• A compact XY flexure-based nanopositioning stage for scanning probe microscope (SPM) Narendra Reddy T, Vithun S N, Prakash Vinod, Mervin Herbert and Shrikantha S Rao 3 • Investigation on machinability in finish turning of AISI 52100 steel using different tool inserts in dry machining Krishnendu Mondal and Santanu Das 9 • An experimental investigation on surface grinding performance Spandan Guha, Syed Irfan Mirza Rahman, Rahul Kumar, Shubhom Paul, Saurav Choudhury 21 Select Bibliography: Nanotechnology 28 Photo Gallery: Vintage Machine: Hendey - Norton Lathe, 1892 30 Manufacturing Technology Abstracts 31 Select Bibliography of Standards: Nanotechnology 43 Calendar of Events 45 Technology Trends 48 Patent Abstracts: Nanofabrication 50 IPR News: A - Z Definions of Intellectual Property Terminology 57 Contents Vol. 15 No. 10 October 2016 Technical Papers Annual Subscription* Inland ₨1000.00 + Service Tax (ST) @15% Single Copy ₨100.00 + ST@15% Foreign USD 100 CMTI members will receive the journal against their membership Editorial Board *All payments are to be made by demand draſt drawn in favour of ‘Central Manufacturing Technology Instute, Bengaluru' Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same. Chairman S Satish Kumar Technical Paper Review Panel K K Rajagopal M Chellamalai V Shanmugaraj V G Yoganath S K Verma Editor Mallikarjun G Editorial Assistants Shashi Rekha N Mala RC Editorial Advisory Committee S Usha N Balashanmugam S Arumugasamy B R Mohanraj Dr. C K Srinivasa, Honorary Member
Transcript
• A compact XY flexure-based nanopositioning stage forscanningprobemicroscope(SPM)
Narendra Reddy T, Vithun S N, Prakash Vinod, Mervin Herbert and Shrikantha S Rao 3
• Investigation on machinability in finish turning of AISI52100steelusingdifferenttoolinsertsindrymachining
Krishnendu Mondal and Santanu Das9
• An experimental investigation on surface grindingperformance
4. Application of nanotechnology in cementbasedmaterials.
Singh, LP; Bhattacharyya, SK; Ahalwat, S [Nano Digest, V 3, N 4, 2011, Starting page 18, 31 Pages] Rec. No: 108159
5. Nanotechnologyanditsapplications.
Singh, R; Goel, A [Nano Digest, V 3, N 3, 2011, Starting page 16, 7 Pages] Rec. No: 108158
6. Optimization of the physical cleaningconditionfornanotechnology.
Shin, WK; An, JN; Jeong, HD [CIRP Annals, V 60, N 1, 2011, Starting page 579, 4 Pages] Rec. No: 108792
7. Nanotechnology:Thebuzzword.
Das, P [The Machinist, V 4, N 7, 2009, Starting page 16, 2 Pages] Rec. No: 104930
8. Absorptive and transformative capacities innanotechnologyinnovationsystems.
Pandza, K; Holt, R [J of Engg Tech & Management, V 24, N 4, 2007, Starting page 347, 19 Pages] Rec. No: 104060
9. Reliability of parameters of associatedbase straight line in step height samples:uncertainty evaluation in step heightmeasurementsusingnanometrologicalAFM.
Krishna Moorthy, V [Invention Intelligence, V 40, N 1, 2005, Starting page 5, 11 Pages] Rec. No: 101849
13.Nanotechnology : Opportunities andchallenges.
Meyyappan, M [Electronics Today, V 37, N 9, 2005, Starting page 61, 3 Pages] Rec. No: 101851
14.Nanotechnology : The next industrialrevolution.
Amritkar, C [Industrial Products Finder, V 34, N 1, 2005, Starting page 168, 3 Pages] Rec. No: 101398
15.Microandnanotechnologies fora life in theinformationage.
Fuhrmann, JU [Electronics Today, V 37, N 9, 2005, Starting page 64, 2 Pages] Rec. No: 101847
16.Strategy for long-term planning for anemergingtechnology:Nanotechnology.
Bhat, JSA [Electronics Today, V 37, N 11, 2005,
“Nanotechnology is the creation of functional materials, devices and systems through control of matter on the nanometer length scale (1-100 nanometers), and exploitation of novel phenomena and properties (physical, chemical, biological, mechanical, electrical...) at that length scale. One nanometer is 10-9 meters or about 3 atoms long. For comparison, a human hair is about 60-80,000 nanometers wide”.
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Manufacturing technology abstracts
JOINING&ASSEMBLY 32
LASERS 35
LASERCALIBRATION 35
MACHINEELEMENTS&MECHANISMS 36
MACHINING 36
NONTRADITIONALMACHINING 37
DIAMONDTuRNING 37
GRINDING 38
LASERMACHINING 38
MANuFACTuRINGSYSTEMS 39
VIRTuALFACTORY 39
MATERIALS&TREATMENT 39
MEASuREMENT&TESTING 40
PRODuCTDESIGN&MANuFACTuRE 40
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Manufacturing technology abstracts
JOINING&ASSEMBLY
110846 Influence of resistance heating on self-piercing riveted dissimilar joints of AA6061 - T6andgalvanizedDP590.
Ming Lou, YongBing Li, Yuan Wang, Bin Wang, Xinmin Lai [J of Materials P r o c e s s i n g Technology, v 214, n 10, Oct 2014, Starting
Page 2119, Pages 8] The hybrid use of aluminum alloy and advanced high strength steel (AHSS) has become an inevitable trend for fabricating a lightweight auto-body. Self-piercing riveting (SPR) as a preferred cold-forming fastening method is facing problem like weak interlocking when joining dissimilar combinations with considerably unequal thickness. In this study, a hybrid joining method, named rivet-welding (RW) was proposed to improve the robustness and strength of the SPR joint, by applying an electric current to it. For better evaluating the new process, the effects of heating time and electrode design on the microstructure, micro-hardness distribution, and mechanical performance of the RW joints were studied and compared systematically with the traditional SPR ones. The results showed that the electric current could improve the microstructure of the steel rivet and bottom DP590, and under long heating time, the inter-metallic compounds (IMC) could be formed at the interface of trapped AA6061-T6 and bottom DP590. Meanwhile, the electric current could increase the micro-hardness of the rivet and bottom DP590, and soften the AA6061-T6 around the rivet leg. In addition, the RW process using lower annular electrode A (LAE_A) could obtain 12.1% higher tensile-shear strength compared with the traditional SPR process.
110847 Mechanical clinching of ultra-highstrengthsteelsheetsandstrengthofjoints.Yohei Abe, Toru Kato, Ken-ichiro Mori, Shoma Nishino [J of Materials Processing Technology, v 214, n 10, Oct 2014, Starting Page 2112, Pages 7] Ultra-high strength steel sheets
having low ductility were joined by mechanical clinching with dies for control of metal flow. The diameter and depth of the die were modified to relieve concentration of deformation of the
sheets for avoidance of the occurrence of sheet fracture. As the tensile strength of the steel sheets increased, the interlock decreased due to small metal flow. Two kinds of the ultra- high strength steel sheets having different ductility were used. The ultra-high strength steel sheets having large ductility were successfully joined using die having modified shape, whereas the sheets having small ductility were not joined. The static and fatigue strengths of the mechanically clinched joint were compared with those of the resistance spot welded joint. Although the static load of the mechanically clinched joint was smaller than that of the resistance spot welded joint in both tension-shearing and cross-tension tests, the fatigue load of the clinched joint was larger in the large number of cycles. It was found that mechanical clinching has superior fatigue strength due to the large yield stress of the sheets and relaxation of the stress concentration.
110848 Strength of spline joints assembled byforming.
Hirota, Kenji; Kitamura, Kazuhiko; Ukai, Yoshihiko; Matsunaga, Keiichi [J of Materials P r o c e s s i n g Technology, v 214, n 10, Oct 2014,
Starting Page 2095, Pages 7] In this paper, a new assembling method of spline joints that enables tight fitting in a simple manner by allowing slight plastic deformation at the spline teeth was introduced. Experiments were carried out for the spline joints of medium carbon steel varying the overlap zone between the male and the female spline teeth. Axial joining strength was increased
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with increase in the overlap length due to the residual compressive stress by forming. The joint by the proposed method also showed higher torsional strength than the conventional joint. Improvement in the torsional strength was explained based on the deformation and hardness distribution around the spline teeth. With respect to the shape of overlap zone, better results were obtained when using the specimen having a uniform overlap length along the axial direction.
110849 Dynamic analyses and verifications ofa hollow shaftwith hot-fit component using 3dfinitecontactelement.Shin-Yong Chen [Transactions of the Canadian Society for Mechanical Engineering, v 37, n 1, 2013, Starting Page 21, Pages 18] In general engineering practice, one key factor in designing a motor built-in high-speed spindle is to assemble the motor rotor and shaft by means of hot-fit to form a new rotor-shaft assembly. In this paper, the dynamic analysis of a hot-fit rotor in a rotor-shaft assembly by using 3D contact element is proposed. Contact pressure between the rotor and the shaft is firstly calculated through contact theory. The stress state is thus determined. The finite element modal analysis then follows with the stress state as a pre-stressed condition. The accuracy and the validity of the finite contact element results are verified by theoretical formulation, equivalent static analysis and experimental modal testing. The results presented herein indicate that it is accurate and effective in analyzing the dynamic behavior of the rotary shaft system with a hot-fit component by using contact element.
110850Influenceofthepressrammotiononthejoining characteristics during indentation plasticjoiningusingaservopress.
Ryo Matsumoto, Takahiro Chida, Shinji Hanami, H i r o s h i Utsunomiya [J of M a t e r i a l s P r o c e s s i n g T e c h n o l o g y , v 214, n 10, Oct
2014, Starting Page 1995, Pages 7] A plastic joining method for fixing bars and hot plates, called “indentation plastic joining”, was carried out using a servo press with press ram speed control. The influence of the press ram motion
control on the indentation joining characteristics of an aluminum alloy bar and plate was examined. The accelerated ram motion was effective in reducing the bar indentation pressure by approximately 15% and the bonding strength of the indented bar–plate was improved by approximately 7%. The bonding mechanism underlying the indention joining method under press ram motion control is discussed in terms of the seizure of the plate and the mechanical clamping associated with the process. It is found that the accelerated ram motion produces heavier seizure at the indented bar–plate interface, whereas the decelerated ram motion reduces the degree of the seizure.
110851 Industrially validated method for weldload balancing in multi station sheet metalassemblylines.
Johan Segeborn, Daniel Segerdahl, Fredrik Ekstedt, Johan S. Carlson, Mikael Andersson, Anders Carlsson and Rikard Söderberg [J of Manufacturing Sci
& Engg:ASME Trans, v 136, n 1, Feb 2014, Starting Page 011002, Pages 7] Sheet metal assembly is investment intense. Therefore, the equipment needs to be efficiently utilized. The balancing of welds has a significant influence on achievable production rate and equipment utilization. Robot line balancing is a complex problem, where each weld is to be assigned to a specific station and robot, such that line cycle time is minimized. Industrial robot line balancing has been manually conducted in computer aided engineering (CAE)-tools based on experience and trial and error rather than mathematical methods. However, recently an automatic method for robot line balancing was proposed by the authors. To reduce robot coordination cycle time losses, this method requires identical reach ability of all line stations. This limits applicability considerably since in most industrial lines, reach ability differs over the stations to further line reach ability and flexibility. Therefore, in this work we propose a novel generalized simulation-based method for automatic robot line balancing that allows any robot positioning. It reduces the need for robot coordination significantly by spatially separating the robot weld work loads. The
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proposed method is furthermore successfully demonstrated on automotive stud welding lines, with line cycle times lower than that of the corresponding running production programs. Moreover, algorithm central processing unit (CPU)-times are mere fractions of the lead times of existing CAE-tools.
Mori, K; Abe, Y; Kato, T [J of M a t e r i a l s P r o c e s s i n g Technology, v 214, n 10, Oct 2014, Starting Page 2002, Pages 7]
Multiple steel and aluminium alloy sheets were joined by self-pierce riveting. Self-pierce riveting is attractive for joining multiple and dissimilar sheets, because joining of individual interfaces is not necessary unlike the conventional joining processes, i.e. sheets except for a lower sheet are merely pieced with a rivet shirt. The steel sheets ranged from mild steel to ultra-high strength one having 980 MPa in tensile strength, and the joinability for three steel and aluminium alloy sheets for various combinations was examined from both experiments and finite element simulation. The joinability was improved by setting a softer sheet uppermost due to smooth piercing. In addition, the joining range for self-piece riveting of three high strength steel and aluminium alloy sheets was extended by optimising a shape of the die, and the ultra-high strength steel, mild steel and aluminium alloy sheets were successfully joined.
110853 Integrated computational weldingmechanics with direct-search optimization formitigationofdistortioninanaluminumbarusingsideheating.
Asadi, Mahyar; Goldak, John A [J of Manufacturing Sci & Engg: ASME Trans, v 136, n 1, Feb 2014, Starting Page 011007,
Pages 10] Using a computational weld mechanics (CWM) frame-work for exploring a design space, a recent direct-search algorithm from Kolda, Lewis and Torczon is modified to use a least-square
approximation to improve the method of following a path to the minimum in the algorithm. To compare the original and modified algorithms, a CWM optimization problem on a 152 × 1220 × 12.5 mm bar of Aluminum 5052-H32 to minimize the weld distortion mitigated by a side heating technique is solved. The CWM optimization problem is to find the best point in the space of side heater design parameters: power, heated area, longitudinal and transverse distance from the weld such that the final distortion is as low as possible (minimized). This CWM optimization problem is constrained to keep the stress level generated by the side heaters, in the elastic region to avoid adding an additional permanent plastic strain to the bar. The number of iterations, size of design of experiments (DOE) matrix required and CPU time to find the minimum for the two algorithms are compared.
110854 Development of a novel test rig toinvestigatethefundamentalsofimpactwelding.
Groche, P; M.F. -X. Wagner, Pabst, C; Sharafiev, S [J of Materials Processing T e c h n o l o g y , v 214, n 10, Oct 2014, Starting Page 2009, Pages 9] Despite the great technological
advantages of impact welding, its application is still not widely spread. One reason is the poor understanding of its mechanisms and the effects on the bond strength. In this paper, a novel test rig is presented, which allows the straight forward investigation of impact welding and its basic principles to help filling this gap of knowledge. Impact angle and velocity, which are known to be the most important process parameters, can now be freely and almost independently varied over a large range of values. The built-up of the test rig and its functionality will be presented in this paper. Furthermore, first numerical and experimental results will be discussed and compared to an industrially implemented process. The investigations show that the test rig is capable of representing the high-speed collision of the real process.
110855 Analytical bonding criteria for jointintegrity prediction in friction stir welding ofaluminumalloys.Gianluca Buffa; Sergio Pellegrino; Livan
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Fratini [J of Materials Processing Technology, v 214, n 10, Oct 2014, Starting Page 2102, Pages 10] In this study, two bonding criteria, previously used for porthole die
extrusion, are applied to FSW starting from the local value of the main field variables calculated through a specifically developed 3D numerical model of the process. Their applicability and effectiveness have been assessed through an experimental and numerical campaign carried out with the main process parameters varying in a wide range. The pressure–time–flow criterion was demonstrated to be better suited for FSW processes when large welding speed is used.
110856 Spot weld layout optimization oftube crash performance with manufacturingconstraints.
Qing Zhou, Xueyuan Wu, Yong Xia and Wayne Cai [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 1, Feb 2014,
Starting Page 011014, Pages 10] Spot weld layout is critical to structural performance of vehicle and its design is also subject to manufacturing constraints. In this study, using thin-walled tube crash as an example, we establish the relation between structural performance and weld layout design with manufacturing constraints from resistance spot welding. First, a straight tube crash performance is evaluated as a function of flange width, weld distance to flange corner, and weld pitch, without consideration of manufacturing constraints. All these parameters exhibit certain influence on the deformation mode and the energy absorption capacity. Then, an S-shaped tube is studied in the design optimization of weld layout by adding manufacturing constraints. The proposed approach can determine optimized results by simultaneously considering crash performance and manufacturing constraints. It is also concluded that weld layout has more significant influence on crash performance in straight tubes than in S-shaped tubes.
LASERS
110857 Effect of laser-induced crystallinitymodification on biodegradation profile of poly(l-lacticacid).
Hsu, Shan-Ting; Tan, Huade; Yao, Y Lawrence [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 1, Feb 2014, Starting Page 011005, Pages 9] Poly(L-lactic acid) (PLLA) is of interest in drug
delivery applications for its biodegradable and biocompatible properties. Polymer-controlled drug delivery relies on the release of embedded drug molecules from the polymer matrix during its degradation. PLLA degradation exhibits an induction period, during which an insignificant amount of degraded products and embedded drug can be released. Due to this induction period, drug release is initially nonlinear, a complication in drug delivery applications. PLLA degradation is a function of crystallinity, such that control over its crystallinity tailors drug release over time. In this study, the effect of laser-induced PLLA crystallinity reduction on degradation is investigated. Samples having lower surface crystallinity are shown to have higher rates of molecular weight reduction and earlier mass loss than nonlaser-treated samples, as observed from gel permeation chromatography and mass change. Wide-angle X-ray diffraction measurements show that crystallinity increases with degradation. A numerical model is implemented from hydrolysis and diffusion mechanisms to investigate the effect of laser irradiation on biodegradation. Controlled laser treatment of PLLA offers a method for constant drug release through the reduction of surface crystallinity.
LASERCALIBRATION
110858 Systematic optimization approach forthe calibration of parallel kinematics machinetoolsbyalasertracker.Wu, Jia-Feng; Zhang, Rui; Wang, Rui-He; Yao, Ying-Xue [Int J of Machine Tools & Manufacture, v 86, Nov 2014, Starting Page 1, Pages 11] Parallel kinematics machine has attracted attention
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as machine tools because of the outstanding features of high dynamics and high stiffness. Although various calibration methods
for parallel kinematics machine have been studied, the influence of inaccurate motion of joints is rarely considered in these studies. This paper presents a high-accuracy and high-effective approach for calibration of parallel kinematics machine. In the approach, a differential error model, an optimized model and a statistical method are combined, and the errors of parallel kinematics machine due to inaccurate motion of joints can be reduced by this approach. Specifically, the workspace is symmetrically divided into four subspaces, and a measurement method is suggested by a laser tracker to require the actual pose of the platform in these subspaces. An optimized model is proposed to solve the kinematic parameters in symmetrical subspaces, and then arithmetical mean method is proposed to calculate the final kinematic parameter. In order to achieve the global optimum quickly and precisely, the initial value of the optimal parameter is directly solved based on the differential error model. The proposed approach has been realized on the developed 5-DOF hexapod machine tool, and the experiment result proves that the presented method is very effective and accurate for the calibration of the hexapod machine tool.
MACHINEELEMENTS&MECHANISMS
110859 Motion planning for 6-DOF assemblypartpositioningandalignmentadjustment.Jun Hong, Shao F Wang, Emenike Chukwuma, Jing H. Zhang, Zhi G. Liu [Transactions of the Canadian Society for Mechanical Engineering, v 37, n 2, 2013, Starting Page 161, Pages 23] In this paper, a 4 – PPPS redundantly actuated parallel mechanism and its motion planning method are proposed. The mechanism can be applied to the positioning and alignment of large subassembly in engineering assembly. The optimization of the positioning and alignment trajectory is performed with the minimum energy consumption as the objective function. The system test data shows that the assembly platform and the motion planning method can
satisfy the requirements of accuracy, efficiency and stability of the positioning and alignment operations.
MACHINING
110860 Investigationofworkpiece temperaturevariation of helical milling for carbon fiberreinforcedplastics(CFRP)Liu, Jie; Chen, Guang; Ji, Chunhui; Qin, Xuda; Li, Hao; Ren, Chengzu [Int J of Machine Tools & Manufacture, v 86, n , Nov 2014, Starting Page 89, Pages 15] Better prediction about the temperature distribution of workpiece has a great significance for improving performance of cutting process, especially relating to the workpiece of carbon fiber reinforced plastics (CFRP). In this paper, a heat transfer model is developed to investigate the temperature distribution of CFRP workpiece in helical milling process. Depending on characteristics of helical milling, two kinds of heat sources have been presented, the geometrical shapes of which are modeled as semicircle arc and line. The complex trajectory of each heat source relative to the stable workpiece has been studied. Based on the analysis, unsteady state three-dimensional governing equation of heat transfer in CFRP workpiece with adiabatic boundary condition is proposed. The solution procedure of this nonhomogeneous heat transfer equation consists of two steps: it is transformed into homogeneous equation according to the heat transfer theory firstly; and then the homogeneous equation is solved using the separation of variables. Basing on the solution of the homogeneous equation, the temperature distribution resulting from the moving semicircle arc heat source and the line heat source has been studied detailedly. In order to calculate the heat generation in the helical milling process, a cutting force model is presented and the heat partition transferring into the CFRP workpiece is solved using the Conjugate Gradient Method. A series of tests of helical milling for CFRP are conducted, and the experiment results agree well with the results calculated by the predicted model. This model can be extended to optimize the cutting condition and restrain the thermal damage of the CFRP workpiece.
110861 Critical cutting speed for onset ofserratedchipflowinhighspeedmachining.Ye, GG; Chen, Y; Xue, SF; Dai, LH [Int J of Machine
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Tools & Manufacture, v 86, Nov 2014, Starting Page 18, Pages 16] The transition of continuously smooth chip flow to periodically serrated
chip flow as the cutting speed increasing is one of the most fundamental and challenging problems in high speed machining. Here, an explicit expression of the critical cutting speed for the onset of serrated chip flow, which is given in terms of material properties, uncut chip thickness and tool rake angle, is achieved based on dimensional analysis and numerical simulations. It could give reasonable predictions of the critical cutting speeds at which chips change from continuous to serrated for various metallic materials over wide ranges of uncut chip thickness and tool rake angle. More interestingly, it is found that, as the turbulent flow is controlled by the Reynolds number, the transition of the serrated chip flow mode is dominated by a Reynolds thermal number. Furthermore, the influences of material properties on the emergence of serrated chip flow are systematically investigated, the trends of which show good agreement with Recht’s classical model.
110862Analyticalpredictionofthecriticaldepthof cut and worst spindle speeds for chatter inendmilling.Zheng, CM; Junz Wang, J.-J; Sung, CF [J of Manufacturing Sci & Engg: ASME Trans, v 136, n 1, Feb 2014, Starting Page 011003, Pages 10] The frequency response function (FRF) method has been well used to determine the worst spindle speeds and their critical limiting chip width for turning operation by finding the maximum negative real part of the FRF. In this study, a modified FRF concept is adapted for a 2 DOF milling system of planar isotropic dynamics to determine the worst spindle speeds and the critical limiting axial depth of cut in explicit, analytic formulas. Analogous to the formulation of worst spindle speeds, similar expression for the best spindle speeds is also obtained. The modified FRF is obtained by multiplying the original FRF of the structure with a complex scaling factor, corresponding to a scaling and a rotation of its original Nyquist plot. The scaling factor is determined analytically from the system characteristic equation with the radial cutting
constant and radial immersion angle as the major system parameters. Through the presented method, it is also shown that the worst spindle speeds for a milling operation can be found without the prior knowledge of modal dynamics and stability lobe diagram. The proposed analytical expressions are confirmed by the existing stability models and experimentally verified.
NONTRADITIONALMACHINING
110863 Developments in the non-traditionalmachining of particle reinforced metal matrixcomposites.
Pramanik, A [Int J of Machine Tools & Manufacture, v 86, Nov 2014, Starting Page 44, Pages 18] The non-traditional machining of particulate reinforced
metal matrix composites is relatively new. However, researchers seem to pay more attention in this field recently as the traditional machining of particulate reinforced metal matrix composites is very complex. This research investigates different non-traditional machining, such as electro-discharge, laser beam, abrasive water jet, electro-chemical and electro-chemical discharge machining of this composite materials. The machining mechanism, material removal rate/machining speed and surface finish have been analysed for every machining process. This analysis clearly shows that vaporisation, melting, chemical dissolution and mechanical erosion are the main material removal mechanisms during non-traditional machining. The thermal degradation and the presence of reinforcement particles mainly damage the machined surface. The understanding of electro-discharge, laser beam and abrasive water jet machining is more developed than that of electro-chemical and electro-chemical discharge machining for particulate reinforced MMC.
DIAMONDTuRNING
110864 Fabrication of hybrid micro/nano-textured surfaces using rotary ultrasonicmachiningwithone-pointdiamondtool.Shaolin Xu, Keita Shimada, Masayoshi Mizutani,
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Tsunemoto Kuriyagawa [Int J of Machine Tools & Manufacture, v 86, Nov 2014, Starting Page 12, Pages 6] A novel rotary ultrasonic texturing (RUT) technique is proposed to fabricate hybrid periodic micro/nano-textures on flat surfaces. Different from conventional rotary ultrasonic machining,
a tailored one-point diamond tool was manufactured and employed for RUT on surfaces of electroless nickel–phosphorus (Ni–P) plating. A one-dimensional longitudinal-vibration mode is used. The combined effect of ultrasonic vibration, rotation and feed motion leads to high-frequency periodic change of cutting edges motion, which is the basic principle for the RUT process. Therefore, to accurately predict and control the texturing process, the cutting locus is firstly mathematically calculated. Hybrid periodic micro/nano-textures comprising linear grooves at the micrometer scale and sinusoidal grooves at the micrometer or nanometer scale were successfully fabricated on machined surfaces, which are in compliance with the results of the mathematical calculations. Different types of surface textures were generated by changing machining conditions. The surface generation mechanism of RUT is illustrated and discussed by analyzing the surface textural features, the cutting locus and the tool tips geometry, including various tool faces, cutting edges, and the cutting corner. The requirements for RUT technique are concluded.
Adibi, Hamed; Rezaei, SM; Sarhan, Ahmed AD [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 1, Feb 2014, Starting Page 011012, Pages 10] Wheel loading entails chip accumulation in
porosities between grains or welding to the top of cutting grains. It is considered one of the most prevalent problems in grinding Nickel-based
super alloys. Identification of wheel loading is an important issue for optimizing the dressing intervals, but it can be a time consuming and an expensive process. A novel technique based on digital image processing to determine the loading areas over the surface of CBN vitrified grinding wheels using the toolbox of MATLAB is presented in this paper. The optical characteristics of the metal chips, the abrasive grains and wheel bond are considered. Experiments were performed to examine the repeatability of the proposed technique. The results were verified by the use of a scanning electron microscope. Based on the proposed technique, the effects of cutting parameters on the loaded area to wheel surface ratio in relation to grinding performance were studied empirically.
LASERMACHINING
110866 Comparative assessment of the laserinducedplasmamicromachiningandthemicro-edmprocesses.
Pallav, K; Han, P; Ramkumar, J; N a ga h a n u m a i a h ; Ehmann, KF [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 1, Feb 2014,
Starting Page 011001, Pages 16] Micro-electro-discharge machining (micro-EDM) is a well-established micromanufacturing process and has been at the center of research for the last few decades. However, it has its own limitations. The limitations are primarily due to the requirement of a tool and electric potential between the tool and the workpiece. The laser induced plasma micromachining (LIP-MM) is a novel tool-less multimaterial selective material removal type of micromachining process. In a manner similar to micro-EDM, it also removes material through plasma-matter interaction. However, instead of a tool and electric potential, it uses an ultra-short laser beam to generate plasma within a transparent dielectric media and thus circumvents some of the limitations associated with micro-EDM. The paper presents an experimental investigation on the comparative assessment of the capabilities of the two processes in the machining of microchannels in stainless steel. For comparative assessment of their processing capabilities, microchannels were machined by
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the two processes at similar pulse energy levels, while other process parameters were maintained at their optimal values for their respective process technology requirements. The comparative assessment was based on the geometric characteristics, material removal rate (MRR), effect of tool wear, and the range of machinable materials.
MANuFACTuRINGSYSTEMS
110867 Evaluation of ductile fracture modelsin finite element simulation of metal cuttingprocesses.
Liu, Jian; Bai, Yuanli; Xu, Chengying [J of Manufacturing Sci & Engg:ASME Trans, v 136,
n 1, Feb 2014, Starting Page 011010, Pages 14] In this paper, a systematic evaluation of six ductile fracture models is conducted to identify the most suitable fracture criterion for metal cutting processes. Six fracture models are evaluated in this study, including constant fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-Wierzbicki fracture criterion. By means of abaqus built-in commands and a user material subroutine (VUMAT), these fracture models are implemented into a finite element (FE) model of orthogonal cutting processes in abaqus/Explicit platform. The local parameters (stress, strain, fracture factor, and velocity fields) and global variables (chip morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. The numerical simulation results are examined by comparing to experimental results of 2024-T3 aluminum alloy published in the open literature. Based on the results, it is found that damage evolution should be considered in cutting process FE simulation Moreover, the B-W fracture model with consideration of rate dependency, temperature effect and damage evolution gives the best prediction of chip removal behavior of ductile metals.
Yu Wang, Baolin Liu, Qin Zhou, Yuanbiao Hu, Guomin Li [Transactions of the Canadian Society for M e c h a n i c a l Engineering, v 37,
n 2, 2013, Starting Page 185, Pages 12] Sonic drilling is a novel sampling technology applied in many fields. Based on Solid Works software, a dynamics virtual prototyping is utilized to develop a physical sonic driller by demonstrating collision detection and optimizing overall layout and key component structures. Key hydraulic and structural parameters are optimized using a mathematical model. Search for the optimized parameters and operating conditions for this multi - body mechanical system is conducted experimentally. The practical results show that the virtual prototype technology not only shortens the design cycle but also improves the quality of the conventional design. The new sonic driller designed by this method is both environmentally friendly and smarter.
MATERIALS&TREATMENT
110869 Annealing of compression moldedasphericalglasslenses.Tao, Bo; He, Peng; Shen, Lianguan; Yi, Allen [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 1, Feb 2014, Starting Page 011008, Pages 8] Residual stresses and refractive index of molded glass lenses are important quality indicators of their optical performance. In this research, the control of residual stresses and refractive index variation of molded glass lenses were experimentally investigated by postmolding annealing. Residual stresses were quantitatively measured using a circular polariscope. Refractive index was reconstructed and calculated by an optical setup based on Mach–Zehnder interferometer. In addition, geometry of the aspherical surface of lens was also evaluated before and after annealing. The comparison between the measured results before and after annealing showed that residual stresses and refractive index variation were well controlled and the shape of the aspherical surface was largely retained. This comprehensive experimental study demonstrated a suggestion to improve quality of the compression molded glass lens by
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postmolding annealing for high-precision optical applications.
MEASuREMENT&TESTING
110870 Machining test to calibrate rotary axiserrormotionsoffive-axismachinetoolsanditsapplicationtothermaldeformationtest
Ibaraki, Soichi; Ota, Yusuke [Int J of Machine Tools & Manufacture, v 86, Nov 2014, Starting Page 81, Pages 8] This paper proposes a machining test to parameterize error
motions, or position-dependent geometric errors, of rotary axes in a five-axis machine tool. At the given set of angular positions of rotary axes, a square-shaped step is machined by a straight end mill. By measuring geometric errors of the finished test piece, the position and the orientation of rotary axis average lines (location errors), as well as position-dependent geometric errors of rotary axes, can be numerically identified based on the machines kinematic model. Furthermore, by consequently performing the proposed machining test, one can quantitatively observe how error motions of rotary axes change due to thermal deformation induced mainly by spindle rotation. Experimental demonstration is presented.
110871 Approach for measuring the frf ofmachine tool structure without knowing anyinputforceMao, Xinyong; Luo, Bo; Li, Bin; Cai, Hui; Liu, Hongqi; Pen, Fangyu [Int J of Machine Tools & Manufacture, v 86, Nov 2014, Starting Page 62, Pages 6] Measuring the dynamics of a machine tool is important for improving its processing or design. In general, the dynamics of the machine tool structure is identified by the experimental modal analysis approaches that require the measurement of both the input loadings and the corresponding structural responses. However, the primary limitation for this method is that the input loadings are difficult or impossible to be measured when the machine tool is under operational conditions. In this paper, a method that is based on random decrement technology was used to identify the operational modal parameters of a machine tool without the
knowledge of any of the inputs. To estimate the frequency response functions, FRFs, a structural change method was proposed. The approach is based on the sensitivity of the eigenproperties to structural modifications caused by the drive positions. The proposed method was verified experimentally by traditional hammer tests. Because no elaborate excitation equipment is used, the dynamics of the machine tool structure with arbitrarily feed rate or working position can be easily identified using the proposed active excitation modal analysis method.
PRODuCTDESIGN&MANuFACTuRE
110872 Design and optimization of a shapememoryalloy-basedself-foldingsheet
Edwin Peraza-Hernandez, Darren Hartl, Edgar Galvan and Richard Malak [J of Mechanical Design, v 135, n 11, Nov 2013, Starting Page 111007, Pages 1 1 ] O r i g a m i engineering—the
practice of creating useful three-dimensional structures through folding and fold-like operations on two-dimensional building-blocks—has the potential to impact several areas of design and manufacturing. In this article, we study a new concept for a self-folding system. It consists of an active, self-morphing laminate that includes two meshes of thermally-actuated shape memory alloy (SMA) wire separated by a compliant passive layer. The goal of this article is to analyze the folding behavior and examine key engineering tradeoffs associated with the proposed system. We consider the impact of several design variables including mesh wire thickness, mesh wire spacing, thickness of the insulating elastomer layer, and heating power. Response parameters of interest include effective folding angle, maximum von Mises stress in the SMA, maximum temperature in the SMA, maximum temperature in the elastomer, and radius of curvature at the fold line. We identify an optimized physical realization for maximizing folding capability under mechanical and thermal failure constraints. Furthermore, we conclude that the proposed self-folding system is capable
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of achieving folds of significant magnitude (as measured by the effective folding angle) as required to create useful 3D structures.
110873Geometric analysis of a foldable barrelvaultwithorigamiJianguo Cai, Yixiang Xu and Jian Feng [J of Mechanical Design, v 135, n 11, Nov 2013, Starting Page 114501, Pages 6] This paper investigates the geometry of a foldable barrel vault with modified Miura-ori patterns, which displays a curvature during the motion. The principal of spherical trigonometry was used to obtain the relationship of the inclined angles between adjacent folded papers of Miura-ori. Then, the radius, span, rise, and longitudinal length of the foldable barrel vault in all configurations throughout the motion are determined. The results show that the radius of curvature grows exponentially and the span increases during deployment. Furthermore, the rise increases first, followed by a decrease with increasing deployment angle.
110874 Structural synthesis of ancient chineseoriginalcrossbow
Hsiao, Kuo-Hung [Transactions of the Canadian Society for Mechanical Engineering Transactions of the Canadian Society for Mechanical Engineering,
v 37, n 2, 2013, Starting Page 259, Pages 13] The original crossbow was one of the most important weapons in ancient China. Since crossbows have diversified types and were widely used in ancient China after the Spring and Autumn Period (770-476BC), the original crossbow should have many designs in different eras and regions. The aim of this work is to synthesize mechanism structures of the original crossbow. Based on the analyses of crossbows, the structural characteristics and design constraints of this device are concluded. Then, according to the concepts of generalization and specialization subject to the concluded design constraints, twelve feasible structures of mechanism that meet the technological standards of the subject’s time period are reconstructed.
110875 workspace of wire - actuated parallelmanipulatorsandvariationsindesignparameters
Vahid Nazari, Leila Notash [Transactions of the Canadian Society for Mechanical Engineering, v 37, n 2, 2013, Starting Page 215, Pages 15] The purpose of the paper is to investigate the effect of small variations (uncertainties) and large variations in design parameters on the size and shape of the workspace of the wire-actuated parallel manipulators. The static force/moment balance equations, taking into account the null space of the Jacobian matrix, are used for the workspace analysis. The parameters exam ined include: the winding direction of wires on the pulleys; the radius of the pulley; the orientation, radius, and mass of the mobile platform; the peg length; and the ratio of the peg radii at the entrance and exit. Also, the effect of the geometric arrangement of wire attachment points and the number of wire connection points on the mobile platform, on the size and shape of the workspace is considered. The simulation results show the effect of small and large variations in the aforementioned parameters on the workspace of wire-actuated parallel manipulators without and with gravity.
110876 Optimum synthesis of path generatingadjustable mechanisms with improved slopecontinuityofthecontrolparameterRaste, Hrishikesh Y; Apte, Ameya P; Gunesh R. Gogate [Transactions of the Canadian Society for Mechanical Engineering, v 37, n 2, 2013, Starting Page 197, Pages 18] Adjustable mechanisms have been studied in literature for path and function generation. In this paper, a path generating four - bar mechanism with an alternate single parameter adjustment is proposed and optimally synthesized, using the method of Differential Evolution. Two new approaches are developed, aimed at improving the slope continuity characteristic of the control parameter. Optimum synthesis results are obtained using the proposed approaches. The results show that the proposed approaches lead to improved slope continuity characteristics of the control parameter.
110877 Design for optimal performance of3-RPS parallel manipulator using evolutionaryalgorithmsRamana Babu, Sabbavarapu; Raju, Vegesina Ramachandra; Ramji, Koona [Transactions of the Canadian Society for Mechanical Engineering, v 37, n 2, 2013, Starting Page 135, Pages 26] This paper presents an optimal kinematic design for a
Abstracts
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general type of 3-RPS spatial parallel manipulator based on multi-objective optimization. The objective functions considered are Global Conditioning Index (GCI), Global stiffness Index (GSI) and Workspace volume. The objective functions are optimized simultaneously to improve the dexterity as well as the workspace volume which represents the working capacity of a parallel manipulator. A multi-objective Evolutionary Algorithm based on the control elitist non-dominated sorting genetic algorithm is adopted to find the true optimal Pareto front. A constraint Jaco-bian matrix is derived analytically and the manipulator workspace is generated by numerical search method. The static analysis of the manipulator is also carried out to determine the compliance of the end-effecter.
110878 Automatic generation of a pattern ofgeometricfeaturesforindustrialdesign.
A n d r a d e , Diego F; S h i m a d a , Kenji [J of M e c h a n i c a l Design, v 135, n 11, Nov
2013, Starting Page 115001, Pages 7] This paper presents a new computational method for the automatic generation of geometric feature patterns for industrial design. Such patterns include speaker holes, showerhead holes, and bumpy textures on a grip, and they play a key role in making a designed object aesthetically pleasing and functional. While modern CAD packages support the automated creation of basic patterns, rectangular grids, and radial grids, they are not applicable to more general cases required in industrial design, including arbitrarily shaped target geometry and graded feature sizes. The proposed computational method takes as input a target region along with sizing metrics and generates feature patterns automatically in three steps: (1) packing circles
tightly in the target region, (2) scaling features according to the specified sizing metrics, and (3) adding features on the base geometry. The proposed method is installed as a plugin module to a commercial CAD package, and a pattern of hundreds of features can be added to a 3D CAD model in less than 5 min. This allows the industrial designer to explore more design alternatives by avoiding the tedious and time-consuming manual generation of patterns.
110879 Accommodating thickness in origami-baseddeployablearrays1.
Shannon A. Zirbel, Robert J. Lang, Mark W. Thomson, Deborah A. Sigel, Phillip E. Walkemeyer,
Brian P. Trease, Spencer P. Magleby and Larry L. Howell [J of Mechanical Design, v 135, n 11, Nov 2013, Starting Page 111005, Pages 11] The purpose of this work is to develop approaches to accommodate thickness in origami-based deployable arrays with a high ratio of deployed-to-stowed diameter. The origami flasher model serves as a basis for demonstrating the approach. A thickness-accommodating mathematical model is developed to describe the flasher. Practical modifications are presented for the creation of physical models and two options are proposed: allowing the panels to fold along their diagonals or applying a membrane backing with specified widths at fold-lines. The mathematical model and hardware modifications are employed to create several physical models. The results are general and apply to a range of applications. An example is provided by the application that motivated the work: a deployable solar array for space applications. The model is demonstrated in hardware as a 1/20th scale prototype with a ratio of deployed-to-stowed diameter of 9.2 (or 1.25 m deployed outer diameter to 0.136 m stowed outer diameter) ◘
"Hard Work Beats Talent When Talent Doesn't Work Hard" - Tim Notke
Events
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NATIONAL
05-06Nov2016IFERP-International Conference on AdvancesNanotechnology and Mechanical Engineering(ICNME-16)The Vijay Park, No.12, Jawaharlal Nehru Salai,Inner Ring Road, Arumbakkam, Chennai,Tamil Nadu Contact: Conference Coordinator, Tel: 08280047516IT Research Email: [email protected] Web: http://iferp.org/Conference/November
06Nov2016IRAJ-International Conference on ComputerScienceandMechanicalEngineering(ICCSME)Hotel Madhav International, 6A, Ramabai Ambedkar Road, Before Hotel Le-Meridien,Behind Pune Railway Station, Pune - 411001Contact: IT ResearchTel: +91-8280047516 Email: [email protected] Web:http://iraj.in/Conference/2016/Pune
16-19Nov2016InternationalMiningandMachineryExhibitionEco Tourism Park, Major Arterial Rd,Action Area II, 700156 Kolkata, West BengalContact: Confederation of Indian Industry, 23, Institutional Area, Lodi Road, 110003 New DelhiTel: +91 (1)1 45771000 Fax: +91 (1) 24626149Email: [email protected] Web: www.cii.in
19-22Nov2016Industria2016KolhapurSasne Ground, Tarabai Park, Kolhapur, MaharashtraContact: Creatives, 595 E Ward, Vasant Rajani Opp. Apple Hospital, Vyapari Peth Shahupuri, Kolhapur-416001Tel: +91-231-2650907 +91-99216-62266, +91-95453-11117 Email: [email protected] Web: http://creativesindia.com/about-us/
16-18Nov2016TradefairformetalprocessingLas Vegas Convention Center - LVCC, 3150 Paradise Road, NV89109 Las Vegas, Nevada, USAContact: AWS American Welding SocietyLeJeune Road, 33126 Miami, USATel: +1 (0)305 4439353 Email: [email protected] Web: www.aws.org
16-18Nov2016InternationalFairforProductionEngineering,ToolingandSubcontractingEstonian Fairs Center, Pirita tee 28, 10127 Tallinn, Harju, EstoniaContact: Estonian Fairs Ltd
