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Tool Condition Monitoring in Face Milling Process Using Decision Tree and Statistical Features of Vibration Signal

B S Abdur Rahman Crescent Institute of Science & Technology-Pradeep Kumar Durairaj, Muralidharan Vaithiyanathan
  • Technical Paper
  • 2019-28-0142
To be published on 2019-10-11 by SAE International in United States
In milling process, the quality of the machined component is highly influenced by the condition of the tool. Hence, monitoring the condition of the tool becomes essential. A suitable mechanism needs to be devised in order to monitor the condition of the tool. To achieve this, condition monitoring of milling tool is taken up for the study. In this work, the condition of the tool is classified as good tool and tool with common faults in face milling process such as flank wear, worn out and breakage of the tool based on machine learning approach using statistical feature and decision tree technique. Vibration signals of the milling tool are obtained during machining of mild steel. Statistical features are extracted from the obtained signal, in which the important features are selected using decision tree. The selected features are given as the input to the same algorithm. The output of the algorithm is utilized for classifying the different conditions of the tool. The experimental results show that the accuracy of decision tree technique is at the acceptable…
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A Study on Mechanical Properties and Multi Response Optimization of Process Parameters for Showing Signs of Improvement Product Quality in Drilling AlSi7Cu4 Utilizing GRA in Taguchi Method

SRM Institute Of Science And Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Krishnaswamy Saravanan, Durai Kumaran, Raj Rajendran
TISHIK University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0058
To be published on 2019-10-11 by SAE International in United States
Showing and streamlining of cutting parameters are a champion among the most essential components in drilling processes. This examination displays the change of drilling procedures parameters on AlSi7Cu4 made by Gravity Die Casting and with replies in light of OA with Taughi GRA and ANOVA. The effects of alloying parts were bear on the Chemical Composition, microstructures, mechanical property, Hardness, X-Ray and S Das response is particularly analyzed. Motivations on the progression of Drilling parameters using the Taguchi strategy to obtain slightest surface Roughness (Ra), Circularity Error, Burr size and Thrust Force. Different Drilling Trails were coordinated using the L9 OA on CNC Milling machine. The examinations were accomplished on AlSi7Cu4 composite piece cutting tool of an ISO 460.1-1140-034A0-XM GC3 of 12 mm measurement with Tool 140 degrees, used all through the preliminary work under dry cutting conditions. The central and participation effect of the data factors on the foreseen responses are analyzed. The foreseen regards and estimated regards are really close. The given system could be utilized to pick the level of infiltrating constraints.…
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Taguchi Based Vikor Method for Optimization of Cutting Parameters for Improving the Efficiency in Machining Process by Considering the Effect of Tool Nose Radius

SRM Institute Of Science And Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Durai Kumaran, Krishnaswamy Saravanan, Harish Sriram
Tishk International University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0138
To be published on 2019-10-11 by SAE International in United States
In order to take advantage of the machining characteristics of magnesium it is useful to consider recommended tool design and angles. The geometry of the tool can have a large influence on the machining process. Tool geometry can be used to aid with chip flow and clearance, reduce excessive heat generation, reduce tool build up, enable greater feed rates to be employed and improved tool life. This paper presents a new approach for the optimization of Machining parameters on face Milling of ZE41 with multiple responses based on Taughi orthogonal array with VIKOR. Machining tests are carried out 12 mm diameter of insert having 1 flute under dry condition. In this study, Machining parameters namely cutting speed, feed and Depth of Cut and Tool Node radius are optimized with the considerations of multi responses such as surface roughness, Material Removal rate, Tool Wear and Trust Force. A VIKOR grade is obtained from the VIKOR analysis. Based on the VIKOR grade, optimum levels of parameters have been identified and significant contribution of parameters is determined by…
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Machining Titanium Aero-Frames

Aerospace & Defense Technology: June 2019

  • Magazine Article
  • 19AERP06_11
Published 2019-06-01 by SAE International in United States

The rise of titanium for aerospace applications has been well documented in recent years. Equally, the challenges associated with the efficient, productive and high-quality machining of this popular material, have also been a topic of debate and scrutiny. Of course, every machine shop wants optimized performance from its cutters when milling titanium, but this can prove less than straightforward without the right technology and know-how in place. Today, however, thanks to a breakthrough in this area, things are beginning to change.

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Machining Titanium Aero-Frames

  • Magazine Article
  • TBMG-34543
Published 2019-06-01 by Tech Briefs Media Group in United States

The rise of titanium for aerospace applications has been well documented in recent years. Equally, the challenges associated with the efficient, productive and high-quality machining of this popular material, have also been a topic of debate and scrutiny. Of course, every machine shop wants optimized performance from its cutters when milling titanium, but this can prove less than straightforward without the right technology and know-how in place. Today, however, thanks to a breakthrough in this area, things are beginning to change.

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A New Method for Multi-objective Optimal Design of Milling Parameters by Considering Chatter Vibrations

K.N.Toosi University of Technology-A. Sohani
Sharif University of Technology-E. Jafarzadeh, S. Khodaygan
Published 2019-05-13 by SAE International in United States
The desired milling process with high material removal rate (MRR) and low surface roughness of the product can be achieved only if machining chatter is absent. Incorporating chatter into the optimal selection of the machining parameters leads to a complex problem. Therefore, the approach of selecting conservative intervals for the machining parameters is usually employed instead. In this paper, a practical approach is proposed to specify the optimal machining parameters (depth of cut and spindle speed) in order to maximize MRR and minimize forced vibrations by considering machining chatter. Firstly, the worst-case scenario-based optimization problem in terms of the surface quality is solved to find the critical time at which maximal amplitude vibrations occur. Then, the time dependency of the problem is eliminated. Secondly, the multi-objective optimization is conducted to achieve the Pareto Optimal Front (POF). The Stability Lobe Diagram (SLD) is obtained independently through well-established analytical methods. Optimal machining parameters on the obtained POF are mapped into the SLD to represent optimal results for the cases at which machining chatter is absent. Finally, these…
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Experimental Studies on Mechanical Properties of Metal Matrix Composites Reinforced with Natural Fibres Ashes

Delhi Technological University-Ravi Butola, Aahan Malhotra, Mukesh Yadav, Ranganath Singari, Qasim Murtaza, Prakash Chandra
Published 2019-04-02 by SAE International in United States
Metal matrix composites have a large range of applications in the automobile industry due to its characteristics and properties. Al-based MMC have aluminum as matrix metal that has properties which are well concerned with the automobile industry. Some of these properties are high strength to weight ratio and lightweight. In this paper we are trying to develop aluminum-based metal matrix composite (MMC) reinforced with natural fibers ashes, we are using fine ashes of Sugarcane (bagasse), Groundnut Shell Ash (GSA), Rice Husk Ash (RHA) and Coconut shell (Jute) ash, different effects are investigated for different percentage of reinforcing material which is being produced by burning in a free atmosphere. Ball milling is used for making fine particle size of different natural fibers ash. Nine samples were made by the stir casting process consisting of Al6063 as base metal and different concentration of reinforcement. Maximum UTS was recorded for the specimen having composition 4% each reinforcement and balance aluminum 84%. Maximum yield Strength was found for the specimen having Coconut (jute) ash 4% and balance aluminum 96%.…
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Additive Manufacturing Using Infrared and X-Ray Imaging

  • Magazine Article
  • TBMG-33892
Published 2019-03-01 by Tech Briefs Media Group in United States

Additive manufacturing is poised to liven the pace and scale of manufacturing. Deploying a range of techniques that use 3-D models to print objects layer by layer, it can generate a variety of intricate designs in less time and with less waste than conventional cutting and milling approaches.

Running Titanium and Other Exotic Metals at Faster Speeds

  • Magazine Article
  • TBMG-28685
Published 2018-04-01 by Tech Briefs Media Group in United States

High-speed machining is typically used in medical equipment manufacturing where machinists often work with exotic alloys and harder metals like titanium.

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Test Slabs, Fluoroelastomer (FKM), 70–80 Hardness, for Improved Gas Turbine Engine Oil Compatibility

AMS CE Elastomers Committee
  • Aerospace Material Specification
  • AMS3217/8A
  • Current
Published 2017-10-18 by SAE International in United States
This specification covers a fluorocarbon (FKM) rubber stock in the form of molded test slabs.
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