A Smart Tool Holder Calibrated by Machine Learning for Measuring Cutting Force in Fine Turning and Its Application to the Specific Cutting Force of Low Carbon Steel S15C

Real-time monitoring of the cutting force in the machining process is critical for improving machining accuracy, optimizing the machining process, and optimizing tool lifetime; however, the dynamometers are too expensive to be widely used by machine tool users. Therefore, this paper presents a simple and cheap apparatus—a smart tool holder—to measure the cutting force of turning tools in the finishing turning. The apparatus does not change the structure of the turning tool. It consists of a tool holder and a piezoresistive force sensor foil, and transmits the signal through Bluetooth wireless communication. Instead of dealing with the circuit hardware, this paper uses the Artificial Neural Network (ANN) model to successfully calibrate the warm-up shift problem of the piezoresistive force sensor. Such a software method is simple, and considerably cheaper than the hardware method. For the force measurement capability of the smart tool holder, the cross-interference between orthogonal forces are very small and thus can be ignored. The force reading of the smart tool holder possesses high repeatability for the same turning parameters and high accuracy within the experiment groups. The authors apply the smart tool holder to cut the low carbon steel S15C, and to determine its specific cutting force in fine turning. The resulting fine turning force model agrees very well with the measurement. Its mean absolute deviation is 3.87% and its standard deviation is 1.55%, which reveals that the accuracy and precision of the smart tool holder and the fine turning force model are both good.

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Decision Making with the Analytical Hierarchy Process (AHP) for Material Selection in Screw Manufacturing for Minimizing Environmental Impacts

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.315.57 ◽

2013 ◽

Vol 315 ◽

pp. 57-62 ◽

Cited By ~ 8

Author(s):

Sia Chee Kiong ◽

Loo Yee Lee ◽

Siaw Hua Chong ◽

Mohd Azwir Azlan ◽

Nik Hisyamudin Muhd Nor

Keyword(s):

Stainless Steel ◽

Titanium Alloy ◽

Cast Iron ◽

Carbon Steel ◽

Environmental Impact ◽

Aluminium Alloy ◽

Low Carbon Steel ◽

Machining Process ◽

Low Carbon ◽

Hierarchy Process

This study is an approach to investigate the environmental impact of screw manufacturing and to choose suitable material for selected screw-making processes for the best performance with minimum environmental impact. The parameters involved were types of material and screw-making process using the environmental data available in Asia region. The two different manufacturing approaches being evaluated were machining and forging. The types of material considered were low carbon steel, stainless steel, titanium alloy and aluminium alloy. As for machining process, the materials being considered in screw manufacturing were low carbon steel, stainless steel, titanium alloy, aluminium alloy, magnesium alloy and cast iron. The information of environmental impact are generated by SolidWorks. Sustainability tool was used in the formation of pair-wise comparison matrices for Analytic Hierarchy Process (AHP). Then, the ranking of global priorities had enabled the determination of appropriate material to be used for those selected screw manufacturing process. As a result, aluminium alloy was found to give minimum environmental impact for forging process whereas cast iron was found to excel in machining process. At the same time, titanium alloy was not suggested to be used in either process.

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The effect of temperature on the softening characteristics of duralumin and low-carbon steel, work, chip and built-up-edge materials as formed in the machining process

Wear ◽

10.1016/0043-1648(70)90179-1 ◽

1970 ◽

Vol 15 (5) ◽

pp. 353-358 ◽

Cited By ~ 5

Author(s):

J.E. Williams ◽

A.B. Wilcox

Keyword(s):

Carbon Steel ◽

Low Carbon Steel ◽

Machining Process ◽

Effect Of Temperature ◽

Low Carbon ◽

Steel Work

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Improvement of Chip Breaking in Machining Low Carbon Steel by Cryogenically Precooling the Workpiece

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2830113 ◽

1998 ◽

Vol 120 (1) ◽

pp. 76-83 ◽

Cited By ~ 24

Author(s):

Y. Ding ◽

S. Y. Hong

Keyword(s):

Carbon Steel ◽

Cutting Speed ◽

Low Carbon Steel ◽

Machining Process ◽

Low Carbon ◽

Ductile Materials ◽

Chip Breaking ◽

Brittle Ductile Transition ◽

Element Simulation ◽

Embrittlement Temperature

Ductile materials such as AISI1008 low carbon steel characteristically exhibit poor chip breaking in conventional machining practices. This paper presents an environmentally clean cryogenic machining process which improves the breakability of AISI1008 chips by lowering the chip temperature to its embrittlement temperature. In this study, the brittle-ductile transition temperature of AISI1008 was experimentally determined to be between −60°C and −120°C. The discussion is focused on whether the chip can reach the embrittlement temperature before it hits an obstacle. A finite element simulation predicted the chip temperatures under various cutting conditions. Liquid nitrogen (LN2) was used to prechill the workpiece cryogenically. The results from the cutting tests indicate a significant improvement in chip breakability for different feeds and speeds by using this cooling technique. However, the effectiveness of cryogenetically prechilling the workpiece was found to be heavily dependent on cutting speed.

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Modeling the Temperature/Force Phenomena of an Extra-Low Carbon Steel in Two-Phase Hot Rolling

10.1115/imece1999-0657 ◽

1999 ◽

Author(s):

Yhu-Jen Hwu ◽

Chang-Huei Wu

Keyword(s):

Carbon Steel ◽

Hot Rolling ◽

Rolling Force ◽

Low Carbon Steel ◽

Phase Transformation Temperature ◽

Force Model ◽

Low Carbon ◽

Two Phase ◽

Finishing Mill ◽

Temperature Force

Abstract Extra-low carbon steel had been rolled in conventional hot rolling mill. For improving its mechanical and metallurgical properties, its high phase transformation temperature typically encountered in the finishing mill section that results in abrupt change of flow stress and consequently the rolling force. A simple temperature/force model is proposed to predict the strip temperature and mill loading force to achieve better understanding of complicated phenomena encountered in the field and also for future initial rolling condition setup. Preliminary results based on the model are satisfactorily close to the on-line rolling data from the seven-stand mill of China Steel Corporation.

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Decision Making of Screw Manufacturing for the Best Environmental and Economic Combination by Using AHP

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.465-466.1065 ◽

2013 ◽

Vol 465-466 ◽

pp. 1065-1069

Author(s):

Mohd Azwir Azlan ◽

Andy Anak Buja ◽

Sia Chee Kiong ◽

Nik Hisyamudin Muhd Nor ◽

Jalil Azlis-Sani

Keyword(s):

Decision Making ◽

Stainless Steel ◽

Carbon Steel ◽

Environmental Impacts ◽

Manufacturing Process ◽

Low Carbon Steel ◽

Machining Process ◽

Steel Alloy ◽

Low Carbon ◽

Forging Process

This study is an approach to investigate the viable impacts of screw manufacturing. At the same time, choose the suitable material and selected manufacturing process of screw by considering environmental aspects without sacrificing the economic aspect. It is important to the organisation to improve the environmental aspect. Therefore in this study, the decision making was focused on economic aspects to produce the synergy results between economic and environmental impact. The parameters involved were types of material and manufacturing process of screw which using the available data of environmental and production volume. The two different manufacturing approaches being evaluated were machining and forging process. The types of material concerned for forging process encompassed low carbon steel, alloy steel stainless steel, and aluminium alloy. On the other hand, for machining process, the material being considered in screw manufacturing were cast iron, low carbon steel, alloy steel, stainless steel and aluminium alloy. The information of environmental impacts that generated from SolidWorks Sustainability tool and screw production cost were calculate using Manufacturing cost model, both information was used in Analytic Hierarchy Process (AHP) analysis to obtain local priority of economic and environmental impacts. Then, the ranking of both global and local priorities from economic impact and environmental impacts had enabled the determination of appropriate material used for those selected screw manufacturing process. As result, low carbon steel was chosen for forging process whereas cast iron was excelled in machining process, at the same time, stainless steel was not suggested to be used in both two processes.

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