Eco-efficient process based on conventional machining as an alternative technology to chemical milling of aeronautical metal skin panels

El fresado químico es un proceso diseñado para la reducción de peso de pieles metálicas que, a pesar de los problemas medioambientales asociados, se utiliza en la industria aeronáutica desde los años 50. Entre sus ventajas figuran el cumplimiento de las estrictas tolerancias de diseño de piezas aeroespaciales y que pese a ser un proceso de mecanizado, no induce tensiones residuales. Sin embargo, el fresado químico es una tecnología contaminante y costosa que tiende a ser sustituida. Gracias a los avances realizados en el mecanizado, la tecnología de fresado convencional permite alcanzar las tolerancias requeridas siempre y cuando se consigan evitar las vibraciones y la flexión de la pieza, ambas relacionadas con los parámetros del proceso y con los sistemas de utillaje empleados. Esta tesis analiza las causas de la inestabilidad del corte y la deformación de las piezas a través de una revisión bibliográfica que cubre los modelos analíticos, las técnicas computacionales y las soluciones industriales en estudio actualmente. En ella, se aprecia cómo los modelos analíticos y las soluciones computacionales y de simulación se centran principalmente en la predicción off-line de vibraciones y de posibles flexiones de la pieza. Sin embargo, un enfoque más industrial ha llevado al diseño de sistemas de fijación, utillajes, amortiguadores basados en actuadores, sistemas de rigidez y controles adaptativos apoyados en simulaciones o en la selección estadística de parámetros. Además se han desarrollado distintas soluciones CAM basadas en la aplicación de gemelos virtuales. En la revisión bibliográfica se han encontrado pocos documentos relativos a pieles y suelos delgados por lo que se ha estudiado experimentalmente el efecto de los parámetros de corte en su mecanizado. Este conjunto de experimentos ha demostrado que, pese a usar un sistema que aseguraba la rigidez de la pieza, las pieles se comportaban de forma diferente a un sólido rígido en términos de fuerzas de mecanizado cuando se utilizaban velocidades de corte cercanas a la alta velocidad. También se ha verificado que todas las muestras mecanizadas entraban dentro de tolerancia en cuanto a la rugosidad de la pieza. Paralelamente, se ha comprobado que la correcta selección de parámetros de mecanizado puede reducir las fuerzas de corte y las tolerancias del proceso hasta un 20% y un 40%, respectivamente. Estos datos pueden tener aplicación industrial en la simplificación de los sistemas de amarre o en el incremento de la eficiencia del proceso. Este proceso también puede mejorarse incrementando la vida de la herramienta al utilizar fluidos de corte. Una correcta lubricación puede reducir la temperatura del proceso y las tensiones residuales inducidas a la pieza. Con este objetivo, se han desarrollado diferentes lubricantes, basados en el uso de líquidos iónicos (IL) y se han comparado con el comportamiento tribológico del par de contacto en seco y con una taladrina comercial. Los resultados obtenidos utilizando 1 wt% de los líquidos iónicos en un tribómetro tipo pin-on-disk demuestran que el IL no halogenado reduce significativamente el desgaste y la fricción entre el aluminio, material a mecanizar, y el carburo de tungsteno, material de la herramienta, eliminando casi toda la adhesión del aluminio sobre el pin, lo que puede incrementar considerablemente la vida de la herramienta.Chemical milling is a process designed to reduce the weight of metals skin panels. This process has been used since 1950s in the aerospace industry despite its environmental concern. Among its advantages, chemical milling does not induce residual stress and parts meet the required tolerances. However, this process is a pollutant and costly technology. Thanks to the last advances in conventional milling, machining processes can achieve similar quality results meanwhile vibration and part deflection are avoided. Both problems are usually related to the cutting parameters and the workholding. This thesis analyses the causes of the cutting instability and part deformation through a literature review that covers analytical models, computational techniques and industrial solutions. Analytics and computational solutions are mainly focused on chatter and deflection prediction and industrial approaches are focused on the design of workholdings, fixtures, damping actuators, stiffening devices, adaptive control systems based on simulations and the statistical parameters selection, and CAM solutions combined with the use of virtual twins applications. In this literature review, few research works about thin-plates and thin-floors is found so the effect of the cutting parameters is also studied experimentally. These experiments confirm that even using rigid workholdings, the behavior of the part is different to a rigid body at high speed machining. On the one hand, roughness values meet the required tolerances under every set of the tested parameters. On the other hand, a proper parameter selection reduces the cutting forces and process tolerances by up to 20% and 40%, respectively. This fact can be industrially used to simplify workholding and increase the machine efficiency. Another way to improve the process efficiency is to increase tool life by using cutting fluids. Their use can also decrease the temperature of the process and the induced stresses. For this purpose, different water-based lubricants containing three types of Ionic Liquids (IL) are compared to dry and commercial cutting fluid conditions by studying their tribological behavior. Pin on disk tests prove that just 1wt% of one of the halogen-free ILs significantly reduces wear and friction between both materials, aluminum and tungsten carbide. In fact, no wear scar is noticed on the ball when one of the ILs is used, which, therefore, could considerably increase tool life

A Novel Minimally Invasive Tumour Localization Device

Lung cancer is one of the leading causes of death, by cancer. The usual treatment is surgical resection of tumours. However, patients who are weak or have poor pulmonary function are deemed unfit for surgery. For these patients, a minimally-invasive approach is desired. A major problem associated with minimally-invasive approaches is tumour localization in real time and accurate measurement of tool--tissue forces. This thesis describes the design, analysis, manufacturing and validation of a minimally-invasive instrument for tumour localization, named Palpatron. The instrument has an end effector that is able to support two previously designed jaws, one containing an ultrasound sensor and the other a tactile sensor. The jaws can move with two degrees of freedom to palpate tissue and rotate about the central axis of the instrument. The Palpatron has uncoupled jaw motion that allows for optimal alignment of sensors to improve data acquisition. The instrument can be easily assembled and disassembled allowing it to be cleaned and sterilized. The mechanism is articulated using push rods, each actuated by a motor. A semi-automatic control system was created for palpation. It is composed of a microcontroller that controls four motors via serial communication. In addition, the Palpatron has the ability to prevent tissue damage by measuring tool--tissue forces. Finite element analysis was used to guide material selection for designed components. Grade 5 titanium was selected for end effector links to provide a factor of safety of 1.2 against yielding under a 10 N point load at the tip of a jaw. The design was fabricated and validated by conducting experiments to test articulation and load carrying capacity. An 8-N force was applied to the instrument, which was successfully supported. The semi-automatic control system was used to perform basic maneuvering tasks to verify jaw motion capabilities. With positive testing results, the Palpatron forms the next step towards a comprehensive robotic-assisted palpation technology

Design of a Hand Held Minimally Invasive Lung Tumour Localization Device

Lung cancer is the leading type of cancer that causes death. If diagnosed, the treatment of choice is surgical resection of the tumour. Traditionally, a surgeon feels for the presence of a tumour in open thoracic surgery. However, a minimally invasive approach is desired. A major problem presented by the minimally invasive approach is the localization of the tumour. This project describes the design, analysis, and experimental validation of a novel minimally invasive instrument for lung tumour localization. The instrument end effector is a two degree of freedom lung tissue palpator. It allows for optimal tissue palpation to increase useful sensor feedback by ensuring sensor contact, and prevents tissue damage by uniformly distributing pressure on the tissue with an upper bound force. Finite element analysis was used extensively to guide the design process. The mechanism is actuated using high strength tungsten cables attached to controlled motors. Heat treatment experiments were undertaken with stainless steel alloy 440C for use in the design, achieving a device factor of safety of 4. This factor of safety is based on a 20 N force on the end effector — the approximate weight of a human lung. The design was prototyped and validation experiments were carried out to assess its articulation and its load carrying capacity. Up to 10 N of force was applied to the prototype. Issues to resolve in the current design include cable extension effects and the existence of joint inflection. The end effector was also designed to allow the inclusion of ultrasound, tactile, and kinaesthetic sensors. It is hypothesized that a plurality of sensors will increase the likelihood of positive tumour localization. These sensors, combined with the presented mechanical design, form the basis for research in robotics-assisted palpation. A proof of concept control system is presented for automated palpation

Robots in machining

Robotic machining centers offer diverse advantages: large operation reach with large reorientation capability, and a low cost, to name a few. Many challenges have slowed down the adoption or sometimes inhibited the use of robots for machining tasks. This paper deals with the current usage and status of robots in machining, as well as the necessary modelling and identification for enabling optimization, process planning and process control. Recent research addressing deburring, milling, incremental forming, polishing or thin wall machining is presented. We discuss various processes in which robots need to deal with significant process forces while fulfilling their machining task

University of Malaya Research Bulletin, Volume 16, Number 1, 2016

Previously known as IPPP UM Research Bulleti

Impulse-Based Manufacturing Technologies

In impulse-based manufacturing technologies, the energy required to form, join or cut components acts on the workpiece in a very short time and suddenly accelerates workpiece areas to very high velocities. The correspondingly high strain rates, together with inertia effects, affect the behavior of many materials, resulting in technological benefits such as improved formability, reduced localizing and springback, extended possibilities to produce high-quality multi material joints and burr-free cutting. This Special Issue of JMMP presents the current research findings, which focus on exploiting the full potential of these processes by providing a deeper understanding of the technology and the material behavior and detailed knowledge about the sophisticated process and equipment design. The range of processes that are considered covers electromagnetic forming, electrohydraulic forming, adiabatic cutting, forming by vaporizing foil actuators and other impulse-based manufacturing technologies. Papers show significant improvements in the aforementioned processes with regard to: Processes analysis; Measurement technique; Technology development; Materials and modelling; Tools and equipment; Industrial implementation

Cumulative index to NASA Tech Briefs, 1986-1990, volumes 10-14

Tech Briefs are short announcements of new technology derived from the R&D activities of the National Aeronautics and Space Administration. These briefs emphasize information considered likely to be transferrable across industrial, regional, or disciplinary lines and are issued to encourage commercial application. This cumulative index of Tech Briefs contains abstracts and four indexes (subject, personal author, originating center, and Tech Brief number) and covers the period 1986 to 1990. The abstract section is organized by the following subject categories: electronic components and circuits, electronic systems, physical sciences, materials, computer programs, life sciences, mechanics, machinery, fabrication technology, and mathematics and information sciences