Comparison of sustainability characteristics of conventional and CNC turning processes

2016 ◽  
Vol 14 (3) ◽  
pp. 422-445 ◽  
Author(s):  
K. Jayakrishna ◽  
R. Jeya Girubha ◽  
S. Vinodh
Keyword(s):  
Environmental Impact ◽  
Manufacturing Process ◽  
Cnc Machining ◽  
Numerical Control ◽  
Machining Parameters ◽  
Environmental Aspects ◽  
Content Type ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Process Level

Purpose The purpose of this paper is to present the comparison of sustainability characteristics of conventional and computer numerical control (CNC) turning process. The sustainability performance measures of both the processes were also being evaluated. Design/methodology/approach The study discusses the achievement of sustainability characteristics at the manufacturing process level of widely used industrial process, mechanical machining. Sustainable development includes improvements in material, product design and manufacturing process orientations. The present study narrates the sustainability characteristics at the process level. Findings The results confirm that the overall sustainability characteristics of CNC machining are potentially high considering the economic and environmental aspects of the machining parameters. A detailed life cycle analysis for both conventional and CNC turning was performed to evaluate the environmental impact and benefits. Research limitations/implications The study contributed in the paper is limited to process dimension of sustainability. The economic and environmental aspects of machining were also being discussed. Practical implications The conduct of the study enabled the comparison of sustainability characteristics of conventional and CNC-turning processes. The approach could also be expanded for the comparison of sustainability characteristics of other manufacturing processes also. Originality/value The study is an attempt to explore the process sustainability by the comparison of environmental impact of making processes. Hence, the contributions are original.

Foam additive manufacturing technology: main characteristics and experiments for hull mold manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Elodie Paquet ◽  
Alain Bernard ◽  
Benoit Furet ◽  
Sébastien Garnier ◽  
Sébastien Le Loch
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Pressure Head ◽  
Manufacturing Technology ◽  
Cnc Machining ◽  
Numerical Control ◽  
Content Type ◽  
Additive Manufacturing Technology

Purpose The purpose of this paper is to present a novel methodology to produce a large boat hull with a foam additive manufacturing (FAM) process. To respond to shipping market needs, this new process is being developed. FAM technology is a conventional three-dimensional (3D) printing process whereby layers are deposited onto a high-pressure head mounted on a six-axis robotic arm. Traditionally, molds and masters are made with computer numerical control (CNC) machining or finished by hand. Handcrafting the molds is obviously time-consuming and labor-intensive, but even CNC machining can be challenging for parts with complex geometries and tight deadlines. Design/methodology/approach The proposed FAM technology focuses on the masters and molds, that are directly produced by 3D printing. This paper describes an additive manufacturing technology through which the operator can create a large part and its tools using the capacities of this new FAM technology. Findings The study shows a comparison carried out between the traditional manufacturing process and the additive manufacturing process, which is illustrated through an industrial case of application in the manufacturing industry. This work details the application of FAM technology to fabricate a 2.5 m boat hull mold and the results show the time and cost savings of FAM in the fabrication of large molds. Originality/value Finally, the advantages and drawbacks of the FAM technology are then discussed and novel features such as monitoring system and control to improve the accuracy of partly printed are highlighted.

Adaptive neuro-fuzzy fusion of multi-sensor data for monitoring of CNC machining

Sensor Review ◽  
2017 ◽  
Vol 37 (1) ◽  
pp. 78-81 ◽  
Author(s):  
Srdjan Jovic ◽  
Obrad Anicic ◽  
Milivoje Jovanovic
Keyword(s):  
Selection Process ◽  
Spindle Speed ◽  
Cnc Machining ◽  
Numerical Control ◽  
Periodic Component ◽  
Sensor Data ◽  
Depth Of Cut ◽  
Inference System ◽  
Content Type ◽  
Neuro Fuzzy

Purpose Acoustic emission (AE) could be used for prevention and detection of tool errors in Computer Numerical Control (CNC) machining. The purpose of this study is to analyze the AE form of CNC machining operations. Design/methodology/approach Experimental measurements were performed with three sensors on the CNC lathe to collect the data of the CNC machining. Adaptive neuro-fuzzy inference system (ANFIS) was applied for the fusion from the sensors’ signals to determine the strength of the signal periodic component among the sensors. Findings There were three inputs, namely, spindle speed, feed rate and depth of cut. ANFIS was also used to determine the inputs’ influence on the prediction of strength of the signal periodic component. Variable selection process was used to select the most dominant factors which affect the prediction of strength of the signal periodic component. Originality/value Results were shown that the spindle speed has the most dominant effect on the strength of the signal periodic component.

Optimal space filling for additive manufacturing

2016 ◽  
Vol 22 (4) ◽  
pp. 660-675 ◽  
Author(s):  
Sajan Kapil ◽  
Prathamesh Joshi ◽  
Hari Vithasth Yagani ◽  
Dhirendra Rana ◽  
Pravin Milind Kulkarni ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Layered Manufacturing ◽  
Closed Curve ◽  
Numerical Control ◽  
Surface Finishing ◽  
Content Type ◽  
Single Pass ◽  
Connected Area ◽  
Area Filling

Purpose In additive manufacturing (AM) process, the physical properties of the products made by fractal toolpaths are better as compared to those made by conventional toolpaths. Also, it is desirable to minimize the number of tool retractions. The purpose of this study is to describe three different methods to generate fractal-based computer numerical control (CNC) toolpath for area filling of a closed curve with minimum or zero tool retractions. Design/methodology/approach This work describes three different methods to generate fractal-based CNC toolpath for area filling of a closed curve with minimum or zero tool retractions. In the first method, a large fractal square is placed over the outer boundary and then rest of the unwanted curve is trimmed out. To reduce the number of retractions, ends of the trimmed toolpath are connected in such a way that overlapping within the existing toolpath is avoided. In the second method, the trimming of the fractal is similar to the first method but the ends of trimmed toolpath are connected such that the overlapping is found at the boundaries only. The toolpath in the third method is a combination of fractal and zigzag curves. This toolpath is capable of filling a given connected area in a single pass without any tool retraction and toolpath overlap within a tolerance value equal to stepover of the toolpath. Findings The generated toolpath has several applications in AM and constant Z-height surface finishing. Experiments have been performed to verify the toolpath by depositing material by hybrid layered manufacturing process. Research limitations/implications Third toolpath method is suitable for the hybrid layered manufacturing process only because the toolpath overlapping tolerance may not be enough for other AM processes. Originality/value Development of a CNC toolpath for AM specifically hybrid layered manufacturing which can completely fill any arbitrary connected area in single pass while maintaining a constant stepover.

Rethinking reverse logistics: role of additive manufacturing technology in metal remanufacturing

2019 ◽  
Vol 31 (1) ◽  
pp. 124-144 ◽  
Author(s):  
Danielle Strong ◽  
Michael Kay ◽  
Thomas Wakefield ◽  
Issariya Sirichakwal ◽  
Brett Conner ◽  
...  
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
Facility Location ◽  
Reverse Logistics ◽  
Small And Medium Enterprises ◽  
Real Data ◽  
Cnc Machining ◽  
Numerical Control ◽  
Content Type ◽  
The Usa

Purpose Although the adoption of metal additive manufacturing (AM) for production has continuously grown, in-house access to production grade metal AM systems for small and medium enterprises (SMEs) is a major challenge due to costs of acquiring metal AM systems, specifically powder bed fusion AM. On the other hand, AM technology in directed energy deposition (DED) has been evolving in both: processing capabilities and adaptable configuration for integration within existing traditional machines that are available in most SME manufacturing facilities, e.g. computer numerical control (CNC) machining centers. Integrating DED with conventional processes such as machining and grinding into Hybrid AM is well suited for remanufacturing of metal parts. The paper aims to discuss these issues. Design/methodology/approach Classical facility location models are employed to understand the effects of SMEs adopting DED systems to offer remanufacturing services. This study identifies strategically located counties in the USA to advance hybrid AM for reverse logistics using North American Industry Classification System (NAICS) data on geographical data, demand, fixed and transportation costs. A case study is also implemented to explore its implications on remanufacturing of high-value parts on the reverse logistics supply chain using an aerospace part and NAICS data on aircraft maintenance, repair and overhaul facilities. Findings The results identify the candidate counties, their allocations, allocated demand and total costs. Offering AM remanufacturing services to traditional manufacturers decreases costs for SMEs in the supply chain by minimizing expensive new part replacement. The hubs also benefit from hybrid AM to repair their own parts and tools. Originality/value This research provides a unique analysis on reverse logistics through hybrid AM focused on remanufacturing rather than manufacturing. Facility location using real data is used to obtain results and offers insights into integrating AM for often overlooked aspect of remanufacturing. The study shows that SMEs can participate in the evolving AM economy through remanufacturing services using significantly lower investment costs.

EFFECT OF MACHINING PARAMETERS ON SURFACE ROUGHNESS FOR ALUMINIUM MATRIX COMPOSITE BY USING TAGUCHI METHOD WITH DECISION TREE ALGORITHM

2021 ◽  
pp. 2150021
Author(s):  
P. RAVEENDRAN ◽  
S. V. ALAGARSAMY ◽  
M. RAVICHANDRAN ◽  
M. MEIGNANAMOORTHY
Keyword(s):  
Surface Roughness ◽  
Decision Tree ◽  
Taguchi Method ◽  
Cutting Speed ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Taguchi’S Design Of Experiments

The intend of this research work is to explore the effect of various parameters in a CNC turning process like cutting speed ([Formula: see text]), feed ([Formula: see text]), and depth of cut ([Formula: see text]) on surface roughness (Ra) of turning AA7075 filled with 10[Formula: see text]wt.% of TiO2 composite fabricated through stir casting method. Taguchi method and decision tree (DT) algorithm were utilized to foresee the surface roughness (Ra) of the proposed composite. The microstructure of composite was ensured with the presence of TiO2 particles dispersed in a homogeneous manner within the matrix material. The machining of composite was carried out by using the CNC turning center and tungsten carbide insert as tool material. This experimental work was designed on L27 (33) orthogonal array using Taguchi’s design of experiments. From its signal-to-noise (S/N) ratio study, the minimum surface roughness (Ra) was obtained at the optimum level of parameters with the cutting speed at 1500[Formula: see text]rpm, feed at 0.15[Formula: see text]mm/rev and depth of cut at 0.3[Formula: see text]mm. Analysis of variance (ANOVA) and decision tree (DT) algorithm were used to identify the significant effect of parameters. The experimental result shows that depth of cut was the major significant parameter on surface roughness (Ra) when compared to cutting speed and feed.

Reliability analysis of CNC turning center based on the assessment of trends in maintenance data

2017 ◽  
Vol 34 (9) ◽  
pp. 1616-1638 ◽  
Author(s):  
Rajkumar Bhimgonda Patil ◽  
Basavraj S. Kothavale ◽  
Laxman Yadu Waghmode ◽  
Shridhar G. Joshi
Keyword(s):  
Reliability Analysis ◽  
Goodness Of Fit ◽  
Numerical Control ◽  
Maintenance Cost ◽  
Repairable Systems ◽  
Content Type ◽  
Cnc Turning ◽  
Warranty Period ◽  
Turning Center ◽  
Support Cost

Purpose The paper presents reliability, maintainability and life cycle cost (LCC) analysis of a computerized numerical control (CNC) turning center which is manufactured and used in India. The purpose of this paper is to identify the critical components/subsystems from reliability and LCC perspective. The paper further aims at improving reliability and LCC by implementing reliability-improvement methods. Design/methodology/approach This paper uses a methodology for the reliability analysis based on the assessment of trends in maintenance data. The data required for reliability and LCC analysis are collected from the manufacturers and users of CNC turning center over a period of eight years. ReliaSoft’s Weibull++9 software has been used for verifying goodness of fit and estimating parameters of the distribution. The LCC of the system is estimated for five cost elements: acquisition cost, operation cost, failure cost, support cost and net salvage value. Findings The analysis shows that the spindle bearing, spindle belt, spindle drawbar, insert, tool holder, drive battery, hydraulic hose, lubricant hose, coolant hose and solenoid valve are the components with low reliability. With certain design changes and implementation of reliability-based maintenance policies, system reliability is improved, especially during warranty period. The reliability of the CNC turning center is improved by nearly 45 percent at the end of warranty period and system mean time between failure is increased from 15,000 to 17,000 hours. The LCC analysis reveals that the maintenance cost, operating cost and support costs dominate the LCC and contribute to the tune of 87 percent of the total LCC. Research limitations/implications The proposed methodology provides an excellent tool that can be utilized in industries, where safety, reliability, maintainability and availability of the system play a vital role. The approach may be improved by collecting data from more number of users of the CNC turning centers. Practical implications The approach presented in this paper is generic and can be applied to analyze the repairable systems. A real case study is presented to show the applicability of the approach. Originality/value The proposed methodology provides a practical approach for the analysis of time-to-failure and time-to-repair data based on the assessment of trends in the maintenance data. The methodology helps in selecting a proper approach of the analysis such as Bayesian method, parametric methods and nonparametric methods.

Track-based analysis for profile generation on globoidal cam in automatic tool changer of CNC machining center

2019 ◽  
Vol 39 (2) ◽  
pp. 369-379 ◽  
Author(s):  
Kuldeep Verma ◽  
R.M. Belokar ◽  
Vinod Kumar Verma ◽  
Klimis Ntalianis
Keyword(s):  
Practical Implication ◽  
Cnc Machining ◽  
Numerical Control ◽  
Practical Implementation ◽  
Cnc Machines ◽  
Content Type ◽  
Automatic Tool Changer ◽  
Cam Profile ◽  
Measuring Machine ◽  
Automatic Tool

PurposeThis paper aims to propose an elementary approach towards the measurement of a globoidal cam profile used in an automatic tool changer (ATC) of computer numerical control (CNC) machines.Design/methodology/approachA simple and unique online method has been designed for the profile metrology of the cam. This simple methodology will replace the traditional methodology of profile metrology of cam by coordinate measuring machine (CMM). A globoidal cam with an indexable turret and roller follower (rotating in an enclosed track) has been evaluated in our analysis. This analysis plays a significant role in the performance determination of the cam as well as the ATC of CNC machines.FindingsA novel model has been designed and implemented to investigate the profile of a globoidal cam. The proposed methodology becomes an enhancement over the old methodology, i.e. measurement through CMM. Theoretical analysis and practical implementation prove the significance of the method.Originality/valueAn enhanced methodology to effectively measure the globoidal cam profile has been proposed. The practical implication of the proposed methodology remains for the CNC machine tool and ATC manufacturers. Finally, analytical explorations have been carried out to prove the validity of the proposal.

Effect of Process Parameters on Performance Measures in CNC Turning Using One Factor at a Time Approach for SS304

2016 ◽  
Vol 854 ◽  
pp. 26-32
Author(s):  
M. Fakkir Mohamed ◽  
B. Praveen Kumar ◽  
P.L. Madhavan ◽  
M. Pradeep
Keyword(s):  
Process Parameters ◽  
Grey Relational Analysis ◽  
Optimal Parameter ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Turning ◽  
Process Factor ◽  
Relational Analysis ◽  
Grey Relational

This work extent with the improvement of machining parameters in turning of SS304 austenitic stainless-steel in Computer Numerical Control (CNC) shaping machine by victimization of coated inorganic compound tools. Throughout the experiment, process parameters like Speed, Feed and Depth of Cut are used to inquire their general intent on the Surface Roughness (Ra) and Material Removal Rate (MRR) as the quality targets. 9 experimental runs supported by one factor at a Time Approach as Design of Experiment and Grey Relational Analysis (GRA) method is applied to see associate degree for optimum CNC turning parameter setting. An optimal parameter combination of the turning method is obtained by victimization of Grey Relational Analysis. By dissecting the Grey Relational Grade matrix, the degree of influence for every controllable process factor onto individual quality targets is found for the higher performance characteristics.

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