Plasma sprayed titanium coatings with/without a shroud

Abstract: Titanium coatings were deposited by plasma spraying with and without a shroud. The titanium coatings were then assessed by scanning electron microscopy. A comparison in microstructure between titanium coatings with and without the shroud was carried out. The results showed that the shroud played an important role in protecting the titanium particles from oxidation. The presence of the shroud led to a reduction in coating porosity. The reduction in air entrainment with t he shroud resulted in better heating of the particles, and an enhanced microstructure with lower porosity in the shrouded titanium coatings were observed compared to the air plasma sprayed counterpart

Surface profile prediction and analysis applied to turning process

An approach for the prediction of surface profile in turning process using Radial Basis Function (RBF) neural networks is presented. The input parameters of the RBF networks are cutting speed, depth of cut and feed rate. The output parameters are Fast Fourier Transform (FFT) vector of surface profile for the prediction of surface profile. The RBF networks are trained with adaptive optimal training parameters related to cutting parameters and predict surface profile using the corresponding optimal network topology for each new cutting condition. A very good performance of surface profile prediction, in terms of agreement with experimental data, was achieved with high accuracy, low cost and high speed. It is found that the RBF networks have the advantage over Back Propagation (BP) neural networks. Furthermore, a new group of training and testing data were also used to analyse the influence of tool wear and chip formation on prediction accuracy using RBF neural networks

Design of an instrumented smart cutting tool and its implementation and application perspectives

This paper presents an innovative design of a smart cutting tool, using two surface acoustic wave (SAW) strain sensors mounted onto the top and the side surface of the tool shank respectively, and its implementation and application perspectives. This surface acoustic wave-based smart cutting tool is capable of measuring the cutting force and the feed force in a real machining environment, after a calibration process under known cutting conditions. A hybrid dissimilar workpiece is then machined using the SAW-based smart cutting tool. The hybrid dissimilar material is made of two different materials, NiCu alloy (Monel) and steel, welded together to form a single bar; this can be used to simulate an abrupt change in material properties. The property transition zone is successfully detected by the tool; the sensor feedback can then be used to initiate a change in the machining parameters to compensate for the altered material properties.The UK Technology Strategy Board (TSB) for supporting this research (SEEM Project, contract No. BD266E

Oil film measurement in polytetrafluoroethylene-faced thrust pad bearings for hydrogenerator applications

There is a growing trend in the replacement of the babbit facing in thrust pad bearings with a composite polytetrafluoroethylene (PTFE) surface layer. The PTFE-faced bearings have been shown to allow a greater specific pressure, reduce thermal crowning, and, in some cases, negate the need for an oil-lift (jacking) system. These designs of bearing require new methods for the measurement of oil film thickness both to assist in their development and for plant condition monitoring. In this work, an ultrasonic method of oil film measurement is evaluated for this purpose. An ultrasonic transducer is mounted on the back face of the thrust pad. Pulses are generated and transmitted through the pad material, bonding interlayer, and PTFE surface layer. The proportion of the wave that reflects back from the oil film layer is determined. This is then related to the oil film thickness using a series of calibration experiments and a spring stiffness model. In practice, the reflected signal is difficult to distinguish, in the time domain, from other internal reflections from the pad. Signals are compared with reflections when no oil film is present and processing is carried out in the frequency domain. Experiments have been performed on a full size PTFE-faced thrust pad destined for a hydroelectric power station turbine. The instrumented pad was installed in a test facility and subjected to a range of loading conditions both with and without oil lift. Although there were some problems with the robustness of the experimental procedure, oil films were successfully measured and used to study the effect of the oil-lift system on film formation. © IMechE 2006

Methods of measuring residual stresses in components

Residual stresses occur in many manufactured structures and components. Large number of investigations have been carried out to study this phenomenon and its effect on the mechanical characteristics of these components. Over the years, different methods have been developed to measure residual stress for different types of components in order to obtain reliable assessment. The various specific methods have evolved over several decades and their practical applications have greatly benefited from the development of complementary technologies, notably in material cutting, full-field deformation measurement techniques, numerical methods and computing power. These complementary technologies have stimulated advances not only in measurement accuracy and reliability, but also in range of application; much greater detail in residual stresses measurement is now available. This paper aims to classify the different residual stresses measurement methods and to provide an overview of some of the recent advances in this area to help researchers on selecting their techniques among destructive, semi destructive and non destructive techniques depends on their application and the availabilities of those techniques. For each method scope, physical limitation, advantages and disadvantages are summarized. In the end this paper indicates some promising directions for future developments

Piezoelectric ultrasonic servo control feed drive renovate electro-discharge machining system industrial applications and transfer the technology into a new era

This paper presents the state of art of the latest development in Electro-Discharge Machining (EDM) system technology. It covers the current and recent development using the electromagentic and piezoelectric ultrasonic servo control feed drive technology. The paper also demonstrates how the ultrasonic technology renovates the system and transfers its industrial applications into a new era. EDM process is one of the most common processes in automotive and aerospace industry. It is mainly used to machine and process alloys and very hard materials for key manufacturing components, such as film cooling holes for Turbine Blades, engine strip sheets, steel sheets for automotive industry, outer vehicle body, … etc. The EDM system that uses electromagnetic servo control feed drive has a number of teething issues and this indicated the necessity to employ a new technology that could overcome these issues and enhance the system level of precision, dynamic time response, machining stability, arcing phenomena and product surface profile. The research undertaken to evaluate both systems showed that the system recently developed using ultrasonic servo control feed drive has a clear improvement in system dynamic time response, stability, a notable reduction in arcing and short-circuiting teething phenomena. This has been verified through the inter-electrode gap voltage variation. The electron microscopic examinations into the machined samples using the ultrasonic system have also indicated a clear improvement in the surface profile of the machined samples

Embedding of fibre optic sensors within flexible host

This work deals with the establishment of a UV polymerisation procedure combined with moulding technology towards the development of a mass production technology for the fabrication of flexible polymers with optical fibres embedded. The concept is to provide an artificial sensing skin based on fibre optic sensors which can be applied to irregular or moveable surfaces for distributed pressure applications, as for instance in structural monitoring or rehabilitation. The selected polymers for such an application are here reviewed and their composition adjusted in order to accommodate the required flexibility. As compared to other techniques, UV polymerisation advantages are pointed out when moving towards industrial applications and large scale productions. Meanwhile, curing tests to embed optical fibres in the developed polymers are carried out with an in house developed glass mould set-up and the results are presented. Laser ablation of polymers is also discussed in order to reply the demand of complex fibre layout as for example meandering or curved shape patterns

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Thin-wall parts are common in the aeronautical sector. However, their machining presents serious challenges such as vibrations and part deflections. To deal with these challenges, di erent approaches have been followed in recent years. This work presents the state of the art of thin-wall light-alloy machining, analyzing the problems related to each type of thin-wall parts, exposing the causes of both instability and deformation through analytical models, summarizing the computational techniques used, and presenting the solutions proposed by di erent authors from an industrial point of view. Finally, some further research lines are proposed

Ultrasonic vibration-assisted ball burnishing tool for a lathe characterized by acoustic emission and vibratory measurements

Article number 5746This paper focuses on a resonant system used to induce a low-amplitude movement and ultrasonic frequency to complement a ball burnishing process on a lathe. The system was characterized through the combination of different techniques. A full vibratory characterization of this process was undertaken with the purpose of demonstrating that the mechanical system—composed of the tool and the machine—does not present resonance phenomena during the execution of the operation that could lead to eventual failure. This dynamic analysis validates the adequateness of the tool when attached to an NC lathe, which is important to guarantee its future implementation in actual manufacturing contexts. A further aim was to confirm that the system succeeds in transmitting an oscillating signal throughout the material lattice. To this end, different static and dynamic techniques that measure different vibration ranges—including impact tests, acoustic emission measurement, and vibration measurement—were combined. An operational deflection shape model was also constructed. Results demonstrate that the only high frequency appearing in the process originated in the tool. The process was not affected by the presence of vibration assistance, nor by the burnishing preload or feed levels. Furthermore, the frequency of the assisting ultrasonic vibration was characterized and no signal due to possible damage in the material of the specimens was detected. These results demonstrate the suitability of the new tool in the vibration-assisted ball burnishing process.Feder (UE) 001-P-001822Ministerio de Ciencia, Innovación y Universidades (España) RTI2018-101653-B-I0

An Early Warning Monitoring System for CNC Spindle Bearing Failure

Equipment employed in a manufacturing environment must be able to operate as long as possible having as little downtime as possible. Therefore, maintenance is crucial in order to allow for the equipment to perform its designated tasks without failure, especially on critical systems. In a CNC machine, if the spindle fails, the machine is useless. Having the ability to detect spindle degradation to the point where a replacement spindle installation can be planned, via condition monitoring, is invaluable to a manufacturer who utilizes these types of machines. An early warning monitoring system for CNC spindle bearing failure has been developed to be utilized directly on a CNC machine\u27s controller employing an open architecture structure. The main system uses an ultrasonic sensor as its primary sensing component and provides a singular value as to the spindle condition. The system allows for both real time data recording as well as provides a trending history for the machine. Additionally, the system allows for the data to be seen remotely via the internet. Accessory devices can be added to perform an in-depth bearing failure analysis. The total system (including accessories) costs just under $2,400, allowing for a very effective system at a very low price. A few thousand dollars towards a predictive and preventive maintenance monitoring solution can prevent tens-of-thousands of dollars in lost production and unnecessary maintenance costs if the system is utilized as intended. System performance was tested to investigate sensor measurement applicability. Spindle speed was found to have an effect on the sensor\u27s output, however excessive vibration did not. Therefore, the same spindle speed must be used each time a measurement is taken. Measurements while the machine is cutting can be performed, however, a test mode is recommended for the most accurate results. The amount of variation for an in-process reading was found to be lower for a harder material (ie: steel vs. aluminum), for the same spindle speed and depth of cut. The system was tested to see if it could detect the various stages of bearing failure. It was unable to detect a plastic/resin bearing cage degradation failure until it was too late as the failure was too quiet to detect