bluuebunny/crossref_metadata_2025_split huggingface dataset:
Effects of Cutting Parameters on Chip Side-Curl Mechanisms and Variable Tool-Chip Contact in Turning
Authors: Balaji A. K. , Jawahir I. S. 
Published: December 2021

Abstract
This paper presents the results of an investigative study on the chip side-curling mechanism and the associated variable tool-chip contact in turning operations. The effect of various cutting and tool geometry parameters such as depth of cut-nose radius ratio, feed, inclination angle, etc. on chip side-curling are established in a hierarchical manner. The importance of variable friction at the tool-chip interface along the developed length of the cutting edge is shown from the experimental observations of the tool-chip contact area using a SEM analysis. The significant influence of the radial cutting force component on the resultant chip side-curl is established using a high speed-filming analysis of comparative experiments in tube and bar turning operations.
Implementation of the Latest Breakthrough in the Physics of Materials in Metal Cutting: Analysis and Preliminary Results
Authors: Astakhov Viktor P. , Komarovskiy A. A. 
Published: December 2021

Abstract
Everyday practice of cutting process planning requires reliable cutting force estimates, which currently can be obtained only from process-dependent machinability databases. The greatest obstacle to developing a more basic, efficient approach is a lack of understanding of material behavior under unique deformation conditions of cutting. The metal cutting process has been defined by the authors earlier as the purposeful fracture of workpiece material and, therefore, a new way to minimize the energy consumption per unit volume of the layer to be removed in cutting should be revealed in order to predict metal cutting performance. Unfortunately, the traditional mechanical metallurgy has too little to be used for such a purpose. This paper deals with practical applications of the equation of state of a solid to the metal cutting process. It is shown theoretically and proven experimentally that the energy consumed in cutting can be effectively controlled by applying external force fields to the workpiece.
High Speed Grinding of Silicon Nitride With Electroplated Diamond Wheels: II — Wheel Topography and Grinding Mechanisms
Authors: Hwang T. W. , Evans C. J. , Malkin S. 
Published: December 2021

Abstract
This is the second in a series of two papers concerned with high speed grinding of silicon nitride with electroplated diamond wheels. In the first paper (Hwang et al., in press), it was shown that grinding of silicon nitride is accompanied by dulling of the abrasive grains and a significant increase in the grinding forces and power. High wheel speed caused more wheel wear, which was attributed to a longer accumulated sliding length between the abrasive grains and the workpiece. This second paper is concerned with the progressive change in wheel topography during grinding and how it affects the grinding process. A statistical model is developed to characterize the wheel topography during grinding in terms of active cutting grains and wear flat area. According to this model, continued grinding is accompanied by an increase in both the number of active grains and the wear flat area on the wheel surface as the wheel wears down. The measured increase in grinding forces and power was found to be proportional to the wear flat area, which implies a constant average contact pressure and friction coefficient between the wear flats and the workpiece. Increasing the wheel speed from 85 m/s to 149 m/s significantly reduced the contact pressure, which may be attributed to a reduction of the interference angle, but had almost no effect on the attritious wear rate of the diamond abrasive. Therefore, more rapid wear of the diamond wheel at higher wheel speeds due to a longer sliding length may be offset by reduced contact pressures and lower grinding forces.
Specific Grinding Energy Causing Thermal Damage in Precision Gear Steels
Authors: Mayer John E. , Price Angie H. , Purushothaman Ganesh K. , Gopalakrishnan Sanjay V. 
Published: December 2021

Abstract
Thermal damage (burn) in carburized and hardened precision gear steels caused by grinding was investigated. Excessive grinding temperatures cause grinding bum and result in excessive scrappage. AISI 9310 and X53 gear steels, used in helicopters and tilt-rotor aircraft, respectively, were prepared and heat-treated by a production partner. Grinding tests were conducted on these steels. Nital etching was used to detect grinding burn. Models were established to predict onset of thermal damage for AISI 9310 and X53 steels based on specific grinding energy determined from grinding force measurements. The models were compared to results published for other steels.
Investigation of the Self-Dressing of Resin Bound Grinding Wheels
Authors: Miller Michele H. , Kakumanu Thrinath S. 
Published: December 2021

Abstract
Wheel self-dressing, a byproduct of wheel wear, is often desirable for maintaining consistent wheel performance. We investigated the self-dressing process by monitoring the cutting force in plunge grinding experiments and by developing a computer model to predict the cutting force as it changes with wheel wear. The experiments show the significant effect of infeed and work material on the evolution of the cutting force. The simulation predicts the effects of infeed, work material strength, and binder strength on the cutting force. In addition, we discuss ways to improve the model and its potential for aiding in the selection of wheel parameters.
Study on Acoustic Emission in the Grinding Process Automation
Authors: Chen Ming , Xue Bing-Yuan 
Published: December 2021

Abstract
Comprehensive experiments have been conducted to investigate the monitoring technique for grinding process automation with acoustic emission (AE) signal. The AE signal generated during the grinding process is analyzed to determine its sensitivity to process. The detection of contact between the grinding wheel and workpiece and in-process prediction of grinding burn have been discussed in sequence. The results have been obtained as follows: (1) AE contact detector can save the non-machine time remarkably, thus high efficiency is available. (2) An effective intelligent sensing system has been developed and grinding burn can predicted. As mentioned above, AE technique has found wide applications in the grinding process automation.
Cost Drivers in Sand Casting Design
Authors: Stoll Henry W. 
Published: December 2021

Abstract
Sand casting offers weight and cost advantages that make it an optimal manufacturing process choice for many situations. However, to fully realize the cost reduction potential of sand casting, the casting designer must specify geometry that is carefully chosen to minimize tooling complexity and lead time and to maximize process yield. This paper systematically explores the sources of cost in sand casting to understand how design decisions impact total cost. A comprehensive cost model for sand casting is proposed, several key design related cost drivers are identified, and the qualitative relationship between the cost drivers and cost sources is discussed.
Collaboration Technologies for Global Manufacturing
Authors: Steves Michelle P. , Knutilla Amy J. 
Published: December 2021

Abstract
One impact of the globalization of manufacturing is the growing requirement for teams that are not co-located to collaborate using shared information. In this paper, we present our approach to instituting and assessing collaboration technologies for manufacturing applications. We provide a brief overview of Computer Supported Cooperative Work (CSCW) and groupware and discuss some potential uses in manufacturing. We describe related research at NIST, focusing on a process engineering collaboration scenario. We also present two approaches to collaboration technology deployment, seeding and accelerated deployment, aimed at reducing deployment costs in the manufacturing environment. Ultimately, the work presented here, in addition to similar systematic deployment and assessment of collaboration tools in other manufacturing scenarios, will provide knowledge that is useful for manufacturers who wish to efficiently deploy and effectively use collaboration technologies.
Modeling and Verification of Interelectrode Gap in Electrochemical Machining With Passivating Electrolyte
Authors: Zhu D. , Rajurkar K. P. 
Published: December 2021

Abstract
The industrial applications of Electrochemical Machining (ECM) technology are limited due to difficulties in tool design, monitoring and control, and sludge generation and disposal. An accurate modeling and prediction of interelectrde gap (i.e. the gap between tool electrode and workpiece electrode) is one of the most important steps to minimize these difficulties. The interelectrode gap distribution depends on electric field distribution which is a function of many process parameters varying in space and time during electrochemical dissolution process. This paper proposes a model and numerical approach to determine the gap distribution. The model is based on determining the electric field in the interelectrode gap and finding a cathode (tool) boundary which will satisfy the Laplace Equation for potential distribution and all other boundary conditions to achieve the desired workpiece shape. The proposed method incorporates the variation of electrochemical machinability and, hence, is applicable to ECM with both non-passivating and passivating electrolytes. The proposed method does not require iterative redesign process, therefore, it provides excellent convergence and computing accuracy. The verification experiments have been conducted using a specially developed electrolytic cell and an industrial scale ECM system. A close agreement has been observed between theoretical and experimental results.
Piezo Actuator Hybrid Modeling for Nonlinear Inverse Control in Diamond Turning
Authors: Song Dongwoo , Li C. James 
Published: December 2021

Abstract
This paper describes a micro-positioning system based on piezo actuators and a spring mechanism, and a hybrid hysteresis model integrating a neural network and Preisach model to identify the inverse dynamics of the micro-positioning system. To improve the workpiece form accuracy in diamond turning, feedforward control using the hybrid inverse model and feedback PID control were applied individually and in combination. The performance of these controllers are compared in actual cutting tests.
Design of Laser Ultrasonic System for In-Process Weld Penetration Monitoring and Control
Authors: Hopko Sandra N. , Ume I. Charles , Erdahl Dathan S. 
Published: December 2021

Abstract
Ultrasonics is a widely used nondestructive testing technique, which is often applied off-line for weld quality inspection. Laser ultrasonic (LU) inspection systems have the potential for on-line application, providing the means to identify unacceptable welds as they are formed. Because LU systems are non-contacting, they can be used for testing moving specimens or for operation in hazardous and/or high temperature environments. A highly versatile system can be created when an optical fiber delivery system is incorporated into the design. Introduction of a focusing objective increases the allowable working distance and permits stronger generation using material ablation as the generating mechanism. This paper describes the development of a laser ultrasonic probe using an optical fiber delivery system with a distal end, focusing objective. The optical fiber delivery system can be configured as a single fiber source, a linear array (fiber bundle) or a phased array. Results include experimentally obtained directivity patterns demonstrating ultrasonic generation using ablation sources. Thermoelastic source results are also included. This paper demonstrates the potential of the fiber tool and presents an overview of the weld control scheme.
Predictive Modeling of Nonlinear Regenerative Chatter via Measurement, Analysis, and Simulation
Authors: Pratt J. R. , Davies M. A. , Kennedy M. D. , Kalmár-Nagy T. 
Published: December 2021

Abstract
A single-degree-of-freedom active cutting fixture is employed to reveal and analyse the hysteretic nature of the lobed stability boundary in a simple machining experiment. Specifically, the seventh stability lobe of a regenerative cutting process is mapped using experimental, analytical, and computational techniques. Then, taking width of cut as a control parameter, the transition from stable cutting to chatter is observed experimentally. The cutting stability is found to possess a substantial hysteresis so that either stable or chattering tool motions can exist at the same nominal cutting parameters, depending on initial conditions. This behavior is predicted by applying nonlinear regenerative chatter theory to an empirical characterization of the cutting force dependence on chip thickness. Time-domain simulations that incorporate both the nonlinear cutting force dependence on chip thickness and the multiple-regenerative effect due to the tool leaving the cut are shown to agree both qualitatively and quantitatively with experiment.
A Control Strategy and Upper Bound Solution for Non-Flat Tool Open Die Forging Automation
Authors: Nye T. J. 
Published: December 2021

Abstract
The open die forging process can provide a number of benefits if its costs can be made competitive through automation. This paper describes a control strategy for automated open die forging forming sequence generation. An upper bound solution for forging with radiused tools is developed, along with a method for using this solution to estimate forming results, a necessary component of the control strategy. Model predictions are compared to physical experimental data using plasticine, and show good agreement.
Mechanical Properties and Cutting Performances of High Purity Polycrystalline cBN Compact
Authors: Uesaka Shinya , Sumiya Hitoshi 
Published: December 2021

Abstract
Mechanical properties and cutting performances of high purity polycrystalline cBN (PcBN) compacts synthesized by the direct conversion method from hexagonal BN under high pressure and high temperature have been investigated. The hardness and transverse rupture strength (TRS) of the compacts in the temperature range of 293 to 1473 K depend strongly on the cBN grain size and the amount of residual hBN in the compact. The fine-grained (&lt; 0.5 μm) and high purity (&gt; 99.9%) PcBN compacts synthesized at 7.7 GPa and about 2550 K. has the highest hardness and TRS at any temperature. All high purity PcBN compacts have high thermal conductivity above 300 W/m.K and show excellent thermal crack resistance in high speed wet cutting of gray cast iron and milling of steel, which are difficult for the conventional cutting tool materials. Especially, the fine-grained compact, which has high strength, exhibits excellent cutting performances.
Design Criteria for Hardturning Machines
Authors: Yasui Shouri , Sakai Kazutoshi 
Published: December 2021

Abstract
The benefits of hardturning include reduced setup costs; shorter tool change times; improved squareness by virtue of the ability to machine cylinder I.D., O.D. and face in one chucking; low energy consumption and elimination of the need to handle grinding sludge and waste fluid.
Hardturning has typically been used as a replacement for grinding, in the processing of fitting surfaces or clad surfaces, and other such relatively straightforward applications not requiring sliding. In recent years, however, due to advances in servo and other machine technology, and tool material improvements (CBN, ceramics), hardturning has entered the realm of finishing curved and complex shaped surfaces that have sliding and rolling contacts.
This paper will present the machine characteristics developed to meet the ever increasing demand for hardturning process accuracy, and introduce each of the factors which ultimately affected the design of machine components, providing examples where appropriate.
Experimental Investigation of Thermo-Mechanical Characteristics in Laser-Assisted Machining of Silicon Nitride Ceramics
Authors: Lei Shuting , Shin Yung C. , Incropera Frank P. 
Published: December 2021

Abstract
Laser-assisted machining (LAM) of silicon nitride (Si3N4) is evaluated for its potential to become an economically viable process in fabricating precision ceramic parts. On-line measurements of cutting force and workpiece temperature are performed, and tool wear and surface integrity are examined. Tool wear characteristics are determined as a function of workpiece temperature, which is measured on-line using a laser pyrometer. Tool wear/failure mechanisms are characterized using optical microscopy, while application of scanning electron microscopy to heated and machined surfaces, as well as to chips, is used to infer material removal mechanisms and the extent of damage caused by LAM. The sub-surface damage of parts produced by LAM is compared with that of typical ground parts.
A New Perspective of Residual Stress Induced by Machining and Grinding
Authors: Liu C. Richard , Yang Xiaoping 
Published: December 2021

Abstract
Residual stress is one of the most important factors affecting product surface integrity. Every machining operation produces a distinctive residual stress in the surface layer. The surface residual stress produced by grinding and face turning were measured in very small surface areas at several locations of each sample using X-Ray diffraction technique. Significant point-to-point residual stress variations were found in the ground surfaces, which poses a potential hazard to applications requiring high surface integrity. On the other hand, only small point-to-point residual stress variations were found in the face turned surface. An explanation to this phenomenon has been given. Residual stress on seven samples undergone multiple-pass grinding were also measured, the results of which show that final residual stress distribution on a ground workpiece depends on the initial residual stress, the number of grinding pass, as well as grinding conditions. It is suggested that single-point cutting be used in place of abrasive grinding.
Achieving Precision Grinding Quality by Hard Turning
Authors: Jochmann Sven , Wirtz Holger 
Published: December 2021

Abstract
In the past decade, the technology of finish machining hardened steels with geometrically defined cutting edges has been developed. Due to its high potential to increase productivity as well as competitiveness, research and development has focused on enlarging the use of hard turning for components with very high requirements on surface quality (Rz &lt; 1 μm), form and shape tolerances (IT3 - IT5). In this paper, a detailed comparison on achievable workpiece quality for finish grinding with Al2O3- and CBN-wheels and finish hard turning is presented. It will be shown that finish hard turning is today capable of achieving and maintaining workpiece qualities within the same high range like finish grinding processes.
Evaluating Variation Reduction Process Control Strategies Through System Modeling
Authors: Suri Rajiv , Otto Kevin 
Published: December 2021

Abstract
This paper presents a method for using a system model to reduce end-of-line variation in a sheet stretch-forming manufacturing system. An integrated set of mathematical models representing the operations in a system can be effectively used to select among four variation reduction strategies: robust process design, input variation reduction, feed-forward control, and feedback control. To compare these alternatives, models that predict both quality characteristic nominal values and standard deviations of the work-in-process are required. Numerical simulation using these models allows for evaluation and comparison of each strategy prior to any activity on the shop floor. This approach is demonstrated on a sheet stretch-forming manufacturing system from the aerospace industry. A feed-forward strategy is selected as having the greatest potential for this system. A subsequent experimental validation on the shop floor showed a 30% reduction in strain variation on a batch of production parts.
Design and Analysis of a New High Performance Electrohydraulic Actuator
Authors: Habibi Saeid , Goldenberg Andrew 
Published: December 2021

Abstract
This paper describes a new high performance robotic actuation system that presents a powerful alternative to existing commercial systems. This actuation system is self-contained and combines the benefits of conventional hydraulic and direct drive electrical actuators, namely high torque/mass ratio and modularity. It is referred to as the ElectroHydraulic Actuator (EHA) and results from the fusion of the above mentioned technologies. EHA is a unique device with its own characteristics and requires hydraulic components that are specifically tailored to its needs. To fulfill these requirements, a new symmetrical Linear Actuator (SLA) was designed as a sub-component of EHA. Experimental data from a prototype of EHA are reported.
Design Methodology for Fluid Power Systems Using Hypermedia
Authors: Hughes Edmund J. , Richards Thomas G. , Tilley Derek G. 
Published: December 2021

Abstract
Fluid power system design is a skilful and complex task requiring significant practical experience and heuristic knowledge gained over many years. Industries specifying and/or designing fluid power systems in their products are at risk should they lose key personnel with this knowledge. This problem is compounded by a lack of formal training at the graduate level, creating a shortfall in qualified fluid power designers.
Design support tools that assist and guide designers in their work, as part of a Concurrent Engineering approach, should be capable of providing both good practice guidance and a framework into which product specific information can be stored for later reuse. This paper discusses the early development of a fluid power system design tool that seeks to offer this support using a methodology developed in hypermedia.
A Future Micro Hydro-Propulsive System
Authors: Bayandor Javid , Abanteriba Sylvester , Bates Ian 
Published: December 2021

Abstract
This paper discusses the development of production of a new type of hydro-propulsive system for the generation of the power. First, the principles which seek to quantitatively describe the behavior of this unconventional system are established. A brief description of the mechanical design is included. A parametric study of the major influences on the performance of the system has been carried out and discussed. Finally, the comparison of theoretical simulation and experimental is indicated and discussed in detail.
Two-Level Hierarchical Control of Hydraulic Elevator Speed
Authors: Ran Longlin , Yang Huayong 
Published: December 2021

Abstract
The speed control of hydraulic elevators is usually carried out by PID controllers. But as the system properties slowly changes with the working situation, the control result is not satisfactory after long time operation. In this paper, a two-level hierarchical controller consist of an intelligent PI controller and a simple upper level expert controller is introduced. The expert controller is based on the expert knowledge accumulated from research experiences on the speed control of hydraulic elevators. The controller is realized on a small chip computer system, which is cheap and flexible to use.