Gear Shaving: Simulation and Technological Studies

2003 ◽  
Author(s):  
Fritz Klocke ◽  
Tobias Schro¨der
Keyword(s):  
Tool Wear ◽  
Manufacturing Industry ◽  
Tolerance Limits ◽  
Machining Processes ◽  
Industrial Practice ◽  
Process Reliability ◽  
Gear Manufacturing ◽  
Numerical Process ◽  
Conventional Machining

Due to its high economical efficiency, the gear shaving process is a widely-used process for soft finishing of gears in the gear manufacturing industry. The wear of the gear shaving tools in industrial practice is determined by the quality of the workpiece which can be achieved with a tool. After the tolerance limits of the gear quality are exceeded, the tool is considered to be worn and must be reground. So far, it has not been studied, what exactly causes the decrease in gear quality and what a worn shaving wheel looks like. Due to the technological peculiarities of the gear shaving process, the tool wear can be expected to appear in a very different way as in conventional machining processes with geometrically defined cutting edges. The knowledge of this tool wear is essential in order to find ways to increase the efficiency as well as the process reliability in gear shaving even further. Therefore, this paper explains the technological peculiarities of the gear shaving process by using a numerical process simulation. Furthermore, it shows examples of worn cutting edges in gear shaving and explains the effects of this tool wear on the quality of the shaved gears.

Schneidkantenpräparation von VHM-Mikrofräsern*/Cutting edge preparation of cemented carbide micro milling tools – A comparison of different fine machining processes

2015 ◽  
Vol 105 (11-12) ◽  
pp. 805-811
Author(s):  
E. Uhlmann ◽  
D. Oberschmidt ◽  
A. Löwenstein ◽  
M. Polte ◽  
I. Winker
Keyword(s):  
Tool Wear ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Machining Processes ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Milling Tools ◽  
Edge Preparation

Die Prozesssicherheit beim Mikrofräsen lässt sich mit einer gezielten Schneidkantenverrundung erheblich steigern. Dabei werden durch verschiedene Präparationstechnologien unterschiedliche Geometrien und Einflüsse auf den Fräsprozess erzeugt. Der Fachbeitrag behandelt den Einsatz präparierter Mikrowerkzeuge in Zerspanversuchen, in denen auf die Zerspankräfte, den Verschleiß sowie die Oberflächengüten eingegangen wird.   Process reliability in micro milling can be increased by a defined cutting edge preparation. Different cutting edge preparations cause different effects on tool behavior in the downstream micro milling process. In this paper, the process forces, the tool wear and the surface quality of prepared micro milling tools are characterized in cutting tests.

Machining

2013 ◽  
pp. 213-270
Keyword(s):  
Electron Beam ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Cutting Fluids ◽  
Machining Parameters ◽  
Machining Processes ◽  
Wire Cutting ◽  
Grinding Operations ◽  
Conventional Machining

Abstract This chapter covers the practical aspects of machining, particularly for turning, milling, drilling, and grinding operations. It begins with a discussion on machinability and its impact on quality and cost. It then describes the dimensional and surface finish tolerances that can be achieved through conventional machining methods, the mechanics of chip formation, the factors that affect tool wear, the selection and use of cutting fluids, and the determination of machining parameters based on force and power requirements. It also includes information on nontraditional machining processes such as electrical discharge, abrasive jet, and hydrodynamic machining, laser and electron beam machining, ultrasonic impact grinding, and electrical discharge wire cutting.

Sensor Fusion Strategy in the Monitoring of Cutting Tool Wear

2006 ◽  
Vol 306-308 ◽  
pp. 727-732 ◽  
Author(s):  
Muslim Mahardika ◽  
Zahari Taha ◽  
Djoko Suharto ◽  
Kimiyuki Mitsui ◽  
Hideki Aoyama
Keyword(s):  
Tool Wear ◽  
Sensor Fusion ◽  
Cutting Tool ◽  
Fusion Technology ◽  
Machining Processes ◽  
Fusion Strategy ◽  
Cutting Tool Wear ◽  
Single Sensor ◽  
Paper Sensor

Cutting tool wear is a major problem in machining processes. It has a great effect on the quality of a workpiece. Thus, monitoring cutting tool wear is very important in order to maintain the workpiece quality as well to reduce production rate and production time. The use of a single sensor in a monitoring system may not be accurate to detect cutting tool wear. In this paper, sensor fusion technology is introduced for monitoring cutting tool wear.

Quality of the Cut Surfaces Processed by AWJC as a Function of the Distance between the Cutting Head and Working Sample

2015 ◽  
Vol 809-810 ◽  
pp. 207-212 ◽  
Author(s):  
Eugen Herghelegiu ◽  
Crina Radu ◽  
Carol Schnakovszky ◽  
Valentin Zichil
Keyword(s):  
Water Jet ◽  
Machining Processes ◽  
Influence Of Process Parameters ◽  
Flexible Technology ◽  
Cutting Head ◽  
Water Jet Cutting ◽  
Abrasive Water Jet Cutting ◽  
High Nickel ◽  
Conventional Machining

Water jet cutting is one of the newest techniques in non-conventional machining processes. It is a flexible technology since the same equipment can be used to cut virtually any material, such as steel stainless steel, high-nickel alloys and polymer composites (usually, for these materials, the water jet is mixed with an abrasive material, the process being known as abrasive water jet cutting - AWJC) . Compared with the classical technologies, water jet cutting presents the following advantages: very low side forces during machining, it is rapid, it is silent, no thermal distortion, a good cutting accuracy and minimal burrs. To optimize the process, it is necessary to analyze the influence of process parameters on the quality of cut. The aim of this paper is to analyze the influence of distance between the cutting head and the working sample on the quality of cut, quantified by the following parameters: width of the processed surface at the jet inlet, jet outlet, deviation from perpendicularity, inclination angle and roughness.

Manufacturing of Mini-Channel by Electrical Chemical Machining Processes

2016 ◽  
Vol 842 ◽  
pp. 111-114
Author(s):  
Muslim Mahardika ◽  
Agung Mulianto ◽  
Andi Sudiarso
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Manufacturing Industry ◽  
Complex Shape ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Hard Material ◽  
Machining Processes ◽  
Conventional Machining

The manufacturing industry is now growing rapidly in the area of non-conventional machining, especially Electrical Chemical Machining (ECM). The ECM can be used for machining of very hard material and very complex shape. This research is performed in order to manufacture mini-channel, which has a complex shape. The ECM machine cutting conditions are as follow; voltage: 7 Volt, feed rate: 1 .0 mm/minute, electrolyte: Natrium Cloride (NaCl), electrolyte concentration: 15 %, electrolyte speed: 3.32 m/s. The result shows that the mini-channel can be manufactured with the average of Material Removal Rate 0.035 g/min with the overcut average is 0.481 mm, and the surface roughness is 5.19 micro meter.

scholarly journals Penerapan Model Pembelajaran Praktik Berbasis Collaborative Skill Sebagai Upaya Peningkatan Mutu Pendidikan Tinggi Vokasi

2016 ◽  
Vol 1 (1) ◽  
pp. 1
Author(s):  
Dwi Rahdiyanta ◽  
Putut Hargiyarto ◽  
Asnawi Asnawi
Keyword(s):  
Learning Outcomes ◽  
Mechanical Engineering ◽  
Manufacturing Industry ◽  
Learning Model ◽  
Practical Work ◽  
Machining Processes ◽  
Purposive Sampling ◽  
Quality Of Learning ◽  
Collaborative Skills

This study aims to: (1) discover a collaborative skills-based learning model for practical work invocational education programs which can improve the quality of learning outcomes; (2) determine the effect ofthe application of collaborative skills-based learning model for practical work towards the students’ attitude andlearning outcome. This R&D and experiments research was carried out in manufacturing industry of machiningfield in Yogyakarta, and in the Mechanical Engineering Department of Faculty of Engineering, Yogyakarta StateUniversity. The population being studied was all of Diploma students of Mechanical Engineering study programwho enrolled in Complex Machining Processes course. Research sample of 33 students, divided in two groups,were determined by purposive sampling technique. The experiment was carried out by posttest-only controldesign. Content validation was done by expert judgment and items reliability with Alpha Cronbach formula andKR-20. Data were analyzed using descriptive analysis and t-test, with significance level of 0.05. The resultsshow that: (1) The collaborative skills-based learning model for practical work is suitable to be implemented inorder to improve the quality of learning outcomes in practical work; (2) The students’ attitude and learningachievement of the model class is better, or higher, than the controlled class.---------------------------------------------------------------------------------------Penelitian ini bertujuan untuk: (1) menemukan model pembelajaran praktik berbasis collaborative skillpada program pendidikan vokasi yang dapat meningkatkan kualitas hasil belajar; (2) mengetahui pengaruhpenerapan model pembelajaran praktik berbasis collaborative skill terhadap sikap dan prestasi belajarmahasiswa. Penelitian R&D dan eksperimen ini dilaksanakan di industri manufaktur bidang pemesinan diwilayah DIY dan di Jurusan Pendidikan Teknik Mesin FT-UNY. Populasi penelitian adalah seluruh mahasiswaprogram studi D3 Teknik Mesin FT-UNY yang melaksanakan kuliah Proses Pemesinan Kompleks. Pemilihansampel ditentukan dengan teknik purposive sampling. Eksperimen dilaksanakan dengan rancangan posttest-onlycontrol design. Validasi isi dilakukan dengan expert judgement dan reliabilitas butir dengan formula AlphaCronbach dan KR-20. Data dianalisis dengan analisis deskriptif dan uji-t, taraf signifikansi 0,05. Hasil penelitianmenunjukkan bahwa: (1) model pembelajaran praktik berbasis collaborative skill cocok digunakan untukmeningkatkan kualitas hasil belajar praktik; (2) Sikap dan prestasi belajar praktik mahasiswa pada kelas modellebih baik atau lebih tinggi dibanding kelas kontrol.

scholarly journals Process parameters effect on material removal mechanism and cut quality of abrasive water jet machining

2013 ◽  
Vol 40 (2) ◽  
pp. 277-291 ◽  
Author(s):  
P. Jankovic ◽  
T. Igic ◽  
D. Nikodijevic
Keyword(s):  
Damage Mechanics ◽  
Water Jet ◽  
High Tech ◽  
Abrasive Water Jet ◽  
Machining Processes ◽  
Pull Out ◽  
Water Jet Cutting ◽  
Cut Surface ◽  
Conventional Machining

The process of the abrasive water jet cutting of materials, supported by the theories of fluid mechanics, abrasive wear and damage mechanics, is a high-tech technologies that provides unique capabilities compared to conventional machining processes. This paper, along the theoretical derivations, provides original contributions in the form of mathematical models of the quantity of the cut surface damage, expressed by the values of cut surface roughness. The particular part of this paper deal with the results of the original experimental research. The research aim was connected with the demands of industry, i.e. the end user. Having in mind that the conventional machining processes are not only lagging behind in terms of quality of cut, or even some requests are not able to meet, but with the advent of composite materials were not able to machine them, because they occurred unacceptable damage (mechanical damage or delamination, fiber pull-out, burning, frayed edges).

scholarly journals Penerapan Metode Taguchi Dalam Optimasi Parameter Pada Proses Electrical Discharge Machining (EDM)

2019 ◽  
Vol 12 (1) ◽  
pp. 7-12
Author(s):  
Farizi Rachman Rachman ◽  
Tri Andi Setiawan ◽  
Bayu Wiro Karuniawan ◽  
Risma Aris Maya
Keyword(s):  
Taguchi Method ◽  
Manufacturing Industry ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Level 3 ◽  
Level 1 ◽  
Electrical Conductors ◽  
Off Time ◽  
Conventional Machining

EDM is a non-conventional machining process with feeding material carried out by electric spark (spark) through a gap between the electrode and the workpiece containing liquid in the electric. The usefulness of the liquid is as a medium for rinsing the remnants of erosion material, electrodes and workpieces as electrical conductors. In the manufacturing industry, EDM is widely used for the manufacture of products that demand the quality of surface roughness resulting from smooth cutting and high precision. The Taguchi method is one method in experimental design that can be used to control product quality. This study considers 3 parameters, namely gap voltage, on time, and off time on the SKD-11 material as one of the 13 mm thick dies / dies. This study uses the Taguchi method to obtain optimal parameters with smaller criteria better. Based on the table above the highest voltage parameter gap at level 1 which is 30 volts, the parameters at the most agreed time at level 3 are 120 μs and the most difficult off time parameter to be reached at level 1 is 20 μs to roughness.   EDM adalah suatu proses permesinan yang bersifat non konvensional dengan pemakanan material benda kerja yang dilakukan oleh loncatan bunga api listrik (spark) melalui celah antara elektroda dan benda kerja yang berisi cairan di elektrik. Kegunaan cairan tersebut adalah sebagai medium untuk flushing sisa-sisa partikel material hasil erosi,pendinginan elektroda dan benda kerja serta sebagai konduktor listrik. Dalam industri manufaktur, EDM banyak digunakan untuk pembuatan produk-produk yang menuntut kualitas kekasaran permukaan hasil pemotongan yang halus dan kepresisian yang tinggi. Metode Taguchi merupakan salah satu metode dalam desain eksperimen yang dapat digunakan untuk mengendalikan kualitas produk. Penelitian ini mempertimbangkan 3 parameter yaitu gap voltage, on time, dan off time pada pengerjaan material SKD-11 sebagai salah satu bahan pembuatan cetakan/dies dengan tebal 13 mm. Penelitian ini menggunakan metode Taguchi untuk mendapatkan parameter yang optimum dengan kriteria smaller is better. Berdasarkan tabel diatas parameter gap voltage paling berpengaruh pada level 1 yaitu 30 volt, parameter on time paling berpengaruh pada level 3 yaitu 120 µs dan parameter off time paling berpengaruh pada level 1 yaitu 20 µs terhadap kekasaran.    

scholarly journals Prediction of Surface Roughness using Sensor Fusion Regression Model

2019 ◽  
Vol 8 (12S) ◽  
pp. 538-540
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Regression Model ◽  
Sensor Fusion ◽  
Cutting Temperature ◽  
Machining Parameters ◽  
Direct Influence ◽  
Machining Processes ◽  
H13 Steel

Surface roughness decides the quality of machined components during machining processes. Output parameters namely cutting temperature, cutting force, tool wear, vibration etc. have direct influence on surface roughness of machined components. It is anticipated that better prediction would be possible if the above mentioned parameters are collectively considered with machining parameters. In this investigation, an effort was made to fuse machining parameters with cutting temperature to predict surface roughness while machining H13 steel. The developed regression model was tested for its ability to predict surface quality. The results proved that the developed sensor fusion regression model can be used for better prediction of cutting performance

scholarly journals Modal Analysis of Replica Boss Hole During the Deburring Process in Aerospace Manufacturing Industry

2018 ◽  
Vol 159 ◽  
pp. 02035 ◽  
Author(s):  
Claudy Andriani ◽  
Wahyu Caesarendra ◽  
Tegoeh Tjahjowidodo ◽  
Tomi Wijaya ◽  
Bobby K Pappachan
Keyword(s):  
Modal Analysis ◽  
Manufacturing Industry ◽  
Vibration Signal ◽  
Surface Finishing ◽  
Machining Processes ◽  
Aerospace Manufacturing ◽  
Key Issues ◽  
Finishing Processes ◽  
Amplitude Level

The monitoring of surface finishing processes in aerospace manufacturing industry becomes one of key issues to maintain the overall quality of product or part. To date, the surface quality monitoring post machining processes such as deburring, use visual inspection, surface roughness test or laser gap gun. The whole manufacturing process then requires a considerable amount of time as the production line must be halted due to these measurements taking place. This study presents an online monitoring system to measure the chamfer quality of replica boss hole post-deburring process. Vibration signal was measured during the deburring process and the features that correlate to the deburring stages (passes) were extracted. This paper focuses on the validation of actual vibration signal with the modal analysis of work coupon (replica boss hole) to obtain the correlation between the vibration amplitude level on particular region and the mode shape of work coupon during the deburring process.

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