scholarly journals Jig and fixture Redesign for Main Bearing Housing Component

2019 ◽  
Vol 5 (2) ◽  
pp. 64
Author(s):  
Asep Indra Komara
Keyword(s):  
Repair Process ◽  
Machining Process ◽  
Fixture Design ◽  
Product Analysis ◽  
Machining Processes ◽  
Main Bearing ◽  
Process Sequence ◽  
Measurement Results ◽  
Housing Component ◽  
Machine Analysis

Main bearing housing is one of the gear transmission product components. The production process of this component needs to be repaired. The repair process is carried out on the fixture construction used today. Redesign is done as one of the solution to improve of the existing fixture design. The measurement results of the products that are machined with the existing fixture are still not in accordance with the requirements of the released product drawing. This is thought to occur because of an error in determining the operating procedur of the machining process that has an impact on the design of the fixture, especially in determining the reference to each machining processes carried out. Therefore, the new fixture needs to be designed so that the resulting product can fit the drawing demands. The repair process is carried out through a gradual study that refers to the methodology of the SME in order to be systematic and structured. Each stage of the design is carried out in detail starting from the study of product analysis, machining analysis, machine analysis, operator analysis and economic analysis. Based on the results of a product analysis study, a new machining process sequence has been produced. The new fixture design has been produced based on this sequence of machining processes. Based on the results of the study, it shows that the results of the redesign of the fixture repair show the conditions that are in accordance with the demands of the product images of the main bearing housing

Locating Error Analysis for Computer-Aided Fixture Design and Verification

1995 ◽  
Author(s):  
Y. Rong ◽  
W. Li ◽  
Y. Bai
Keyword(s):  
Arbitrary Point ◽  
Geometric Error ◽  
Machining Process ◽  
Fixture Design ◽  
Geometric Errors ◽  
Machining Processes ◽  
Relative Slip ◽  
Locating Error ◽  
Computer Aided ◽  
Position And Orientation

Abstract In this paper, locating error effects are analyzed on geometric errors produced in machining processes, such as the parallelism, perpendicularity, and angularity of machining plane or hole surfaces. Inaccurate placement of locator positions in a fixture design may cause a change of workpiece position and orientation, and in turn, contribute to the geometric error of the products. This effect could be complex even if only the variation of one locator’s position is considered because relative slip motions between the workpiece and locators are usually allowed in fixture design. In this research, locating reference planes are established according to the positions of locators. When the locators’ positions change, the variation of these planes can be estimated. The coordinates of an arbitrary point on a machining surface of the workpiece can be determined relative to these reference planes. The coordinate variations of the points on the machining surface can be identified based on the change of locators’ positions, which is used for estimating the geometric errors produced in a machining process due to the inaccuracy of locators’ positions. This information is utilized in computer-aided fixture design and verification.

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.

Lyapunov Control Strategy for Thermoelectric Cooler Activating an Ice-Clamping System

2018 ◽  
Vol 10 (4) ◽  
Author(s):  
Alexandra Mironova ◽  
Paolo Mercorelli ◽  
Andreas Zedler
Keyword(s):  
Manufacturing Systems ◽  
Control Strategies ◽  
Industrial Applications ◽  
Machining Process ◽  
Free Form ◽  
Cooling Power ◽  
Machining Processes ◽  
Clamping System ◽  
Ice Strength ◽  
Free Form Surfaces

Deformation-free clamping plays an important role in manufacturing systems helping to ensure zero-defect production. The fixture of workpieces during machining processes poses challenges not only for microparts but also for thin-walled pieces or free-form surfaces in macromanufacturing. To address this challenge, a nontraditional adhesive technique, using frozen water to clamp, is introduced in this paper. By increasing the cooling power and thus reducing the temperature of the clamping plate, higher adhesive ice strength and, therefore, a safer clamping system during machining process, can be achieved. The objective of this investigation is to ensure a stable low temperature and to compensate for thermal disturbances. Thanks to their structural robustness, Lyapunov-based control strategies demonstrate an appropriate capability to achieve these results in real industrial applications. Model design of the clamping system as well as simulation and experimental results are shown and discussed.

scholarly journals Improvement of Machining Processes: A Case Study

2019 ◽  
Vol 2 (3) ◽  
pp. 634-641
Author(s):  
Hakan Gökçe ◽  
Ramazan Yeşilay ◽  
Necati Uçak ◽  
Ali Teke ◽  
Adem Çiçek
Keyword(s):  
Material Removal ◽  
Current Practice ◽  
Complex Geometry ◽  
Vital Role ◽  
Machining Process ◽  
Machining Processes ◽  
Machining Time ◽  
Machining Strategy ◽  
Removal Processes

In material removal processes, determination of optimal machining strategy is a key factor to increase productivity. This situation is gaining more importance when machining components with complex geometry. The current practice in the determination of machining strategy mostly depends on the experience of the machine operator. However, poorly designed machining processes lead to time-consuming and costly solutions. Therefore, the improvement of machining processes plays a vital role in terms of machining costs. In this study, the machining process of a boom-body connector (GGG40) of a backhoe loader was improved. Improvements of toolpaths and cutting conditions of 22 different material removal processes were checked through a CAM software. According to the simulation results, the process plan was rearranged. Besides, some enhancements in casting model were conducted to decrease in the number of machining operations. When compared to current practice, a reduction of 55% in machining time was achieved.

Späne- und Stauberfassung bei der CFK-Zerspanung*/Extraction of chips and dust in machining operations of CFRP. Investigation on CFRP dry machining in industrial applications

2018 ◽  
Vol 108 (06) ◽  
pp. 473-478
Author(s):  
A. Gebhardt ◽  
M. Schneider
Keyword(s):  
Industrial Applications ◽  
Machining Process ◽  
Dry Machining ◽  
Machining Processes ◽  
Dry Cutting ◽  
Clamping System ◽  
Cutting Processes ◽  
Machining Operations

Bauteile aus CFK (kohlenstofffaserverstärkte Kunststoffe) werden meist spanend endbearbeitet. Diese Bearbeitung kann unter Überflutung durch KSS (Kühlschmierstoffe) oder trocken stattfinden. Die hier vorgestellte Studie zeigt für die Trockenzerspanung, wie die notwendige Erfassung von Stäuben und Spänen stattfindet, welche Technologien eingesetzt werden und wie eine Maschinen- und Bauteilreinigung aussieht.   A machining process is mostly used as a last step in the production of workpieces made of CFRP. In this machining process lubricants may be used or dry cutting processes are applicated. The here presented study shows for dry machining processes, which technologies are used for the dust and chip extraction. Furthermore, the techniques for the cleaning of the machine, the clamping system and workpiece are presented.

Rotary Engine Rotor Side Seals Using New Machining Processes

2021 ◽  
pp. 1-46
Author(s):  
Yu-yuan Hsieh ◽  
Ming-Yi Tsai ◽  
Zhi-Zhe Xu
Keyword(s):  
Manufacturing Process ◽  
Electrical Discharge Machining ◽  
Iron Alloy ◽  
Machining Process ◽  
Machining Processes ◽  
Manufacturing Method ◽  
Rotary Engine ◽  
Traditional Manufacturing ◽  
The Cost ◽  
Engine Rotor

Abstract The study has developed a new machining process for the side seal components of gray cast iron alloy of rotor engine, which is different from the traditional WEDM (wire electrical discharge machining) process. The new manufacturing process (milling + grinding process) will save 78% of the cost and 83% of the time for making each side seal component, and the accuracy of the average surface roughness of the component will be 2.1 times that of the traditional manufacturing method. If the components are polished with a self-made polishing rod, the accuracy will be increased by almost 20 times compared with the new manufacturing process.

Sign in / Sign up

Export Citation Format

Share Document