bluuebunny/crossref_metadata_2025_split huggingface dataset:
Investigation of Orthogonal Turn-Milling for Higher Machining Efficiency and Accuracy: Relationship Between Material Removal Rate and Measured Tool Flank Temperature
Authors: Shimanuki Koji , Hosokawa Akira , Koyano Tomohiro , Furumoto Tatsuaki , Hashimoto Yohei 
Published: January 2021

Abstract
Tool flank temperature at various intervals after cutting in dry turn-milling of AISI 1045 steel is measured using a two-color pyrometer with an optical fiber. Complicated undeformed chip geometry, which depends on cutting tool diameter, nose radius, number of tooth, workpiece diameter, tool-work revolution speed ratio, depth of cut, feed per tooth, tool axis offset and cutting distance, is analyzed and visualized by the 3D-CAD system. The effect of cutting parameters associated with material removal rate MRR such as workpiece diameter, workpiece revolution speed and feed rate on tool flank temperature is investigated in this paper. Workpiece diameter affects tool flank temperature, and 10 mm larger diameter causes approximately 40 °C higher temperature in any workpiece revolution speed due to the variation of undeformed chip geometry analyzed by 3D-CAD. Tool flank temperature increases with feed rate and workpiece revolution speed because the cross-sectional cutting area of undeformed chip increases with workpiece revolution speed, and cutting time during the engagement of each flute also increases with feed rate. Almost same values are obtained between the tool flank temperature and the material removal rate MRR when both workpiece revolution speed and feed rate are changed.
Optimization Method of Rotational Axis Motion in 5-Axis Controlled Machining to Keep Command Tool Feed Rate
Authors: Nakamura Takayuki , Ichikawa Kohei , Hasegawa Masanobu , Kaneko Jun'ichi , Abe Takeyuki 
Published: January 2021

Abstract
In recent machining processes, 5-axis controlled machine tool is widely used for machining complicated workpiece shape with curved surface. In such process, to achieve high productivity, planning method of cutting conditions to satisfy both following the commanded tool feed rate in machining process and realization of good surface roughness are required. In conventional study, it is known that lead angle of tool posture against local machined surface influence the surface roughness. Then, common commercial CAM systems have already functioned to avoid interference and control the lead angle in each cutter location. However, in the generated cutter locations by the conventional algorithms, when the tool posture changes rapidly, there is a problem that actual feed rate does not reach the command value and machining time becomes longer than expected. In this paper, we propose the new tool posture correction algorithm. In the proposed method, first, the rotational axis that causes the feed speed rate decline is specified by preliminary experiments. And, the jerk value that is the threshold for the feed speed decline is investigated. After that, for the NC program, the command value of the target axis is modified within a range where interference of cutting tool does not occur, thereby preventing a decline in the actual feed rate. This paper describes an outline of the proposed modification method and the effect of the modification of the target axis positions on the lead angle and the actual feed rate.
Micro Grooving of Cemented Carbide Using PCD Blade
Authors: Yamaguchi Keishi , Sugimoto Takumi , Ota Minoru , Egashira Kai 
Published: January 2021

Abstract
Ultra–Agile Advanced Manufacturing System (U–AMS) has been proposed for an agile prototyping system of research and development, and Super Processing Center (SPC) has been developing as a core machine tool of U–AMS. SPC has high accuracy and rigidity by double column structure based on a vertical precision machining center, hydrostatic oil guides and hydro static/dynamic hybrid oil bearing. In addition, SPC can perform various processing functions by mounting various processing units. Micro grooving by grinding has been researching for one of the SPC unit. PCD blade was developed for micro grooving using SPC. PCD blade was made from PCD disc using wire electrical discharge machining. This paper describes the fabrication method of PCD blade, and the machining characteristics of cemented carbide using PCD blade. In the fabrication method of PCD blade, it was clarified that the cross-sectional shape of PCD blade depended on the feed speed of wire electrode. Micro grooving on cemented carbide surface was performed using developed PCD blade and SPC. As a result, it was confirmed that the micro grooves can be machined using PCD blade, and the width of groove was almost same value as the width of PCD blade. The wear of PCD blade after grooving with 200 grooves was estimated by the depth of grooves. As a result, it was clarified that the wear of PCD blade is approximately 5 μm.
Development of a Machining Center Structure Made of Carbon Fiber Reinforced Plastic and Aluminum Honeycomb
Authors: Kizaki Toru , Iwama Masatoshi , Shiraishi Masaru , Sugita Naohiko 
Published: January 2021

Abstract
Reduction of size and weight are required in a development of machine tools that are mainly used in prototyping purposes. It is generally known, however, that when the reduction of size and weight of the structure were both pursued the machining accuracy can possibly be degraded due to insufficient stiffness. It is important to increase the specific stiffness and thermal stability of a machine tools structure for better machining accuracy. In this study we have applied a sheet of carbon fiber reinforced plastic and a sheet of aluminum honeycomb. A sandwich structure made of both materials and the ribs made of carbon fiber reinforced plastic was proposed. The proposed structure showed the increased specific stiffness and the thermal stability which are suited to the machine tools of high accuracy. We investigated the basic performance of the proposed structure by using several beam-shaped samples, in which the static stiffness and thermal expansion was measured and compared. The inserted ribs in the proposed structure was revealed to be suppressing the thermal expansion of the aluminum honeycomb core. After the basic investigation, a 5-axis machining center with the proposed structure was designed. The mechanical and thermal performance of the structure was tested in the finite element analyses. Finally the machining center was manufactured.
Effect of Casting Conditions on Fluidity of Aluminum Alloy in Die Casting
Authors: Haga Toshio , Imamura Sinjiro , Watari Hisaki , Nishida Shinichi 
Published: January 2021

Abstract
The fluidity of pure aluminum and Al-Si alloys was investigated for casting thin products using a spiral die in die casting. An aluminum alloy with good fluidity can be die-cast into thin products. For a Si content of less than 6 mass%, the fluidity increased with decreasing Si content. For a Si content of greater than 6 mass%, the fluidity increased with increasing Si content. The fluidity was affected by latent heat, flowability in the semisolid state, and heat transfer between the die and metal. For pure aluminum, the latent heat is small and there is no semisolid state. However, pure aluminum has excellent fluidity because the heat transfer between the die and metal is small. For Al-25%Si, the latent heat is very large and flowability increases in the semisolid state. Therefore, the fluidity of Al-25%Si is high. Fluidity typically increases with increasing die temperature. The increase in fluidity due to an increase in die temperature for the pure aluminum is small compared with that for hypoeutectic Al-Si alloys. This means that the heat transfer between the pure aluminum and the die is smaller than that for hypoeutectic Al-Si alloys. Therefore, the influence of die temperature on the fluidity of the pure aluminum is small. It is estimated that the chill layer of the pure aluminum rapidly peels from the die, decreasing the heat transfer between the pure aluminum and the die.
3D Laser Forming of Metal Foam Sandwich Panels
Authors: Bucher Tizian , Finn Connor , Verma Ravi , Li Wayne , Yao Y. Lawrence 
Published: January 2021

Abstract
Metal foam sandwich panels have been subject of many concept studies, due to their exceptional stiffness, light weight, and crash absorption capacity. Yet, the industrial production of the material has been hampered by the fact that it is challenging to bend the material into practical engineering shapes. Only recently it has been shown that bending of metal foam sandwich panels is possible using lasers. It was shown that the material can be bent into Euclidean (2D) geometries, and the governing laser-induced bending mechanisms were analyzed.
This study was focused on laser forming of metal foam sandwich panels into non-Euclidean (3D) geometries. It was investigated whether the knowledge about the bending mechanisms translates to 3D deformation, and whether the combination of process parameters that were identified for 2D laser forming are still appropriate. Moreover, the impact of the laser scan length was determined by comparing different scan patterns that achieve the same 3D geometries.
It was shown that 3D deformation could be induced for both the bowl and saddle shapes, the two most fundamental non-Euclidean geometries. The amount of laser-induced bending and in-plane strains vary depending on process conditions and thus bending mechanisms. Lastly, the laser scan length was shown to become more important for metal foam sandwich panels, where the panel thickness tends to be large.
Material Flow Behavior Modelling and Strain Distribution Prediction During Self-Reacting Friction Stir Welding Process Based on Computational Fluid Dynamics Method
Authors: Zhao Chenyu , Liu Xun , Zhang Wei , Cao Weiyu 
Published: January 2021

Abstract
Self-reacting friction stir welding (SRFSW) is an advanced variant of friction stir welding (FSW) and shows several superiorities with the double-sided tool configuration. Despite the considerable amount of experimental studies in this field, most of the tool development efforts are still empirical and resort to trial-and-error solutions. To reveal effects of tool features on process physics and guide tool designs, in this study, a multi-physics SRFSW process model is developed within the framework of computational fluid dynamics (CFD). A shear stress boundary condition is applied at the tool-workpiece contact interface. First, the velocity distribution at weld cross section are calculated and the results show that the threads on the pin contribute to the enhancement of stirring effect. Second, the temperature evolutions at advancing side (AS) and retreating side (RS) are compared, and position in RS has higher temperature than position in AS accordingly. Finally, the plastic strain distribution behind pin tool is calculated by integrating effective stain rate along pathlines. The result shows that AS has a more definable strain boundary than RS, which corresponds to the general macroscopic observations in SRFSW. The results may provide a reference on SRFSW tool design.
Fiber Filled Hybrid Hydrogel for Bio-Manufacturing
Authors: Habib Ahasan , Khoda Bashir 
Published: January 2021

Abstract
The extrusion based three-dimensional (3D) bio-printing deposits cell-laden bio-ink with high spatial resolution and may offer living tissue regeneration. Due to the biocompatibility, less cytotoxicity and high water content, natural hydrogels are commonly considered as the bio-ink for scaffold fabrication. However, due to the low mechanical integrity, a large scale scaffold (&gt; 10 layers) with intricate architecture is a challenge. In this paper, Cellulose-based nano-fiber and CMC are added with alginate material to improve the rheological behavior of the hybrid hydrogel. Shear-thinning behavior, shape fidelity, printability of the composition are investigated and evaluated for various compositions. Finally, both regular and freeform 3D scaffolds are fabricated with the proposed hybrid hydrogel to validate its printability and shape fidelity. The required properties of bio-ink are highly dependent upon the percentage composition and the solid content.
In-Situ Monitoring of Laser Powder Bed Fusion Process Anomalies via a Comprehensive Analysis of Off-Axis Camera Data
Authors: Vallabh Chaitanya Krishna Prasad , Xiong Yubo , Zhao Xiayun 
Published: January 2021

Abstract
In-situ monitoring of a Laser Powder-Bed Fusion (LPBF) additive manufacturing process is crucial in enhancing the process efficiency and ensuring the built part integrity. In this work, we present an in-situ monitoring method using an off-axis camera for monitoring layer-wise process anomalies. The in-situ monitoring is performed with a spatial resolution of 512 × 512 pixels, with each pixel representing 250 × 250 μm and a relatively high data acquisition rate of 500 Hz. An experimental study is conducted by using the developed in-situ off-axis method for monitoring the build process for a standard tensile bar. Real-time video data is acquired for each printed layer. Data analytics methods are developed to identify layer-wise anomalies, observe powder bed characteristics, reconstruct 3D part structure, and track the spatter dynamics. A deep neural network architecture is trained using the acquired layer-wise images and tested by images embedded with artificial anomalies. The real-time video data is also used to perform a preliminary spatter analysis along the laser scan path. The developed methodology is aimed to extract as much information as possible from a single set of camera video data. It will provide the AM community with an efficient and capable process monitoring tool for process control and quality assurance while using LPBF to produce high-standard components in industrial (such as, aerospace and biomedical industries) applications.
Evaluation of Soybean Oil-Based MQL As a Potential Replacement for Emulsion Flood Cooling Strategy for High-Speed Face Milling of Inconel 718
Authors: Okafor Anthony Chukwujekwu , Nwoguh Theodore Obumselu 
Published: January 2021

Abstract
This paper presents the results of comparative evaluation of soybean oil based MQL oil flow rates at 10, 30, 50, 70, and 90 ml/h with emulsion flood coolant (EC) at 1200 l/h as a benchmark in face milling of Inconel 718 using coated carbide inserts. Resultant cutting force, tool wear/ mechanism, and surface roughness are the machining performance parameters analyzed. The results show that MQL oil flow rate at 70 ml/h gave the least tool wear comparable to that of EC, while 10 ml/h gave the highest tool wear. Also, 70 ml/h gave the lowest resultant cutting force among all MQL flow rates. Increasing soybean oil-based MQL flow rate improves surface roughness and reduces tool wear by providing enough thin lubrication film but also leads to an increase in chip affinity and formation of large built-up-edges (BUEs) as the MQL flow rate reaches 90 ml/h. At lower soybean oil-based MQL flow rate, tool wear mechanism is predominantly abrasion due to large surface friction, while at higher soybean oil-based MQL flow rate, tool wear mechanism is adhesion leading to excessive BUEs. Soybean oil-based MQL flow rate at 70 ml/h is recommended when face milling Inconel 718 and is demonstrated to be a potential replacement of EC for machining difficult-to-cut metal.
The Geometric Error Measurement and Compensation for a Five-Axis Machining Center’s Tilting Rotary Table
Authors: Liu Kuo , Han Wei , Liu Haibo , Sun Mingjia , Xie Nan , Wang Yongqing 
Published: January 2021

Abstract
The geometric error measurement and compensation for a five-axis machining center’s tilting rotary table is a difficult problem in the machine tool industry. Aiming at this problem, and based on a thorough study of the geometric error of a vertical five-axis machining center’s tilting rotary table, a method has been suggested in this paper to measure the geometric error of the tilting rotary table using the ball bar performing a three-axis circular interpolation. Eight center bias values in the X and Y directions were obtained by the use of four specific three-axis circular interpolation tests. According to the geometric relations of these four specific forms of circular tests, a geometric error separation model of the tilting rotary table was established. The process of circle test of A-axis and C-axis for vertical five-axis machining center is given in detail. The contrast tests, before and after compensation, were carried out in a vertical five-axis machining center. The experimental results showed that the positional errors and angular errors after compensation were much smaller than those before compensation. The positional error decreased from the maximum value of - 0.089 mm before compensation to the maximum value of - 0.004 mm, and the angle error decreased from the maximum value of - 0.012° before compensation to the maximum value of 0.002°. This method has provided an important reference for the geometric error measurement and compensation for a vertical five-axis machining center’s tilting rotary table.
Asset Condition Management: A Framework for Smart, Health-Ready Manufacturing Systems
Authors: Diaz-Elsayed Nancy , Hernandez Luis , Rajamani Ravi , Weiss Brian A. 
Published: January 2021

Abstract
Unscheduled downtime in manufacturing systems can be a major source of lost productivity, profits, and, ultimately, reduced process quality and reliability. However, the incorporation of asset condition management (ACM) into manufacturing systems offers an approach to improve equipment and plant operations by providing real-time condition awareness, system diagnostics, and estimates of future health to enable predictive maintenance. ACM is a framework for assessing the current and future state of health of a manufacturing system and integrating that knowledge with enterprise applications to meet the demand of production operations. In manufacturing systems, successful operations rely on the ability to maintain production assets at their optimal working levels to optimize operations and system performance. Some large corporations have made great strides in incorporating smart technologies to enhance their asset management strategy; however, small- and medium-sized enterprises (SMEs) face distinct challenges. One of the key challenges is that most SMEs do not have the wherewithal to invest in new machines nor is there standard guidance on how older machines can be integrated into an ACM solution, so that their end-to-end manufacturing process can be optimized from a health management point of view. This research presents a framework for ACM to facilitate its introduction into manufacturing systems based on their “health-ready” capabilities. Specifically, an ACM system architecture is defined for manufacturing systems, the health-ready principles and capability levels from the aerospace and automotive industries are adapted to the manufacturing domain, and the results from the outreach effort to the manufacturing community are discussed.
Simulation of Fabry-Perot Resonance for 3D Printable Complex Holey Acoustic Metamaterials
Authors: Ravichandran Sanjay , Wu Xin , Su Yutai , Shi Jing 
Published: January 2021

Abstract
An acoustic metamaterial is a kind of material that is artificially designed in such a way that it can manipulate, control and direct sound waves. To date, various designs for acoustic metamaterials in the imaging applications have been proposed. However, these designs are generally simple due to the restriction from conventional manufacturing methods. By taking advantage of the additive manufacturing (AM) techniques, many complex acoustic metamaterials could be realized. However, the research on the complex structures for imaging applications has been very limited. In this paper, various 3D printable holey structured metamaterials with only one aperture are proposed, and the application possibility for sub-wavelength acoustic imaging in the audible frequency range is investigated. By using numerical simulation method, the effect of transmission properties of incident evanescent waves is analyzed to see whether these waves can completely transmit through the metamaterial. The phenomenon of Fabry-Perot resonances (FPR) that occur inside the hole for five different aperture shapes which are air-filled is studied, and the possibility of operating in a broadband resonance condition for the five designs are analyzed. These results can also be used to obtain valuable information for realizing a broadband acoustic hyperlens, which is an emerging application of 3D printable acoustic metamaterials.
Fabrication and Characterization of Conical Micro Dimple Textures on Ti6Al4V for Higher Biocompatibility
Authors: Jain Ankit , Yatirajula Suresh Kumar , Bajpai Vivek 
Published: January 2021

Abstract
In lab-developed micromachining facility has been utilized to fabricate conical micro dimple textured surfaces of different density on the Ti6Al4V implant surface to improve the surface properties for higher biocompatibility and osseointegration rate. The surface topography, roughness, quality, shape, and size of the formed textures were analyzed by cross-sectional form measurement using probe-type contact surface profilometer and FESEM (Field Emission Scanning Electron Microscope) analysis. Further, the surface composition of both textured and un-textured surfaces was studied by EDS (Energy-dispersive X-ray spectroscopy) analysis. The equilibrium contact angle of water was measured using the sessile drop technique of drop shape analyzer on both (textured and un-textured) surfaces. Further, the thermodynamic work of adhesion has been calculated by the Young-Dupre equation for both the surfaces. The formed textures are in good shape, size and quality. Each texture is uniform and equally spaced as per the design of experiment. Further, EDS analyses show that the surface composition of textured surfaces does not alter due to micromachining. The surface roughness values inside the dimple are almost the same, which indicates that the effect of tool wear is negligible. The hydrophilicity and work of adhesion of textured surfaces are significantly improved as compared to the untextured surface.