Tel:+85259198048E-mail:[email protected]:http://theiier.org/contactus.php

14 - 15 Jun 20152015 The 5th Intl Conf on Mechanics, Simulation and Control (ICMSC 2015)SaintPetersburg,RussianFederationContact: SCIEI,Tel:+1-562-606-1057E-mail:[email protected]:http://www.icmsc.org/

14 - 15 Jun 20152015 Intl Conf on Smart Manufacturing Technologies (ICSMT 2015)SaintPetersburg,RussianFederationContact: SCIEI,Tel:+1-562-606-1057Web:http://www.icsmt.org/program.html

15 - 16 Jun 2015Intl Conf on Aeronautical, Robotics and Manufacturing Engineering (ARME'2015)Arnoma Hotel Bangkok, 99 Ratchadamri Road,Pathumwan,Bangkok10330,ThailandContact: EAMAE,Tel:+918699350603E-mail:[email protected]:http://arme.eamae.org/index.php

16 - 20 Jun 2015Trade fair for casting productsMesse Düsseldorf, Stockumer Höfe, 40474Düsseldorf,NorthRhine-Westphalia,GermanyContact: MesseDüsseldorfGmbH,StockumerKirchstr.6140474Düsseldorf,GermanyTel:+49(0)211456001Fax:+49(0)2114560668E-mail:[email protected]:http://www.tradefairdates.com

16 - 20 Jun 2015Trade fair for thermal processesMesse Düsseldorf, Stockumer Höfe, 40474Düsseldorf,NorthRhine-Westphalia,GermanyContact: MesseDüsseldorfGmbH, Stockumer Kirchstr. 61,40474Düsseldorf,GermanyTel:+49(0)211456001Fax:+49(0)2114560668E-mail:[email protected]:http://www.tradefairdates.com

16 - 20 Jun 2015Metallurgy trade fair

Messe Düsseldorf, Stockumer Höfe, 40474Düsseldorf,NorthRhine-Westphalia,GermanyContact: MesseDüsseldorfGmbH,StockumerKirchstr.6140474Düsseldorf,GermanyTel:+49(0)211456001Fax:+49(0)2114560668E-mail:[email protected]:http://www.tradefairdates.com

24 - 27 Jun 2015Trade fair for assembly technologyBITEC - Bangkok Intl Trade & Exhibition Center,Bangna-TradRoad,BangNa,Bangkok,ThailandContact: Reed Tradex, 100/68-69 North Sathon Road,Bangkok,ThailandTel:+66(0)26867299 Fax:+66(0)26867288E-mail:[email protected]:http://www.tradefairdates.com

24 - 27 Jun 2015Thailand's largest manufacturing and supporting industries eventBITEC - Bangkok International Trade& ExhibitionCenter, Bangna-Trad Road, Bang Na, Bangkok,ThailandContact: ReedTradex,100/68-69NorthSathonRoad,10500Bangkok,ThailandTel:+66(0)26867299 Fax:+66(0)26867288E-mail:[email protected]:http://www.tradefairdates.com

24 - 27 Jun 2015Trade fair for automotive parts manufacturingBITEC - Bangkok Intl Trade & Exhibition Center,Bangna-TradRoad,BangNa,Bangkok,ThailandContact: ReedTradex,100/68-69NorthSathonRoad,10500Bangkok,ThailandTel:+66(0)26867299 Fax:+66(0)26867288E-mail:[email protected]:http://www.tradefairdates.com

27 - 30 Jun 20152015 Intl Conf on Advances in Engineering Materials (ICAEM 2015)JUPITER Tismana Club Hotel on the romanianborderoftheBlackSea,RomaniaContact: IACSIT,Tel:+1-518-478-2659E-mail:[email protected]:http://www.icaem.org/index.htm◘

Bibliography


SELECT BIBLIOGRAPHY: HARD TURNING

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2. Multi-physics modeling and simulations of surface microstructure alteration in Hard Turning

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5. Nano structural evolution of hard turning layers in response to insert geometry, cutting parameters and material microstructure

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6. Measurement of Transient Tool-Internal Temperature Fields During Hard Turning by Insert-Embedded Thin Film Sensors

Li, Xiaochun; Ehmann, Kornel [Journal of Manufacturing Science and Engineering, V 134, N 6, 2012, Starting page 061004, 9 Pages] Rec. No: 109008

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11. Investigations on hard turning of hard chrome plated surfaces.

Mohandas, KN; Balashanmugam, N; Ramesh,CS;Shashikumar,PV [3rd Int. & 24th AIMTDR Conf, Visakhapatnam, Dec 2010, Vol. 1, 2010, Starting page 75, 5 Pages]

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L; Rigal, J-F [J of Materials Processing Tech, V 209, N 2, 2009, Starting page 1092, 13 Pages] Rec. No: 106791

13. Surface finish on hardened bearing steel parts produced by superhard and abrasive tools.

Grzesik,W;Rech,J;Wanat,T [Int J of Machine Tools & Manufacture, V 47, N 2, 2007, Starting page 255, 08 Pages] Rec. No: 106744

14. Capability of high pressure cooling in the turning of surface hardened piston rods.

Kramar, D; Krajnik, P; Kopac, J [J of Materials Processing Tech, V 210, N 2, 2010, Starting page 212, 07 Pages] Rec. No: 106505

15. Hard turning in continuous and interrupted cut with PCBN and whisker-reinforced cutting tools.

Oliveria, A J; Diniz, A E; Ursolino, D J [J of Materials Processing Tech, V 209, N 12-13, 2009, Starting page 5262, 09 Pages] Rec. No: 106387

16. Effect of tool edge geometry and cutting conditions on experimental and simulated chip morphology in orthogonal hard turning of 100Cr6 steel.

Kountanya,R;Al-zkeri,I;Altan,T [J of Materials Processing Tech, V 209, N 11, 2009, Starting page 5068, 09 Pages] Rec. No: 106364

17. Optimization of process parameter of residual stresses for hard turned surfaces.

Xueping, Z; Erwei, G; Liu, R [J of Materials Processing Tech, V 209, N 09, 2009, Starting page 4286, 06 Pages] Rec. No: 106248

18. Use of TiAlN coated carbide tool when finish machining hardened stainless steel.

Noordin,MY;Tang,YC;Kurniawan,D [Int J of Precision Technology, V 1, N 1, 2007, Starting page 21, 9 Pages] Rec. No: 105169

Bibliography


19. Hard turning of stainless steel using wiper coated carbide tool.

Noordin,MY; Kurniawan,D; Sharif, S [Int J of Precision Technology, V 1, N 1, 2007, Starting page 75, 10 Pages] Rec. No: 105163

20. Investigations on hard turning with minimal multiple jet of cutting fluid.

RamKumar, P; LeoDevWins, K;Ganandurai,RR;Varadarajan,AS [Proc Int Conf on Frontiers in Design & Mfg Engg (ICDM-08), 2008, Starting page 188, 4 Pages] Rec. No: 105127

21. Hard turning vis a vis cylindrical grinding. Shivakumar, MR [Industrial Products Finder

Annual, V 37, N 2B, 2009, Starting page 593, 3 Pages] Rec. No: 105123

22. Effect of multiple pass cutting on surface integrity when hard turning of AISI D2 cold work tool steel.

Kamely, MA; Noordin, MY; Venkatesh, VC [Int J of Precision Technology, V 1, N 1, 2007, Starting page 97, 9 Pages] Rec. No: 105121

23. Novel hybrid predictive model and validation of unique hook-shaped residual stress profiles in hard turning.

Guo, YB; Anurag, S; Jawahir, IS [CIRP Annals, V 58, N 1, 2009, Starting page 81, 4 Pages] Rec. No: 105049

24. Optimal parametric combination for achieving the desired surface roughness in finish hard turning of AISI 52100 steel.

Rao, SG; Rao, NA [Competitive Mfg- Proc.of 2nd Intl. & 23rd AIMTDR Conf., V 2, 2008, Starting page 861, 6 Pages] Rec. No: 104963

25. Effect of cutting conditions on forces in finish hard turning of MDN300 steel.

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26. Effect of cutting parameters on surface roughness and tool wear in hard turning.

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27. Hard turning with variable micro-geometry PcBN tools.

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28. Icing hard turning. Vernyi, B [American Machinist, V 150,

N 11, 2006, Starting page 38, 3 Pages] Rec. No: 103198

29. Making easy work of hard turning. Gillespie,LK [Cutting Tool Engg, V 58, N 6, 2006,

Starting page 18, 2 Pages] Rec. No: 10310830. Performance improvement of hard turning

with solid lubricants. Dilbag, S; Rao, PV [AIMTDR Conference

Proceedings (22nd)- Mfg Technologies & Sys, 2006, Starting page 575, 6 Pages] Rec. No: 102559

31. Surface finish generated in hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts.

Grzesik, W; Wanat, T [Int J of Machine Tools & Manufacture, V 46, N 15, 2006, Starting page 1988, 8 Pages] Rec. No: 102509

32. Optimization of surface roughness in hard turning AISI D2 steel using ceramic inserts.

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33. High-power diode laser assisted hard turning of AISI D2 tool steel.

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34. Effects of edge preparation and feed when hard turning a hot work die steel with polycrystalline cubic boron nitride tools.

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35. Modelling of material side flow in hard turning.

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36. Modeling the progression of flank wear on uncoated and ceramic-coated polycrystalline cubic boron nitride tools in hard turning.

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37. White layer formation in hard turning of H13 tool steel at high cutting speeds using CBN tooling.

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38. Advanced tool edge geometry for high precision hard turning.

Klocke, F; Kratz, H [CIRP Annals, V 54, N 1, 2005, Starting page 47, 4 Pages] Rec. No: 101158

39. On predicting softening effects in hard turned surfaces-- Pt. 2: finite element modeling and verification.

Bibliography


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40. On predicting softening effects in hard turned surfaces - Pt. I: Construction of material softening model.

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41. Modeling of cutting forces under hard turning conditions considering tool wear effect.

Huang, Y; Liang, SY [J of Manufacturing Sci & Engg: ASME Trans, V 127, N 2, 2005, Starting page 262, 9 Pages] Rec. No: 100957

42. Tool wear and chip formation during hard turning with self-propelled rotary tools.

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43. Influences of the cutting and fluid application parameters on the surface roughness in hard turning with minimum fluid application.

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44. Decomposition of thermal and mechanical effects on microstructure and hardness of hard turned surfaces.

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45. Modeling of CBN tool flank wear progression in finish hard turning.

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46. Comparative study of hard turned and cylindrically ground white layers.

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47. Building on hard turning. Soroka, DP [American Machinist, V 148,

N 5, 2004, Starting page 56, 5 Pages] Rec. No: 99161

48. Model for surface roughness in ultraprecision hard turning.

Knuefermann, MMW [CIRP Annals, V 53, N 1, 2004, Starting page 99, 4 Pages] Rec. No: 98929

49. Development of a tool wear-monitoring system for hard turning.

Scheffer, C; Kratz, H; Heyns, PS; Klocke, F [Int J of Machine Tools & Manufacture, V 43, N 10, 2003, Starting page 973, 13 Pages] Rec. No: 98722

50. Surface integrity in finish hard turning of case-hardened steels.

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51. Influence of the microstructure of hardened tool steel workpiece on the wear of PCBN cutting tools.

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52. Influence of refrigeration / lubrication condition on SAE 52100 hardened steel turning at several cutting speeds.

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53. Cutting forces modeling considering the effect of tool thermal property - application to CBN hard turning.

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54. Tool-life and wear mechanisms of CBN tools in machining of Inconel 718.

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55. Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning.

Varadarajan, AS; Philip, PK; Ramamoorthy, B [Int J of Machine Tools & Manufacture, V 42, N 2, 2002, Starting page 193, 8 Pages] Rec. No: 97007

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& Engg:ASME Trans, V 124, N 2, 2002, Starting page 189, 11 Pages] Rec. No: 96514

57. Effect of tool wear on roughness in hard turning.

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58. Machining centre for hard turning and grinding.

Vetter, K [Industrial Diamond Review, V 62, N 1, 2002, Starting page 46, 3 Pages] Rec. No: 96378

59. Piezo tool actuator for precision turning of hardened shafts

Altintas, Y; Woronko, A [CIRP Annals, V 51, N 1, 2002, Starting page 303, 4 Pages] Rec. No: 96374 ◘

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

CASTING & FOUNDRY PRACTICE 39

COATING & FINISHING 39

ELECTRICALS & ELECTRONICS 40

FORMING 40

WARM FORMING 41

SHEET METAL WORKING 42

INDUSTRIAL ENGINEERING 45

MANUFACTURING INFORMATION TECHNOLOGY 46

JOINING & ASSEMBLY 46

LASERS 47

MACHINE ELEMENTS & MECHANISMS 48

MACHINE TOOLS 48

MACHINING 48

NON TRADITIONAL MACHINING 51

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

CASTING & FOUNDRY PRACTICE

110275 Alternative approach in ceramic shell investment casting of AZ91D magnesium alloy: In situ melting techniqueJafari,Hassan;Idris,MohdHasbullah;Ourdjini,Ali[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting 88, Pages 10] Inthis research, the possibility of ceramic shellinvestment casting of a magnesium alloy usingin situ melting technique was explored. AZ91Dgranules were charged into shell investmentmouldandinsitumeltedundervariousprocessingparameters including heating temperature,flux application, shell mould thickness andpermeability. Scanning electron microscopy,energy dispersive X-ray spectroscopy and X-raydiffraction techniques were used to characterisethecastsamples.Thermalanalysiswasemployedto further investigate the effect of mouldthickness on the solidification behaviour of themetal. It was found that mixing flux with thegranules not only reduced the temperature atwhich melting can be achieved, but it alsocontributed to produce castings withacceptable surface quality. The use of thinnermould provided higher solidification rate,which is believed to favour in situ meltingofthegranules.Itenabledmeltingofthegranulesat 650 °C, which in turn helped to suppress themould–metal reaction and produce castingswith good surface quality. Shell mouldpermeabilityshowednoinfluenceonsuppressingthe mould–metal reaction at 650 °C. (24 refs,13figs,2tables)(AA)

110276 Top side-pouring twin-roll caster for metals stripsWang,De;Zhou,Cheng[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 916, Pages 9] Threedifferentmetals (lead,Al–10(w%)CualloyandAA1050)werecastinto100mm-wide,2mm-thickstrips.Combinedwithbothexperimentalandnumericalresults,thesurfaceconditionsandmicrostructure of the strips were investigatedto reveal the formation of themelt-pool and itseffectsonthestrips.Theresultsshowthat,thetopside-pouring twin roll castinghas ability to applyto the production of different metal strips withvarious “productionwindows”. Rolling effectwasobservedonthestripsofLeadandAA1050,andthegrainswere deformed,while strips of Al–10(w%)

Cu alloy were mostly pressed together, withequiaxed crystalline in the microstructure.The steady state can be established easily andquickly, and the higher themelt-pool, the betterthe strip surface conditions. (16 refs, 11 figs,3tables)(AA)

COATING & FINISHING

110277 Microstructure and properties of laser cladding FeCrBSi composite powder coatings with higher Cr contentWang, Yibo; Zhao, Shusen; Gao, Wenyan; Zhou,Chunyang;Liu,Falan;Lin,Xuechun[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 899, Pages 7] FeCrBSialloypowderwithhigherCrcontentwasusedforlasercladdingby employing a 3 kW solid-state laser. Ni- andFe-basedalloypowders,whichweremoreresistanttocracking,wereaddedintoFeCrBSialloypowderwith higher Cr content to increase the ductilephases, lower thermal expansion coefficient, andreduce the crack sensitivityof the cladding layer.FeCrBSi alloy powder with higher Cr contentcombined Ni- and Fe-based alloy powder werecladdedonthesubstrates,whichyieldtwodifferentphases. The hard phases of the cladding layerweremainly composedof carbidephaseM23C6,andtheductilephaseswhichplayedalubricationfunction in the cladding layer were mainlycomposedofausteniteγ-Feandγ-Ni.Theductilephases increased by adding Ni- and Fe-basedalloy powder into FeCrBSi alloy powder withhigher Cr content, and the hard phases becamesparser relatively. Smooth cladding layers, whichwere free ofmacroscopic pores, cracks and voidbetween the adjacent tracks, were achieved.Therefore, the toughness of the cladding layerwas improved, and the crack tendency wasreduced. Three kinds of composite powderwereobtained.Thecompositionandmorphologyofthecladding layer were analyzed, and themicrohardness between the hard phases andthe ductile phases was compared. The averagemicrohardnesses of the three cladding layersvaried from HV0.2 760 to HV0.2 950. (15 refs,15figs,2tables)(AA)

110278 Vibration-assisted dry polishing of fused silica using a fixed-abrasive polisherLi, Yaguo; Wu, Yongbo; Zhou, Libo; Fujimoto,Masakazu[Int J of Machine Tools & Manufacture,

Abstracts


v 77, Feb 2014, Starting Page 93, Pages 10] Glass is a ubiquitous but essential material ineveryday life and industry. The most commonmethod for polishing glass involves the use offree abrasives. However, thismethod is basicallynon-deterministic and lacks efficiency. Therefore,vibrationhasbeenemployedtoaidfixed-abrasivepolishing in our research. It is found that thevibration can increase the material removal ratewhile maintain surface quality in fixed abrasivepolishing. Normalized Preston coefficients thatare the index of the polishing capability of acertainpolishingprocessconsiderably increase invibration-assistedpolishingprocess.Amathematicmodel is set up to interpret the increase inmaterial removal rate for vibration process.The modeled results show that the vibrationcan improve material removal by increasingvibrationamplitudeinverticaldirectionwhilethehorizontalvibrationcontributeslittletoincreasingmaterial removal rate, which agrees well withexperimentalresults.Asidefrommaterialremoval,surface morphology of polished glass was alsomodeled for both vibration and conventionalprocesses. Both experimented and simulatedmorphology evidence that the vibration someperiodic structure on polished surface. Thepossiblemechanismindryfixedabrasivepolishingwas also chemically analyzed and a probablemechanism is put forward to clarify thematerialremoval in dry fixed abrasive polishing. (30 refs,14figs,4tables)(AA)

ELECTRICALS & ELECTRONICS

110279 Characterization of electrically-assisted micro-rolling for surface texturing using embedded sensorNg, Man-Kwan; Fan, Zhaoyan; Gao, Robert X;SmithIII, Edward F; Cao, Jian [CIRP Annals, v 63, n 1, 2014, Starting Page 269, Pages 4] Electrically-assisted micro-rolling (EAmR) takes advantageof localized heating by loading current throughthe deformation zone to enhance the texturingcapability of Ti-6Al-4V and AA3003-H14.The challenge to achieve a desired deformationpattern is the lack of reliablemodels to capturethe often non-uniform mechanical and thermalbehaviors.Inthispaper,pressuredistributionsaremeasured by a custom-designed, tool-embeddedsensor. Further more, the effects of current ontexturing are first characterized using a coupledmechanical and thermal model. Comparisonbetween modeling and experimental resultsconfirmedtheeffectivenessofEAmRontexturingand the importance of multi-physics modeling.

(14refs,8figs,1table)(AA)

FORMING

110280 Numerical modelling of electrohydraulic free-forming and die-forming of DP590 steelHassannejadasl, Amir; Green, Daniel E;Golovashchenko, Sergey F; Samei, Javad; Maris,Chris[J of Manufacturing Processes, v 16, n 3, Aug 2014, Starting Page 391, Pages 14] Electrohydraulicforming (EHF) is a high energy rate formingprocessinwhichthestrainrateinthesheetmetalcan vary from 5 × 102 to 105 s−1 depending onvarious factors. Several mechanisms have beenreported to causean improvement in formabilityinEHFsuchasmaterialdeformationmechanisms,inertial effects and the dynamic impact of thesheetagainstthedie.EHFisacomplexhighspeedforming process and experimental work alone isnotsufficienttoproperlyunderstandthisprocess.To understand the variation of some influentialvariables in EHF, electrohydraulic die-forming(EHDF) and free-forming (EHFF) of DP590 dualphase steel were simulated in ABAQUS/Explicitby considering the fluid/structure interactions.Three-dimensional finite element simulationswere conducted by modelling the water withEulerianelementswithaviewtoinvestigatingtheeffectofreleasedenergyonthesheetdeformationprofile history, strain distribution, loading pathand damage accumulation type. The Johnson–Cook constitutive material model was usedto predict the sheet behaviour and theparameters in this model were calibratedbased on experimental test results availablefor DP590 at various strain rates. The Johnson–Cook phenomenological damage model wasalso used to predict the ductile failure (damageaccumulation) in both EHDF and EHFF. Predictedfinal strain values and damage accumulationtype showed good agreement with theexperimental observations. (49 refs, 20 figs,6tables)(AA)

110281 Twisting analysis of ultra-thin metallic sheetsPham,CH;Thuillier,S;Manach,PY[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 844, Pages 12] Twisting is one ofthedeformationmodeoccurringafterspringbackand characterized by a torsion of a part aroundthe axis aligned with its highest dimension.This phenomenon is experimentally difficultto highlight, because its occurrence has beenevidenced in the case of elongated parts, whenone of the part dimensions ismuch higher than

Abstracts


the others, usually of the order of the meter.This leads to complex set-ups and often toscattered experimental results. The aim of thiswork is to investigate the influence of the blankalignment relative to the tools on twistingmagnitude, in order to build a reliable databaseuseful for finite element validation. Firstly, adedicateddevicewasdesignedtodrawU-shapedrails of length 100 mm, made of ultra-thinmetallic sheets, in order to deal with small-sizeparts. Experiments were carried out for twoconfigurations, one with the sample alignedwith the tools and another onewith the sampleintentionallyslightlymisalignedwithregardtothetools. Accuracy of themeasurements is analyzedandreproducibilityoftheintensityoftwistingforboth configurations is presented, as well as therelationshipsbetweenspringbackofthesections,like opening of the U-shaped rail, and twisting.Parametersinfluencingtheoccurrenceoftwistingarediscussed.(23refs,17figs,3tables)(AA)

110282 Vaporizing foil actuator used for impulse forming and embossing of titanium and aluminum alloysVivek, A; Brune, RC; Hansen, SR; Daehn, GS[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 865, Pages 11] Electricallydriven rapid vaporization of thin conductors isknowntoproduceshort-durationpressurepulsesof highmagnitude. This impulse can be used forapplications such as high strain rate forming,shearing, collision welding, and springbackcalibration. Mechanical impulse was developedfromaluminumfoilsofvariousthicknesses,whichwere vaporized using a capacitor bank dischargewithamaximumchargingvoltageof8.6kV.Peakcurrentwasdeliveredontheorderof100kAwithrisetimesofabout12μs.Inthiswork,polyurethanewas used as a medium to transfer pressurefrom the aluminum foil vaporization zone to theworkpiece. Fundamental experiments, whereAA 3003-H14 aluminum alloy was formed intoperforated plates, show that for a given foilthickness, a limit existed over which supplyinghigher electrical energy from a givencapacitor bank did not necessarily resultin higher pressure. The magnitude ofgenerated pressure was proportional to theexcess Joule heat deposited into the foil beforeit burst. Although the polyurethane layer helpedspread the pressure pulse over a larger area,the resulting pressure distribution remainedheterogeneous. Practical applications, such asforming into cavities and embossing into shallowdies, were possible with this method. Sheets of0.508mmthickcommerciallypuretitaniumwere

nearlyfullyformedintoacellphonecasedieusinga hybrid process that combined a quasistaticpre-forming step with a vaporizing foil formingstep. Sheets of 0.508 mm thick AA 2024-T3aluminum alloy were embossed into a die withfeatures of varying depths. Aluminum foils withstraight and curved active sections were usedas actuators. The curved-section foils resultedin higher conformation of the workpiece tothe die in the center region, while the straight-section foils produced better conformity tothe die features on the ends. (25 refs, 13 figs,2tables)(AA)

110283 Stress relaxation behavior of an Al–Zn–Mg–Cu alloy in simulated age-forming processChen,JF;Jiang,JT;Zhen,L;Shao,WZ[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 775, Pages 9] The stress relaxationbehavior of age-forming for an Al–Zn–Mg–Cualloy was studied using a designed device thatcan simulate the age forming process. Themechanismofstressrelaxationwasalsorevealedthroughcalculatingthermalactivationparametersand analyzing the microstructures. The resultssuggested that the stress relaxation behaviorof the Al–Zn–Mg–Cu alloy in the simulated age-formingprocess canbedivided into three stagesaccording to the stress level. The three stagesof stress relaxation are: (i) the initial high stressstage, (ii) thesubsequentmiddlestresstransitionstage and (iii) the last low stress equilibriumstage, respectively. The deformation activationenergies are 132 kJ/mol in the initial high stressstage, 119 kJ/mol in the subsequent middlestress transition stage and 91 kJ/mol in the lastlow stress equilibrium stage, respectively. Theanalysisofthethermalactivationparametersandmicrostructures revealed that dislocation creepwas the dominant deformation mechanism inthe initial and subsequent stages of the stressrelaxation; whereas diffusion creep is themechanism in the last stage of the stressrelaxation.Additionally,a special threshold stressphenomena was present in the stress relaxationof theage-formingprocess,whichwasscribedtothe interaction between precipitation anddislocation in the Al–Zn–Mg–Cu alloy (38 refs,10figs,2tables)(AA)

WARM FORMING

110284 Simulation and experimental study on thermal deep drawing of carbon fiber woven compositesZhang,Q;Cai,J;Gao,Q[J of Materials Processing

Abstracts


Technology, v 214, n 4, Apr 2014, Starting Page 802, Pages 9] Carbon fiber woven compositesare composed of carbon fiber woven and resinmatrix. To reduce themanufacture cost, thermalstamping, a new forming technology, wasproposedandinvestigatedtofabricatecompositepart. The mechanical properties of carbon fiberhave great influence on the deformation ofcarbon fiber composites. In this study, shearangle–displacement curves and shear load–shearangle curves were obtained from picture frametest. Thermal deep drawing experiments andsimulationwere conducted, and the shear load–displacement curves under different formingtemperatures and shear angle–displacementcurves were obtained. The results show thecompression and shear between fiber bundlesare the main deformationmechanism of carbonfiber woven composite. The maximum shearangle for the composites in this study is 33°. Inthe drawing process, the forming temperatureaffects the drawing force, which drops rapidlywith the increasing temperature. The suitableforming temperature in deep drawing of thecarbon fiber woven composite is approximately170°C.(11refs,20figs)(AA)

110285 Warm deep-drawing and post drawing analysis of two Al–Mg–Si alloysGhosh, M; Miroux, A; Werkhoven, RJ; Bolt, PJ;Kestens,LAI[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 756, Pages 11] The increasing use of aluminium alloys inlight weight structural applications is restrictedmainly due to their lower room temperatureformabilitycomparedtosteels.Formingathighertemperature is seen as a promising solution tothis problem. In the present investigation twoAl–Mg–Si alloys (EN AW-6016 and EN AW-6061)were deep-drawn at room temperature and250 °C and their behaviour during drawingwerecompared.Theeffectoframspeed,drawingratio,holding time, and temper was also investigated.Among the parameters investigated temperaturewas found to have the most significant effecton the force–displacement response. Becauseanisotropyhasbeenanimportantconcernduringthe deep-drawing process, this parameter wasalso investigatedby looking at theearingprofile.With increasing temperature the amplitudeof earing decreased while the number of earsremained the same, indicating that there is nochange in anisotropy with temperature. The cupthicknessincreasesfromthebottomofthecuptotheflangewithalocalminimumaroundthemid-heightofthewall.(27refs,14figs,3tables)(AA)

SHEET METAL WORKING

110286 Finite element modeling and experimental results of brass elliptic cups using a new deep drawing process through conical diesDhaiban, Abdullah A; Soliman, M.-Emad S; El-Sebaie,MG[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 828, Pages 11] This paper introduces a new technique for deepdrawingofellipticcupsthroughaconicaldiewithoutblank holder or draw beads. In this techniquean elliptic-cup is produced by pushing a circularblankusingaflat-headedellipticpunchthroughaconical die with an elliptic aperture in a singlestroke.A3Dparametricfiniteelement(FE)modelwas built using the commercial FE-packageANSYS/APDL. Effects of die and punch geometryincluding, half-cone angle, die fillet radius,die aperture length and punch fillet radiuson limiting drawing ratio (LDR), drawing loadand thickness strain of the cup have beeninvestigated numerically for optimal processdesign. A die with half cone angle of 18° hasshownthebestdrawabilityforthenewtechnique.An experimental set-up has been designed,manufactured, and used for experimentalproduction of elliptical shaped sheet-metal cups.A total of seven punches having aspect ratiosranging from2 to 2.25 and a diewith an aspectratio of 2 have been manufactured and used.Tensile tests were carried out to obtain thestress–strain behavior for the formed sheetmetal. Experimentswereconductedonblanksofbrass (CuZn33) with initial thicknesses of1.5, 1.9, 2.4 and 3 mm at different clearanceratios (c/t). Effects of blank thickness andclearance ratio on limiting drawing ratio,drawing load and thickness strain werenumerically and experimentally investigated.Finite element model results showed goodagreement with experimental results. An ellipticcupwithalimitingdrawingratio(LDR)of2.28hasbeen successfully achieved using the proposedtechniqueandset-up.(18refs,26figs,5tables)(AA)

110287 Dimpling process in cold roll metal forming by finite element modelling and experimental validationNguyen,VB;Wang,CJ;Mynors,DJ; English,MA;Castellucci, MA [J of Manufacturing Processes, v 16, n 3, Aug 2014, Starting Page 363, Pages 10] The dimpling process is a novel cold-roll formingprocess that involves dimpling of a rolled flatstrip prior to the roll forming operation. This isa process undertaken to enhance the material

Abstracts


properties and subsequent products’ structuralperformance while maintaining a minimum stripthickness. In order to understand the complexand interrelated nonlinear changes in contact,geometry and material properties that occur intheprocess, it isnecessarytoaccuratelysimulatetheprocessandvalidatethroughphysicaltests.Inthis paper, 3D non-linear finite element analysiswas employed to simulate the dimpling processand mechanical testing of the subsequentdimpled sheets, in which the dimple geometryand material properties data were directlytransferred from the dimpling process. Physicalmeasurements, tensile and bending tests ondimpled sheet steel were conducted to evaluatethesimulationresults.Simulationofthedimplingprocess identified the amount of non-uniformplastic strain introduced and the manner inwhichthiswasdistributedthroughthesheet.Theplastic strain resulted in strain hardening whichcould correlate to the increase in the strengthof the dimpled steel when compared to plainsteel originating from the same coil material.A parametric study revealed that the amountof plastic strain depends upon on the processparameters such as friction and overlappinggap between the two forming rolls. The resultsderived from simulations of the tensile andbending tests were in good agreement with theexperimental ones. The validation indicates thatthefiniteelementanalysiswasabletosuccessfullysimulate the dimpling process and mechanicalproperties of the subsequent dimpled steelproducts.(14refs,14figs,2tables)(AA)

110288 Local heating method by near-infrared rays for forming of non-quenchable advanced high-strength steelsLee,Eun-Ho;Hwang,June-Sun;Lee,Chang-Whan;Yang, Dong-Yol; Yang, Woo-Ho [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 784, Pages 10] A forming processby localheatingusingnear-infrared rays (NIRs) isproposedtoreducespringbackofnon-quenchableadvanced high-strength steels, such as dual-phase steels, that are not suitable materialsfor hot stamping. NIR lamps show outstandingcost performance, and the width of the heatingarea can be controlled by designed reflectors.To confirm the advantages of NIR local heating,DP980sheetswereheatedbytwomethods–NIRlocalheatingandfurnaceheating,whichheatsthewholematerial. V-bending and 2D-draw bendingwereconductedwithheatedDP980sheets.Resultsshowed that NIR local heating has advantagesover furnaceheating inboth shapeaccuracyandhardness.(17refs,18figs,2tables)(AA)

110289 Experimental and numerical analysis of friction in high aspect ratio combined forward-backward extrusion with retreat and advance pulse ram motion on a servo pressMatsumoto,Ryo;Hayashi, Kazunori;Utsunomiya,Hiroshi [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 936, Pages 9] A method for maintaining lubrication in thebackwardextrusionofdeepholes for lightweightstructural components is proposed utilizingaservopressandapunchwithaninternalchannelforliquidlubricantsupply.Inthisformingmethod,the punch is pushed into the specimen witha servo press in amanner that combines pulsedand stepwise modes. Sufficient liquid lubricantis periodically supplied to the deformation zonethrough the internal channel upon the retreatof the punch. This forming method with pulsepunch ram motion was tested in combinedforward-backward extrusion process with a highaspect ratio (height/diameter) in this study. Thematerial flow of the aluminum specimen duringthe extrusion with pulse punch ram motionwas investigated to determine the coefficient ofshear friction at the specimen–punch interface.The punch wear was assessed by a finiteelement analysis of the material flow of thespecimen during the extrusion with pulse punchrammotion.(13refs,18figs,1table)(AA)

110290 Approach to triangular induction heating in final precision forming of thick steel platesLee, Kwang Seok; Hwang, Byoungchul [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 1008, Pages 10] Anautomatichigh-frequency (HF) induction-heating (IH)-basedtriangular heating process was introduced inorder to investigate the influence of designingheating patterns on the permanent deformationbehavior of an SS400 thick plate. Temperaturedistribution and permanent plate deformationduring triangular heating were predicted basedon electromagnetic–thermal and thermal–structural analyses, respectively. Both analyticaland experimental permanent deformation valuesobtained by zigzag-type triangular heating weresignificantly higher than those by fan-shapedtriangular heating, presumably because ofthe different temperature gradient along thethickness. Proper design of triangular heatingpattern appeared to be the most importantfactor in determining the final shape of thethick plate. All predicted results were in goodagreement with the experimentally observedpermanent deformation. (23 refs, 18 figs,2tables)(AA)

Abstracts


110291 Electrohydraulic trimming of advanced and ultra high strength steelsGolovashchenko, Sergey F; Gillard, Alan J;Mamutov, Alexander V; Bonnen, John F; Tang,Zejun [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 1027, Pages 17] Electrohydraulic trimming (EHT) is a novel method of trimming sheet metalpanels and is based upon the electro-hydrauliceffect: a complex phenomenon related to thedischarge of high voltage electrical currentthroughaliquid.InEHT,electricalenergyisstoredin a bank of capacitors and is converted intokinetic energy within the liquid and the sheetmetal blank by rapidly discharging the storedenergy across a pair of electrodes submerged inafluid. Theobjectiveof thispaper is todescribethe newly developed EHT process, to report theresults of early proof-of-concept experiments,and to provide an explanation for the observedresults through the use of a numericalmodeling technique developed as a part ofthis work. The key innovation behind theEHT concept is the chamber design, whichconsists of a narrow fluid channel positioneddirectly below a sharp trim steel. The narrowchannel can transmit fluid pressure veryefficiently, and the design has enough inherentflexibility such that it canbeused to cut straightlines and can also be applied to more complexcurvature. The new, channel chamber designconcept was successfully demonstrated forelectrohydraulic trimming of Advanced andUltra High Strength Steels, including DP500 at0.65 mm thick, DP590 at 1.0 mm thick, DP980at1.0mmand1.4mmthick,andAISI4130steelat2.0mmthick.Separationof theoffal fromthepart initiates in the area of the blank directlyabove the discharge channel. Furtherseparation along the remainder of the trimline is influenced by a number of factors,including the strength and thickness of thesheet material, the mass density of the sheetmaterial, and the propagation of pressurewavesalong the fluid channel and their reflection fromthe walls at the ends of the fluid channel.A numerical model was developed which isable to predict the offal separation mechanismand the sequence of offal separation duringelectrohydraulic trimming. The developed modelincorporates several individual models intoone integrated simulation, including modelsfor the plasma channel, the liquid withinthe fluid channel, the steel chamber andtrim blade, and the deformable blank. (40 refs,25figs)(AA)

110292 Analysis of sheared edge formability of aluminumLe,QuochungB;deVries,JamesA;Golovashchenko,SergeyF;Bonnen,JohnJF[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 876, Pages 16] Edgequalityproducedbyshearingprocesses often leads to reduced materialformabilitywhichwasobservedinmultiplestudiesand summarized in the reference literature. Theintentiontomaketheshearededgeperformancemore predictable has motivated developmentof several experimental techniques such as theholeexpansion testand thehalfdogbone tensiletest. The paper presents a detailed review ofpublished results for both of these techniquesand illustrates very limited researchdedicated toshearededgeperformanceofaluminumalloys.Theexperimentalstudy,performedonabroadlyusedaluminum alloy, 6111-T4, illustrated the effectsof cutting clearance on longitudinal, transverseanddiagonalorientationsofthetrimlinerelativetotherollingdirection.Forallsheetorientations,increasing the cutting clearance resulted in asubstantialreductioninmaterialstretchabilityalongtheshearedsurface.However, forall investigatedconditions a cutting clearance of 5% of materialthickness resulted in stretching performancesimilar to the standard tensile test. In this casethe sheared edge does not affect the stretchingbehavioroftestedmaterial.Theanalysisofmaterialprestrain on sheared surface stretchability for avarietyofcombinationsofminorandmajorstrainsindicated that for the widely accepted industrystandardgapof10%ofthematerialthickness,theprestrain has significant effects on stretchabilitywhich only gets strongerwith increased thinningof the sheet in the prestraining process. For anextendedclearanceof40%,theeffectofprestrainwas less visible indicating that the sheared edgehas a stronger effect on these cutting conditionsthanprestrain.Analysisoftheeffectofthecuttingangle on stretchability indicated that higherelongations were observed with cutting anglesof 10° and 20° for broadly used 10% clearancecompared toorthogonalcuttingwithan identicalclearance.Theresultsofhalfdogbonetensiletestswerecomparedwiththeresultsofholeexpansiontestsperformedonthesamesheetmaterial.Thiscomparison indicated that a substantial amountof localization occurs in the hole expansion testand leads to amuchhigher hole expansion ratioforsmallcuttingclearancescomparedtothetotalelongations observed in tensile tests. However,thelocalstrainsmeasuredintheareaadjacenttofracture in the tensile test were above the holeexpansionratio.(30refs,21figs,2tables)(AA)

Abstracts


INDUSTRIAL ENGINEERING

110293 Dynamic programming approach to GA-based heuristic for multi-period CF problemsSharifi, Shahram;Chauhan, Satyaveer S; Bhuiyan,Nadia [J of Manufacturing Systems, v 33, n 3, Jul 2014, Starting Page 366, Pages 10] In thispaper we have introduced a multi-periodcell formation (CF) model which is morecomputationally challenging than the mostcomprehensive CF models in the literature. Adynamic programming (DP) based approachcoupled with GA-based heuristic is proposedto solve the multi-period problem. Since, theintroduced dynamic programming is general andcanbeappliedtoanyGA-basedheuristicwithfullrejuvenationcyclestosolvethemulti-periodpartofthemodel,wefocusedonlyontheDPapproachin this paper but have explained the interfacewith the GA-based heuristic. Illustrative examplehas been provided that clarifies the applicationof DP-heuristic. The performance of the DP-heuristic has been evaluated against LINGO andmulti period GA-based heuristic. (25 refs, 2 figs,13tables)(AA)

110294 Rescheduling of parallel machines with stochastic processing and setup timesArnaout, Jean-Paul [J of Manufacturing Systems, v 33, n 3, Jul 2014, Starting Page 376, Pages 9] Thispaper tackles rescheduling for theunrelatedparallel machine problem with sequencedependent setup times and different rates ofbreakdowns or urgent jobs arrivals. The jobs’processing and setup times are stochastic forbetterdepictionoftherealworld.Anewrepairrulewhich will be referred to asMinimumWeightedCmax Difference (MWCD) is developed andcomparedtoexistingalgorithmsusingsimulation.The rules are evaluated based on both schedulequality and stability. Design of Experimentsand optimization were used with simulationto generate optimal values for MWCD’sparameter. The results and analysis obtainedfrom the computational experiments proved thesuperiorityoftheproposedrepairruleMWCDovertheother algorithmspresented. (26 refs, 12figs,5tables)(AA)

110295 Impact of lot-sizing in multiple product environments with congestionKang, Yongha; Albey, Erinc; Hwang, Sangwook;Uzsoy,Reha[J of Manufacturing Systems, v 33, n 3, Jul 2014, Starting Page 436, Pages 9] Wepresentaproductionplanningmodelforamultipleproduct

single machine dynamic lot-sizing problem withcongestion.Usingqueuingmodels,wedevelop asetoffunctionstocapturethenonlinearrelationshipbetween theoutput, lot sizesandavailableworkin process inventory levels of all products in thesystem. We then embed these functions in anonlinear optimization model with continuousvariables, and construct an approximate solutiontotheoriginalproblembyrounding theresultingfractional solution. Computational experimentsshow that our model with congestion providessignificantly better flow time and inventoryperformance than a benchmarkmodel that doesnot consider the effects of congestion. Theseadvantagesarisefromtheuseofmultiplesmallerlots in a period instead of a single large lot assuggested by conventional fixed-charge modelswithoutcongestion.(48refs,4figs,7tables)(AA)

110296 Mean time imbalance effects on unreliable unpaced serial flow linesShaaban, Sabry; McNamara, Tom; Hudson,Sarah[J of Manufacturing Systems, v 33, n 3, Jul 2014, Starting Page 357, Pages 9] This paperinvestigates the benefits of deliberatelyunbalancing operationtimemeans for unreliablenon-automated production lines. The lineswere simulated with various line lengths, buffercapacities, degrees of imbalance and patterns ofimbalance. Data on two performance measures,namelythroughputandaveragebufferlevelweregathered, analyzed and compared to a balancedline counterpart. A number of conclusionswere made with respect to the ranking ofconfigurations, as well as to the relationshipsamong the independent design parameters andthe dependent variables. It was found that thebest configurations are a balanced linearrangement and a monotone decreasing order,withthefirstgenerallyresulting in lowerthroughput and the second leading to lower averagebuffer levels than those of a balanced line.Preliminary results show that unbalanced linescopewellwithunreliability.(35refs,9tables)(AA)

110297 Multi-echelon production–inventory system with supply disruptionPal, Brojeswar; Sana, Shib Sankar; Chaudhuri,Kripasindhu [J of Manufacturing Systems, v 33, n 2, Apr 2014, Starting Page 262, Pages 15] The article investigates an integrated multi-layer supply chain model consisting of supplier,manufacturerandretailerwhilesupplydisruption,machine breakdown, safety stock, maintenancebreakdown occur simultaneously. At beginningof theproduction,manufacturerkeepssomeraw

Abstracts


materialsinstockreceivedfromsecondsupplierathighprice,assafetystockduetosupplydisruptionof first supplier. Corrective maintenance is doneimmediately to restore its normal stage whenmachine breakdown occurs. Stock out situationsatmanufacturerandretailerareconsideredduetodisruptionofproductionformachinebreakdown.The integrated expected costs of the chain incentralized (collaborating) and decentralized(Stakelberg approach) system are compared.A numerical example and its sensitivity analysisare provided to test feasibility of the model.(30refs,5figs,1table)(AA)

MANUFACTURING INFORMATION TECHNOLOGY

110298 Hybrid simulation and MIP based heuristic algorithm for the production and distribution planning in the soft drink industrySel, Çağrı; Bilgen, Bilge [J of Manufacturing Systems, v 33, n 3, Jul 2014, Starting Page 385, Pages 15] This study addresses the productionand distribution planning problem in the softdrinkindustry.Theprobleminvolvestheallocationof production volumes among the differentproduction lines in the manufacturing plants,and the delivery of products to the distributioncenters(DCs).Amixedintegerlinearprogramming(MILP)modelisdevelopedfortheproblem.Inthispaper,wepresentahybridsolutionmethodologycombining simulation and mixed integerprogramming (MIP) based Fixed and Optimizeheuristic to solve the considered problem.First, MIP based Fix and Relax (F&R), Fix andOptimize (F&O) heuristics are proposed.The solution quality and performance of theproposed heuristics are analyzed with therandomlygenerateddemandfiguresforthethreegranularity categories and various capacityload scenarios. Computational performances ofthese heuristic procedures are compared withthe standard MIP results. The computationalexperimentscarriedoutonalargesetofinstanceshave shown that the F&O heuristic algorithmprovides good quality solutions in a reasonableamount of time. Second, simulation modelis introduced to represent the problem withstochastic machine failures. Hybrid methodologycombining the MIP based F&O heuristic andsimulationmodelisimplemented.Theoptimizationmodel uses an F&O heuristic to determine theproduction and delivered quantity. Subsequentlythe simulation model is applied to capture theuncertainty in the production rate. Numericalstudies from the data which have a tight

productioncapacityandhighdemandgranularitydemonstratethatthedevelopedhybridapproachis capable of solving real sized instancewithin areasonableamountoftimeanddemonstrate theapplicability of the proposed approach. (58 refs,10figs,7tables)(AA)

JOINING & ASSEMBLY

110299 Linear friction welding of Ti–5Al–2Sn–2Zr–4Mo–4Cr alloy with dissimilar microstructureJi, Yingping; Chai, Zhenzhen; Zhao, Dalong; Wu,Sujun[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 979, Pages 9] Dissimilar linear friction welding of Ti–5Al–2Sn–2Zr–4Mo–4Cr with bimodal and lamellarmicrostructureswasproduced.Themicrostructureevolution of the joint was investigated via OM,SEM, XRD, TEM andmicrohardness analysis. Thetemperature field of joint was calculated by anumerical model. The typical microstructuresof weld center were recrystallized β grains withsome acicular α′′ martensites. In the case ofthermo-mechanically affected zone, some partialre-crystallization grains formed in severelydeformed microstructures, where a mass ofdislocationswereobserved.However,dislocationswere rarely found in therecrystallized β grains ofweld center, the temperaturefieldofweld jointscalculatedwasconsistentwiththemicrostructuralevolution.(23refs,11figs,3tables)(AA)

110300 Experimental investigation on high strength steel (HSS) tailor-welded blanks (TWBs)Xu, Fengxiang; Sun,Guangyong; Li,Guangyao; Li,Qing[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 925, Pages 11] This paper aims to investigate mechanicalcharacteristics of the new tailor-welded blank(TWB) components made of high strength steel(HSS). A series of HSS-TWB thin plates withdifferent orientations of weld line are studiedthrough three-point bending tests to evaluatethe effects of different design parameters, suchasweld line locationsandmaterialcombinations,on the deformation behaviors. The experimentalresultsexhibitgoodrepeatabilityoftests.Andtherelativeshiftphenomenonbetween indenterandspecimen is observed and analyzed for the TWBsteel sheetswith differentweld line orientationsat parallel and 45° to the bending moment,respectively. The results from the experimentincludetheforceversusdisplacementcurvesandsomedetailedphotographical images throughouttheloadingprocess.Itisfoundthatthediscrepancyof different combinations is quite noteworthy.

Abstracts


In this paper, the peak force, absorbed energyand bending strength are presented to evaluatethe mechanical characteristics of HSS-TWB thinplates with different weld line orientationsand material combinations. The comparisondemonstrates that the TWB structures with theweld orientation at 45° angle to the bendingmomenthavethegreatestadvantagesofdifferentTWBsteelsheets.(11refs,12figs,5tables)(AA)

110301 Influence of alloy elements on microstructure and mechanical property of aluminum–steel lap joint made by gas metal arc weldingSu, Yongchao; Hua, Xueming; Wu, Yixiong [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 750, Pages 6] 5052aluminumalloysheetsandgalvanizedmildsteelsheetswerejoined in lap configuration by alternate-currentdoublepulsegasmetalarcweldingwithpureAl,Al–5Si,Al–12SiandAl–4.5Mg(wt%)fillerwires.Theeffectofalloyingelementson themicrostructureof intermetallic compounds (IMC) layers formedbetweenweldseamandsteel,andtensilestrengthof the resultant joints were investigated. Thethicknessof IMClayer inallsamplesvariedalongthe cross-section of the joint, the intermediatepart of the IMC layerwas thicker than the headandrootparts.ThediffusionofSiintoFe2Al5sub-layercouldrestrainthegrowthofFe2Al5sub-layerand IMC layer, and joint’s mechanical propertyimprovedwiththeincreasingSicontentinFe2Al5phase. Due to the high hot crack sensitivity ofAl–4.5Mg alloy, cracks generated at the root ofjointmadewithAl–4.5Mgfiller, resulting inpoormechanicalproperty.(19refs,6figs,5tables)(AA)

110302 Characterization of ultrasonic spot welded joints of Mg-to-galvanized and ungalvanized steel with a tin interlayerPatel, VK; Bhole, SD; Chen, DL [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 811, Pages 7] Ultrasonicspotwelded(USWed)Mg-to-baresteel,Mg-to-galvanizedsteelandMg-to-baresteelwithSninterlayer(placedin-betweenMgandbare steel)were studied.Weakjoining occurred in the USWedMg-to-bare steel,sinceMgandFedonotreactwitheachother.Theintermetallic compounds (IMCs) of Mg7Zn3 andMg2Zn11,whichledtothefailureofthejoint,werelargely present in the USWed Mg-to-galvanizedsteel joint. The introduction of a Sn interlayer intheUSWedMg-to-baresteelactivelyworkedasanintermediatemediumtojoinMgtoFe,andledtothepresenceofadistinctivecomposite-likeSnandMg2Sneutectic structure. The lap shear strengthof Mg-to-bare steel with Sn interlayer joint was

significantly higher than that of the Mg-to-baresteel and Mg-to-galvanized steel joints. Failureduringthetensilelapsheartestsoccurredmainlyinthepartialnuggetpull-outmodeinthedissimilarjoints of Mg-to-bare steel with Sn interlayer. Allthe joints of Mg-to-galvanized steel failed fromthe interface (cohesive failure). The addition ofSn interlayer resulted in energy saving since theweldingenergyrequiredtoachievethemaximumstrength decreased from 1750 to 1500 J in theMg-to-steeljoints.(17refs,6figs)(AA)

110303 Fiber Bragg grating sensors for on-line welding diagnosticsRodriguez-Cobo, Luis; Mirapeix, Jesus; Ruiz-Lombera, Ruben; Cobo, Adolfo; López-Higuera,Jose-Miguel[J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 839, Pages 5] On-line monitoring of an arc-weldingprocess is performed in this paper by means offiber Bragg grating transducers (FBGs) in twodifferent configurations. FBGs were glued tothe plate surfaces next to the weld joint, anda FBG transducer was designed to sense theperturbations in the air surrounding theweldingplasma column. Sensitivity to both temperatureand vibrations during the process was analyzedduring several tungsten inert gas (TIG) weldingtests, showing the feasibility of the proposeddesigntoperformanon-linedetectionofdifferentweldingperturbations.Toenhancetheanalysis,asetup based on plasma optical spectroscopywasalsoemployed toallowa comparisonamong theresponseofbothtechniquestotheappearanceoftheseperturbations.(14refs,6figs)(AA)

LASERS

110304 Modelling of droplet detachment in the laser droplet brazing processJeromen, Andrej; Held, Carolin; Govekar, Edvard;Roth, Stephan; Schmidt, Michael [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 737, Pages 13] The laser dropletbrazingprocesshasbeen recentlyexperimentallyconsidered for the electrical contacting ofthermally sensitive components. In this process,a spherical brazing preform, placed in a taperingnozzle, ismeltedbya laserpulse,detached fromthe nozzle by a shielding gas overpressure, anddeposited on the brazing spot. The detachmentof the brazing droplet from the nozzle has beenstudiedtheoreticallyinthispaperwiththeaimofproviding guidance for the selection of themainprocessparameters,i.e.thegasoverpressureandthedropletcontactangle.Thedropletdetachment

Abstracts


is describedby twomodels: an algebraic dropletforce balancemodel and a numerical isothermaltwo-phase fluid flow model. Using the dropletforcebalancebasedmodel,analgebraicexpressiondefining the dependence of the maximum gasoverpressure before droplet detachment onthe droplet contact angle was obtained. Thenumerical model was used to determine thedroplet detachment occurrence in terms ofthe main process parameters. Additionally, thenonlinear dependencies of the time of dropletdetachment, the detached droplet velocity andvertical position, and the droplet shape on thegasoverpressureand thebrazingdroplet contactangleweredefined, and canbeused forprocessparameter selection. It was also found that thedetached droplet shape is influenced, besidethe gas overpressure and the droplet contactangle, by oscillation of the droplet, which canbe significant at droplet contact angle valuesof less than 75°. Based on comparisons of themodelled and experimental results of dropletdetachment time, vertical position of thedetacheddroplet,anditsshape,itwasconcludedthat the contact angle of the CuSn11 brazingmaterial on the WC/Co nozzle was, in theexperiments,near105°.Furthermore,comparisonsof the results indicated that the laser meltingphase of the preform significantly influencesdroplet detachment, and should therefore betaken into consideration for the improvement ofthenumericalmodel.(13refs,21figs,1table)(AA)

MACHINE ELEMENTS & MECHANISMS

110305 Further insight into the chip formation of ferritic-pearlitic steels: Microstructural evolutions and associated thermo-mechanical loadingsCourbon, C; Mabrouki, T; Rech, J; Mazuyer, D;Perrard, F; D’Eramo, E [Int J of Machine Tools & Manufacture, v 77, n , Feb 2014, Starting Page 34, Pages 13] Themainobjectiveof thispaper istoclarifythedeformationmechanismsofferritic-pearlitic steels in metal cutting and correlatethem to the associated thermo-mechanicalloadings. Dry orthogonal cutting tests have beenperformed on a normalised AISI 1045 steel withcoated carbide tools. Experimental evidences ofa drastic grain refinement process in the maindeformation zones are advanced on the basisof optical microscope, Field Emission ScanningElectron Microscope (FESEM) and ElectronBackScattered Diffraction (EBSD). Microstructuralevolutionsleadingtoagrainsizedownto200nmand fragmented cementite are especially

emphasized. A numerical approach is furtheremployed to target and quantify the loadingsapplied to the machined material and extractfurther information on the Secondary ShearZone (SSZ). Strains amplitude appears to bethe driving parameter of these evolutions viaa dynamic recrystallisation process promotedby an intense and localised heat generation.The present contribution highlights that in-depthand microscale investigations of chip formationincluding microstructural aspects are stillrequired.(57refs,13figs,1table)(AA)

MACHINE TOOLS

110306 Geometric error measurement and identification for rotary table of multi-axis machine tool using double ballbarChen, Jian-xiong; Lin, Shu-wen; He, Bing-wei [Int J of Machine Tools & Manufacture, v 77, Feb 2014, Starting Page 47, Pages 9] In this paper,comprehensive geometric errors, includinglinkage errors and volumetric errors, of a rotarytablearemeasuredtotallybyemployingadoubleballbar andobtainedby a two-step identificationprocedure. The derivations of the center of theball installed on the table are measured in theerror sensitive directions with newly developedserial of two axes controlled circular paths.Hence, there are nine results measured fromthree mounting positions of the ball at thesame rotation angle. These results are usedto form the identification model based on thehomogeneous transformation. Moreover, asensitivityanalysismethodisappliedtoselecttheoptimum installation parameters of the ballbarto diminish the influence of the inaccuracy ofthe measurement parameters. As the mountingposition errors of the socket on the table areinevitable during the installation of the balls,a new correction procedure is developed aswell. Finally, an experiment is conducted on thefour-axis machining center. The comparisonresults between the predicted errors and themeasured results are shown to verify theproposedmethod.(21refs,14figs,1table)(AA)

MACHINING

110307 Bio-inspired self-sharpening cutting tool surface for finish hard turning of steelWenping, Jiang [CIRP Annals, v 63, n 1, 2014, Starting Page 517, Pages 4] This researchpresents the structural analysis and machiningresults of a 3-Dnanostructured coatingdesignedfor finish turning of ferrous alloys. The coating

Abstracts


design, inspired from sea urchin and shark teetharchitectures, delivers serrated cutting edgesand self-sharpening. The coating is realizedusingcubic boron nitride particles (<2 mm insize) insoft titanium nitride matrix to produce superiortool life and consistent surface finish (<1.6mm),on-par or better than polished PCBN inserts,during finish hardturning of 4340 alloysteel. This research also discusses mechanismbased on coating materials and morphologyfor reducing surface contact and slidingfriction at the tool–workpiece interface.(21refs,6figs,1table)(AA)

110308 Characterization of deformation induced surface hardening during cryogenic turning of AISI 347Aurich, Jan C; Mayer, Patrick; Kirsch, Benjamin;Eifler, Dietmar; Smaga,Marek; Skorupski, Robert[CIRP Annals, v 63, n 1, 2014, Starting Page 65, Pages 4] Theuseofcryogeniccooling inmaterialremoval processes has been reported by severalresearchers. The objectives were enhancedtool life and an expanded range of machinablematerials. In this paper, a novel application ofcryogenic cooling is presented: its use achievedirect surfacehardening ofmetastable austeniticsteels during cutting. Metastable austenitecan transform into martensite due to plasticdeformation if a sufficiently low temperatureis maintained. In order to use this effect duringcutting,cryogenicconditionsmustbemaintainedat all times. With this approach, cutting andhardening can be combined in one process.(17refs,7figs,1table)(AA)

110309 Evaluative approach to correlate machinability, microstructures, and material properties of gamma titanium aluminidesSettineri, Luca; Priarone, Paolo C; Arft, Martin;Lung,Dieter; Stoyanov, Todor [CIRP Annals, v 63, n 1, 2014, Starting Page 57, Pages 4] Severalgenerations of gamma titanium aluminides havebeendevelopedovertime,andtheyarenowadayscommerciallyavailable.Thedifferencesinchemicalcomposition, as well as the thermal treatments,greatlyinfluencethepropertiesofthealloys.Thisimplies considerable effects on the productionprocess performances. Benchmark trials wereperformed on three g-TiAl alloys: Ti–48Al–2Cr–2Nb, Ti–43.5Al–4Nb–1Mo–0.1B,andTi–45Al–2Nb–2Mn+0.8vol.%TiB2 XD, focusing on machinabilityand material characterization.The extremelydissimilar results obtained when turning andmilling can be traced back to the differentmicrostructures,aswellastothealloyingelements,

factorsbothaffectingthemechanicalandthermalmaterialproperties.(12refs,9figs)(AA)

110310 On the mechanics of chip formation in Ti–6Al–4V turning with spindle speed variationChiappini, Elio; Tirelli, Stefano; Albertelli,Paolo; Strano, Matteo; Monno, Michele [Int J of Machine Tools & Manufacture, v 77, Feb 2014, Starting Page 16, Pages 11] Titanium alloys arehard-to-cut materials and need to be machinedat relatively low cutting speeds with obviousnegative consequences on the profitability ofmachining. Inorder toenhancematerial removalrate(MRR),astrategythatreliesonhigherdepthsof cut could be chosen if vibrational issues dueto regenerative chatter did not occur. A lot ofresearch was done to suppress regenerativechatterwithoutdetrimentaleffectsonproductivity.One of the most interesting chatter suppressionmethods, mainly due to its flexibility andrelative ease of implementation, is spindlespeed variation (SSV), which consists in acontinuous modulation of the nominal cuttingspeed. Sinusoidal spindle speed variation (SSSV)is a specific technique that exploits a sinusoidallaw to modulate the cutting speed. The vastscientific literature on SSV was mainly focusedoncuttingprocess stability issues fullyneglectingthe study of themechanics of chip formation inSSVmachining.Theaimof thiswork is tofill thisgap: thus, finite element method (FEM) modelsof Ti–6Al–4V turning were setup to simulateboth SSSV and constant speed machining(CSM). The models consider both the micro-geometryoftheinsertandthecoating.Numericalresults were experimentally validated on dryturning tests of titanium tubes exploiting theexperimentalassessmentofcuttingforces,cuttingtemperatures and chip morphology. Tool–chipcontact pressure, tool engagement mechanismand the thermal distribution in the insert aresomeof theanalysednumericaloutputsbecausethey cannot be easily assessed by experimentalprocedures. These quantities were useful tocompare thermo-mechanical loads of the insertbothinCSMandSSSVmachining:itwasobservedthat the loads significantly differ. Comparedto CSM, the modulation of the cutting speedinvolves a higher tool–chip contact pressurepeak, a higher maximum temperature andhigher temperature gradients that could fosterthemaintoolwearmechanisms.(29refs,16figs,6tables)(AA)

110311 Novel approach to machining condition monitoring of deep hole boringXiao, Wenrong; Zi, Yanyang; Chen, Binqiang;

Abstracts


Li, Bing; He, Zhengjia [Int J of Machine Tools & Manufacture, v 77, Feb 2014, Starting Page 27, Pages 7] In theoptimizationofdeepholeboringprocesses,machiningconditionmonitoring(MCM)plays an important role for efficient tool changepolicies, product quality control and lower toolcosts. This paper proposes a novel approach totheMCMofdeepholeboringonthebasisofthepseudo non-dyadic second generation wavelettransform(PNSGWT).Thisapproach isdevelopedvia constructing a valuable indicator, i.e., thewaveletenergyratioaroundthenaturalfrequencyof boringbar. Self-excited vibrationoccurs at thefrequency of the most dominant mode of themachine tool structure. Via modeling dynamiccutting process and performing its simulationanalysis during deep hole boring, it is foundthat the vibration amplitudes at the naturefrequency of themachine tool risewith the toolwear. The PNSGWT that has relative adjustabledyadic time-frequency partition grids, goodtime-frequency localizability and exact shift-invariance is used to extract the wavelet energyin the specified frequencyband.Accordingly, theMCM of deep hole boring can be implementedby means of normalizing the wavelet energy.Finally, a field experiment on deep hole boringmachine tool is conducted, and the result showsthat the proposed method is effective in theprocessofmonitoringtoolwearandsurfacefinishquality for deep hole boring. (20 refs, 11 figs,2tables)(AA)

110312 Effect of heat treatment on green machinability of SiAlON compactsÇelik, Ali; Yaman, Halil; Turan, Servet; Kara,Alpagut; Kara, Ferhat [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 767, Pages 8] SiAlON based ceramics arepromising materials for wear applications suchas wire extrusion dies, pipe bending rollers, etc.due to their outstanding mechanical propertiesboth at high and low temperatures. To be ableto utilize these materials for such applications,they should have specific geometrical details asholes,threads,groves,etc.fortheeaseoffixation.Machining of a ceramic component in its greenstate is one of the most common techniqueswhich enable producing SiAlON wear partswith desired geometries. It is a prerequisite forgreenmachining that thecompactshouldhaveasufficient green strength to withstand againststresses at the cutting zone during machining.In this study, the required green strength wasobtained by a simple heat treatment stepperformedbetween1100and1400°C.Theeffect

of this process on the microstructure, phasedevelopment, strength and machinability ofSiAlON green compacts were investigated.It was observed that the compacts heattreated at 1400 °C provide a sufficientstrength against damage formation on themachined part and a relatively low toolwear as a result of the formation of fragmentedchips during the cutting process. Although thesefragmented chips have beneficial effects onthe tool wear, they resulted in a relatively poorsurface quality in the machined parts. (22 refs,10figs,1table)(AA)

110313 Analysis of a free machining α+β titanium alloy using conventional and ultrasonically assisted turningMuhammad, Riaz; Hussain, Mohammad Sajid;Maurotto, Agostino; Siemers, Carsten; Roy,Anish; Silberschmidt, Vadim V [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 906, Pages 10] Rapidadvancementsinpowergenerationandaviation industrieshavewitnessed a widespread use of titanium and itsalloys inmany applications. This is primarily duetotheirexcellentmechanicalpropertiesincluding,amongst other, high strength-to-density ratio,outstanding fatigue properties and corrosionresistancewiththeabilitytowithstandmoderatelyhigh temperatures. However, this combinationof properties results in poor machinability ofthe material, increasing the cost of componentsmachined with conventional cutting techniques.Recently, Ti6Al2Sn4Zr6Mo,amoderntitaniumalloy with improved mechanical properties, hasbeen introduced as a possible replacement of Ti6Al 4V in aerospace industry. However, its poormachinability and formation of long chips inconventional turning are main limitations for itswide-spread application. Therefore, a new alloybased on Ti 6Al 2Sn 4Zr 6Mo, namely Ti 6Al 7Zr6Mo 0.9La, was developed; it shows enhancedmachinabilitygeneratingshortchipsduringmetalcutting,whichpreventsentanglementwithcuttingtools improving productivity. To further enhancethemachinabilityof thismaterial, anovel hybridmachiningtechniquecalledultrasonicallyassistedturning(UAT)wasused.Experimentalinvestigationswere carried out to study the machinability,chip shapes, cutting forces, temperature inthe process zone and surface roughness forconventional and ultrasonically assisted turningofbothalloys.UATshowsimprovedmachinabilitywith reduced nominal cutting forces, improvedsurfaceroughnessofthemachinedworkpieceandgeneration of shorter chips when compared to

Abstracts


conventionalmachiningconditions.(37refs,16figs,2tables)(AA)

NON TRADITIONAL MACHINING

110314 Simulation model of debris and bubble movement in consecutive-pulse discharge of electrical discharge machiningWang, Jin; Han, Fuzhu [Int J of Machine Tools & Manufacture, v 77, Feb 2014, Starting Page 56, Pages 10] Debris concentration and bubblevolume fraction in the bottom gap betweenthe electrode and workpiece affect the state ofconsecutive-pulse discharge and the efficiencyof electrical discharge machining (EDM). Thus,themechanismsofdebrisandbubblemovementduring consecutive-pulse discharge should beelucidated. However, these mechanisms havenot been fully understood because of debrisand bubble movement in the machining gapare difficult to simulate and observe. This studyproposesathree-dimensionalmodelofflowfieldwith liquid, gas, and solid phases for machininggap in EDM. The mechanisms of debris andbubble movement in the machining gap duringconsecutive-pulse discharge were analyzedthroughthemodel.Debrisandbubblemovementin consecutive-pulse discharge was observedthrough experiments. The results showed thatthe proposed simulation model is feasible. Thebubble expansion is the main way that thebubbles exclude from machining gap. Muchdebrismovesoutsidethemachininggapfollowingthe excluded bubbles, which is the main waythat the debris excludes from machining gap.The bubble expansion becomes strong withthe increase of the discharge current andpulse-ontime.(17refs,14figs,1table)(AA)

110315 Adaptive control of deposited height in GMAW-based layer additive manufacturingXiong, Jun; Zhang, Guangjun [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 962, Pages 7] A passive visionsensor system has been developed to monitorthe nozzle to the top surface distance (NTSD) inlayer additive manufacturing (LAM) using gasmetal arc welding (GMAW). The deviations inthe NTSD are compensated by the movementof the working flat, and the adjustment of thedeposition rate on next deposition layer. Aftersimplification of the controlled process into alinear system, an adaptive control system hasbeen designed to keep the NTSD constant.The effectiveness of the controller is evaluatedthrough deposition of single-bead multi-layer

walls, and the experimental results confirm thatthe process stability can be improved whenapplyingthedevelopedcontroller.(14refs,12figs,2tables)(AA)

110316 Experimental investigation of spark generation in electrochemical discharge machining of non-conducting materialsJiang, Baoyang; Lan, Shuhuai; Ni, Jun; Zhang,Zhaoyang [J of Materials Processing Technology, v 214, n 4, Apr 2014, Starting Page 892, Pages 7] Electrochemical discharge machining(ECDM), also known as spark assisted chemicalengraving (SACE), is aneffectivemicro-machiningprocess for non-conducting materials. Processmodeling of ECDM, including spark generation and material removal, is not fully establishedhowever. Empirical estimation for dischargeenergyresultsinlargepredictionerrorofmaterialremoval and is hard to experimentally validate.In this paper, an experiment-based stochasticmodel for spark energy estimation is presented.Tapered tool electrodes were fabricated byelectrochemicalmachining (ECM) to improve theconsistencyofsparkgeneration.Energyofsparkswas experimentally determined and fit into atwo-component mixture log-normal distributionto reveal electrochemical characteristics of toolelectrodes. A finite element based model wasestablished to correlate spark energy and thegeometryof removedmaterial.Material removalwas treated as heat transfer problem becauseelectrical energy released by spark generationtransfers into thermal energy on the workpiece,resulting in material removal due to thermalmelting and chemical etching. Predictions ofmaterial removal by the model demonstratedgood consistency with experimental results.(20refs,11figs,1table)(AA)◘

editorial board vol. 14 no. 5 may 2015 contents technical papers · 2015. 6. 5. · 12 pages] rec....

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