Browse Topic: Machining processes
ABSTRACT Ground vehicles are complex systems with many interrelated subsystems - finding the sweet-spot among competing objectives such as performance, unit cost, O&S costs, development risk, and growth potential is a non-trivial task. Whole Systems Trade Analysis (WSTA) is a systems analysis and decision support methodology and tool that integrates otherwise separate subsystem models into a holistic system view mapping critical design choices to consequences relevant to stakeholders. As a highly integrated and collaborative effort WSTA generates a holistic systems and Multiple Objective Decision Analysis (MODA) model. The decision support model and tool captures and synthesizes outputs from individual analyses into trade-space visualizations designed to facilitate rapid and complete understanding of the trade-space to stakeholders and provide drill down capability to supporting rationale. The approach has opened up trade space exploration significantly evaluating up to 1020+ potential
Many performance sport passenger vehicles use drilled or grooved cast iron brake rotors for a better braking performance or a cosmetic reason. Such brake rotors would unfortunately cause more brake dust emission, appearing with dirty wheel rims. To better understand the effects of such brake rotors on particle emission, a pin-on-disc tribometer with two particle emission measurement devices was used to monitor and collect the emitted airborne particles. The first device was an aerodynamic particle sizer, which is capable of measuring particles ranging from 0.5 to 20 μm. The second device was a condensation particle counter, which measures and collects particles from 4 nm to 3 μm. The testing samples were scaled-down brake discs (100 mm in diameter) against low-metallic brake pads. Two machined surface conditions (plain and grooved) with uncoated or ceramic-coated friction surfaces were selected for the investigation. The results showed that the grooved friction surface led to a higher
Have you ever gazed at the vastness of the stars and wondered what else your CNC machine can create? Greg Green had the opportunity to find out when he joined the staff at the Canada-France-Hawaii Telescope (CFHT) in Waimea, Hawaii
To learn about the use of digital twins for machining operations in industry, I interviewed Gisbert Ledvon, VP of Marketing at HEIDENHAIN Corporation, Schaumburg, Illinois
Medical component manufacturing must meet stringent regulations for quality and product consistency, making process control a critical issue with materials, machining, assembly and packaging. This is vitally important with fluid dispensing applications used in the assembly of medical devices, point-of-care testing and near-patient testing products, medical wearables and other life sciences applications, which require accurate and consistent deposition of fluid amounts of UV-cure adhesives, silicones and other fluids in their manufacture
In the 1990s and early 2000s, the field of parallel kinematics was viewed as being potentially transformational in manufacturing, having multiple potential advantages over conventional serial machine tools and robots. Many prototypes were developed, and some reached commercial production and implementation in areas such as hard material machining and particularly in aerospace manufacturing and assembly. There is some activity limited to niche and specialist applications; however, the technology never quite achieved the market penetration and success envisaged. Yet, many of the inherent advantages still exist in terms of stiffness, force capability, and flexibility when compared to more conventional machine structures. This chapter will attempt to identify why parallel kinematic machines (PKMs) have not lived up to the original excitement and market interest and what needs to be done to rekindle that interest. In support of this, a number of key questions and issues have been identified
Metal cutting/machining is a widely used manufacturing process for producing high-precision parts at a low cost and with high throughput. In the automotive industry, engine components such as cylinder heads or engine blocks are all manufactured using such processes. Despite its cost benefits, manufacturers often face the problem of machining chips and cutting oil residue remaining on the finished surface or falling into the internal cavities after machining operations, and these wastes can be very difficult to clean. While part cleaning/washing equipment suppliers often claim that their washers have superior performance, determining the washing efficiency is challenging without means to visualize the water flow. In this paper, a virtual engineering methodology using particle-based CFD is developed to address the issue of metal chip cleanliness resulting from engine component machining operations. This methodology comprises two simulation methods. The first is the virtual chip test
The Electroimpact Automatic Fan Cowl Riveter exhibits new and unique design features and automated process capabilities that address and overcome three primary technical challenges. The first challenge is satisfying the customer-driven requirement to access the entire fastening area of the fan cowl doors. This necessitates a unique machine design which is capable of fitting ‘inside’ a fan cowl door radius. The second challenge is determining drill geometry and drill process parameters which can produce consistent and high-quality countersunk holes in varying mixed-metal stack-up combinations consisting of aluminum, titanium, and stainless steel. The third challenge is providing the capability of fully automatic wet installation of hollow-ended titanium rivets. This requires an IML-side countersinking operation, depositing sealant throughout the OML and IML countersinks and the hole, automatically feeding and inserting a rivet which is only 5mm long and 6mm in head diameter and flaring
In numerous industries such as aerospace and energy, components must perform under significant extreme environments. This imposes stringent requirements on the accuracy with which these components are manufactured and assembled. One such example is the positional tolerance of drilled holes for close clearance applications, as seen in the “EN3201:2008 Aerospace Series – Holes for metric fasteners” standard. In such applications, the drilled holes must be accurate to within ±0.1 mm. Traditionally, this required the use of Computerised Numerical Control (CNC) systems to achieve such tight tolerances. However, with the increasing popularity of robotic arms in machining applications, as well as their relatively lower cost compared to CNC systems, it becomes necessary to assess the ability of robotic arms to achieve such tolerances. This review paper discusses the sources of errors in robotic arm drilling and reviews the current techniques for improving its accuracy. The main sources of
This specification covers a corrosion- and heat-resistant steel in the form of bars, wire, forgings, and forging stock
In this work the design and development of a device that shortens the engagement distance of the gearbox for the Volkswagen MQ200 gearbox was developed specifically for the VW UP! TSi. This project was initially developed in CAD 3D and after that, all the necessary parts were produced in a machining laboratory in the university campus. All the respective stress analysis were made with the FEA solver of the Autodesk Inventor software as well as all the machining processes. After de development of the parts and manufacture of the prototype, its effectiveness was verified in a test car during seven days which shown that the prototype had a compliance to all the calculation done prior to its production
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