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

Application of Audible Signals in Tool Condition Monitoring using Machine Learning Techniques

Machining is always accompanied by many difficulties like tool wear, tool breakage, improper machining conditions, non-uniform workpiece properties and some other irregularities, which are some of major barriers to highly-automated operations. Effective tool condition monitoring (TCM) system provides a best solution to monitor those irregular machining processes and suggest operators to take appropriate actions. Even though a wide variety of monitoring techniques have been developed for the online detection of tool condition, it remains an unsolved problem to look for a reliable, simple and cheap solution. This research work mainly focuses on developing a real-time tool condition monitoring model to detect the tool condition, part quality in machining process by using machine learning techniques through sound monitoring. The present study shows the development of a process model capable of on-line process monitoring utilizing machine learning techniques to analyze the sound signals collected during machining and train the proposed system to predict the cutting phenomenon during machining. A decision-making system based on the machine learning technique involving Support Vector Machine approach is developed. The developed system is trained with pre-processed data and tested, and the system showed a significant prediction accuracy in different applications which proves to be an effective model in applying to machining process as an on-line process monitoring system. In addition, this system also proves to be effective, cheap, compact and sensory position invariant. The successful development of the proposed TCM system can provide a practical tool to reduce downtime for tool changes and minimize the amount of scrap in metal cutting industry

Novel Techniques for Tissue Imaging and Characterization Using Biomedical Ultrasound

The use of ultrasound technology in the biomedical field has been widely increased in recent decades. Ultrasound modalities are considered more safe and cost effective than others that use ionizing radiation. Moreover, the use of high-frequency ultrasound provides means of high-resolution and precise tissue assessment. Consequently, ultrasound elastic waves have been widely used to develop non-invasive techniques for tissue assessment. In this work, ultrasound waves have been used to develop non-invasive techniques for tissue imaging and characterization in three different applications.;Currently, there is a lack of imaging modalities to accurately predict minute structures and defects in the jawbone. In particular, the inability of 2D radiographic images to detect bony periodontal defects resulted from infection of the periodontium. They also may carry known risks of cancer generation or may be limited in accurate diagnosis scope. Ultrasonic guided waves are sensitive to changes in microstructural properties, while high-frequency ultrasound has been used to reconstruct high-resolution images for tissue. The use of these ultrasound techniques may provide means for early diagnosis of marrow ischemic disorders via detecting focal osteoporotic marrow defect, chronic nonsuppurative osteomyelitis, and cavitations in the mandible (jawbone). The first part of this work investigates the feasibility of using guided waves and high frequency ultrasound for non-invasive human jawbone assessment. The experimental design and the signal/image processing procedures for each technique are developed, and multiple in vitro studies are carried out using dentate and non-dentate mandibles. Results from both the ultrasonic guided waves analysis and the high frequency 3D echodentographic imaging suggest that these techniques show great potential in providing non-invasive methods to characterize the jawbone and detect periodontal diseases at earlier stages.;The second part of this work describes indirect technique for characterization via reconstructing high-resolution microscopic images. The availability of well-defined genetic strains and the ability to create transgenic and knockout mice makes mouse models extremely significant tools in different kinds of research. For example, noninvasive measurement of cardiovascular function in mouse hearts has become a valuable need when studying the development or treatment of various diseases. This work describes the development and testing of a single-element ultrasound imaging system that can reconstruct high-resolution brightness mode (B-mode) images for mouse hearts and blood vessels that can be used for quantitative measurements in vitro. Signal processing algorithms are applied on the received ultrasound signals including filtering, focusing, and envelope detection prior to image reconstruction. Additionally, image enhancement techniques and speckle reduction are adopted to improve the image resolution and quality. The system performance is evaluated using both phantom and in vitro studies using isolated mouse hearts and blood vessels from APOE-KO and its wild type control. This imaging system shall provide a basis for early and accurate detection of different kinds of diseases such as atherosclerosis in mouse model.;The last part of this work is initialized by the increasing need for a non-invasive method to assess vascular wall mechanics. Endothelial dysfunction is considered a key factor in the development of atherosclerosis. Flow-mediated vasodilatation (FMD) measurement in brachial and other conduit arteries has become a common method to assess the endothelial function in vivo. In spite of the direct relationship that could be between the arterial wall multi-component strains and the FMD response, direct measurement of wall strain tensor due to FMD has not yet been reported in the literature. In this work, a noninvasive direct ultrasound-based strain tensor measuring (STM) technique is presented to assess changes in the mechanical parameters of the vascular wall during post-occlusion reactive hyperemia and/or FMD, including local velocities and displacements, diameter change, local strain tensor and strain rates. The STM technique utilizes sequences of B-mode ultrasound images as its input with no extra hardware requirement. The accuracy of the STM algorithm is assessed using phantom, and in vivo studies using human subjects during pre- and post-occlusion. Good correlations are found between the post-occlusion responses of diameter change and local wall strains. Results indicate the validity and versatility of the STM algorithm, and describe how parameters other than the diameter change are sensitive to reactive hyperemia following occlusion. This work suggests that parameters such as local strains and strain rates within the arterial wall are promising metrics for the assessment of endothelial function, which can then be used for accurate assessment of atherosclerosis

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

Tooth Position Determination by Automatic Cutting and Marking of Dental Panoramic X-ray Film in Medical Image Processing

This paper presents a novel method for automatic segmentation of dental X-ray images into single tooth sections and for placing every segmented tooth onto a precise corresponding position table. Moreover, the proposed method automatically determines the tooth’s position in a panoramic X-ray film. The image-processing step incorporates a variety of image-enhancement techniques, including sharpening, histogram equalization, and flat-field correction. Moreover, image processing was implemented iteratively to achieve higher pixel value contrast between the teeth and cavity. The next image-enhancement step is aimed at detecting the teeth cavity and involves determining the segment and points separating the upper and lower jaw, using the difference in pixel values to cut the image into several equal sections and then connecting each cavity feature point to extend a curve that completes the description of the separated jaw. The curve is shifted up and down to look for the gap between the teeth, to identify and address missing teeth and overlapping. Under FDI World Dental Federation notation, the left and right sides receive eight-code sequences to mark each tooth, which provides improved convenience in clinical use. According to the literature, X-ray film cannot be marked correctly when a tooth is missing. This paper utilizes artificial center positioning and sets the teeth gap feature points to have the same count. Then, the gap feature points are connected as a curve with the curve of the jaw to illustrate the dental segmentation. In addition, we incorporate different image-processing methods to sequentially strengthen the X-ray film. The proposed procedure had an 89.95% accuracy rate for tooth positioning. As for the tooth cutting, where the edge of the cutting box is used to determine the position of each tooth number, the accuracy of the tooth positioning method in this proposed study is 92.78%

Evaluating spatial and frequency domain enhancement techniques on dental images to assist dental implant therapy

Dental imaging provides the patient's anatomical details for the dental implant based on the maxillofacial structure and the two-dimensional geometric projection, helping clinical experts decide whether the implant surgery is suitable for a particular patient. Dental images often suffer from problems associated with random noise and low contrast factors, which need effective preprocessing operations. However, each enhancement technique comes with some advantages and limitations. Therefore, choosing a suitable image enhancement method always a difficult task. In this paper, a universal framework is proposed that integrates the functionality of various enhancement mechanisms so that dentists can select a suitable method of their own choice to improve the quality of dental image for the implant procedure. The proposed framework evaluates the effectiveness of both frequency domain enhancement and spatial domain enhancement techniques on dental images. The selection of the best enhancement method further depends on the output image perceptibility responses, peak signal-to-noise ratio (PSNR), and sharpness. The proposed framework offers a flexible and scalable approach to the dental expert to perform enhancement of a dental image according to visual image features and different enhancement requirements

Rolling contact fatigue failures in silicon nitride and their detection

The project investigates the feasibility of using sensor-based detection and processing systems to provide a reliable means of monitoring rolling contact fatigue (RCF) wear failures of silicon nitride in hybrid bearings. To fulfil this investigation, a decision was made early in the project to perform a series of hybrid rolling wear tests using a twin disc machine modified for use on hybrid bearing elements.The initial part of the thesis reviews the current understanding of the general wear mechanisms and RCF with a specific focus to determine the appropriate methods for their detection in hybrid bearings. The study focusses on vibration, electrostatic and acoustic emission (AE) techniques and reviews their associated sensing technologies currently deployed with a view of adapting them for use in hybrids. To provide a basis for the adaptation, an understanding of the current sensor data enhancement and feature extraction methods is presented based on a literature review.The second part describes the test equipment, its modifications and instrumentation required to capture and process the vibration, electrostatic and AE signals generated in hybrid elements. These were identified in an initial feasibility test performed on a standard twin disc machine. After a detailed description of the resulting equipment, the thesis describes the calibration tests aimed to provide base data for the development of the signal processing methods.The development of the signal processing techniques is described in detail for each of the sensor types. Time synchronous averaging (TSA) technique is used to identify the location of the signal sources along the surfaces of the specimens and the signals are enhanced by additional filtering techniques.The next part of the thesis describes the main hybrid rolling wear tests; it details the selection of the run parameters and the samples seeded with surface cracks to cover a variety of situations, the method of execution of each test run, and the techniques to analyse the results.The research establishes that two RCF fault types are produced in the silicon nitride rolling element reflecting essentially different mechanisms in their distinct and separate development; i) cracks, progressing into depth and denoted in this study as C-/Ring crack Complex (CRC) and ii) Flaking, progressing primarily on the surface by spalls. Additionally and not reported in the literature, an advanced stage of the CRC fault type composed of multiple and extensive c-cracks is interpreted as the result of induced sliding in these runs. In general, having reached an advanced stage, both CRC and Flaking faults produce significant wear in the steel counterface through abrasion, plastic deformation or 3-body abrasion in at least three possible ways, all of which are described in details

Modeling and rendering for development of a virtual bone surgery system

A virtual bone surgery system is developed to provide the potential of a realistic, safe, and controllable environment for surgical education. It can be used for training in orthopedic surgery, as well as for planning and rehearsal of bone surgery procedures...Using the developed system, the user can perform virtual bone surgery by simultaneously seeing bone material removal through a graphic display device, feeling the force via a haptic deice, and hearing the sound of tool-bone interaction --Abstract, page iii

Efficacy of ultrasound imaging to detect periodontal bone defects

Objectives. Clinicians are always searching for a non-invasive method to diagnose periodontal defects. Two-dimensional radiographs are limited in the ability to describe a three-dimensional periodontal defect. Ultrasound has been used in dentistry for caries detection and enamel cracks diagnosis. Its non-ionizing radiation properties are attractive to clinical use in dentistry. The purpose of the present study is to investigate the efficacy of ultrasound imaging to accurately detect periodontal defects.;Methods. Twenty mandibles with simulated defects of specific dimensions were imaged using ultrasound and measured. The measurements were compared to the actual defects and to 2-D radiographs measurements. A panel of three evaluators compared ultrasound images of simulated defects to 2-D radiographs of the same defects. 3-D reconstructed images of two mandibles with natural periodontal defects were compared to cone beam images of the same mandibles.;Results. The results have shown that conventional radiographs were not accurate in imaging the posterior mandible, while measurements made from ultrasound images were accurate for both anterior and posterior mandibles. Measurements of the simulated defects from ultrasound images were accurate. The ultrasound images were rated favorably in image clarity, image detail, overall image quality and fatigue level in comparison to conventional radiographs and cone beam imaging.;Conclusions. These results suggest that ultrasound imaging may provide a reliable diagnostic alternative to conventional two-dimensional radiographs. Optimizing ultrasound technology for use in dentistry may increase interest in its use. Enough interest exists for further clinical evaluation

A machine-learning based solution for chatter prediction in heavy-dutymilling machines

The main productivity constraints of milling operations are self-induced vibrations, especially regenerative chatter vibrations. Two key parameters are linked to these vibrations: the depth of cut achievable without vibrations and the chatter frequency. Both parameters are linked to the dynamics of machine component excitation and the milling operation parameters. Their identification in any cutting direction in milling machine operations requires complex analytical models and mechatronic simulations, usually only applied to identify the worst cutting conditions in operating machines. This work proposes the use of machine learning techniques with no need to calculate the two above-mentioned parameters by means of a 3-step strategy. The strategy combines: 1) experimental frequency responses collected at the tool center point; 2) analytical calculations of both parameters; and, 3) different machine learning techniques. The results of these calculations can then be used to predict chatter under different combinations of milling directions and machine positions. This strategy is validated with real experiments on a bridge milling machine performing concordance roughing operations on AISI 1045 steel with a 125 mm diameter mill fitted with nine cutters at 45°, the results of which have confirmed the high variability of both parameters along the working volume. The following regression techniques are tested: artificial neural networks, regression trees and Random Forest. The results show that Random Forest ensembles provided the highest accuracy with a statistical advantage over the other machine learning models; they achieved a final accuracy of 0.95 mm for the critical depth and 7.3 Hz for the chatter frequency (RMSE) in the whole working volume and in all feed directions, applying a 10 × 10 cross validation scheme. These RMSE values are acceptable from the industrial point of view, taking into account that the critical depth of this range varies between 0.68 mm and 19.20 mm and the chatter frequency between 1.14 Hz and 65.25 Hz. Besides, Random Forest ensembles are more easily optimized than artificial neural networks (1 parameter configuration versus 210 MLPs). Additionally, tools that incorporate regression trees are interesting and highly accurate, providing immediately accessible and useful information in visual formats on critical machine performance for the design engineer.Hidrodamp Project (IDI-20110453) of the Centre for Industrial Technological Development (CDTI