Development and Fabrication of an Innovative Smart Tool to Monitor the Impact Carving Process on Brittle Stones and Marble

The art of sculpting is related to the processing of brittle materials, such as granite, marble, and stone, and is implemented using percussive hand tools or rotational roughing tools. The outcome of percussion carving is still directly related to the technique, experience, and capacity of the sculptor. Any attempt to automate the art of sculpturing is exhausted in the subtraction method of brittle materials using a rotating tool. In the process of percussion carving, there is no equivalent expertise. In this work, we present the design, manufacturing (3D printing and CNC machining), and use of a smart, percussion carving tool, either manually by the hand of a sculptor, adjusted in a percussive pneumatic hammer, or guided by a digitally driven machine. The scope is to measure and record the technological variables and sizes that describe and document the carving process through the sensors and electronic devices that the smart tool incorporates, the development and programming of which was implemented for the purposes of this work. The smart carving tool was meticulously tested in various carving stones and stressing scenarios to test the functionality and efficacy of the tool. All the tests were successfully implemented according to the specifications set.

DESIGN AND VIBRATIONS IN THE ROTARY HAMMER

The vibrations generated by manual machines can cause occupational diseases with both vascular and osteoarticular affectations, also known as hand-arm vibration syndrome. The pneumatic rotary hammer is one of these machines, widely used in the construction sector. In the bibliography consulted, it is found that the transmission of vibrations from the handle to the hand-arm system depends on both the composition of the material and the design of the handle. Although there are already improvements in this damping of vibrations received through the handles, there is a great field for its optimization, redesign and the search for new materials not yet used in the handles of pneumatic hammers. This article presents a methodology for the study of new materials used in the grip, including the analysis of the design, real tests for the characterization of the materials and their simulation by finite elements. The results obtained show that the design is a decisive factor for both vibration damping and weight. The redesigned grip that generates more damping at 33 seconds with a weight of 0.51kg is the "R1" with a value of 0.6346% better than the original grip, "Segeda original", with a weight of 0.55kg and with a damping value of 0.605%. Keywords: industrial design, pneumatic hammer, handle, elastomers, vibrations

Analysis of initiation of instability zones of drilling string and intensification of drilling process at well boring by rotating an d rotating-bit methods

Instable operation of a drilling string can be caused by design flaws, unreasonably selected drilling modes, as well as specific features of the drilling by bit, fixed on a long flexible rod with initial irregularities. It was established that a drilling string under the influence of constant torque and longitudinal feed load is deformed along a screw line. It was shown that the source of the dynamic state initiation of a rotating drilling string is an alternative friction between rock and the instrument, as well as variation of potential energy of the drilling string at its twisting and untwisting. At the string twisting the potential anergy is accumulating, at the untwisting it is released. In this case the drilling sting length begins to increase and the work of feed force is imposed to this shifting resulting in the instrument beat over the rock. The torsion oscillating process causes longitudinal periodic shifting of the string end, which lead to joint longitudinal and bending oscillations of the whole drilling column. Systems of differential equations obtained describing the joint bending-longitudinal oscillations of a drilling string, caused by torsion vibrations, initiating at the contact of a drilling instrument with rock. Approximate solutions of the systems presented, which take place with the basic natural frequency of the torsion oscillations of a two-mass system instrument - string - rotator drive. In this case the amplitudes of the drilling string bending oscillations are associated with characteristics variation of the friction between the instrument and the rock as well as with the angular frequency of the drilling string rotation. Zones of dynamic instability at rotation of the deformed drilling string due to acting force factors, as well as initial irregularities and centrifugal forces revealed. It was shown that they are initiated at critical speeds of the drilling string rotation, which coincides with any natural frequency of the bending oscillations of the stave. To intensify the drilling process, recommendation elaborated for equipping the rotary drilling rig with an additional pneumatic hammer. A calculated diagram of a drilling string, equipped by an additional pneumatic hammer considered. Parameters of the hammer in terms of frequency and amplitude are matched with the translational speed of well drilling. The total longitudinal and transverse shifts can be obtained by superposition of self-exciting and induces shifts.

Process Capability Based Tolerance Allocation in Pneumatic Percussive Riveting

Pneumatic percussive riveting is an important way to join the sheet metals. In order to ensure the load transfer and the fatigue performance of riveted joint, the interference of the rivet/hole is strictly specified. The interference of the rivet/hole is highly correlated with the process capability of the pneumatic hammer and the diameter of the pre-hole. It is a critical step to choose the appropriate pneumatic hammer to ensure the interference requirements. Energy per blow of the pneumatic hammer is a proclaimed parameter from the riveting hammer manufacturer. It is difficult for the designer to choose the riveting hammer in practical riveting scheme based on energy per blow. Tolerance analysis is an efficient way to model the manufacturing variation and implement process control. This paper presents the tolerance allocation of the pneumatic percussive riveting based on the process capability of the pneumatic hammer. In order to obtain the designed interferences of the rivet/hole, a tolerance chain is built with the process capability of the pneumatic hammer, the diameter of the pre-hole and the diameter of the rivet shank. The process capability of the pneumatic hammer is represented with the interferences of the rivet/hole after riveting. It is an intuitive parameter for the designer to choose the riveting hammer in practical riveting scheme. The process capability of the pneumatic hammer is obtained from the designed riveting experiments with the pneumatic percussive riveting platform. The diameter of the pre-hole affects the interference of the rivet/hole also. The tolerance for manual hole-drilling should be determined to assure the interference requirements and high drilling operation efficiency simultaneously. The variation of the pre-hole is obtained from the manual drilling experiments and diameter measurements. Different hole-drilling results in different mating conditions between the pre-hole and the rivet. The fit conditions of different pre-holes are modeled and the final interferences after riveting are analyzed. Worst case method and statistical analysis method are two common methods for tolerance analysis. For the manual hole-drilling and the pneumatic percussive riveting, worst case method is employed to analyze the constructed tolerance chain in order to accomplish the interferences of the rivet/hole. The different analyzed dimensions, rivet-hole clearances and pre-hole drilling variation, are investigated respectively. The reported work enhances the understanding of the tolerance allocation for the pneumatic percussive riveting. The interference based process capability of the pneumatic hammer provides good reference for pneumatic hammer choosing in riveting scheme. The reported tolerance chain of the interference could be used for the tolerance determination of manual hole-drilling with good quality and high efficiency.

IMPROVEMENT OF DESIGN OF PNEUMATIC HAMMER FOR DRIVING VERTICAL PIPES WITH LARGE DIAMETER INTO SOIL

A brief description of the equipment used for trenchless pipe laying is given. The basic parameters of a pneumatic hammer designed for driving pipes into soil with an open end greater than 426 mm in diameter are substantiated. The description of the device and operating principle of a pneumatic hammer with an air distribution system using an elastic circular valve as the main element is presented. Based on the analysis of many-year operation of equipment for trenchless pipe laying and driving vertical pipes, the frequency and sequence of crack appearance, destruction and failure of the main parts of the pneumatic hammer are determined. New principles of calculation and design of a pneumatic hammer with a large mass of the striking part without loss of work performance are proposed. The solution to the problems associated with fatigue failure of the main parts is a decrease in striking velocity.

COMBINED METHOD FOR CLEANING PIPES FROM SOIL CORE

The paper is devoted to solving an urgent problem - improving the technology of soil excavation during trenchless pipe laying by vibro-impact pushing with the leading steel casing of the well. A new method for core extraction is proposed, which is based on the effect of its vibration transportation under the influence of combined static-dynamic load. The optimum level of soil moisture is experimentally determined, which contributes to a decrease in lateral friction when it moves along a metal pipe cavity. The results of pilot tests on cleaning a pipe 530 mm in diameter, immersed in soil at full design length of transition using Typhoon-190 pneumatic hammer with a mass of 190 kg are presented. The velocity characteristic of core displacement at changing its moisture content is obtained.

Improving Capacity, Stiffness and Pneumatic Hammer Stability of Aerostatic Thrust Bearing Using Damping Orifice and Virtual Recess

An aerostatic thrust bearing is designed using damping orifice and virtual recess. Finite element simulations and measurements are performed and results indicate that with damping orifice and virtual recess, the maximum capacity of the designed aerostatic bearing increases from 1590 N to 2285 N and its maximum stiffness increases from 106 N/μm to 145 N/μm, while the range of pneumatic hammer decreases from 8.5 μm to 4.5 μm at 4 bar. It is therefore concluded that damping orifice and virtual recess are one of the means which can be used to improve the capacity, stiffness and pneumatic hammer stability of aerostatic bearing.An aerostatic thrust bearing is designed using damping orifice and virtual recess. Finite element simulations and measurements are performed and results indicate that with damping orifice and virtual recess, the maximum capacity of the designed aerostatic bearing increases from 1590 N to 2285 N and its maximum stiffness increases from 106 N/μm to 145 N/μm, while the range of pneumatic hammer decreases from 8.5 μm to 4.5 μm at 4 bar. It is therefore concluded that damping orifice and virtual recess are one of the means which can be used to improve the capacity, stiffness and pneumatic hammer stability of aerostatic bearing.

Pneumatic hammer instability in the aerostatic journal bearing–rotor system: A theoretical and experimental analyses

In this study, the pneumatic hammer instability phenomena in the aerostatic journal bearing–rotor system is analysed and discussed for different feeding hole configurations theoretically and experimentally. The influences of the configuration of the feeding holes on the nonlinear dynamics of the system are also investigated. The air flow between the surfaces is modelled with Reynold’s equation and it is numerically solved with differential transform and finite difference hybrid method. Three different aerostatic bearings are modelled and simulated to investigate the ınfluences of the configuration of the holes for different angular speeds. An experimental test rig is designed and tested for different rotor speeds to validate the obtained numerical results. The dynamic response of the system is analysed using waterfall plots, bifurcation diagrams, orbit plots, phase portrait and Poincaré map, which are drawn to determine the pneumatic hammer instability region of the modelled system. The results reveal a nonlinear dynamic response of the rotor centre. In addition, the analysis shows that the feeding hole configuration affects the rotor dynamics and the pneumatic hammer instability region.