vol. 15 no. 4 april 2016 editorial board contents ... april_ 2016.pdf · contents technical papers...

Vol. 15 No. 4 April 2016

ContentsTechnical Papers

• Dynamic analysis of transverse crack in rotor by using finite element method

Rajasekhar K and Prasad TVSRK3

• Effect of tool velocity ratio on microstructural characteristics of friction stir processed aluminium based metal matrix composite

Vijayavel P and Balasubramanian V

11

• Predicting corrosion rate of weld nugget (stir zone) of friction stir welded dissimilar joints of aluminium – magnesium alloys

Kamal Jayaraj R, Malarvizhi S and Balasubramanian V

20

• Study on multi responses in turning of EN19 steel using fuzzy taguchi methodVishnuvardhan Reddy D and Salonica Sravani P

31

Photo Gallery: Vintage Machine: The Atlas Metal Lathe by D & N Machining Co., US, 1932

29

Select Bibliography of Standards: Finite Element Analysis 30

Calendar of Events 39

Manufacturing Technology Abstracts 42

Select Bibliography: Finite Element 50

Technology Trends 51

Patent Abstracts: Finite Element 53

IPR News: A - Z Definitions of Intellectual Property Terminology 57

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Editorial Board

*All payments are to be made by demand draft drawn in favour of ‘Central Manufacturing Technology Institute, Bengaluru'

Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same.

ChairmanS Satish Kumar

Technical Paper Review PanelS UshaN BalashanmugamDr. C K SrinivasaK K RajagopalB R Mohanraj

EditorMallikarjun G

Editorial Assistants

Shashi Rekha NMala RC

Events

Manufacturing Technology Today, April 2016 39

NATIONAl

08 - 10 Jun 2016IMhlS - India Material handling & logistics Show New Delhi: International logistic ShowPragati Maidan Exhibition Center,Mathura Road, New DelhiContact: Reed Manch Exhibitions Ltd.1st Floor, A 78, Sector -4, NoidaTel: +91 (0)120 4273921 Fax: +91 (0)120 4273922Email: [email protected] Web: www.tradefairdates.com

24 - 26 Jun 2016Intl trade fair for logistics and material handlingChennai Trade Center,Poonamali High Road, Chennai, Tamil NaduContact: Smart Expos & Fairs India Pvt. Ltd.No. 116 Mount Road, ChennaiTel: +91 (0)44 22501987 Fax: +91 (0)44 22501988Email: [email protected] Web: www.tradefairdates.com

10 - 12 Aug 2016International exhibition for minerals, metals and metallurgy materialsPragati Maidan Exhibition Center,Mathura Road, 110002 New DelhiContact: International Trade and Exhibitions India Pvt. Ltd.11th Floor, Kailash Building Kasturba Gandhi Marg110001 New DelhiEmail: [email protected] Web: www.tradefairdates.com

10 - 12 Aug 2016Tech India New Delhi: International Exhibition on Engineering and ManufacturingPragati Maidan Exhibition Center,Mathura Road, New DelhiContact: International Trade and Exhibitions India Pvt. Ltd.Kailash Building Kasturba Gandhi Marg, New DelhiEmail: [email protected] Web:http://www.tradefairdates.com

10 - 12 Aug 2016Imex New Delhi: Intl Machine Tools ExpoPragati Maidan Exhibition Center,Mathura Road, 110002 New DelhiContact: ITEI International Trade and Exhibitions India Pvt.

Ltd., E519 Floral Deck Plaza, Central MIDC Road, Opp SEEPZ, MumbaiTel: +91 (0)22 28398000 Fax: +91 (0)22 28390502Email: [email protected] Web: http://www.tradefairdates.com

08 - 10 Sep 2016The corrugated manufacturing showBombay Convention & Exhibition Centre BCEC,Western Express Highway, Mumbai, MaharashtraContact: Reed Manch Exhibitions Ltd.1st Floor, A 78, Sector - 4, 201301 NoidaTel: +91 (0)120 4273921 Fax: +91 (0)120 4273922Email: [email protected] Web: http://www.tradefairdates.com

23 - 25 Sep 2016International exhibition & conference for automation & roboticsAuto Cluster Exhibition Center, Pune, MaharashtraContact: IBK Media, 224, B Wing, Pranik Chambers, Sakinaka, Andheri East, MumbaiTel: +91 (2)2 28574011 Fax: +91 (2)2 28574011Email: [email protected] Web: www.tradefairdates.com

05 - 07 Oct 2016International exhibition on metallurgical technology, products and services in IndiaBombay Convention & Exhibition Centre BCEC,Western Express Highway, Mumbai, MaharashtraContact: Messe Düsseldorf India Pvt. Ltd.Sarita Vihar, 110 076 New DelhiTel: +91 (0)11 26971745 Fax: +91 (0)11 26971746Email: [email protected] Web: www.tradefairdates.com

05 - 07 Oct 2016International trade fair for joining and separating and coatingBombay Convention & Exhibition Centre BCEC,Western Express Highway, Mumbai, MaharashtraContact: Messe Essen GmbHNorbertstr., 45131 Essen, GermanyTel: +49 (0)201 72440 Fax: +49 (0)201 7244248Email: [email protected] Web: www.messe-essen.de

11 - 13 Oct 2016Trade fair for used machineryChennai Trade Center,

Events

Manufacturing Technology Today, April 201640

INTERNATIONAlPoonamali High Road, Chennai, Tamil NaduContact: ITEI International Trade and Exhibitions India Pvt. Ltd., E519 Floral Deck Plaza, Central MIDC Road, Opp SEEPZ, MumbaiTel: +91 (0)22 28398000 Fax: +91 (0)22 28390502Email: [email protected] Web: www.tradefairdates.com

19 - 21 Oct 2016International exhibition for solar technology and energyBombay Convention & Exhibition Centre BCEC,Western Express Highway, Mumbai, MaharashtraContact: Freiburg Wirtschaft Touristik und Messe GmbHEuropaplatz 1, Freiburg im Breisgau, GermanyTel: +49 (0)761 388102 Fax: +49 (0)761 38813006Email: [email protected] Web: www.tradefairdates.com

16 - 19 Nov 2016International Mining and Machinery ExhibitionEco Tourism Park, Major Arterial Rd, Action Area II, 700156 Kolkata, West BengalContact: Confederation of Indian Industry23, Institutional Area, Lodi Road, New DelhiTel: +91 (1)1 45771000 Fax: +91 (1) 24626149Email: [email protected] Web: www.cii.in

23 - 26 Nov 2016International trade fair for engineering, machine tools, automation & automotive technologyRace Course Ground, Race Course Road, Sadar, Rajkot, GujaratContact: K & D Communication Ltd., 4th Floor, Chinubhai House, 7-B Amrutbaug Society, AhmedabadTel: +91 (0)79 26469725 Fax: +91 (0)79 26403087Email: [email protected] Web: http://www.tradefairdates.com

01 - 03 Dec 2016International exhibition for materials handling, intralogistics, storage and logisticsBandra Kurla Complex, Maharashtra, 400051 Mumbai, MaharashtraContact: Hannover Milano Fairs India Pvt Ltd.MumbaiTel: +91 (0)22 42369710 Fax: +91 (0)22 42019191Web: http://www.tradefairdates.com

10 - 12 May 2016Trade Fair for Sensor, Measurement and Testing TechnologyNürnbergMesse, Messezentrum 1, 90471 Nuremberg, Bavaria, GermanyContact: AMA Service GmbH, Von-Münchhausen-Str. 4931515 Wunstorf, GermanyTel: +49 (0)50 3396390 Fax: +49 (0)50 3310Email: [email protected] Web: www.tradefairdates.com

10 - 13 May 2016For Automation Prague: International trade fair of automation, regulation and measuring equipmentPVA Expo Praha, Beranových, 19900 Prague, Prague, Czech RepublicContact: ABF, a.s., Mimonská 64519000 Prague, Czech RepublicTel: +420 (0)222 891135 Fax: +420 (0)222 891191Email: [email protected] Web: http://www.tradefairdates.com

16 - 18 May 2016Montreal Manufacturing Technology ShowPlace Bonaventure | Montreal, QCContact: Tel: 1-888-322-7333 ext. 4416 Email: [email protected] Web: http://www.mmts.ca

17 - 19 May 2016The Malaysia International Exhibition on Coating & CorrosionPutra World Trade Center,41, Jalan Tun Ismail, 50480 Kuala Lumpur, Kuala Lumpur, MalaysiaContact: ECMI ITE Asia Sdn Bhd23-6, Subang Business Centre47620 Subang Jaya, MalaysiaTel: +60 (0)3 80230820 Fax: +60 (0)3 80230830Email: [email protected] Web:http://www.tradefairdates.com

17 - 20 May 2016Exhibition of the metal and metallurgical industryBeijing International Convention Center BICC,No.8 Beichen Dong Road, Chaoyang District,

Events


100101 Beijing, Beijing, ChinaContact: Hannover Milano Fairs Shanghai Ltd.301 B&Q Pudong Office Tower 393 Yinxiao Road, Pudong, Shanghai, ChinaTel: +86 (0)21 50456700 Fax: +86 (0)21 50459355Email: [email protected] Web: www.tradefairdates.com

24 - 27 May 2016International Exhibition of Casting and MetallurgyInternational Exhibition Center Agrokomplex,Výstavná 4, 94901 Nitra, Nitriansky, Slovak RepublicContact: Agrokomplex-VýstavníctvoVýstavná 4, 9401 Nitra, Slovak RepublicTel: +421 (3)7 65721113 Fax: +421 (3)7 7335859Email: [email protected] Web: www.tradefairdates.com

24 - 27 May 2016International Trade Exhibition of Machine Manufacturing and Welding TechnologyHungexpo - Budapest Fair Center, Albertirsai út 10., H-1101 Budapest, Budapest, HungaryContact: Hungexpo C.Co.Ltd., Albertirsai út 10H-1101 Budapest, HungaryTel: +36 (0)1 2636000 Fax: +36 (0)1 2636098Email: [email protected] Web: www.tradefairdates.com

24 - 27 May 2016International Engineering Fair Nitra: International Engineering FairInternational Exhibition Center Agrokomplex,Výstavná 4, 94901 Nitra, Nitriansky, Slovak RepublicContact: Agrokomplex-VýstavníctvoVýstavná 4, 9401 Nitra, Slovak RepublicTel: +421 (3)7 65721113 Fax: +421 (3)7 7335859Email: [email protected] Web: www.tradefairdates.com

25 - 28 May 2016ASsean International Machine Tools & Metalworking Technology ExhibitionPutra World Trade Center,41, Jalan Tun Ismail, 50480 Kuala Lumpur, Kuala Lumpur, MalaysiaContact: Trade Link ITE Sdn BhdF-1-48, Jalan PJU 1A/347301 Petaling Jaya, MalaysiaEmail: [email protected] Web: www.tradefairdates.com

31 May - 02 Jun 2016Trade fair for automotive test, evaluation and quality engineeringMesse Stuttgart, Messepiazza 1, 70629 Stuttgart, Baden-Wurttemberg, GermanyContact: UKIP Media & Events Ltd., Abinger House Church Street, RH41DF Dorking, United Kingdom of Great Britain and Northern IrelandTel: +44 (0)1306 743744 Fax: +44 (0)1306 742525Email: [email protected] Web: www.tradefairdates.com

01 - 04 Jun 2016Fair of the metalworking industryRomexpo Exhibition Center, 65-67 Marasti Boulevard, 011465 Bucharest, Bucharest, RomaniaContact: EuroexpoGarlei Street, Intact Building, 2nd floorBucharest, RomaniaTel: +40 (0)21 4091849 Fax: +40 (0)21 4091854Email: [email protected] Web: www.tradefairdates.com

07 - 10 Jun 2016Mach Tool: Machines and Tools ExhibitionPoznan International Fair Ltd, Glogowska street 1460-734 Poznan, PolandContact: Tel: +48 61 869 2000 Fax: +48 61 869 2999Email: [email protected] Web: machtool.mtp.pl/en

07 - 10 Jun 2016Trade fair for metallurgy, metal processing and foundry technologyPoznan International Fair Grounds, Glogowska Street 14, 60734 Poznan, Greater Poland, PolandContact: Poznan International Fair Ltd.ul. Glogowska 14, 60734 Poznan, PolandTel: +48 (0)61 8692000 Fax: +48 (0)61 8692999Email: [email protected] Web: www.tradefairdates.com

07 - 10 Jun 2016hydraulics, pneumatics and drives exhibitionPoznan International Fair Grounds, Glogowska Street 14, 60734 Poznan, Greater Poland, PolandContact: Poznan International Fair Ltd.ul. Glogowska 14, 60734 Poznan, PolandTel: +48 (0)61 8692000 Fax: +48 (0)61 8692999Email: [email protected] Web: www.tradefairdates.com ◘

Abstracts


Manufacturing technology abstracts

COATING & FINIShING 43

CAD/CAM/CAE 43

FORMING 43

JOINING & ASSEMBly 44

MAChINE TOOlS 45

MAChINING 45

NON TRADITIONAl MAChINING 45

GRINDING 46

lASER MAChINING 46

MANUFACTURING SySTEMS 47

MATERIAlS & TREATMENT 47

MEASUREMENT & TESTING 47

COMPUTER NUMERICAl CONTROl 48

PRODUCT DESIGN & MANUFACTURE 48

RAPID PROTOTyPING 49

TOOlS & TOOlING 49

TRIBOlOGy 49

Abstracts


Manufacturing technology abstracts

COATING & FINIShING

110661 Development of on the machine process monitoring and control strategy in Robot Assisted Polishing

Pilny, Lukas; Bissacco, Giuliano [CIRP Annals, v 64, n 1, 2015, Starting Page 313, Pages 4] Robot Assisted Polishing (RAP) can be used to polish rotational

symmetric and free form components achieving surface roughness down to Sa 10 nm. With the aim to enable unmanned robust and cost efficient application of RAP, this paper presents the development of a monitoring and control strategy for automatic detection of process end point as well as on the machine total surface characterization and local defects identification. The approach is based on a multisensory polishing arm allowing measurement of Acoustic Emission and process forces and a scattered light sensor mounted on the machine. The multisensory approach was experimentally validated in polishing with bonded abrasives demonstrating its suitability for process control in RAP. (10 refs, 7 figs) (AA)

110662 Investigation and characterization of Stellite-based wear-resistant coatings applied to steel moulds by cold-spray

Lucchetta, G; Giusti, R; Vezzu, S; Bariani, PF [CIRP Annals, v 64, n 1, 2015, Starting Page 535, Pages 4] The potential of the cold-spray process in depositing Stellite coatings on annealed steel was explored in the manufacture of wear-

resistant injection moulds. Aspects related to both the deposition process and the topography, such as roughness, chemical composition, hardness and wear resistance were investigated. Stellite 6, Stellite 31 and Stellite 31 + 10% AISI 316L coatings were deposited and the effects of composition were analyzed to identify the optimumprocess conditions. The performance of the coated samples was evaluated through a specially developed compression test. Cold-spray deposition of Stellite coatings proved to be a valid alternative to heat treatment in manufacturing wear-resistant moulds. (12 refs, 6 figs, 5 tables) (AA)

CAD/CAM/CAE

110663 Responsive fixture design using dynamic product inspection and monitoring technologies for the precision machining of large-scale aerospace parts

Li, Yingguang; Liu, Changqing; Hao, Xiaozhong; Gao, James X; Maropoulos, Paul G [CIRP Annals, v 64, n 1, 2015, Starting Page 173, Pages 4]

When machining a large-scale aerospace part, the part is normally located and clamped firmly until a set of features are machined. When the part is released, its size and shape may deform beyond the tolerance limits due to stress release. This paper presents the design of a new fixing method and flexible fixtures that would automatically respond to workpiece deformation during machining. Deformation is inspected and monitoredon-line, and part location and orientation can be adjusted timely to ensure follow-up operations are carried out under low stress and with respect to the related datum defined in the design models. (13 refs, 5 figs) (AA)

110664 Recognition of complex engineering objects from large-scale point clouds

Erdos, Gabor; Nakano, Takahiro; Horvath, Gergely; Nonaka, Youichi;

Vancza, Jozsef [CIRP Annals, v 64, n 1, 2015, Starting Page 165, Pages 4] This work was aimed at reconstructing the structural model of as-built industrial facilities like plants purely from on-site point cloud measurement data. Focus was set on finding the internal structure of complex objects hidden behind themassive point cloud by exploiting connectivity information in the data and the linear characteristics of the typical components. A workflow is presented with emphasis on data filtering, connectivity graph construction, as well as the recognition of elementary objects and their relations. Results are demonstrated using data of an industrial case study. (12 refs, 8 figs, 1 table) (AA)

FORMING

110665 Feasibility of electrically assisted progressive forging of aluminum 6061-T6 alloy

Abstracts


Hong, Sung-Tae; Yo n g - H a J e o n g , C h o w d h u r y , Mahmudun Nabi; Chun, Doo-Man; Kim, Moon-Jo; Han, Heung Nam [CIRP Annals, v 64, n 1,

2015, Starting Page 277, Pages 4] The feasibility of electrically assisted (EA) progressive forging is experimentally investigated by applying an electric current with a short duration to a specimen after each progressive compressive displacement. EA-continuous forging with a pulsed electric current during continuous deformation is also investigated. Experimental results show that the improvement in formability with reduced compressive load is more pronounced in EA-progressive forging with a lower specimen temperature during deformation. Microstructural observations suggest that electrically induced annealing occurred. The present study proves the effectiveness of EA-forging, while confirming that electroplasticity is a phenomenon distinct from Joule heating. (15 refs, 7 figs, 1 table) (AA)

110666 Physical and numerical modelling of backward extrusion of Mg alloy with Al coating

Madej, Lukasz; Tokunaga, Toko; Matsuura, Kiyotaka; Ohno, Munekazu; Pietrzyk, Maciej [CIRP Annals, v 64, n 1, 2015, Starting Page 253, Pages 4] Although Mg alloys possess many attractive properties, their

use has been limited due to their poor corrosion resistance. Therefore, in the present paper a process for Al coating on Mg alloys by hot extrusion was investigated. Physical simulations confirmed capabilities of this process and Al coating on aMg alloy was obtained. Prediction of microstructure evolution and determination of optimal process parameters were the objectives of the present numerical simulations. Cellular automata were used to reach the former goal, while for the latter goal optimization analysis was applied to find the best technological parameters. (16 refs, 9 figs, 1 table) (AA)

JOINING & ASSEMBly

110667 Genetic algorithm for a self-learning parameterization of an aerodynamic part feeding system for high-speed assemblyBusch, Jan; Quirico, Melissa; Richter, Lukas; Schmidt, Matthias; Raatz, Annika; Nyhuis, Peter

[CIRP Annals, v 64, n 1, 2015, Starting Page 5, Pages 4] The aerodynamic feeding technology developed at the IFA allows feeding rates up to

800 parts perminute while maintaining high reliability and variant flexibility. The machine’s setup procedure requires the adaptation of only four machine parameters. Currently, optimal parameter configurations need to be identified manually. This task is greatly time-consuming and requires a high level of expertise. Prospectively, the machine should utilize an algorithm that autonomously identifies optimal parameter configurations for new workpieces to realize fast setup procedures. This paper presents a genetic algorithm for a self-learning feeding system that has been validated in comprehensive simulation studies. (12 refs, 6 figs) (AA)

110668 Investigation into the influence of inter-component assembly gaps upon the geometry of tack welded annular structures

L o w t h , S t e w a r t ; A x i n t e , Dragos A; Sun, Wei [ C I R P

Annals, v 64, n 1, 2015, Starting Page 1, Pages 4] Large accurate annular weldments are important to a number of heavy industries, such as power generation and civil aero-engine. This research examines the interaction between small assembly gaps and the Preliminary Welding Process (PWP), colloquially known as tack welding. This study has identified two fundamental weld distortion geometries prevalent within ring structures; the quantized saddle and the quantized conic, both a consequence of the small assembly gaps. Furthermore, physical weld trials and finite element modelling, in both simple two plate assemblies and full ring assemblies have shown that volumetric weld shrinkage is the principle thermal-mechanical mechanism driving the identified distortions, so careful placement of the initial welds to avoid assembly gaps can yielda 19 x reduction in out-of-plane distortions in the final weldment. (9 refs, 9 figs, 1 table) (AA)

110669 Optimization of selective assembly and adaptive manufacturing by means of cyber-physical system based matching

Abstracts


Lanza, Gisela; Haefner, Benjamin; Kraemer, Alexandra [CIRP Annals, v 64, n 1, 2015, Starting

Page 399, Pages 4] In high-tech production, companies often deal with the manufacturing of assemblies with quality requirements close to the technological limits. Selective and adaptive production systems are means to cope with this challenge. In this context new measurement technologies and IT-systems offer the opportunity to generate and use real-time quality data along the process chain and to control the production system adaptively. In this article, a holistic matching approach to optimize the performance of selective and adaptive assembly systems is presented and its industrial application within an automotive electric drive assembly is demonstrated. (20 refs, 4 figs, 2 tables) (AA)

MAChINE TOOlS

110670 Defect-driven diagnostic method for machine tool spindlesVogl, Gregory W; Donmez, MA [CIRP Annals, v 64, n 1, 2015, Starting Page 377, Pages 4] Simple vibration-based metrics are, in many cases, insufficient to diagnose machine tool spindle condition. These metrics couple defect-based motion with spindle dynamics; diagnostics should be defect-driven. A new method and spindle condition estimation device (SCED) were developed to acquire data and to separate system dynamics from defect geometry. Based on this method, a spindle condition metric relying only on defect geometry is proposed.Application of the SCED on various milling and turning spindles shows that the new approach is robust for diagnosing the machine tool spindle condition. (12 refs, 8 figs, 2 tables) (AA)

MAChINING

110671 Quantitative analysis of chip extraction in drilling of Ti6Al4V

B r i n k s m e i e r, Ekkard; Pecat, Oliver; Rentsch, Rudiger [CIRP Annals, v 64, n 1, 2 0 1 5 , S t a r t i n g Page 93, Pages 4] Drilling of ductile

materials like Ti6Al4V often comes along with insufficient chip extraction which leads to process

disruptions. In the present study a characteristic variable, which quantitatively describes the quality of the chip extraction is introduced to evaluate the process reliability and the resulting workpiece quality. Vibration assisted drilling with kinematically enforced chip breaking was applied. The results of the experimental tests reveal a direct correlation between the process temperatures, the exit burr height and the introduced chip extraction index. This index can be used to identify suitable cutting parameters and process conditions for a reliable drilling process. (10 refs, 7 figs, 2 tables) (AA)

NON TRADITIONAl MAChINING

110672 Real-time evaluation of gap flushing in electrical discharge machining

Goodlet, Alexander; Koshy, Philip [CIRP Annals, v 64, n 1, 2015, Starting Page 241, Pages 4] This paper reports on acoustic emission

(AE) from electrical dischargemachining (EDM) in the context of gap flushing, and demonstrates its sensitivity to gap contamination from both metallic debris and gas bubbles. AE is further shown to relate to the local medium (liquid or gas bubble) through which individual discharges occur, and hence comprise unique and valuable process information on the effectiveness with which material is removed at the scale of a single discharge. This enabling technology is readily implemented for the in-process quantification, monitoring and optimization of flushing, and may constitute the basis for flushing-related adaptive control of EDM. (12 refs, 11 figs) (AA)

110673 Material removal mechanism in low-energy micro-EDM process

Qian, Jun; Yang, Fei; Wang, Jun; Lauwers, Bert; Reynaerts, Dominiek [CIRP Annals, v 64, n 1, 2015, Starting Page 225, Pages 4] Extensive experiments have been carried out to understand

the fundamentals in micro-EDM and especially the material removal mechanism in the finishing regimes of micro-EDM with a RC type generator. Oscillation of the sparking current and voltage has been observed when a high open-voltage was applied and this phenomenon has been predicted by electrical simulations and further

Abstracts


experimentally verified. Experiments show that the effect of negative current flow in the sparking gap is not a simple polarity switch. Contrary to the conventional understanding, the negative current flow in a single sparking cycle is also contributing to effective material removal on the workpiece. (11 refs, 10 figs) (AA)

110674 Interdisciplinary modelling of the electrochemical machining process for engine bladesKlocke, F; Zeis, M; Klink, A [CIRP Annals, v 64, n 1, 2015, Starting Page 217, Pages 4] In this paper an interdisciplinary simulation model of the electrochemical machining (ECM) process for aero engine blades is set up. Simulation results of a compressor vane are presented and compared to optical measurements of actual manufactured workpieces. The simulation model is based on conservation equations for the electric field, fluid flow and heat transfer in combination with analytical functions for the influence of temperature and gas evolution on the specific electrical conductivity. Validation is done by optical in situ measurements. Finally construction rules for an inverse modelling approach are examined and simulation results of the calculated cathode geometry are presented. (22 refs, 9 figs) (AA)

GRINDING

110675 Grinding of sub-micron-grade carbide: Contact and wear mechanisms, loading, conditioning, scrubbing and resin-bond degradationBadger, Jeffrey [CIRP Annals, v 64, n 1, 2015, Starting Page 341, Pages 4] An investigation was made into grinding of sub-micron-grade tungsten-carbide in a cobalt matrix. Grit- workpiece contact and loading mechanisms were analyzed. Loading-removal methods – via conditioning and a cleaning nozzle – were analyzed both in terms of fundamental mechanisms and removal efficacy. A novelmethod of quantifying wheel-conditioning parameters was developed and validated experimentally. Wheel-wearmechanismswere investigatedinterms of thermally-inducedgrainpull-out,particularlyunder low-aggressiveness conditions. A fundamental difference in the size-effectwas seen for sub-micron grades. (23 refs, 5 figs) (AA)

110676 Fabrication of micro-textured and plateau-processed functional surface by angled fine particle peening followed by precision grindingKameyama, Yutaka; Ohmori, Hitoshi; Kasuga, Hiroshi; Kato, Teruko [CIRP Annals, v 64, n 1, 2015,

Starting Page 549, Pages 4] To fabricate novel micro-textured

surfaces with valleys, dimples and plateaus as well as patterned composition as a strategy to improve surface characteristics, we combine fine particle peening (FPP) and precision surface grinding. Combined with a shallow angled FPP to form self-patterned ridge texture on aluminium surface, precision surface grinding with the specific conductive-bonded wheel removes the ridge peaks and simultaneously deposits Cu on the valleys by reducing Cu ions which are condensed in the grinding fluid. The series of those methods are the promising way to create well-processed surfaces which can be applied to tribological and biological devices. (21 refs, 12 figs, 3 tables) (AA)

110677 hybrid tool with both fixed-abrasive and loose-abrasive phases

Ya m a g u c h i , H i t o m i ; Nteziyaremye, Valens; Stein, Max; Li, Weisi

[CIRP Annals, v 64, n 1, 2015, Starting Page 337, Pages 4] The use of multiple pole tips in a Magnetic Abrasive Finishing (MAF) system allows for shorter processing times, but it can also exacerbate any difficulties encountered in abrasive insertion and distribution. This paper proposes a hybrid tool that initially works as fixed abrasive but works as loose abrasive once the abrasive binder dissolves into the lubricant. The fixed-abrasive configuration simplifies the abrasive insertion, and the loose-abrasive configuration ensures the abrasive uniform distribution along the workpiece surface. The internal finishing of needles demonstrated that the hybrid tool saves about 80% abrasive insertion time while achieving a smooth surface equivalent to the conventional MAF method. (14 refs, 8 figs, 1 table) (AA)

lASER MAChINING

110678 Nonlinear laser lithography to control surface properties of stainless steel

Orazi, L; Gnilitskyi, Ia; Pavlov, I; Serro, AP; Ilday, S; Ilday, FO [CIRP Annals, v 64, n 1, 2015, Starting Page 193, Pages 4] In the present work a novel method to improve the surface

Abstracts


properties of stainless steel is presented and discussed. The method, based on the use of a high repetition rate femtosecond Yb fibre laser, permits generation of highly reproducible, robust, uniform and periodic nanoscale structures over a large surface area. The technique is characterized by high productivity, which, in itsmost simple form, does not require special environmental conditioning. Surface morphology is scrutinized through SEM and AFM analyses and wettability behaviour is investigated by means of the sessile drop method using distilled–deionized water. It is shown that optimization of process parameters promotes anisotropic wetting behaviour of the material surface. (16 refs, 7 figs, 4 tables) (AA)

MANUFACTURING SySTEMS

110679 Preventive maintenance opportunities for large production systemsNi, Jun; Gu, Xi; Jin, Xiaoning [CIRP Annals, v 64, n 1, 2015, Starting Page 447, Pages 4] Traditionally, production and maintenance – two major objectives of manufacturing systems – are not coordinated. Production is often interrupted by pre-scheduled preventive maintenance (PM) without considering the throughput target, and PM tasks are not cost-effectively conducted. This paper investigates the extra hidden opportunities for PMs during production time without violating the system throughput requirement. We develop a prediction model to identify such PM opportunity windows for large production systems based on real-time factory information system data. (15 refs, 3 figs, 1 table) (AA)

110680 Simulation study of large production network robustness in uncertain environmentPutnik, Goran D; Skulj, Gasper; Vrabic, Rok; Varela, Leonilde; Butala, Peter [CIRP Annals, v 64, n 1, 2015, Starting Page 439, Pages 4] Robustness is an important success factor for production networks in which the operation of enterprises is subjected to an uncertain environment. In this paper, the robustness of networks is studied as a function of network size. The study is performed through a simulation experiment in which the uncertain environment is modelled by introducing perturbations in demand. The decision-making model mimics the behaviour of socially connected human subjects. The results show how robustness and production rate are affected by system size and social network structure, and how this is relevant for the design and operation of future manufacturing systems. (17 refs, 5 figs) (AA)

110681 Dynamics of resource sharing in production networks

Freitag, Michael; Becker, Till; Duffie, Neil A [CIRP Annals, v 64, n 1, 2015, Starting Page 435, Pages 4] Future cyber-physical

production systems will support new business models such as sharing concepts for the joint use of resources by different companies. This paper explores resource sharing in a production network and explains how different sharingmechanisms impact the performance of the stakeholders and the dynamics of the entire network. These analyses are carried out using a simulation model and a control-theoretic model. The results show that the introduced sharing approach controls inventory and resource utilization, but it can cause shifts and fluctuations in performance depending on the information that is exchanged. (16 refs, 5 figs, 1 table) (AA)

MATERIAlS & TREATMENT

110682 Determining cyclic flow curves using the in-plane torsion test

Yin, Qing; Tekkaya, A Erman; Traphoner, Heinrich [CIRP Annals, v 64, n 1, 2015, Starting Page 261, Pages 4] A new

method of determining cyclic stress–strain curves for characterizing kinematic hardening of sheet materials is introduced utilizing the in-plane torsion test and optical strain measurement. The test enables the simultaneous recording of multiple cyclic stress–strain curves with different amplitudes of plastic strain at load reversal in one single test and with one single specimen. Cyclic flow curves are obtained for DP600, DP800, DX54D, and AA5182, and compared with the Miyauchi shear test. Material parameters for a typical kinematic hardening model are determined. Multiple cyclic stress–strain curves result significantly different model parameters as obtained by a single cyclic curve. (19 refs, 8 figs, 2 tables) (AA)

MEASUREMENT & TESTING

110683 Non-destructive evaluation of nanoscopic subsurface features in fabricated samplesEdward, Kert; Farahi, Faramarz [CIRP Annals, v 64, n 1, 2015, Starting Page 503, Pages 4] Non-invasive precision measurements of complex

Abstracts


3D micro-structures is a critical aspect of the fabrication p r o c e s s . C o n v e n t i o n a l approaches allow for microscopic characterization, but there is an

increasing need for nanoscopic analysis of sub-structures. Atomic forcemicroscopy facilitates this level of examination but subsurface interrogation is substantially precluded. We hereby present the results of a near-field scanning optical microscope with quantitative phase imaging capabilities. In addition to morphological characterization, the approach also facilitates integrated refractive index mapping, which is indicative of sample inhomogeneity distribution. Results for Reactive Ion etched (RIE) samples with both surface and subsurface features are presented. (13 refs, 7 figs) (AA)

110684 Enhancing the accuracy of high-speed laser triangulation measurement of freeform parts at elevated temperature

Ghiotti, A; Schoch, A; Salvadori, A; Carmignato, S; Savio, E [CIRP Annals, v 64, n 1, 2015, Starting Page 499, Pages 4] Geometrical distortions due to inappropriate setting of process parameters are one

of the main causes of variability in manufacturing hot forged thin parts. Their identification and measurement at the earliest steps of the process chain may permit significant benefit especially in case of small batch production. The paper presents a coordinate measuring system for fast inspection of freeform parts at elevated temperatures through high-speed laser triangulation. Main error sources are discussed, including a new method for the correction of systematic errors due to imperfect laser planes alignment. A procedure for testing the metrological performances at elevated temperature is also presented. (25 refs, 6 figs, 2 tables) (AA)

COMPUTER NUMERICAl CONTROl

110685 Direct sliding mode current control of feed drivesLaptev, Igor; Zahn, Peter; Pritschow, Gunter [CIRP Annals, v 64, n 1, 2015, Starting Page 373, Pages 4] Dealing with cascade control of electrical

feed drives involves optimizing the current loop regarding precision, dynamics, robustness and energy efficiency. This is challenging using switching inverters with pulse width modulation. A direct method based on

a switching controller is presented, which needs no downstream modulator. Control takes place in field-oriented as well as in phase-oriented coordinates of the machine, providing benefits compared to other direct methods. Control rules and structures are derived and a comparison between conventional and novel approach is shown. Implementation and measurement were performed in a practical setup, proving higher dynamics and less energy consumption. (9 refs, 9 figs, 2 tables) (AA)

PRODUCT DESIGN & MANUFACTURE

110686 Prediction of residual stresses and distortions induced by nitriding of complex 3D industrial parts

Depouhon, P; Sprauel, JM; Mermoz, E [CIRP Annals, v 64, n 1, 2015, Starting Page 553, Pages 4] A

multi-scale and multi-physical model, based on finite element methods, is developed to predict the residual stresses and distortions induced by the nitriding of industrial parts. It describes the diffusion of nitrogen and carbon, the precipitation of nitrides and carbides and the dissolution of previously formed precipitates. The residual stresses and distortions are then derived from the calculated volumetric and thermal eigenstrains accompanying the precipitations. This requires accounting for the creep existing in the treatment. The model is applied to the nitriding of complex helicopter gear box components. The realized measurements are in very good agreement with the theoretical predictions. (9 refs, 5 figs) (AA)

110687 DhRM: A new model for PlM dedicated to product design heritage

Laroche, Florent; Bernard, Alain; Hervy, Benjamin [CIRP Annals, v 64, n 1, 2015, Starting Page 161, Pages 4]

Abstracts


Cultural heritage is often considered to be a social duty, rather than an economic opportunity. Enterprises do not consider their own heritage because studying and capitalizing ancient know-how is too complex. The main problem is that digitizing old objects required specific methodology with dedicated tools and competences. Consequently, museums are the core centre for conserving inert old objects. A scientific proposition is a framework coupled to a multi-business information system: the Digital Heritage Reference Model. This new PLM is based on a product-process approach adapted to manage historical knowledge for cultural heritage. A new modelling language has been defined to support spatio- temporal problematics and human beings. A use case will demonstrate our contribution. Thanks to advanced technology, users can interact with linked heterogeneous data such as semantics, geometry, and temporal information. (12 refs, 7 figs) (AA)

110688 Incorporating customer indifference into the design of flexible options for customized productsTang, Guohua; Tseng, Mitchell M [CIRP Annals, v 64, n 1, 2015, Starting Page 427, Pages 4] This paper introduces flexible option to address the challenge of customer indifference within a product customization context. A flexible option is a predefined set of alternatives for configuring a customizable attribute, and allows a manufacturer to assign one out of the set to fulfil orders. It could be offered with price discount as an incentive to influence demand in a favourable manner. Therefore, alternative set and discount are two most essential parameters in designing option features. In this paper, customer indifference is explicitly characterized and incorporated into a holistic modelling framework to valuate flexible options and optimize the design. (10 refs, 5 figs) (AA)

RAPID PROTOTyPING

110689 Stereo photogrammetry scanning methodology, for precise and accurate 3D digitization of small parts with sub-millimeter sized featuresGalantucci, LM; Pesce, M; Lavecchia, F [CIRP Annals, v 64, n 1, 2015, Starting Page 507, Pages 4] This paper presents a scanning methodology based on close-range stereo photogrammetry, suitable for precise and accurate 3D digitization of objects of fewmillimeters in length and features in sub-millimeter scale. The authors propose an efficient alternative to other scanning methodologies currently used for such applications, as the

conoscopic holography, with the aim to reduce the scanning time and obtain a result which also contains information related to the real texture of the object. An experimental plan has been designed and implemented in order to investigate the accuracy and precision of the 3D scans. (26 refs, 6 figs, 2 tables) (AA)

TOOlS & TOOlING

110690 Interferometric measurements of single crystal diamond tool wearEvans, CJ; Browy, EC; Childs, THC; Paul, E [CIRP Annals, v 64, n 1, 2015, Starting 5, Pages 4] Interferometric measurements of plunge cuts made in a reference component intermittently during cutting tool wear tests allow measurement of the detail of tool edge recession without removing the tool from the machine. Hence the evolution of the tool wear can be evaluated with a resolution of less than 5 nm. A plunge cut using the new tool is subtracted from subsequent measurements, providing a direct measure of wear and removing bias from the scanning white light interferometer that would arise from non-zero slopes in the field of view. The method is illustrated with results from single crystal diamond tool wear tests when machining a family of nickel-copper alloys of varying composition. The dominant wear mechanism depends on the alloy and the cutting parameters. Nose flattening, leading edge recession, chipping, and formation of Pekelharing grooves can all be identified. (22 refs, 10 figs, 1 table) (AA)

TRIBOlOGy

110691 Evaluation of lubricants without zinc phosphate precoat in multi-stage cold forgingWang, ZG; Komiyama, S; Yoshikawa, Y; Suzuki, T; Osakada, K [CIRP Annals, v 64, n 1, 2015, Starting Page 285, Pages 4] The performance of lubrication coatings developed for replacing zinc phosphate conversion coating in multi-stage cold forging is evaluated with a newly devised testing method. In this test, the coated filmon the side surface of the billet is first subjected to free expansion in upsetting and then squeezed in ironing with bearing balls. It is revealed that the coated filmis peeled off in the upsetting stage, and cannot show good anti-galling ability in the subsequent stage. The billet surface treated bywet blasting before coating improves the performance by preventing the coated film from peeling off. (8 refs, 15 figs, 2 tables) (AA) ◘

Bibliography


SElECT BIBlIOGRAPhy: FINITE ElEMENT

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vol. 15 no. 4 april 2016 editorial board contents ... april_ 2016.pdf · contents technical papers...

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