A Review of Advances in Modeling of Conventional Machining Processes: From Merchant to the Present

This paper presents a review of recent advances in modeling and simulation of conventional metal machining processes, which continue to dominate a significant part of all machining processes, and in recent years, the need for predictive models for machining processes has grown in importance in the digital manufacturing age. Significant advances have been made in modeling the mechanics of cutting in conventional machining, driven by industrial need and enabled by rapid advances in computational power. The paper surveys the state-of-the-art in analytical and numerical modeling of conventional metal machining processes with a focus on their ability to predict useful performance attributes including chip geometry, forces, temperatures, tool wear, residual stress, and microstructure. Also included in the review is a discussion of the industrial use of modeling and simulation tools for conventional machining. Additionally, the practical applicability, implementation benefits, and methodological limitations of conventional machining process modeling have been examined. The paper concludes with a summary of future research directions in modeling and simulation of conventional metal machining processes.

Development of HTU-model variable chipping clearance cassava chipper

The objective of this research was to design, construct and evaluate a variable chipping clearance cassava chipper for processors which will produce uniform and varying cassava chip geometry for multipurpose usage. It consists of a drive shaft with varying chipping clearances (6, 18, and 28 mm) to produce varied chip geometry. The average throughput capacity of the chipper was found to be 475.5 kg·h^–1 at a speed range of 460–800 rpm with a chipping clearance of 6–28 mm. The average chipping efficiency ranges from a minimum–maximum of 76.6–99.4% for the selected operational speeds and chipping clearances. The chipping capacity and the output to input ratio is dependent on the operational speeds and chipping clearances of the machine.

Shear-based deformation processing of age-hardened aluminum alloy for single-step sheet production

Shear-based deformation processing by hybrid cutting-extrusion and free machining are used to make continuous strip, of thickness up to one millimeter, from low-workability AA6013-T6 in a single deformation step. The intense shear can impose effective strains as large as 2 in the strip without pre-heating of the workpiece. The creation of strip in a single step is facilitated by three factors inherent to the cutting deformation zone: highly confined shear deformation, in situ plastic deformation-induced heating and high hydrostatic pressure. The hybrid cutting-extrusion, which employs a second die located across from the primary cutting tool to constrain the chip geometry, is found to produce strip with smooth surfaces (Sa < 0.4 μm) that is similar to cold-rolled strip. The strips show an elongated grain microstructure that is inclined to the strip surfaces – a shear texture – that is quite different from rolled sheet. This shear texture (inclination) angle is determined by the deformation path. Through control of the deformation parameters such as strain and temperature, a range of microstructures and strengths could be achieved in the strip. When the cutting-based deformation was done at room temperature, without workpiece pre-heating, the starting T6 material was further strengthened by as much as 30% in a single step. In elevated-temperature cutting-extrusion, dynamic recrystallization was observed, resulting in a refined grain size in the strip. Implications for deformation processing of age-hardenable Al alloys into sheet form, and microstructure control therein, are discussed.

A Spliced Satellite Optical Camera Geometric Calibration Method Based on Inter-Chip Geometry Constraints

When in orbit, spliced satellite optical cameras are affected by various factors that degrade the actual image stitching precision and the accuracy of their data products. This is a major bottleneck in the current remote sensing technology. Previous geometric calibration research has mostly focused on stitched satellite images and has largely ignored the inter-chip relationship among original multi-chip images, resulting in accuracy loss in geometric calibration and subsequent image products. Therefore, in this paper, a novel geometric calibration method is proposed for spliced satellite optical cameras. The integral geometric calibration model was developed on inter-chip geometry constraints among multi-chip images, including the corresponding external and internal calibration models. The proposed approach improves uncontrolled geopositioning accuracy and enhances mosaic precision at the same time. For evaluation, images from the optical butting satellite ZiYuan-3 (ZY-3) and mechanical interleaving satellite Tianhui-1 (TH-1) were used for the experiments. Multiple sets of satellite data of the Songshan Calibration field and other regions were used to evaluate the reliability, stability, and applicability of the calibration parameters. The experiment results found that the proposed method obtains reliable camera alignment angles and interior calibration parameters and generates high-precision seamless mosaic images. The calibration scheme is not only suitable for mechanical interleaving cameras with large geometric displacement among multi-chip images but is also effective for optical butting cameras with minor chip offset. It also significantly improves uncontrolled geopositioning accuracy for both types of spliced satellite images. Moreover, the proposed calibration procedure results in multi-chip satellite images being seamlessly stitched together and mosaic errors within one pixel.

Comparison of the machinability of the 316L and 18Ni300 additively manufactured steels based on turning tests

This paper focuses on the machinability of additively manufactured steel alloys (316L stainless steel and 18Ni300 Maraging steel) by reference to their conventional metallurgical conditions. The machinability of both metallurgical conditions has been evaluated by longitudinal turning tests under laboratory conditions using two different cutting tool geometries (flat rake face and chip-breaker geometry) and covering different cutting speeds, depths of cut and feed values. Cutting forces, chip morphology and surface roughness were investigated as machinability indicators. The influence of chip-breaker on process performance was also analysed. For a comprehensive discussion of the results, microstructure, chemical composition, surface roughness and mechanical strength of both metallurgical conditions were studied. The paper quantitatively demonstrates that despite the higher mechanical strength of additively manufactured alloys, no significant power requirements were verified for the finishing cutting of tested alloys, when compared with conventional materials. Also noteworthy, is the surface quality improvement of the printed samples due to the most favourable conditions for chip formation. The usage of a chip breaker insert had higher impact on reducing required cutting energy than on controlling chip geometry.