bluuebunny/crossref_metadata_2025_split huggingface dataset:
Some Observations on the Uniqueness of Machining
Authors: Madhavan V. , Chandrasekar S. 
Published: March 2022

Abstract
It has been suggested by R.Hill (1954b) that the machining process is not uniquely determined by the input conditions. A finite element simulation capable of representing the physics behind machining with high fidelity is used to explore the uniqueness of the machining process. It is found that a stable unique mode of deformation does exist for a given set of input conditions. Experimental and theoretical studies also indicate that the mode of deformation is indeed unique and that this uniqueness is possibly due to the applicability of the principle of minimization of plastic work to the machining process.
A Study of Wave-Removing Cutting Process Using a Model of Shear Zone With Parallel Boundaries
Authors: Hayajneh M. T. , Osman M. O. M. , Latinovic V. N. 
Published: March 2022

Abstract
A shear zone model with parallel boundaries is used to formulate a cutting force model and analyze the dynamic behavior of the machining process in orthogonal cutting. The cutting system was modeled using a single degree-of freedom dynamic system where the variations of the cutting forces are represented by their total differentials. The model is derived based on the principles of the cutting mechanics, and takes into account the variations of the shear stress in the primary deformation zone as well as at the chip-tool interface (secondary deformation zone).
Closing the Gap Between CAD/CAM and Machining Process Simulation: A Generic Solution
Authors: El-Mounayri Hazim A. , Imani Behnam M. , Elbestawi Mohamed. A. , Spence Allan D. 
Published: March 2022

Abstract
In this paper, an enhanced CAD/CAM system for simulating 3-axis milling of complex parts is proposed. The system consists of the conventional CAD/CAM system enhanced with a milling process simulator. The latter includes a geometric module and a physical module. The geometric simulator integrates solid, surface and curve modelling to accurately represent the geometric entities involved in the milling simulation and extract the geometric information required for predicting different process parameters. The physical simulator is composed of force models for flat and ball end mills which compute instantaneous cutting forces. The applicability of the approach is demonstrated for the case of 3-axis milling using a ball end tool. The validity is shown by predicting cutting forces and comparing them with experimental measurements. This system can be used to verify and optimize NC codes, thus contributing to improving the reliability, accuracy, and productivity of NC machining.
A Dynamic Model of the Cutting Force System in Peripheral Milling Characterizing the Effects of Flank Face Interference
Authors: Narayanan Kannan , Ranganath Santosh , Sutherland John W. 
Published: March 2022

Abstract
An enhanced model for the dynamic behavior of the end milling process is described. The model predicts the cutting forces and cutter deflections by including the effects of the flank face interference mechanism in addition to the chip removal effects. The interference mechanism is accounted for by considering the flank interference forces to be proportional to the interference volume. The volume of interference is estimated numerically. The total force acting on the tool is a combination of the forces due to the cutting action and forces due to the interference. Experiments performed on 6061-T6 Aluminum validate the simulation results.
A 3-D Kinematic Model of Complex Chip Curling With Chip Breaker Tools in Metal Cutting: Part I — Analytical Modelling
Authors: Fang Y. J. , Fang X. D. , Basu A. 
Published: March 2022

Abstract
It has been realised that the analytical model of 3-D chip curling plays a central role in the chip formation that would predict the chip forms/shapes efficiently for the aim of chip control. The purpose of the two-part paper is to investigate and model the 3-D chip curling processes in theory. In part I, an analytical modelling procedure is described in detail and a general mathematical model for predicting chip forms /shapes in 3-D cutting processes with complex chip breaker tools is presented on the basis of three basic chip curling patterns, i.e. up-curl, side-curl and twisting. In part II, the theoretical analysis and discussion have been done systematically based on the model presented. Therefore a group of criterions for the effects of three chip angular velocity components ωx, ωy, ωz, and chip flow angle η0 on the chip forms/shapes is derived. The varying tendency of the chip radius and chip pitch with varying ωx, ωy, ωz, and η0 is discussed based on the group of criterions. For better understanding, a group of 3-D diagrams is given to visualise the varying tendency of chip geometry. The 3-D analytical model and the group of criterions presented in part I and part II of the paper reveal new insights in to the nature of chip curling in 3-D machining in theory and are significant for the analytical prediction of the chip curling and the chip breaking, as well as the geometric design of the chip breaker/groove.
An Experimental Investigation of the Variability of Edge Hones and Their Effects on Machining Forces
Authors: Schimmel Roy J. , Manjunathaiah Jairam , Endres William J. 
Published: March 2022

Abstract
A new, non-contact instrument is identified for measuring the edge radii of cutting tools to a very high degree of accuracy. The instrument uses white light interferometry combined with accurate axis movements and software algorithms to make the measurements. Using this technique, the edges of several commercial cutting inserts are measured and compared. It is found that the radius of the hone varies along the length of the edge in a parabolic manner. The difference between the edge radius at the center of the edge to the radius at the start of the nose can be as large as 25μm (0.001in). The variation between the edges on an insert and across inserts in a batch of tools can be as high as 25μm (0.001in). In order to investigate the effect of these variations in edge radii on cutting forces, orthogonal cutting tests are performed with tools of measured edge radius in the zone of cut. The results indicate that the machining forces (especially the thrust force component) are sensitive to changes in edge radius on the order of measured variations.
Design of a High Speed Milling Machine for Aluminum Aircraft Parts
Authors: Tlusty Jiri , Smith Scott , Badrawy Sinan J. , Smith David A. , Smith Andrew P. 
Published: March 2022

Abstract
This paper deals with the design of a medium-sized high speed milling machine for end milling of thin-walled aluminum parts. Specifications for top parameters of spindle speed, feedrates, and accelerations are derived, and it is shown how the worldwide maximum values have been achieved. Design criteria of stiffness of the individual subsystems and high gain of control loops are discussed, and solutions are presented. Strategies for milling of thin ribs and thin webs arc explained, and examples of cutting conditions for two sample parts are given as machined on the three-axis configuration of the machine Alternative designs for extending the machine to five axes are described.
Analysis of Tapered Roller Bearing Stiffness
Authors: Rowell Timothy , Shin Yung C. 
Published: March 2022

Abstract
This paper presents a computational model and analysis of tapered roller bearing stiffness. A five degree of freedom model is coupled with a spindle model and implemented in a computer code. The predicted results are verified by other published data. The importance of proper modeling of the spindle and bearing interaction is identified. A sensitivity analysis of the bearing stiffness in terms of geometric and operational parameters is presented.
Nonlinearities in a Single Nut, Preloaded, Precision Ball Screw
Authors: Cuttino James F. , Dow Thomas A. , Knight Byron F. 
Published: March 2022

Abstract
The nonlinear performance of a single-nut, preloaded ball screw actuator is analyzed in this paper. The study identifies the source of nonlinear torque in the ball screw and subsequently maps that torque into the nonlinear displacement response due to windup in the shaft. The study is complemented with an experimental verification using a small angle rotation fixture (ARC) to input very small amplitude angular displacements to the screw while measuring induced torque and displacements. The experimental results are obtained from a Precision Linear Optimization Testbed (PLOT) which was developed to study the ability of different actuator systems to provide long range motion with nanometer accuracy. The analysis is conducted for the case of no axial loading. The study shows that the nonlinearities in the ball screw originate in the rolling friction between the balls and the races which induces torque in the nut and subsequently windup in the shaft. It also shows that the torque can be deduced from a relationship of the torque between a ball spinning in a race.
Simulation and Measurement of Chatter in Diamond Turning
Authors: Yantek David S. , Marsh Eric R. , Davies Matthew A. , Gilsinn David E. 
Published: March 2022

Abstract
This paper considers chatter in diamond turning of aluminum. A nonlinear chip area model is developed for use with the classic single degree of freedom cutting model. The chip area model is formulated as a function of the change in depth of cut between consecutive passes. This function is shown to be highly dependent on the quadratic term when turning the diameter of cylindrical workpieces with round-nosed diamond tools. The cutting model is further extended to include an impact disturbance to the cutting process. The recent research in ultra-precision machining is incorporated to properly account for the rise in specific cutting energy at extremely light depths of cut. Simulations of the resulting tool displacement show close agreement with experimental measurements.
Autonomous Calibration of Hexapod Machine Tools
Authors: Zhuang Hanqi , Liu Lixin , Masory Oren 
Published: March 2022

Abstract
Hexapod machines are emerging as a new type of CNC machine tools. Among other things, stringent calibration is an important means to improve their accuracy. Traditionally, to perform system calibration, one needs to measure a number of machine poses using an external measuring device. However, this process is often labor-intensive and invasive, and difficult for on-line calibration.
In this paper, a systematic way of self-calibrating a hexapod machine tool is introduced. By adding a small number of redundant internal sensors, errors of the hexapod machine tool can be measured. This approach has the potential of automatically producing accurate measurement data over the entire workspace of the system with an extremely fast measurement rate. Once the measurement data is available, a recursive filter is applied to estimate machine parameter errors from the predicted geometric errors, and to update the model residing in the machine controller. Thus, it is possible to dynamically calibrate and compensate for various types of machine errors including those induced by thermal and loading variations, without interrupting the normal operation of the machine tool. To verify the concept, preliminary experimental studies were conducted on a Stewart platform built at Florida Atlantic University.
Compatibility Analysis of Vehicle-to-Vehicle in Head-On Collision
Authors: Jawad Saad A. W. 
Published: March 2022

Abstract
An eight-degrees of freedom, two dimensional lumped-mass simulation model have been developed to study aggressivity of mass and stiffness ratio of vehicles in head-on collisions. Other factors like length of crumple zone, offset overlap and speed are also considered. The model assumes that the two colliding structures geometrically interact with each other. Engine assembly mass, primary and secondary stiffness parameters are considered in the model. Three injury risk criteria have been considered in this study; delta V or change in velocity of vehicle after impact, maximum acceleration sustained by the passenger compartment throughout impact, and length of deformation sustained by the car front. The most crucial aggressivity parameter is the mass ratio for the delta V criterion. The second and third aggressivity parameters are mass ratio and stiffness ratio for deformation length criterion. A slightly softer and longer crumple zone is proposed to be used for heavier vehicles to achieve compatibility of crashes of vehicles of different mass. This measure would alleviate aggressivity by a factor of about 20%. It was found that both mass and stiffness ratio have no aggressivity on the partner vehicle, as far as acceleration injury criterion is concerned. Acceleration is determined by the vehicle’s own mass and stiffness.
Aluminum Intensive Vehicle Crashworthiness Design Approach
Authors: Barbat Saeed D. , Mahmood Hikmat F. , Prasad Priya P. 
Published: March 2022

Abstract
A successful design approach and procedures for Ford’s Aluminum Intensive Vehicle (AIV) build and evaluation with emphasis on crashworthiness and front end design are described. Several issues and concerns related to design and assembly of all-aluminum body structure such as material selection, joining techniques, crush behavior and structural integrity were addressed and resolved. An experimental and analytical approach was adopted to investigate the static and dynamic behavior of spot-welded and weld-bonded aluminum crush members. Design and analyses tools for establishing target component forces, assessing energy absorption and stability of collapse of the front end structure are also presented. Sections, components and sub-system analyses were conducted to establish the AIV target forces, energy levels and collapse modes. Extensive testing on generic section columns and production component and sub-systems were also performed. This helped in addressing critical issues associated with the introduction of all aluminum body structure into high volume production. Other tests were also conducted for design verification.
Aluminum alloys AA5XXX and AA6XXX-T4 were used for the structural components of the AIV. AA5XXX was used for the front end frame and a mix of AA5XXX/AA6XXX was used for the roof structure. Doors and hoods utilized AA6XXX-T4 alloy for their construction. It was demonstrated that the all-aluminum body structure can achieve equivalent crashworthiness performance as its steel counterpart with a weight saving of 30%. The all-aluminum vehicles were tested in frontal and rear crash, roof crush, side intrusions in side impact and all met or exceeded the Federal Motor Vehicle Safety Standard (FMVSS) requirements.
Application of Optical Triangulation Ranging in Automobile Collision Avoidance
Authors: Saikia Siddarth 
Published: March 2022

Abstract
This system is conceptualised for the avoidance of extensive damage during collision in road vehicles. The system uses optical triangulation to gauge distances in the environment.
A laser beam will scan the environment horizontally, a camera will locate the image of the reflected ray. The data of the scan will be analysed as per the formulated algorithm, if certain parameters are exceeded and a collision is deduced to be inevitable, then external airbags mounted in the front and on the sides of the car will be inflated.
Better accuracy of optical triangulation ranging over radar ranging in short distances, enables the use of external air bags along with other regular collision avoidance features.
Investigation of Brain Injury Kinematics: Introduction of a New Technique
Authors: Hardy Warren N. , Foster Craig D. , King Albert I. , Tashman Scott 
Published: March 2022

Abstract
The principal focus of this study is the measurement of relative brain motion with respect to the skull and between different regions of the brain. Using a high-speed bi-planer x-ray system and reduced density targets (RDT’s), the strain in a relatively small volume of brain can be determined. Relative motion between the brain and skull can be determined using implanted triaxial neutral density accelerometers (NDA-3’s) and a rigid-body accelerometer array (3-2-2-2) mounted to the apex of the skull. A suspension fixture is used for inverted, isolated-head testing. Two occipital impacts, 2.7 m/s and 4.2 m/s, are conducted on a single specimen. The high-speed x-ray system provides validation of the NDA-3 performance, and allows tracking of the RDT locations. Relative displacements between the brain and skull are found to be on the order of 3–5 mm, and stretch levels within the RDT array reach approximately 9 percent. These initial results provide the opportunity to introduce the new technologies and techniques designed for use in this ongoing study.
Numerical Characterization of the Viscoelastic Behavior of the Butyl Rubber in the Hybrid III Dummy Neck
Authors: Deng Yih-Charng , Li Xiaowei 
Published: March 2022

Abstract
Quasi-static and stress relaxation tests were conducted to characterize the rubber material in the Hybrid III dummy neck structure. Test data showed that the rubber can sustain large deformation without failure and the material exhibited nonlinear elastic behavior and high viscous properties. Analytical relaxation responses were obtained for material model Type 6 and Type 77 in the DYNA3D program for linear loading conditions. Based on these analytical responses a numerical procedure was developed for identifying the viscoelastic parameters for the two material types. Due to its generality we found that material Type 77 is better suited to simulate the viscoelastic behavior of the rubber. Using this material model, the relaxation response of the rubber can be captured with a high degree of accuracy.
Accident Investigation for Safety Regulations, Crashworthiness, Occupant Protection, Biomechanics: A Survey of the CIC Approach
Authors: Kecman Dusan 
Published: March 2022

Abstract
The paper presents a summary of the recent activities in the Cranfield Impact Centre (CIC) in the fields of : accident investigation leading to development of the new international safety regulations in buses, heavy goods vehicles (also with reference to Formula I cars); air accident investigation and flight data visualiser software ; crashworthiness of aircraft, cars, buses, rail vehicles, safety seats and crash data recording ; pedestrian and occupant / pilot protection in vehicle cab interiors and military aircraft cockpits and biomechanics studies of the brain injuries and femur tolerance levels to bending. The general approach combines the systems approach to problems, hybrid method of treating components both separately and as part of the whole system and uses design, analysis and test work under one roof.
Characterisation of Open-Cell Aluminum Alloy Foams as Heat Sinks for High Power Electronic Devices
Authors: Bastawros A.-F. , Evans A. G. 
Published: March 2022

Abstract
A heat sink comprising an Al alloy open cell material within an insulated channel is described. It is attached to a silicon substrate and cooled with circulating air. The influence of foam morphology and heat sink dimensions on both the heat transfer coefficient and the pressure drop are measured. Trends in the cell wall diameter, d, the heat sink thickness, b, and the air velocity, v, are established. The findings are compared with a model based on the cross flow of a fluid over a bank of cylinders. There is qualitative consistency with the measured effects of d and v, but significant differences in details. Moreover, measured trends with b oppose those in the model. The implication is that the fluid flows are influenced by the heat sink thickness. Further studies are needed to assess these effects.
Thermo-Mechanical Analysis of Solder-Sealed Electronic Modules During Power Cycling
Authors: Sherif Raed A. , Edwards David L. , Ellsworth Michael J. 
Published: March 2022

Abstract
This paper is concerned with the design of hermetic, solder-sealed electronic modules. In particular, the thermal strains developing in the solder seal, potentially leading to solder cracking and module loss of hermeticity are analyzed using a 3D FEM model. It is shown that a full transient thermo-mechanical analysis of the module during power cycling is needed to be able to select the right lid material in order to maximize the solder fatigue life. This is especially true when the module power dissipation is too high for thermal cycling to be representative of module operating conditions.
The IBM AS/400 MCM, called Muskie, is considered as a model problem. This high performance MCM dissipates about 4–5 times the power of its predecessors. At this high power, it is shown via modeling that traditional alumina lids which match the ceramic substrate CTE will lose hermeticity prematurely in the field. Model verification was done by power cycling a set of nine modules and reading out their hermeticity level every few hundred cycles. The experimental results agreed well with the model. The model was then used to select another lid material with an optimized lid-substrate CTE mismatch. The new lid material, made of WCu, has been used successfully by IBM over the past two years.
Experimental Study of Automotive Brake System Temperatures
Authors: Emery A. F. , Kumar P. , Firey J. C. 
Published: March 2022

Abstract
Modern automotive disk brake systems can generate extremely high temperatures under high but short time braking loads or relatively light but continuous braking. One consequence of the high disk and pad temperatures is a gradual heating of the brake hydraulic fluid which can lead to boiling of absorbed water and loss of braking. This paper describes an experiment in which fluid and braking system temperatures, pressures, and operating conditions (vehicle speed, braking energy dissipation, etc) were measured in three different classes of operating vehicles during brake application and subsequent brake release. Brake failure was observed and correlated to moisture content of the fluid, severity of brake application and application time. Temperatures predicted by a finite element analysis agree well with the measured temperatures and can be used to estimate the time at which the fluid boils.
Hydrostatic Response of Piezoresistive Stress Sensors
Authors: Kang Y. , Mian A. K. M. , Suhling J. C. , Jaeger R. C. 
Published: March 2022

Abstract
The (111) surface of silicon offers unique advantages for fabrication of piezoresistive stress sensors. Resistive sensor elements fabricated on this particular surface respond to all six components comprising the state of stress. Hence, a multi-element rosette has the capability of measuring the complete stress state at a point in the material. To extract the stress state at points on the die from the resistance changes measured with the sensor rosettes, it is necessary to have accurately calibrated values of six piezoresistive coefficients. Four-point bending and wafer-level calibration methods can measure four out of six piezoresistive coefficients for both p- and n-type resistors. To measure the other two coefficients, a hydrostatic test method has been developed where a high capacity pressure vessel is used to apply triaxial load on a single die. During the test procedure, resistance changes of resistors on the die are monitored. The slopes of the adjusted resistance change versus pressure plots are then used to calculate the desired last two coefficients. A step-by-step hydrostatic test procedure is demonstrated and sample data are presented.