Design and analysis of the internally cooled smart cutting tools with the applications to adaptive machining

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Adaptive machining with internally cooled smart cutting tools is a smart solution for industrial applications, which have stringent manufacturing requirements such as contamination free machining (CFM), high material removal rate, low tool wear and better surface integrity. The absence of cutting fluid in CFM causes the cutting tool and the workpiece subject to great thermal loads owing to higher friction and adhesion, and as a result may increase the levels of tool wear drastically. The increase in cutting temperature may influence the chip morphology which in return producing metal chips in unfavourable ribbon or snarl forms. CFM is difficult to be realized as contaminants can be in various forms in the machining operation and to avoid them totally requires a very tight controlled condition. However, the ecological, economical and technological demands compel the manufacturing practitioners to implement environmentally clean machining process (ECMP). Machining with innovative cooling techniques such as heat pipe, single-phase microduct, cryogenic or minimum quantity lubrication (MQL) has been intensely researched in recent years in order to reduce the cutting temperature in ECMP, thus enabling the part quality, the tool life and the material removal rate achieved in ECMP at least equate or surpass those obtained in conventional machining. On the other hand, the reduction of cutting temperature by using these techniques is often superfluous and is adverse to the produced surface roughness as the work material tends to inherent brittle and hard property at low temperature. Open cooling system means the machining requires a constant cooling supply and it does not provide a solution for process condition feedback as well.This Ph.D. project aims to investigate the design and analysis of internally cooled cutting tools and their implementation and application perspectives for smart adaptive machining in particular. Circulating the water based cooling fluid in a closed loop circuit contributes to sustainable manufacturing. The advantage of reducing cutting temperature from localized heat at the tool tip of an internally cooled cutting tool is enhanced with the smart features of the tool, which is trained by real experimental data, to cognitively vary the coolant flow rate, cutting feed rate or/and cutting speed to control the critical machining temperature as well as optimum machining conditions. Environmental friendly internal micro-cooling can avoid contamination of generated swarf which can also reduce the cutting temperature and thus reduce tool wear, increase machining accuracy and optimize machining economics. Design of the smart cutting tool with internal micro-cooling not only takes into account of the environmental aspects but also justifies with its ability to reduce the machining cost. Reduction of production cost can be achieved with the lower consumption of cooling fluid and improved machining resources/ energy efficiency. The models of structural, heat transfer, computational fluid dynamics (CFD) and tool life provide useful insight of the performance of the internally cooled smart cutting tool. Experimental validation using the smart cutting tool to machine titanium, steel and aluminium, indicates that the application of internally cooled smart cutting tools in adaptive machining can improve machining performance such as cutting temperature, cutting forces and surface quality generated. The useful tool life span is also extended significantly with internally cooled smart cutting tools in comparison to the tool life in conventional machining. The internally cooled smart cutting tool has important implications in the application to ECMP particularly by overcoming the stigma of high uncontrollable cutting temperature with the absence of cooling fluid.Brunel Universit

Propagation Characterization of LEO/MEO Satellite Systems at 900-2100 MHz

This paper focuses on the propagation characterization of satellite communication systems in non-geostationary orbits at 900-2100MHz. An overview of available statistical propagation models for the mobile satellite communications channel is provided. Path loss equations for satellite communication systems in the range of 900-2100MHz for different environments and different probabilities of link closure are addressed. We also introduce a series of experiments being conducted to deepen understanding of these issues

DEVELOPMENT AND OPERATION OF A MOBILE TEST FACILITY FOR EDUCATION

The automotive industry saw a large shift towards vehicle electrification after the turn of the century. It became necessary to ensure that new and existing engineers were qualified to design and calibrate these new systems. To ensure this training, Michigan Tech received a grant to develop a curriculum based around vehicle electrification. As part of this agenda, the Michigan Tech Mobile Laboratory was developed to provide hands-on training for professional engineers and technicians in hybrid electric vehicles and vehicle electrification. The Mobile Lab has since then increased the scope of the delivered curriculum to include other automotive areas and even customizable course content to meet specific needs. This thesis outlines the development of the Mobile Laboratory and its powertrain test facilities. The focus of this thesis is to discuss the different hardware and software systems within the lab and test cells. Detailed instructions on the operation and maintenance of each of the systems are discussed. In addition, this thesis outlines the setup and operation of the necessary equipment for several of the experiments for the on and off campus courses and seminars

Wi-Fi and Satellite-Based Location Techniques for Intelligent Agricultural Machinery Controlled by a Human Operator

In the new agricultural scenarios, the interaction between autonomous tractors and a human operator is important when they jointly perform a task. Obtaining and exchanging accurate localization information between autonomous tractors and the human operator, working as a team, is a critical to maintaining safety, synchronization, and efficiency during the execution of a mission. An advanced localization system for both entities involved in the joint work, i.e., the autonomous tractors and the human operator, provides a basis for meeting the task requirements. In this paper, different localization techniques for a human operator and an autonomous tractor in a field environment were tested. First, we compared the localization performances of two global navigation satellite systems’ (GNSS) receivers carried by the human operator: (1) an internal GNSS receiver built into a handheld device; and (2) an external DGNSS receiver with centimeter-level accuracy. To investigate autonomous tractor localization, a real-time kinematic (RTK)-based localization system installed on autonomous tractor developed for agricultural applications was evaluated. Finally, a hybrid localization approach, which combines distance estimates obtained using a wireless scheme with the position of an autonomous tractor obtained using an RTK-GNSS system, is proposed. The hybrid solution is intended for user localization in unstructured environments in which the GNSS signal is obstructed. The hybrid localization approach has two components: (1) a localization algorithm based on the received signal strength indication (RSSI) from the wireless environment; and (2) the acquisition of the tractor RTK coordinates when the human operator is near the tractor. In five RSSI tests, the best result achieved was an average localization error of 4 m. In tests of real-time position correction between rows, RMS error of 2.4 cm demonstrated that the passes were straight, as was desired for the autonomous tractor. From these preliminary results, future work will address the use of autonomous tractor localization in the hybrid localization approach

Mobility Analysis and Management for Heterogeneous Networks

The global mobile data traffic has increased tremendously in the last decade due to the technological advancement in smartphones. Their endless usage and bandwidth-intensive applications will saturate current 4G technologies and has motivated the need for concrete research in order to sustain the mounting data traffic demand. In this regard, the network densification has shown to be a promising direction to cope with the capacity demands in future 5G wireless networks. The basic idea is to deploy several low power radio access nodes called small cells closer to the users on the existing large radio foot print of macrocells, and this constitutes a heterogeneous network (HetNet). However, there are many challenges that operators face with the dense HetNet deployment. The mobility management becomes a challenging task due to triggering of frequent handovers when a user moves across the network coverage areas. When there are fewer users associated in certain small cells, this can lead to significant increase in the energy consumption. Intelligently switching them to low energy consumption modes or turning them off without seriously degrading user performance is desirable in order to improve the energy savings in HetNets. This dynamic power level switching in the small cells, however, may cause unnecessary handovers, and it becomes important to ensure energy savings without compromising handover performance. Finally, it is important to evaluate mobility management schemes in real network deployments, in order to find any problems affecting the quality of service (QoS) of the users. The research presented in this dissertation aims to address these challenges. First, to tackle the mobility management issue, we develop a closed form, analytical model to study the handover and ping-pong performance as a function of network parameters in the small cells, and verify its performance using simulations. Secondly, we incorporate fuzzy logic based game-theoretic framework to address and examine the energy efficiency improvements in HetNets. In addition, we design fuzzy inference rules for handover decisions and target base station selection is performed through a fuzzy ranking technique in order to enhance the mobility robustness, while also considering energy/spectral efficiency. Finally, we evaluate the mobility performance by carrying out drive test in an existing 4G long term evolution (LTE) network deployment using software defined radios (SDR). This helps to obtain network quality information in order to find any problems affecting the QoS of the users

Optimization of the WPI Kite-Powered Water Pump

This project furthers the design and testing of the WPI kite-powered water-pump system. The purpose is to provide developing nations with an inexpensive airborne wind energy system capable of efficiently and consistently pumping water. After initial field testing in fall 2013, several design modifications were made. These included developing improved kite stall techniques, a mobile trailer system, and designing and building an automated water-pumping volume measurement system. The trailer allows for field testing of a wider range of locations. Modifications were successfully field tested in spring 2014. An existing MATLAB simulation was also modified to model random wind variations

Cognitive Vehicle Platooning in the Era of Automated Electric Transportation

Vehicle platooning is an important innovation in the automotive industry that aims at improving safety, mileage, efficiency, and the time needed to travel. This research focuses on the various aspects of vehicle platooning, one of the important aspects being analysis of different control strategies that lead to a stable and robust platoon. Safety of passengers being a very important consideration, the control design should be such that the controller remains robust under uncertain environments. As a part of the Department of Energy (DOE) project, this research also tries to show a demonstration of vehicle platooning using robots. In an automated highway scenario, a vehicle platoon can be thought of as a string of vehicles, following one another as a platoon. Being equipped by wireless communication capabilities, these vehicles communicate with one another to maintain their formation as a platoon, hence are cognitive. Autonomous capable vehicles in tightly spaced, computer-controlled platoons will lead to savings in energy due to reduced aerodynamic forces, as well as increased passenger comfort since there will be no sudden accelerations or decelerations. Impacts in the occurrence of collisions, if any, will be very low. The greatest benefit obtained is, however, an increase in highway capacity, along with reduction in traffic congestion, pollution, and energy consumption. Another aspect of this project is the automated electric transportation (AET). This aims at providing energy directly to vehicles from electric highways, thus reducing their energy consumption and CO2 emission. By eliminating the use of overhead wires, infrastructure can be upgraded by electrifying highways and providing energy on demand and in real time to moving vehicles via a wireless energy transfer phenomenon known as wireless inductive coupling. The work done in this research will help to gain an insight into vehicle platooning and the control system related to maintaining the vehicles in this formation

Vehicular Communication in Obstructed and Non Line-of-Sight Scenarios

Since the invention of the first car available to masses, the 1908 Ford Model T, technology has advanced towards making car travel safer for occupants and bystanders. In recent years, wireless communication has been introduced in the vehicular industry as a means to avoid accidents and save lives.Wireless communication may sometimes be challenging due to obstacles in the physical world that interact with wireless signals. Such obstacles may be dynamic, e.g. other vehicles in the traffic flow, or static, e.g. nearby buildings. Two scenarios are defined to describe those cases. The obstructed line-of-sight (OLOS) scenario is described as the case where a smaller obstacle, usually a vehicle, is placed in-between a transmitter and a receiver. This obstacle usually partially blocks communication and the receiver often moves in an out of the line-of-sight. The non line-of-sight (NLOS) scenario is described as the case where a larger obstacle completely blocks communication between a transmitter and a receiver. An example would be a building at an intersection which shadows the communication between two vehicles. In this thesis the OLOS and NLOS scenarios are investigated from different points of view.In chapter 2, a road side unit (RSU) that has been constructed and evaluated for integrating older vehicles without wireless communication with newer vehicles using wireless communication is described. Older vehicles are being detected using a universal medium-range radar and their position and speed vectors are broadcasted wirelessly to newer vehicles. Tests have been performed by using the system in parallel with wireless enabled vehicles; by comparing the content in the messages obtained from both systems, the RSU has been found to perform adequately. Accuracy tests have been performed on the system and Kalman filtering has been applied to improve the accuracy even further.Chapter 3 focuses on the OLOS scenario. A truck as an obstacle for wireless vehicular communication is being investigated. Real life measurements have been performed to characterize and model the wireless channel around the truck. The distance dependent path loss and additional shadowing loss due to the truck is analyzed through dynamic measurements. The large scale fading, delay and Doppler spreads are characterized as a measure of the channel dispersion in the time and frequency domains. It has been found that a truck as an obstacle reduces the received power by 12 and 13 dB on average in rural and highway scenarios, respectively. Also, the dispersion in time and frequency domains is highly increased when the line-of-sight is obstructed by the truck. A model for power contributions due to diffraction around the truck has also been proposed and evaluated using the previously mentioned real life measurements. It has been found that communication may actually be possible using solely diffraction around a truck as a propagation mechanism.Finally, in chapter 4 a wireless channel emulator that has been constructed and evaluated is described. Modem manufacturers face a challenge when designing and implementing equipment for highly dynamic environments found in vehicular communication. For testing and evaluation real-life measurements with vehicles are required, which is often an expensive and slow process. The channel emulator proposed is designed and implemented using a software defined radio (SDR). The emulator together with the proposed test methodology enables quick on-bench evaluation of wireless modems. It may also be used to evaluate modem performance in different NLOS and OLOS scenarios