A statistical data-based approach to instability detection and wear prediction in radial turning processes

Radial turning forces for tool-life improvements are studied, with the emphasis on predictive rather than preventive maintenance. A tool for wear prediction in various experimental settings of instability is proposed through the application of two statistical approaches to process data on tool-wear during turning processes: three sigma edit rule analysis and Principal Component Analysis (PCA). A Linear Mixed Model (LMM) is applied for wear prediction. These statistical approaches to instability detection generate results of acceptable accuracy for delivering expert opinion. They may be used for on-line monitoring to improve the processing of different materials. The LMM predicted significant differences for tool wear when turning different alloys and with different lubrication systems. It also predicted the degree to which the turning process could be extended while conserving stability. Finally, it should be mentioned that tool force in contact with the material was not considered to be an important input variable for the model.The work was performed as a part of the HIMMOVAL (Grant Agreement Number: 620134) project within the CLEAN-SKY program, linked to the SAGE2 project for geared open-rotor development and the delivery of the demonstrator part. Funding through grant IT900-16 is also acknowledged from the Basque Government Department of Education, Universities and Research

Aplicacion de modelos matematicos para el mantenimiento predictivo

149 p.La presente memoria de tesis presenta una revisión sobre la actividad de investigación aplicada que se ha realizado mediante varios proyectos relacionados con el mantenimiento predictivo asociado a procesos industriales. Uno de los resultados principales es la realización de una herramienta web que permite al operador consultar el tiempo estimado hasta el fallo en un proceso de mecanizado y junto a ello un histórico de datos del sistema. Se han obtenido otros resultados que generan una evolución en el mantenimiento de los sistemas estudiados, lo que reduce el coste y aumenta la productividad de estos. Para ello se han aplicado metodologías híbridas donde el objetivo principal radicaba en la creación de una metodología de mantenimiento predictivo para cada uno de los procesos y en algún caso la posibilidad de generalización de esta a procesos similares

Aplicacion de modelos matematicos para el mantenimiento predictivo

149 p.La presente memoria de tesis presenta una revisión sobre la actividad de investigación aplicada que se ha realizado mediante varios proyectos relacionados con el mantenimiento predictivo asociado a procesos industriales. Uno de los resultados principales es la realización de una herramienta web que permite al operador consultar el tiempo estimado hasta el fallo en un proceso de mecanizado y junto a ello un histórico de datos del sistema. Se han obtenido otros resultados que generan una evolución en el mantenimiento de los sistemas estudiados, lo que reduce el coste y aumenta la productividad de estos. Para ello se han aplicado metodologías híbridas donde el objetivo principal radicaba en la creación de una metodología de mantenimiento predictivo para cada uno de los procesos y en algún caso la posibilidad de generalización de esta a procesos similares

Prediction Methods and Experimental Techniques for Chatter Avoidance in Turning Systems: A Review

The general trend towards lightweight components and stronger but difficult to machine materials leads to a higher probability of vibrations in machining systems. Amongst them, chatter vibrations are an old enemy for machinists with the most dramatic cases resulting in machine-tool failure, accelerated tool wear and tool breakage or part rejection due to unacceptable surface finish. To avoid vibrations, process designers tend to command conservative parameters limiting productivity. Among the different machining processes, turning is responsible of a great amount of the chip volume removed worldwide. This paper reports some of the main efforts from the scientific literature to predict stability and to avoid chatter with special emphasis on turning systems. There are different techniques and approaches to reduce and to avoid chatter effects. The objective of the paper is to summarize the current state of research in this hot topic, particularly (1) the mechanistic, analytical, and numerical methods for stability prediction in turning; (2) the available techniques for chatter detection and control; (3) the main active and passive techniques.Thanks are addressed to Basque country university excellence group IT1337-19. The authors wish to acknowledge also the financial support received from HAZITEK program, from the Department of Economic Development and Infrastructures of the Basque Government and from FEDER funds. This research was funded by Tecnologico de Monterrey through the Research Group of Nanotechnology for Devices Design, and by the Consejo Nacional de Ciencia y Tecnologia (CONACYT), Project Numbers 242269, 255837, 296176, and the National Lab in Additive Manufacturing, 3D Digitizing and Computed Tomography (MADiT) LN299129

High strain rate effect on tensile ductility and fracture of AM fabricated Inconel 718 with voided microstructures

The paper describes Electromagnetic Ring Expansion Tests (ERET) performed on Laser Melting Powder Bed Fusion (LPBF) Inconel 718 stress relieved test pieces, to establish the effect of a randomly dispersed spherically voided microstructure on tensile ductility, fracture, and fragmentation at high strain rate (10-3 < e < 104 s-1). An empirical model to predict porosity type and growth rates as a function of laser energy density was established, to select the LPBF process parameters to fabricate test pieces under stable conduction and keyhole melting. The size, shape, distribution of macro and keyhole pores in the test pieces obtained for ERET testing were characterised. At high strain rate the number of ring fragments for the highest porosity doubled, accompanied by a reduction in true strain at maximum uniform elongation and fracture strain. The trend for reducing fracture strain with increasing porosity at high strain rate was described by a decaying power law. Overall, there was a significant positive strain rate effect on tensile ductility at lower porosities attributed strain rate hardening (Hart, 1967) [1]. Fracture surfaces containing the highest porosity identified four different void coalescence mechanisms that helped explain the influence of larger pores on the stress state in the alloy.The AM of IN718 and tensile testing was funded by the UoD, College of Science and Engineering Research Excellence Framework (REF) funding for the Director of IISE (P. Wood) and AM Researcher (U. Gunputh). The support of G. Williams for IN718 sample preparation and M. Pawlik for tensile testing is acknowledged. A. Rusinek acknowledges the program UC3M-Santander Chair of Excellence in additive manufacturing. The expanding ring tests investigations were funded by the Polish Ministry of Science and Higher Education, Centre for Research and Development under research grant No. TECHMATSTRATEG2/410049/12/NCBR/2019

Bibliography of Lewis Research Center technical publications announced in 1986

This compilation of abstracts describes and indexes the technical reporting that resulted from the scientific and engineering work performed and managed by the Lewis Research Center in 1986. All the publications were announced in the 1986 issues of Scientific and Technical Aerospace Reports (STAR) and/or International Aerospace Abstracts (IAA). Included are research reports, journal articles, conference presentations, patents and patent applications, and theses

Aeronautical engineering: A continuing bibliography with indexes (supplement 255)

This bibliography lists 529 reports, articles, and other documents introduced into the NASA scientific and technical information system in June 1990. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Aeronautical Engineering: a Continuing Bibliography with Indexes (Supplement 243)

This bibliography lists 423 reports, articles, and other documents introduced into the NASA scientific and technical information system in August 1989. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Structures Division 1994 Annual Report

The NASA Lewis Research Center Structures Division is an international leader and pioneer in developing new structural analysis, life prediction, and failure analysis related to rotating machinery and more specifically to hot section components in air-breathing aircraft engines and spacecraft propulsion systems. The research consists of both deterministic and probabilistic methodology. Studies include, but are not limited to, high-cycle and low-cycle fatigue as well as material creep. Studies of structural failure are at both the micro- and macrolevels. Nondestructive evaluation methods related to structural reliability are developed, applied, and evaluated. Materials from which structural components are made, studied, and tested are monolithics and metal-matrix, polymer-matrix, and ceramic-matrix composites. Aeroelastic models are developed and used to determine the cyclic loading and life of fan and turbine blades. Life models are developed and tested for bearings, seals, and other mechanical components, such as magnetic suspensions. Results of these studies are published in NASA technical papers and reference publication as well as in technical society journal articles. The results of the work of the Structures Division and the bibliography of its publications for calendar year 1994 are presented

On deformation characterisation of machined surfaces and machining-induced white layers in a milled titanium alloy

Machining-induced white layers and severely deformed layers are undesirable surface integrity features which can be formed when machining high-strength aerospace alloys. An orthogonal milling process has been designed and performed to assess the impact of cutting speeds, tool wear, cutting edge radius and climb vs conventional milling on white layer formation and plastic strain distribution. The plastic deformation in the machined surface associated with the formation of white layers in Ti-6Al-4V has been quantified using micro-grids of different length scales printed using the electron beam lithography technique. It was found that white layers formed via the severe plastic deformation mechanism, at equivalent plastic strain values in excess of 1.2 and in regions of the cutting arc with the instantaneous chip thickness of less than the cutting-edge radius and ploughing and rubbing being the dominant mechanisms. The results indicated that the magnitude of the measured strains and the depth of plastically deformed material was greater at lower cutting speeds, during climb milling and when machining with a larger cutting edge radius and tool flank wear land