vol. 15 no. 5 may 2016 editorial board contents technical ... · pdf filecontents technical...

Vol. 15 No. 5 May 2016

ContentsTechnical Papers

• Evaluation of canola based cutting fluid with extreme pressure additive in turning AISI 1040 steelBrahma Reddy ALS, Satheesh Kumar B and Padmanabhan G 3

• Optimization of TIG welding parameters for AISI 304 using taguchi techniqueRavindra Reddy P V R, Radhakrishna Prasad P, Sriramakrishna AA, Prabhakar Reddy P, Srinivasulu NV 10

• Performance of plasma transferred ArC hard faced friction stir welding tools for joining AA7075-T6 aluminium alloyBaskaran A, Shanmugam K and Balasubramanian V 17

• Processing time dependent behaviour of electrochemical honingSingh H and Jain PK 31

Select Bibliography: Cutting Fluids 27

Select Bibliography of Standards: Cutting Fluids 29

Photo Gallery: Vintage Machine: Jig Borer, SIP -Société Genevoise d'Instruments de Physique, 1950s to 1970s 30

Calendar of Events 37

Technology Trends 40

Manufacturing Technology Abstracts 42

Patent Abstracts: Cutting Fluids 52

Product Information: Cutting Fluids 56

IPr News: A - Z Definitions of Intellectual Property Terminology 57

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Editorial Board

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Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same.

ChairmanS Satish Kumar

Technical Paper review PanelS UshaN BalashanmugamDr. C K SrinivasaK K RajagopalB R Mohanraj

EditorMallikarjun G

Editorial Assistants

Shashi Rekha NMala RC

Bibliography

Manufacturing Technology Today, May 2016 27

SElECT BIBlIOGrAPhy: CUTTING FlUIDS

1. Use of vegetable oil in water emulsion achieved through ultrasonic atomization as cutting fluids in micro-milling

Burton, Geoff; Goo, Chan-Seo; Zhang, Yanqiao; Jun, Martin BG [J of Manufacturing Processes, V 16, N 3, 2014, Starting page 405, 9 Pages] Rec. No: 110348

2. Influence of vegetable oil based cutting fluids on tool wear and surface roughness in turning EN8 steel using tungsten carbide tool

Pinto, Thomas; Milton, George; Rao, Gangadhar [Manufacturing Technology Today, V 12, N 2, 2013, Starting page 5, 6 Pages] Rec. No: 109087

3. Effect of fluid concentration in titanium machining with an atomization-based cutting fluid (ACF) spray system

Chandra Nath; Kapoor, Shiv G; Srivastava, Anil K; Iverson, Jon [J of Manufacturing Processes, V 15, N 4, 2013, Starting page 419, 7 Pages] Rec. No: 109734

4. Enhancement of surface finish using water-miscible nano-cutting fluid in ultra-precision turning

Chan, CY; Lee, WB; Wang, H [Int J of Machine Tools & Manufacture, V 73, 2013, Starting page 62, 9 Pages] Rec. No: 109836

5. Analysis of droplet spreading on a rotating surface and the prediction of cooling and lubrication performance of an atomization-based cutting fluid system

Ghai, Isha; Samuel, Johnson; DeVor, Richard E; Kapoor, Shiv G [J of Manufacturing Sci & Engg:ASME Trans, V 135, N 3, 2013, Starting page 031003-1, 12 Pages] Rec. No: 109846

6. Characterization of fluid film produced by an atomization-based cutting fluid spray system during machining

Hoyne, Alexander C; Chandra Nath; Kapoor, Shiv G [J of Manufacturing Sci & Engg:ASME Trans, V 135, N 5, 2013, Starting page 051006, 8 Pages] Rec. No: 110546

7. Investigations on hard milling with minimal cutting fluid application.

Raj, A; Wins, LD; Gnanadurai, RR; Varadarajan, AS [Proc Int Conf on Frontiers in Design & Mfg Engg (ICDM-08), 2009, Starting page 183, 5 Pages] Rec. No: 105252

8. Investigation into minimal-cutting-fluid application in high-speed milling of hardened steel using carbide mills.

Thepsonthi, T; Hamdi, M; Mitsui, K [Int J of Machine Tools & Manufacture, V 49, N 2, 2009, Starting page 156, 7 Pages] Rec. No: 105974

9. Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using vegetable oil-based cutting fluid.

Khan, M M A; Mithu, M A H; Dhar, N R [J of Materials Processing Tech, V 209, N 15-16, 2009, Starting page 5573, 11 Pages] Rec. No: 106427

10. Investigation into the use of gaseous and liquid nitrogen as a cutting fluid when turning BS 970-80A15 (En32b) plain carbon steel using wC–Co uncoated tooling.

Stanford, M; Lister, P M; Morgan, C; Kibble, K A [J of Materials Processing Tech, V 209,N 2, 2009, Starting page 961, 12 Pages] Rec. No: 106836

11. Study of the convection heat transfer coefficients of grinding fluids.

Jin, T; Stephenson, DJ [CIRP Annals, V 57, N 1, 2008, Starting page 367, 4 Pages] Rec. No: 104321

12.Effectiveness and resolution of tests for evaluating the performance of cutting fluids in machining aerospace alloys.

Axinte, DA; Chiffre, Lde [CIRP Annals, V 57, 2008, Starting page 129, 4 Pages] Rec. No: 104403

13.Dynamic simulations of alumina membrane fouling from recycling of semisynthetic metalworking fluids.

Cutting fluid is a type of coolant and lubricant designed specifically for metalworking processes, such as machining and stamping. There are various kinds of cutting fluids, which include oils, oil-water emulsions, pastes, gels, aerosols (mists), and air or other gases. They may be made from petroleum distillates, animal fats, plant oils, water and air, or other raw ingredients. Depending on context and on which type of cutting fluid is being considered, it may be referred to as cutting fluid, cutting oil, cutting compound, coolant, or lubricant.

Bibliography

Manufacturing Technology Today, May 201628

Wentz, JE; Kapoor, SG; DeVor, RE, Rajagopalan, N [J of Manufacturing Sci & Engg: ASME Trans, V 130, N 6, 2008, Starting page 061015-1, 11 Pages] Rec. No: 104734

14.Experimental evaluation of an atomization-based cutting fluid application system for micromachining.

Jun, MBG; Joshi, SS; DeVor, RE; Kapoor, SG [J of Manufacturing Sci & Engg: ASME Trans, V 130, N 3, 2008, Starting page 031118-1, 8 Pages] Rec. No: 105009

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

Ram Kumar, P; Leo Dev Wins, 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

16.Cutting fluids & coolants – The eco-friendly avatar.

Mestry, D [Modern Machine Tools, V 6, N 3, 2008, Starting page 48, 6 Pages] Rec. No: 105171

17.Experimental Evaluation of an Atomization-Based Cutting Fluid Application System for Micromachining

Jun, MBG; Joshi, SS; DeVor, RE; Kapoor, SG [J of Manufacturing Sci & Engg: ASME Trans, V 130, N 3, 2008, Starting page 031118-1, 8 Pages] Rec. No: 97614

18.Characteristic properties of water-soluble cutting fluids additives for iron and aluminium materials.

Watanabe, S [Int J of Materials & Product Tech, V 30, N 4, 2007, Starting page 309, 31 Pages] Rec. No: 103876

19.Engineering metalworking fluids. Benes, J [American Machinist, V 151, N 3, 2007,

Starting page 48, 3 Pages] Rec. No: 10295720.Performance testing of cryogenic CO2 as

cutting fluid in parting/grooving and threading austenitic stainless steel.

De Chiffre, L; Andreasen, JL; Lagerberg, S; Thesken, I-B [CIRP Annals, V 56, N 1, 2007, Starting page 101, 4 Pages] Rec. No: 103463

21.Machining performance and health effects of cutting fluid application in drilling of A390.0 cast aluminium alloy.

Jayal, AD; Balaji, AK; Sesek, R; Gaul, A; Lillquist, R [J of Manufacturing Processes, V 9, N 2, 2007, Starting page 137, 10 Pages] Rec. No: 103683

22. Influence of the direction and flow rate of the cutting fluid on tool life in turning process of AISI 1045 steel.

Diniz, Anselmo Eduardo; Micaroni, Ricardo [Int J of Machine Tools & Manufacture,

V 47, N 2, 2007, Starting page 247, 08 Pages] Rec. No: 106743

23.Significance of solid lubricants in metal cutting.

Deshmukh, SD; Basu, SK [AIMTDR Conference Proceedings (22nd)- Mfg Technologies & Sys, 2006, Starting page 613, 4 Pages] Rec. No: 102560

24.Analysis of the different forms of application and types of cutting fluid used in plunge cylindrical grinding using conventional and superabrasive CBN grinding wheels.

Monici, RD; Bianchi, EC; Catai, RE; Aguiar, PR [Int J of Machine Tools & Manufacture, V 46, N 2, 2006, Starting page 122, 10 Pages] Rec. No: 101991

25.Development of environmentally friendly fluid for CBN grinding.

Oliveira, JFG; Alves, SM [CIRP Annals, V 55, N 1, 2006, Starting page 343, 4 Pages] Rec. No: 102558

26.Experimental investigation to identify the influence of cutting fluids on turning of AISI 304 using tungsten carbide insert.

Xavior, MA; Kuppan, P; Ignatius, JR [COPEN-2005- Proc of the 4th National Conf on Precision Engg, 2005, Starting page 94, 6 Pages] Rec. No: 102042

27.Character and behavior of mist generated by application of cutting fluid to a rotating cylindrical workpiece, Part 1: Model Development.

Yue, Y; Sun, J; Gunter, KL; Michalek, DJ; Sutherland, JW [J of Manufacturing Sci & Engg: ASME Trans, V 126, N 3, 2004, Starting page 417, 9 Pages] Rec. No: 99621

28.Character and behavior of mist generated by application of cutting fluid to a rotating cylindrical workpiece, Part 2: Experimental validation.

Sun, J; Ju, C; Yue, Y; Gunter, KL; Michalek, DJ; Sutherland. JW [J of Manufacturing Sci & Engg: ASME Trans, V 126, N 3, 2004, Starting page 426, 9 Pages] Rec. No: 99622

29.Performance evaluation of cutting fluids on Machining Al-SiC metal matrix composite

Sampath Kumar, T; Mohan, B; Rajadurai, A [AIMTDR Conference Proc, V 21, 2004, Starting page 490, 9 Pages] Rec. No: 99875

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

Vikram Kumar, CHR; Varadharajan, AS; Ramamoorthy, B [Manufacturing Technology Today, V 3, N 10, 2004, Starting page 10, 3 Pages] Rec. No: 99819 ◘

Events


NATIONAl 11 Jun 2016IrF-Intl Conf on Civil, Mechanical, Biological and Medical Engineering (ICMBME - 2016)Grand Nagarjuna Hotel, Shankar Vilas, Brodipet Main Road, Guntur, Andhra PradeshContact: Tel: +91 7064188896 Email: [email protected] Web:http://irfconference.org

18 Jun 2016IITr-Intl Conf on Electrical, Electronics, Computer Science, Management & Mechanical Engineering (ICE2CSM2E-2016)Hotel Royal Cliff, Opp. Motijheel Gate No.1, Kanpur Contact: IITR, Tel: +91 7735082562 Email: [email protected] Web:http://iitr.org.in

24 - 26 Jun 2016logmat Chennai: International trade fair for logistics and material handlingChennai Trade Center,Poonamali High Road, Chennai, Tamil NaduContact: Smart Expos & Fairs India Pvt. Ltd.No. 116 Mount Road, 600032 ChennaiTel: +91 (0)44 22501987 Fax: +91 (0)44 22501988Email: [email protected] Web: www.tradefairdates.com

01 Jul 2016ISETE-The Intl Conf On recent Innovations in Electrical, Electronics, Computer, Information, Communication & Mech Engg ICrIEECICME-2016Hotel Rainbow, 10, CV Raman Road, Sriram Colony, Alwarpet, Chennai, Tamil Nadu 600018Contact: Coordinator - Sumita Nayakphone: +91 7205807246Swarnada Samal, Tel: +91 7205807246 Email: [email protected] Web:http://isete.org

10 - 12 Jul 2016Intl Conf on Modelling and ManufacturingKrishnagiriContact: Ramachandra Educational and Sports TrustEmail: [email protected] Web: www.restpublisher.com

12 Jul 2016IITr-Intl Conf on Electrical, Electronics, Computer Science, Management & Mechanical Engineering (ICE2CSM2E-2016)Hotel Grandplaza, (A Unit of M/S. M.S. Guest Line Services), 5-9-88/A/1, Beside Haj House, Opp. Public Gardens, Nampally, Hyderabad, APContact: Swarnada Samal, Tel: +91 7735082562 Email: [email protected] Web:http://iitr.org.in

15 Jul 2016ISETE- The Intl Conf On recent Innovations in Electrical, Electronics, Computer, Information, Communication & Mech Engg ICrIEECICME-2016Classic Avenue, Manjalikulam Road, Thampanoor Trivandrum - 695001, Kerala Contact: Coordinator - Sumita Nayak, Tel: +91 7205807246Swarnada SamalFax: +91 7205807246 Email: [email protected] Web:http://isete.org

24 Jul 2016IITr- Intl Conf on Electrical, Electronics, Computer Science, Management & Mechanical Engineering (ICE2CSM2E-2016)Patel Nagar, Niranjanpur, Opp. Telephone Exchange, (Near Lal Pul), Saharanpur road, Dehradun UttarakhandContact: Swarnada Samal, Tel: +91 7735082562 Email: [email protected] Web: http://iitr.org.in

30 Jul 2016IITr- Intl Conf on Electrical, Electronics, Computer Science, Management & Mechanical Engineering (ICE2CSM2E-2016)Hotel Raj Palace, 12/1, Thanikachalam Rd, Parthasarathy Puram, T. Nagar, Chennai, Tamil Nadu Contact: Swarnada Samal, Tel: +91 7735082562 Email: [email protected] Web: http://iitr.org.in

10 - 12 Aug 2016Tech India New Delhi: International Exhibition on Engineering and ManufacturingPragati Maidan Exhibition Center,Mathura Road, New DelhiContact: Intl Trade and Exhibitions India Pvt. Ltd., 11th Floor, Kailash Building Kasturba Gandhi Marg, New DelhiEmail: [email protected] Web: www.itei.in

Events


INTErNATIONAl 10 - 12 Aug 2016MMMM Minerals Metals Metallurgy Materials New DelhiPragati Maidan Exhibition Center,Mathura Road, 110002 New DelhiContact: Intl Trade & Exhibitions India Pvt. Ltd., 11th Floor, Kailash Building Kasturba Gandhi Marg, New DelhiEmail: [email protected] Web: www.tradefairdates.com

10 - 12 Aug 2016Imex New Delhi: Intl Machine Tools ExpoPragati Maidan Exhibition Center,Mathura Road, 110002 New DelhiContact: ITEI International Trade and Exhibitions India Pvt. Ltd., E519 Floral Deck Plaza, Central MIDC Road, Opp SEEPZ, MumbaiTel: +91 (0)22 28398000 Fax: +91 (0)22 28390502Email: [email protected] Web: http://itei.in/home

23 - 25 Sep 2016Automation & robotics Expo 2016Autocluster Exhibition Centre, Chinchwad, PuneContact: China Pavilion, MerandaGuangzhou Lead Moo Exhibition Co.,LtdRm.528, Tian Xin Mansion, No.13 Jiangong RoadTianhe District Guang Zhou,ChinaTel: +91-22-28574011 +91-97022-93599 Web: www.automationexpo.net/index.php

05 - 07 Oct 2016Metallurgy India Mumbai: Intl exhibition on metallurgical tech, products & services in IndiaBombay Convention & Exhibition Centre BCEC,Western Express Highway, Mumbai, MaharashtraContact: Messe Düsseldorf India Pvt. Ltd.Sarita Vihar, 110 076 New DelhiTel: +91 (0)11 26971745 Fax: +91 (0)11 26971746Email: [email protected] Web: www.tradefairdates.com

6 - 7th Oct 20166th International Conference on ‘Additive Manufacturing Technologies-AM 2016Hotel Lalit Ashok, BengaluruContact: Additive Manufacturing Society of India (AMSI)#42, BSK 3rd Stage, 3rd Phase, 3rd Block9th Cross, Bangalore-560 085Tel: +91 9483717449Fax: +91 80 26729437/ 32422663Email: [email protected] Web: http://amsi.org.in

07 - 10 Jun 2016Mach-Tool Poznan: Intl Machine Tools ExhibitionPoznan International Fair Grounds, Glogowska Street 14, 60734 Poznan, Greater Poland, PolandContact: Poznan International Fair Ltd.ul. Glogowska 14, 60734 Poznan, PolandTel: +48 (0)61 8692000 Fax: +48 (0)61 8692999Email: [email protected] Web: www.mtp.pl

15 - 16 Jun 2016Ameri Mold Novi: Intl trade fair for moldmaking and tooling, design and application developmentSuburban Collection Showplace, Grand River Avenue, 48374 Novi, Michigan, USAContact: Demat GmbH, Carl-von-Noorden-Platz 560041 Frankfurt, GermanyTel: +49 (0)69 2740030 Fax: +49 (0)69 27400340Email: [email protected] Web: www.demat.com

18 - 20 Jun 20162016 International Conference on Power, Energy and Mechanical EngineeringChulalongkorn University-Chamchuri Square Building, Address: Chulalongkorn UniversityPathumwan, Bangkok ThailandContact: Tel: +1-562-606-1057 Email: [email protected]. Web: http://icpeme.com/contact.html

22 - 25 Jun 2016Inter Mold Thailand Bangkok: Exhibition and Conference for toolingBITEC - Bangkok International Trade & Exhibition Center, 88 Bangna-Trad Road, Bang Na, 10260 Bangkok, Bangkok , ThailandContact: Reed Tradex, 32nd fl., Sathorn Nakorn Tower, 100/68-69 North Sathon Road SilomBangkok, ThailandTel: +66 (0)2 6867299 Fax: +66 (0)2 6867288Email: [email protected] Web: www.reedtradex.com

26 - 30 Jun 201624th ICONE – Intl Conf on Nuclear EngineeringCharlotte Convention Center, 501 South College Street, Charlotte, North CarolinaContact: ASME Sponsorship and Exhibitor Sales

Events


Greg Valero, Tel: 1.212.591.8356, Email: [email protected] Web: www.asme.org

28 - 30 Jun 2016Additive Manufacturing Europe 2016RAI Amsterdam, EuropapleinNL-1078 GZ, AmsterdamContact: Tel: +44 (0)20 8846 2740 Web: www.amshow-europe.com

29 Jun - 1 Jul 2016The 2016 Intl Conference of Mechanical EnggLondon, U.KContact: Email: [email protected] Web: www.iaeng.org

02 - 09 Jul 2016Nanotexnology Thessaloniki: Intl exhibition and conf on nanotechnology and organic electronicsHelexpo - Thessaloniki Intl Exhibition Centre, 154 Egnatia Str., 54636 Thessaloniki, Thessaloniki, Central Macedonia, GreeceContact: Helexpo SA, 154 Egnatia Street,54636 Thessaloniki, GreeceTel: +30 (2)310 291111 Fax: +30 (2)310 256827Email: [email protected] Web: www.helexpo.gr

6 - 9 Jul 20168th European Postgraduate Fluid Dynamics ConfWarsaw, PolandContact: Email: [email protected] Web: https://epfdc2016.fuw.edu.pl

10 - 15 Jul 2016Conf on Precision Electromagnetic MeasurementsThe Westin Ottawa, 11 Colonel By DriveOttawa, Ontario K1N 9H4, CanadaContact: Conference Secretariat, CPEM 2016, Management Office, National Research Council Canada, Bldg M-19, 1200 Montreal RoadOttawa, Ontario K1A 0R6, CanadaTel: +1-613-991-2060Email: [email protected] Web: www.cpem2016.com

18 - 22 Jul 20162016 7th International Conference on Mechanical and Aerospace EngineeringLondon, UKContact: Renne Gao, Conference Secretary

E-mail: [email protected] Web: www.icmae.org/contact.html

25 - 26 Jul 2016Intl Conf on Design and Production EngineeringCourtyard Berlin City CenterAxel-Springer-Straße 55, 10117, Berlin, GermanyContact: Web: design-production.conferenceseries.com

27 - 30 Jul 2016Machine Tool Surabaya: Intl trade fair for machine tools, metalworking and allied industriesGrand City Expo, Jl Gubeng Pojok Dalam Surabaya, Surabaya, East Java, Java, IndonesiaContact: PT Pamerindo Indonesia, Deutsche Bank Building, 13th Floor, Jl. Imam Bonjol 80, Jakarta, IndonesiaTel: +62 (0)21 3162001 Fax: +62 (0)21 31619812Email: [email protected] Web: www.pamerindo.com

15 - 17 Aug 20165th International Conference on Production, Energy and reliability 2016Kuala Lumpur Convention Centre, MalaysiaContact: Mechanical Engineering DepartmentUniversiti Teknologi PETRONAS32610 Bandar Seri Iskandar,Perak Darul Ridzuan, MalaysiaTel: +605 368 7144 Fax: +605 365 6461Email: [email protected] Web: http://usite.utp.edu.my/icper2016/

18 - 19 Aug 2016Fourth Intl Conference on Advances in Mechanical and Automation Engineering - MAE 2016Rome, ItalyContact: IRED Headquarters, 42 Broadway, Suite 12-217, New York, NY 10004, USATel: +1-(212) 901-3781 Fax: +1-(212) 901-3786Email: [email protected] Web: http://mae.theired.org/

21 - 24 Aug 2016Additive Manufacturing + 3D PrintingConference & ExpoCharlotte Convention Center501 South College Street Charlotte, NC 28202Contact: ASME Sponsorship and Exhibitor SalesGreg ValeroTel: 1.212.591.8356 Email: [email protected] Web: https://www.asme.org ◘

Abstracts


Manufacturing technology abstracts

COATING & FINIShING 43

CAD/CAM/CAE 43

FOrMING 44

INDUSTrIAl ENGINEErING 44

MANUFACTUrING INFOrMATION TEChNOlOGy 45

JOINING & ASSEMBly 45

MAChINING 46

DIAMOND TUrNING 46

lASEr MAChINING 47

TUrNING 48

lASEr wElDING 48

MEASUrEMENT & TESTING 48

PrECISION ENGINEErING 49

PrODUCT DESIGN & MANUFACTUrE 49

rAPID PrOTOTyPING 50

TOOlS & TOOlING 50

TrIBOlOGy 51

Abstracts


Manufacturing technology abstracts

COATING & FINIShING

110692 Modeling of vibratory finishing machinesHashimoto, Fukuo; Johnson, Stephen P [CIRP Annals, v 64, n 1, 2015, Starting Page 345, Pages 4]

Although vibratory finishing machines have been widely employed in industry for over 50 years, modeling the vibratory excitation system of the machine has not been previously published. This paper proposes a novel mathematical model of the bowl type vibratory finishing machine. This model is used to analyze the dynamic behavior of the mechanical excitation system considering both free and forced vibrations. The influence of key parameters identified by the proposed model and their impact on machine performance is discussed. Furthermore, implications for machine design and process optimization are presented. Finally, validation of the developed model is presented through correlation of results obtained from the theoretical analysis with data from experimental tests. (20 refs, 10 figs) (AA)

110693 Development of highly durable and low friction micro-structured PDMS coating based on bio-inspired surface design

Ryu, Byung – Hoon; Kim, Dae - Eun [CIRP Annals, v 64, n 1, 2015, Starting Page 519, Pages 4] A novel micro-structured PDMS coating with high

durability and relatively low friction was successfully replicated from a lotus leaf. Unlike the bio-inspired coatings developed previously, the micro-structured PDMS specimen could be fabricated in the form of a coating which could be successfully deposited on a solid surface. Results showed that friction and wear of the micro-structured PDMS specimens were significantly lower than those of the smooth specimens. It was also found that the wear resistance of micro-structured PDMS coating with 200 mm thickness was much higher than that of the micro- structured PDMS bulk specimen. The drastically high durability of the PDMS coating specimen was attributed to frictional energy dissipation through elastic deformation of the micro-structures. (20 refs, 6 figs, 1 table) (AA)

110694 Atmospheric pressure plasma enabled polishing of single crystal sapphire

Bastawros, Ashraf F; Chandra, Abhijit; Poosarla, Pavan A [CIRP Annals, v 64, n 1, 2015, Starting Page 515, Pages 4] Single crystal sapphire substrates with high

quality surface finish and integrity significantly enhance performance and reliability of various microelectronics and LED devices. Traditional Chemical Mechanical Polishing necessitates highly alkaline slurries or ultra-hard abrasives owing to sapphire’s ultra-high hardness and chemical inertness. Such trade-off is obviated by utilizing an atmospheric pressure plasma (in He–H2O mixture) for chemical action, facilitating higher material removal rate at neutral pH by buffing alone, without abrasives. Plasma induced surface modification is studied by nano indentation. A2_ improvement in MRR is achieved, and 40_ projected. Effects of plasma parameters and polishing conditions on planarization effectiveness are discussed. (18 refs, 7 figs) (AA)

CAD/CAM/CAE

110695 Computer-aided design assessment of products for end of life separation and material handling

P a p a k o s t a s , Nikolaos; Pintzos, G e o r g e ; Triantafyllou, Chris [CIRP Annals, v 64, n 1, 2015, Starting Page 185, Pages 4] A

methodology is presented for the estimation of recyclability indicators of product designs. It combines an automated CAD-integrated disassembly sequence generation algorithm and a recyclability assessment module. The algorithm employs collision detection and CAD feature recognition for the extraction of disassembly tiers and sequences of specific components. This information together with the components’ characteristics, including materials, is then processed by the corresponding module, which is capable of providing an initial evaluation about the product’s recyclability. The methodology is demonstrated through an industrial case study,

Abstracts


involving rear axle designs that are associated to different truck models. (12 refs, 6 figs, 2 tables) (AA)

110696 Design specifications with engineering terminology in a geometric context for CADCAM

Hedlind, Mikael; Kjellberg, Torsten [CIRP Annals, v 64, n 1, 2015, Starting Page 169, Pages 4]

Industry needs integration of product specific terminology and product generic data schemas for man- model interaction and data exchange in next generation of CADCAM systems to improve product realization. The use of engineering terminology in a geometric context to represent design parameters as functional features, kinematic requirements, and GD&T, is presented. This will give new possibilities for increased productivity in design and manufacturing. The main principle of relating data to its valid context is applied to reduce information fragmentation causing data duplication and comprehensive data management and maintenance. The solution is illustrated for modelling truck chassis and cutting tools. (15 refs, 7 figs) (AA)

FOrMING

110697 Flexible rotary reduction of tube tips by dies with relief surfaces for attaining high forming limit and productivity

K u b o k i , Takashi; Abe, M i t s u m a s a ; Y a m a d a , Yohei; Murata, Makoto [CIRP Annals, v 64,

n 1, 2015, Starting Page 269, Pages 4] This paper presents an innovative flexible rotary reduction method of tube tip using a relieved die. The relieved die is composed of contact surfaces and relief surfaces, which are connected smoothly. The proposed method realizes both high formability and productivity without heat generation so as to maintain the material strength. Diversified shapes of products used for catalyst cases, exhaust manifolds, pipe connections and so on would be able to be manufactured by changing the die cone angle, the raw- tube shape, the eccentricity between the die and tube axes and the inclination of the die. (8 refs, 12 figs, 2 tables) (AA)

110698 Form filling behaviour of preforms generated by laser rod end melting

Bruning, H; Vollertsen, F [CIRP Annals, v 64, n 1, 2015, Starting Page 293, Pages 4] Multi-stage mechanical upsetting processes become inefficient in micro range due to size effects. A promising approach is the laser rod end melting process wherein a laser beam is focused at a rod end to inducemelting whereas surface tension causes the melt to form spherically. These preforms are calibrated by mechanical upsetting. In this paper the form filling behaviour of the preforms of chromium–nickel steel within cone-shaped dies is investigated. It is found that forming products with high shape accuracy allow a scatter of preform volume within 3%, while the tolerable preform eccentricity decreases with increasing required shape accuracy. (10 refs, 10 figs, 2 tables) (AA)

INDUSTrIAl ENGINEErING

110699 how automobile parts supply network structures may reflect the diversity of product characteristics and suppliers’ production strategies

Kito, Tomomi; New, Steve; Ueda, Kanji [CIRP Annals, v 64, n 1, 2015, Starting Page 423, Pages 4] This study quantitatively investigates the heterogeneous nature of the structures and characteristics of real- life auto-parts supply networks, through complex network analysis of large-scale empirical data. Comprehensive data containing ‘‘who-supplies-what-to-whom’’ information successfully highlights the wide diversity of product characteristics, companies’ production capabilities, and also their resulting strategies. Furthermore, by using an advanced complex network analysis technique, the supply networks are projected into a different information space, generating another network

Abstracts


that elucidates the proximities between product types and between companies’ production strategies. Analysis of this network provides profound insights into how supply network structures may emerge reflecting various factors. (10 refs, 5 figs) (AA)

110700 Alternative view to assessing antifragility in an organisation: A case study in a manufacturing SMEKennon, Denzil; Schutte, Corne´ SL; Lutters, Eric [CIRP Annals, v 64, n 1, 2015, Starting Page 177, Pages 4] In complex adaptive systems, antifragility designates the positive sensitivity to volatility, caused by (exceptional or ‘black swan’) external stressors that intervene with the intended functionality of these systems. SystemEngineers can purposefully employ the concept antifragility to engender better systems. Prerequisite for this is the ability to adequately assess system changes and especially system improvements as the consequence of stressors. Albeit antifragility measurements do exist, their practicality is limited. This publication proposes a novel approach for antifragility measurement. A case study on a manufacturing SME depicts the antifragile spectrum rating of an SME to test the effects of system changes. (11 refs, 5 figs, 2 tables) (AA)

MANUFACTUrING INFOrMATION TEChNOlOGy

110701 Integrating ontology into PlM-tools to improve sustainable product development

Stark, Rainer; Pfortner, Anne [CIRP Annals, v 64, n 1, 2015, Starting Page 157, Pages 4] Sustainability aspects are predominantly

considered outside engineering departments by designated organizational units. Some PLM-vendors have already integrated application modules to assess, primarily environmental, sustainability within design environments by giving feedback to engineers but only on predefined options. This paper describes how to combine engineering tools with ontology to enable the identification of multiple viable options covering the functional dimension and all three sustainability dimensions. The approach reduces time consuming trial and error assessment

processes and opens up alternative options for sustainable solutions. The proposed solution is demonstrated based on material decisions occurring during the engineering process of a pedelec. (13 refs, 3 figs, 1 table) (AA)

JOINING & ASSEMBly

110702 Joining sheet metals by electrically-assisted roll bonding

Ng, Man-Kwan; Li, Lanyun; Fan, Zhaoyan; Gao, Robert X; SmithIII, Edward F; Ehmann, Kornel F; Cao, Jian [CIRP Annals, v 64, n 1, 2015, Starting Page 273, Pages 4]

Roll bonding is asolid-state welding process performed by means of rolling. During the process, virgin metal is extruded to the surface from underneath the surface through micro cracks leading to the formation of new metallic bonds. Electrically – assisted roll bonding (EARB) was applied to roll bond 127 mm aluminum sheet to 127 mm aluminum or copper sheets. The quality of the bonds was examined through micrographs and peel tests. It was found that the Joule heating effect in EARB lowered rolling forces and increased the bond strengths of bonded sheets by as much as three times. (16 refs, 8 figs) (AA)

110703 Surface modification of Ti6Al4V alloy by pulsed yb-laser irradiation for enhanced adhesive bonding

R o t e l l a , G i o v a n n a ; Alfano, Marco; C a n d a m a n o , Sebastiano [CIRP Annals, v 64, n 1, 2015, Starting Page 527, Pages 4] This work presents a comprehensive

experimental study on the effect of pulsed laser ablation (Yb-fiber) on Ti6Al4V titanium alloy substrates for adhesive bonding. The modification of surface morphology and chemistry is assessed by means of SEM, XRD and wettability measurements. In addition, surface and subsurface mechanical properties are probed through an extensive series of instrumented indentation tests. Based on the results of the

Abstracts


afore mentioned analyses, a suitable processing window is identified and adhesive bonded T-peel joints are fabricated and tested. The obtained results indicate that pulsed laser irradiation can substantially improve the performance of Ti6Al4V/epoxy joints. (19 refs, 8 figs, 1 table) (AA)

MAChINING

110704 Physically based constitutive model for simulation of segmented chip formation in orthogonal cutting of commercially pure titanium

M e l k o t e , Shreyes N; Liu, Rui; Fernandez-Zelaia, Patxi; Marusich, Troy [CIRP Annals, v 64, n 1, 2015, Starting Page 65, Pages 4] The accuracy

of cutting simulations depends on the knowledge of micro-scale physics included in the constitutive and microstructure evolution models of the cutting process. This paper presents an enhanced physically based material model that accounts for microstructure evolution induced flowsoftening due to the inverse Hall–Petch effect below a critical grain size. The model’s ability to simulate segmented chip formation and grain refinement in the shear bands produced in orthogonal cutting of commercially pure titanium is evaluated through finite element simulations and experiments. Results show good prediction accuracy for the cutting and thrust forces, chip morphology, and segmentation frequency (23 refs, 6 figs, 3 tables) (AA)

110705 Energy efficient machining of Ti–6Al–4VDenkena, Berend; Helmecke, Patrick; Hulsemeyer, Lars [CIRP Annals, v 64, n 1, 2015, Starting Page 61, Pages 4] Main spindles and high pressure pumps for internal coolant supply are main energy consumers of machine tools. Great energy savings can be achieved by a demand-oriented flowrate reduction. However, reliable indicators of the optimal amount of cutting fluid supply concerning the existing trade-off between energy savings and the avoidance of tool wear are still unexplored. For machining of titanium alloys, this paper demonstrates a correlation between process power and cutting fluid demand represented by tool wear appearance. Furthermore, it is shown that optimized cutting parameters lead to energy savings of more than 40

percent at the working spindle. (15 refs, 9 figs) (AA)

DIAMOND TUrNING

110706 Evaluation of subsurface damage caused by ultra-precision turning in fabrication of CaF2 optical micro resonator

K a k i n u m a , Yasuhiro; Azami, Shunya; Tanabe, Takasumi [CIRP Annals, v 64, n 1, 2015, Starting 7, Pages 4] The optical micro-resonator,

which stores light at a certain spot, is essential in next-generation optical signal processing. Single-crystal calcium fluoride (CaF2) is the most suitable material for this element. Ultra-precision turning is a feasible fabrication process forCaF2 optical micro-resonators. In this study, the influence of subsurface damage on the resonator’s Q factor is investigated. TEM observation shows that the subsurface layer of upto several tens of nano meters thickness changed from single-crystalto polycrystalline morphology due to ultra-precision turning. A diamond tool with 08 rake angle results in lower damage than one with negative rake angle, which enhances the resonator’s performance. (8 refs, 12 figs, 2 tables) (AA)

110707 Effect of atmospheric-pressure plasma jet on polycrystalline diamond micro-milling of silicon carbide

Katahira, Kazutoshi; Ohmori, Hitoshi; Takesue, Shogo; Komotori, Jun; Yamazaki, Kazuo [CIRP Annals, v 64, n 1, 2015, Starting Page 129, Pages 4] A study

was performed to investigate the effects of the application of an atmospheric – pressure plasma jet during polycrystalline diamond (PCD) micro-end-milling. A comparison was made between SiC surfaces after milling, with and without the application of the plasma jet. The plasma jet was found to allow the formation of a high-quality surface with an average roughness (Ra) of 0.73nm. The proposed plasma jet is highly effective in improving both the chip formation process, by imparting hydrophilicity to the tool and workpiece surfaces, and removing surface contamination at

Abstracts


the tool edge during machining. (12 refs, 12 figs, 3 tables) (AA)

110708 Changes in surface layer of silicon wafers from diamond scratching

Zhang, Zhenyu; Wang, Bo; Kang, Renke; Zhang, Bi; Guo, D o n g m i n g [CIRP Annals,

v 64, n 1, 2015, Starting Page 349, Pages 4] This study investigates diamond scratching at a high speed comparable to that in a grinding process on an ultraprecision grinder. Diamond tips are prepared for the study. The scratched silicon wafer is observed for changes in the surface layer with transmission electronmicroscopy. The observation discovers that an amorphous layer is formed on top of the pristine Si-I phase before the onset of chip formation. This discovery is different from the previous findings in which a damaged silicon layer is identified underneath the amorphous layer. Furthermore, no high pressure phase is found before the onset of chip formation. (16 refs, 7 figs, 2 tables) (AA)

lASEr MAChINING

110709 Concept for laser-assisted nano removal beyond the diffraction limit using photocatalyst nanoparticles

Takahashi, S; Horita, Y; Kaji, F; Yamaguchi, Y; Michihata, M; Takamasu, K [CIRP Annals, v 64, n 1, 2015, Starting Page 201, Pages 4] A new concept for the laser-assisted removal of material is proposed for achieving nano scale correction in next-generation functional microstructures such as nano structured photo resist surfaces and micro3-D objects fabricated using microstereolithography. This proposed method is characterized by the entrapment of TiO2 photocatalyst nano particles by a remotely controlled radiation force, which allows not only for remote processing using the inherent properties of light, but also a fine process resolution that goes beyond the limits of diffraction focusing. Both theoretical and experimental

analyses are used to verify the basic feasibility of this proposed concept. (21 refs, 11 figs) (AA)

110710 Surface forming on glass material by femtosecond laser modification with hF etching process

Tsai, Hung-Yin; Luo, Shao-Wei; Chang, Tien-Li [CIRP Annals, v 64, n 1, 2015, Starting Page 205, Pages 4] A rapid surface-microstructuring by femtosecond laser modification without profile scanning is

demonstrated on glass. The embedded grating and grid patterns are scribed inside the glass by the laser. After that, the glass is immersed in 10 wt% HF for developing. Additionally, the numerical calculation and simulation are utilized to compute the modification with etching. A fast approach to calculate the modified volume and shape by considering the fluence and material absorption is proposed. The obtained structure formed by anisotropic etching between modified and intrinsic material can be simulated for different etching selectivity. The simulated results agree well with the experimental ones. (24 refs, 9 figs, 2 tables) (AA)

110711 laser assisted hybrid process chain for high removal rate machining of sintered silicon nitride

F o r t u n a t o , Alessandro; Guerrini, Giacomo; Melkote, Shreyes N; Bruzzone, Alessandro AG [CIRP Annals, v 64, n 1, 2015, Starting Page 189, Pages 4] This paper presents a

hybrid process chain for efficiently machining hard silicon nitride. The process includes a laser treatment phase to weaken the material, followed by diamond grinding. Optimized laser parameters have been identified to control the generation of a network of cracks that weakens the volume of material to be ground. Comparison of data between traditional and hybrid process chain shows a reduction in grinding force of about thirty per cent in the latter case. A finite element model has been developed for the analysis of thermal stresses generated by laser exposure and the prediction of crack formation. (11 refs, 9 figs, 2 tables) (AA)

Abstracts


TUrNING

110712 Analytical time-domain turning model with multiple modes

B e r g l i n d , Luke; Ziegert, John [CIRP A n n a l s , v 64, n 1, 2 0 1 5 , Starting Page

137, Pages 4] An analytical time domain model is developed to predict the motion of a multi-mode cutting tool during orthogonal turning operations. This model is an extension of a single mode model that finds the solution to the governing delay differential equation (DDE) as a combination of constituent curves (sequential responses) which are independent of the delay term, t. In the current model, the delay independent constituent curves are found through a recursive state-space solution where in the individual modal displacements are determined for each sequential response. In this paper, the solution process is described in detail for a two mode system and the resulting analytical time responses are compared with numerical simulations. (11 refs, 6 figs, 1 table) (AA)

lASEr wElDING

110713 Comparison of laser welds in thick section S700 high-strength steel manufactured in flat (1G) and horizontal (2G) positions

Guo, Wei; Liu, Qiang; Francis, John A; Crowther, Dave; Thompson, Alan; Liu, Zhu; Li, Lin [CIRP Annals, v 64, n 1, 2015, Starting Page 197, Pages 4] Lack of penetration, undercut and melt sagging are common welding defects for single-pass laser welds in thick plates, particularly when using a traditional 1G welding position (laser directed towards ground). This investigation shows, for the first time, that welding 13 mm thick high-strength S700 steel plates in the 2G position (laser beam perpendicular to the direction of gravity) can mitigate some of the common welding

defects including undercut and sagging. A computational fluid dynamic analysis indicates that the 2G welding position can assist in achieving an appropriate balance between surface tension, hydrostatic pressure (gravity) and recoil-pressure from the metal vapour. (15 refs, 8 figs, 1 table) (AA)

110714 rapid deployment of remote laser welding processes in automotive assembly systems

Ceglarek, Dariusz; Colledani, Marcello; Vancza, Jozsef; Kim, Duck-Young; Marine, Charles; Kogel-Hollacher, Markus; Mistry, Anil; Bolognese, Luca [CIRP Annals, v 64, n 1, 2015, Starting Page 389, Pages 4] Remote laser welding (RLW) has received increased attention in the recent years due to its benefits in terms of process sing speed, lower investment, cost per stitch, and process flexibility. However, its potential in automotive assembly remains under exploited, mainly due to challenges involving system, process and fixture design, and part variation challenges. In this paper, an integrated rapid deployment framework for RLW process is proposed to improve ‘right-first-time’ implementation of RLW in assembly systems. It enables closed-loop optimization of system layout, task assignment, fixture layout, process parameters, robot path planning and programming as an interlinked iterative approach. The results are demonstrated in an automotive door assembly pilot study. (25 refs, 14 figs) (AA)

MEASUrEMENT & TESTING

110715 Simulation and measurement of environmental influences on machines in frequency domainMayr, Josef; Ess, Markus; Pavlicˇek, Florentina; Weikert, Sascha; Spescha, Daniel; Knapp, Wolfgang [CIRP Annals, v 64, n 1, 2015, Starting Page 479, Pages 4] Thermal errors of manufacturing machines induced by fluctuating environmental temperatures are one of the largest error sources in precision manufacturing. With the increased demand in high precision workpieces less thermal sensitive manufacturing machines are a requirement. In this paper a new simulative

Abstracts


evaluation procedure of thermal tool centre point errors in frequency domain and its validation via measurements is presented. The approach allows evaluation of the thermal behaviour and the thermal errors influencing the positioning error of themachine. It is presented, that selective insulation of machine structure can reduce the amplitude of thermal errors at the thermal resonance frequency. (7 refs, 8 figs, 1 table) (AA)

110716 Active suppression of structural chatter vibrations using machine drives and accelerometers

Munoa, Jokin; Beudaert, Xavier; Erkorkmaz, Kaan; AlexIglesias, Barrios, Asier; Zatarain, Mikel [CIRP Annals, v 64, n 1, 2015, Starting Page 385, Pages 4] Chatter vibrations coming from the machine tool

structure are a major limitation for heavy duty milling operations. Passive and active dampers can be added to increase the productivity. However, the price and required space of these absorbers are important drawbacks for their use in the industry. In this work, the machine tool’s own drives are used to suppress chatter with the help of an external accelerometer located close to the tool centre point. The measured acceleration is fed back as an additional control loop. A significant increase in the chatter stability limit is demonstrated experimentally on a large milling machine. (12 refs, 6 figs) (AA)

PrECISION ENGINEErING

110717 Development of low-cost material measures for calibration of the metrological characteristics of areal surface texture instruments

Leach, Richard; Giusca, Claudiu; Guttmann, Markus; Jakobs, Peter-Jurgen; Rubert, Paul [CIRP Annals, v 64, n 1, 2015, Starting Page 545, Pages 4] In this paper, the development of a number of material measures, which are designed to allow users to calibrate areal surface texture instruments, is

presented. The material measures include grid structures, for the determination of the

amplification, linearity and squareness of the x, y and z-axes, and star patterns, for the determination of the lateral period limit. Relatively complex methods of manufacture have been used to produce master artefacts, which are then replicated to produce cost-effective material measures for users. The process chain for the material measures is presented along with the methods used to calibrate them. (20 refs, 7 figs, 2 tables) (AA)

110718 Verification of an optical micro-CMM using the focus variation technique: Aspects of probing errorsSun, Wenjuan; Claverley, James D [CIRP Annals, v 64, n 1, 2015, Starting Page 511, Pages 4] Optical systems based on the focus variation technique are able to collect surface topography measurements from machined parts at high speed and a considerably lower cost than a contacting coordinate measuring machine (CMM). This paper presents a preliminary study of probing characteristics of a focus variation instrument within a single field of view, following the guidance of the international standard ISO 10360-8 (a recently published standard for acceptance and reverification testing of CMMs which use optical distance sensors). The selection of test samples and test strategies is also discussed, with specific emphasis on the adaptations made to the ISO 10360-8 guidance to realise accurate measurements. (15 refs, 1 fig, 6 tables) (AA)

PrODUCT DESIGN & MANUFACTUrE

110719 New coevolution process for conceptual design

Liu, Ang; C-Y Lu, Stephen [CIRP Annals, v 64, n 1, 2 0 1 5 , S t a r t i n g Page 153,

Pages 4] Conceptual design involves coevolution of decisions between functional and physical domains. Different methods prescribe different processes to achieve coevolution, hence are suitable for different kinds of design practices. Analytical Target Cascading (ATC) features successive decompositions followed by coordinated optimizations to improve existing systems. Axiomatic Design Theory (ADT) follows a back- and-forth zigzagging process to create completely new systems. A new coevolution process, which is a hybrid between ATC and ADT, is

Abstracts


developed from our Innovative Design thinking (IDT) research. This paper explains its theoretical underpinnings and illustrates its suitability for practices between the two extremes, e.g., innovative design on existing systems. (15 refs, 3 figs, 2 tables) (AA)

110720 hierarchical synthesis of multi-level design parameters in assembly systemFranciosa, Pasquale; Ceglarek, Dariusz [CIRP Annals, v 64, n 1, 2015, Starting Page 149, Pages 4] This paper proposes a novel methodology to optimize heterogeneous design tasks with competing parameters. It is based on the principle of design parameter sensitivity, taking into account the notion of robustness at an early phase of process design. The aim is to improve the quality of the assembly system in order to make it less sensitive to variations/changes of design parameters. The methodology is based on the development of: (i) analytical design task function; (ii) inner- and outer-sensitivity; (iii) design parameter sensitivity; and (iv) decision making module. The methodology is demonstrated using results involving an automotive door assembly. (13 refs, 3 figs, 3 tables) (AA)

110721 Exploring design space in embodiment design with consideration of models accuracy

Perry, Nicolas; El Amine, Mehdi; Pailhes, Jerome [CIRP Annals, v 64, n 1, 2015, Starting Page 181, Pages 4] Rework tasks in c o l l a b o r a t i v e d e v e l o p m e n t projects dealing with immature design concepts are very frequent and are responsible

of cost overruns and schedule delays. Taking into account uncertainty and accuracy of models (and data) improves decision making according to strategic orientation for product development. Based on a real design of light, slender but rigid solar collector supports, multiple tools have been developed and tested to support decision making at different stages of development process. The objective of this paper is to investigate the integration of these accuracy evaluations into the design process. This proposal is validated by the industrial development and validation. (16 refs, 5 figs) (AA)

rAPID PrOTOTyPING

110722 Process planning for additive and subtractive manufacturing technologies

Newman, Stephen T; Zhu, Zicheng; Dhokia, Vimal; Shokrani, Alborz [CIRP Annals, v 64, n 1, 2015, Starting Page 467, Pages 4] In recent years, techniques that combine different manufacturing processes such as additive and subtractive technologies are gaining significant attention. This is due to their ability to capitalize on consolidated advantages of combining these processes. However, there are limited process planning methods available to effectively synthesise additive and subtractive manufacturing technologies. In this paper a framework termed iAtractive is proposed to enable the strengths of additive and subtractive technologies to be combined with the inspection process. Based on iAtractive a process planning system, Re-Plan has been developed which shows the capabilities of combined process manufacture througha number of case studies. (18 refs, 5 figs) (AA)

TOOlS & TOOlING

110723 Evolutionary algorithms for generation and optimization of tool paths

N a s s e h i , A y d i n ; E s s i n k , W e s l e y ; B a r c l a y , Jack [CIRP A n n a l s , v 64, n 1,

2015, Starting Page 455, Pages 4] The efficiency ofmany manufacturing processes is dependent on the properties of the motion path that an end-effector or cutting tool follows. Consequently, algorithms have been developed for generating such tool paths with the aim of optimizing various objectives. In this paper, evolutionary algorithms for generation of continuous motion paths have been investigated to propose a novel method for creation and adaptable optimization of paths that

Abstracts


allows the objective to be modified without revising the algorithm. An example test case based on milling with a sequence of objectives has been used to demonstrate the advantages of the proposed method. (18 refs, 4 figs, 1 table) (AA)

110724 Tool wear behaviour and workpiece surface integrity when turning Ti– 6Al–2Sn–4zr–6Mo with polycrystalline diamond tooling

Pretorius, Cornelius J; Soo, Sein Leung; Aspinwall, David K; Harden, Peter M; M’Saoubi, Rachid; Mantle, Andrew L [CIRP Annals, v 64, n 1, 2015, Starting Page 109, Pages 4] The paper details the performance of a range of polycrystalline diamond (PCD) tools (_1.3–39 mm average diamond grain size) when turning Ti–6Al–2Sn–4Zr–6Mo with 150 bar cutting fluid. The alloy is used for aeroengine components such as turbine discs due to its superior mechanical and elevated temperature properties. Tool life improved from _30 to 80 min with increasing grain size except with the ultra-coarse (_39 mm) PCD grade, which failed via chipping/edge fracture after _8 min. In general, the principal wear modes were crater formation and workpiece adhesion. Workpiece integrity assessment showed no major subsurface damage with surface compressive residual stresses of _600 MPa. (23 refs, 9 figs, 1 table) (AA)

TrIBOlOGy

110725 Advanced approach for a demand-oriented fluid supply in grinding

Heinzel, C; Meyer, D; Kolkwitz, B; Eckebrecht, J [CIRP Annals, v 64, n 1, 2015, Starting Page 333, Pages 4] The productivity of grinding processes is often limited by the risk of thermal damage of the workpiece surface layer. Therefore, the control of thermal conditions in the grinding arc is of utmost importance for both, industrial practice and academia. Inorder to optimize the application of

the metal working fluid in grinding, devices and methodologies are needed which can assure the measurement of temperatures in grinding or within set-up mode and the control of demand-oriented fluid supply parameters (nozzle angle, nozzle height, nozzle outlet area, fluid jet velocity). The systematic use of such devices and methodologies for fluid supply optimization is enabling reliable and economic grinding processes. _ 2015 CIRP. This is an open access article under the CCBY-NC-ND license (http://creativecommons.org/ licenses/by-nc-nd/4.0/). (17 refs, 9 figs ) (AA)

110726 FEM-simulation of machining induced nanocrystalline surface layers in steel surfaces prepared for tribological applications

Ambrosy, Florian; Zanger, Frederik; Schulze, Volker [CIRP Annals, v 64, n 1, 2015, Starting Page 69, Pages 4] A formation of n a n o c r y s t a l l i n e grains due to dynamic r e c r y s t a l l i z a t i o n within the workpiece surface layer (AISI4140) resulting from machining has

proven to be suitable for obtaining improved tribological and fatigue behaviour. In the work presented an optimization of the machining process is carried out with cutting simulations using a continuous remeshing method and describing surface layer generation. The simulations describe the influence of process parameters and tool geometry on evolution of grain size distributions within the subsurface and affected depth after this thermo-mechanical processing. The validation is performed by experimental analyses based on cutting technology and focused ion beam technique. (25 refs, 4 figs) (AA) ◘

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