Optimization on the Performance of a Precision Flank-Locking Locknut Considering the Machining and Operational Parameters

2017 ◽  
Vol 35 (1) ◽  
pp. 41-49 ◽  
Author(s):  
C. M. Chen ◽  
C. Y. Lee
Keyword(s):  
Taguchi Method ◽  
Axial Force ◽  
Machining Process ◽  
Average Error ◽  
Optimized Design ◽  
Control Parameters ◽  
Operational Parameters ◽  
Machining Processes ◽  
Tightening Torque ◽  
Force Ratio

AbstractIn this study, the anti-loosening characteristics of a precision flank-locking locknut fabricated under various machining processes and tested in different dynamic environments were investigated. The control parameters considered include the tightening torque and thread pitch of the set screw, machining process on the end plane of locknut, and vibration amplitude and frequency of dynamic loading in service, etc. Their sensitivities on the axial force ratio and anti-loosening ratio of the locknut were evaluated using Taguchi method. It was found that the pretension of locknut, the tightening torque and the pitch of set screw, and the machining process of the nut's end plane were the significant control parameters for the anti-loosening performance of the locknut. Moreover, the results of experimental measurements were employed in the regression fit on the performance of the locknut. The regression model was able to predict the anti-loosening ratio with 4.42% average error comparing with the measurements. Furthermore, the optimized design of the locknut through the Taguchi method was able to increase the axial force ratio and anti-loosening ratio by 20.4% and 16.8%, respectively, comparing with standard locknut.

Method and Application of Multistage Machining Quality Control Based on Minimum Overall Mean Quality Loss

2011 ◽  
Vol 213 ◽  
pp. 557-561
Author(s):  
Yi Yong Yao ◽  
Li Ping Zhao ◽  
Guo Qiang Shao ◽  
Yong Tao Qin
Keyword(s):  
Quality Control ◽  
Control Chart ◽  
Machining Process ◽  
Manufacturing Cost ◽  
Quality Loss ◽  
Control Parameters ◽  
Machining Processes ◽  
Loss Model ◽  
Machining Quality ◽  
Optimal Function

To improve the quality control effect and decrease the manufacturing cost in the product’s multistage machining processes, based on the quality loss of single stage machining process, an overall mean quality loss model of multistage machining processes is established by the integration of Duncan cost model, Taguchi quality loss model, mean shift index and average time to signal (ATS). By using this quality loss model, the overall mean quality loss optimal function of multistage machining processes is constructed and the control parameters of this function are optimally solved. Besides, The Shewhart control chart and Cause-selecting control chart can be optimally designed with the control parameters of this optimal function. Finally, on the basis of an application, the multistage machining quality control based on minimum overall mean quality loss is verified to improve the control chart’s performance under the condition of the minimum overall mean quality loss.

Review of Composite Machining and Related Optimization Techniques

2015 ◽  
Vol 813-814 ◽  
pp. 398-403
Author(s):  
M.M. Thamizharasan ◽  
Y.J. Nithiya Sandhiya ◽  
K.S. Vijay Sekar
Keyword(s):  
Composite Materials ◽  
Taguchi Method ◽  
Weight Ratio ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Processes ◽  
Surface Method ◽  
Simulated Algorithm ◽  
Modeling Techniques ◽  
Experimental Trials

This paper provides an inclusive review of literature, mostly from the past decade, on optimization techniques of composite materials machining, both conventional and non-conventional process. Composite materials are continually replacing conventional materials due to their excellent corrosion resistance, higher strength to weight ratio, but the machining of composites is a challenging process. Experimental trials notwithstanding, researchers have also used various optimization techniques such as Taguchi method, Genetic Algorithm, Simulated Algorithm, Response Surface Method, and Fuzzy Logic with ANOVA etc., to identify the optimal parameters for the machining processes. Also predictive modeling techniques such as Artificial Neural Networks and Finite Element Methods have also been employed as an optimization tools for studying the composite machining process. It was found that Taguchi method is the most preferred technique in the optimization studies.

scholarly journals Optimization of Process Parameter of Surface Grinding Process of Autenitic Stainless Steel (AISI 304) BY Taguchi Method

2019 ◽  
pp. 72-76
Author(s):  
M. A. Deore ◽  
R. S Shelke
Keyword(s):  
Taguchi Method ◽  
Feed Rate ◽  
Metal Removal ◽  
Removal Rate ◽  
Surface Grinding ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Grinding Process ◽  
Machining Processes

The manufacturing process of surface grinding has been established in the mass production of slim, rotationally symmetrical components. Due to the complex set-up, which results from the large sensitivity of this grinding process to a multiplicity of geometrical, kinematical and dynamical influence parameters, surface grinding is rarely applied within limited-lot production. The substantial characteristics of this grinding process are the simultaneous guidance and machining of the work piece on its periphery. Surface grinding is an essential process for final machining of components requiring smooth surfaces and precise tolerances. As compared with other machining processes, grinding is costly operation that should be utilized under optimal conditions. Although widely used in industry, grinding remains perhaps the least understood of all machining processes. The proposed work takes the following input processes parameters namely Work speed, feed rate and depth of cut. The main objective of this work is to predict the grinding behavior and achieve optimal operating processes parameters. a software package may be utilized which integrates these various models to simulate what happens during surface grinding processes. predictions from this simulation will be further analyzed by calibration with actual data. It involves several variables such as depth of cut, work speed, feed rate, chemical composition of work piece, etc. The main objective in any machining process is to maximize the Metal Removal Rate (MRR) and to minimize the surface roughness (Ra). In order to optimize these values Taguchi method, ANOVA and regression analysis is used.

scholarly journals Parametric optimization of non-traditional machining processes using Taguchi method and super ranking concept

2019 ◽  
Vol 29 (2) ◽  
pp. 249-271 ◽  
Author(s):  
Partha Das ◽  
Shankar Chakraborty
Keyword(s):  
Taguchi Method ◽  
Optimization Technique ◽  
Dimensional Accuracy ◽  
Optimization Techniques ◽  
Machining Process ◽  
Simultaneous Optimization ◽  
Drilling Process ◽  
Regression Equations ◽  
Machining Processes ◽  
Electro Discharge Machining

In order to achieve higher dimensional accuracy along with better surface quality, the conventional machining processes have now-a-days being replaced by non-traditional machining (NTM) processes, because of their ability to generate intricate shape geometries on various advanced engineering materials. In order to exploit their fullest machining potential, it is often recommended to operate those NTM processes at their optimal parametric settings. Several optimization tools and techniques are now available which can be effectively applied to obtain the optimal parametric conditions of those processes. In this paper, Taguchi method and super ranking concept are integrated together to present an efficient optimization technique for simultaneous optimization of three NTM processes, i.e. electro-discharge machining process, wire electro-discharge machining process and electro-chemical discharge drilling process. The derived results are validated with the help of developed regression equations, which show that the proposed approach outperforms the other popular multi-response optimization techniques. Analysis of variance is also performed to identify the most influencing control parameters for the considered NTM processes. The developed response surface plots further help the process engineers in identifying the effects of various NTM process parameters on the calculated sum of squared rank values.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

scholarly journals Temperature monitoring in the subsurface during single lip deep hole drilling

2020 ◽  
Vol 87 (12) ◽  
pp. 757-767
Author(s):  
Robert Wegert ◽  
Vinzenz Guski ◽  
Hans-Christian Möhring ◽  
Siegfried Schmauder
Keyword(s):  
Cutting Parameters ◽  
Drill Hole ◽  
Machining Process ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Machining Processes ◽  
Deep Hole Drilling ◽  
Feed Force ◽  
Cutting Zone

AbstractThe surface quality and the subsurface properties such as hardness, residual stresses and grain size of a drill hole are dependent on the cutting parameters of the single lip deep hole drilling process and therefore on the thermomechanical as-is state in the cutting zone and in the contact zone between the guide pads and the drill hole surface. In this contribution, the main objectives are the in-process measurement of the thermal as-is state in the subsurface of a drilling hole by means of thermocouples as well as the feed force and drilling torque evaluation. FE simulation results to verify the investigations and to predict the thermomechanical conditions in the cutting zone are presented as well. The work is part of an interdisciplinary research project in the framework of the priority program “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG).This contribution provides an overview of the effects of cutting parameters, cooling lubrication and including wear on the thermal conditions in the subsurface and mechanical loads during this machining process. At first, a test set up for the in-process temperature measurement will be presented with the execution as well as the analysis of the resulting temperature, feed force and drilling torque during drilling a 42CrMo4 steel. Furthermore, the results of process simulations and the validation of this applied FE approach with measured quantities are presented.

scholarly journals Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

2021 ◽  
Author(s):  
Dina Becker ◽  
Steffen Boley ◽  
Rocco Eisseler ◽  
Thomas Stehle ◽  
Hans-Christian Möhring ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Closed Loop ◽  
Deposition Process ◽  
Metal Wire ◽  
Machining Process ◽  
Machining Processes ◽  
Initial State ◽  
Additive Process ◽  
Shape Accuracy ◽  
Loop Control

AbstractThis paper describes the interdependence of additive and subtractive manufacturing processes using the production of test components made from S Al 5356. To achieve the best possible part accuracy and a preferably small wall thickness already within the additive process, a closed loop process control was developed and applied. Subsequent machining processes were nonetheless required to give the components their final shape, but the amount of material in need of removal was minimised. The effort of minimising material removal strongly depended on the initial state of the component (wall thickness, wall thickness constancy, microstructure of the material and others) which was determined by the additive process. For this reason, knowledge of the correlations between generative parameters and component properties, as well as of the interdependency between the additive process and the subsequent machining process to tune the former to the latter was essential. To ascertain this behaviour, a suitable test part was designed to perform both additive processes using laser metal wire deposition with a closed loop control of the track height and subtractive processes using external and internal longitudinal turning with varied parameters. The so manufactured test parts were then used to qualify the material deposition and turning process by criteria like shape accuracy and surface quality.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

scholarly journals Analysis of Forces in Vibro-Impact and Hot Vibro-Impact Turning of Advanced Alloys

2011 ◽  
Vol 70 ◽  
pp. 315-320 ◽  
Author(s):  
Riaz Muhammad ◽  
Agostino Maurotto ◽  
Anish Roy ◽  
Vadim V. Silberschmidt
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Element Model ◽  
Machining Process ◽  
Strain Rates ◽  
Machining Processes ◽  
Machined Surface ◽  
Cutting Zone

Analysis of the cutting process in machining of advanced alloys, which are typically difficult-to-machine materials, is a challenge that needs to be addressed. In a machining operation, cutting forces causes severe deformations in the proximity of the cutting edge, producing high stresses, strain, strain-rates and temperatures in the workpiece that ultimately affect the quality of the machined surface. In the present work, cutting forces generated in a vibro-impact and hot vibro-impact machining process of Ti-based alloy, using an in-house Ultrasonically Assisted Turning (UAT) setup, are studied. A three-dimensional, thermo-mechanically coupled, finite element model was developed to study the thermal and mechanical processes in the cutting zone for the various machining processes. Several advantages of ultrasonically assisted turning and hot ultrasonically assisted turning are demonstrated when compared to conventional turning.

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