Analysis of the Machining Process of Inconel 718 Parts Manufactured by Laser Metal Deposition

Laser metal deposition (LMD) is an additive manufacturing process that allows the manufacturing of near-net-shape products. This could mean significant savings in terms of materials and costs in the manufacturing of high-performance components for the aeronautical industry. In this work, an analysis of how the LMD processing of alloy 718 affects the final machining has been carried out. For this purpose, a comparative study has been done by means of the monitoring of the end milling process of a part manufactured by LMD and a rough-milled part from forged material. Differences between process outputs such as chip morphology and cutting forces were studied. Material characteristics such as microstructure, hardness and mechanical properties were also analyzed.This research was funded by European Commission grant number 723440 (PARADDISE project), which is an initiative of the Photonics and Factories of the Future Public Private Partnership, and by the Vice-Counselor of Technology, Innovation and Competitiveness of the Basque Government grant number KK-2018/00115 (ADDISEND project) and grant number KK-2019/00004 (PROCODA project)

Metals AM Design for Manufacturing

We are looking to improve upon the current post processing techniques for metal additive manufacturing (AM). This project, sponsored by Lawrence Livermore National Laboratory (LLNL), will investigate ways to improve the design of stainless steel 316 parts made by AM, and how these designs will help with post processing techniques. We hope that the findings regarding stainless steel will apply to to improve the AM and post processing handshake in general. In particular, the project will focus on including different features in different basic part design shapes to aid in fixturing and post-processing of the part made by AM. This will largely focus on including features for kinematic mounting that can be used to fixture the part in a machine for post processing or for inspection. Kinematic mounts will be added to parts that are to be milled and extension will be added to parts processed by the mill. This type of mounting can improve the accuracy of the part orientation in the machines as well as making positioning of the part more easily repeatable. Various ways of incorporating these mounts into the part design will be tested with post-processing to determine the most beneficial configuration. The information gathered will be used to create a design guide for LLNL to use with their AM processes when determining which type of mounting system would be the most useful in each situation

Application analysis of intelligent robot numerical control technology in mechanical manufacturing

under the background of the new era, the innovation and development of science and technology promote the development of all fi elds in the direction of intelligence, integration and informatization. At the same time, the fi eld of mechanical manufacturing has achieved remarkable development results, but there is still room for the improvement of mechanical manufacturing capacity, which can meet people’s production and living needs in the end. With the advent of the Internet of things era, the rapid development of science and technology, the emergence of intelligent and digital technology, and plays a vital role in the fi eld of mechanical manufacturing. The wide application of intelligent robot numerical control technology has greatly improved the effi ciency and quality of mechanical manufacturing, which can provide basic equipment for the innovation and development of other fields. How to further analyze the application and development of robot numerical control technology in the fi eld of mechanical manufacturing is an important issue for researchers to solve. This paper will carry out in-depth exploration around this issue, in order to provide theoretical reference for researchers

Micro-milling Machinability of DED Additive Titanium Ti-6Al-4V

This work investigates the micro-milling machinability of Ti-6Al-4V alloy produced by a Laser Engineered Net Shaping (LENS) additive manufacturing (AM) process with a specific focus on surface quality, cutting forces and burr formation. The effects of additive deposition parameters are also investigated since the material thermal history during processing can affect porosity and mechanical behavior of the samples, giving different milling performances. The material characterization of samples is done through micrographies, hardness tests and porosity evaluation. The roughness of the machined surfaces shows a statistical distinction between the AM and wrought titanium samples. Similar behavior is seen with the cutting forces, which increase with an increase of hardness of the AM samples. The results also show an increased trend towards burr formation in case of down milling of AM samples compared to wrought titanium samples. The future prospective is to take into account the machinability properties as functional material characteristics to optimize through the deposition process

An Application Case Study on Multi-sensor Data fusion System for Intelligent Process Monitoring

AbstractMulti-sensor data fusion is a technology to enable combining information from several sources in order to form a unified picture. Focusing on the indirect method, an attempt was made to build up a multi-sensor data fusion system to monitor the condition of grinding wheels with force signals and the acoustic emission (AE) signals. An artificial immune algorithm based multi-signals processing method was presented in this paper. The intelligent monitoring system is capable of incremental supervised learning of grinding conditions and quickly pattern recognition, and can continually improve the monitoring precision. The application case indicates that the accuracy of condition identification is about 87%, and able to meet the industrial need on the whole

Computer vision-based monitoring of abrasive loading during wood machining

Surface quality is an important characteristic commonly assessed in wooden products. Sanding relies on coated abrasives as tooling for both dimensioning and surface finishing but their performance is dependent on chip loading and grit wear. Traditionally, the useful life of abrasive belts in sanding operation has been manually assessed. This type of inspection is highly subjective and dependent upon individual expertise, consequently leading to under utilization or over utilization of the abrasive. This, in turn, affects the production costs and quality of the product. In this work, an intelligent classification method that determines the optimal replacement policy for a belt exposed to known manufacturing parameters is developed. Controlled experiments were conducted to develop abrasive belts of known exposure, followed with digital microscopy to capture images and process them with pattern recognition and classification algorithms. Grit size and machining time were the parameters of interest while response of the experiments included image information from the abrasive sheets after every experimental run. These images were used in training an artificial neural network that in turn, help in determining data to categorize the useful life of the abrasive. The results show a 95% success rate in accurately classifying abrasive images of similarly conditioned abrasives. Also, the results show that the classification of interpolated and extrapolated times of abrasive usage are classified with a 95% success rate. A classification of abrasive images is proposed to be used as one of the inputs to a decision system that would help in evaluating the life of the abrasive and replacement policies. Further research on the relationship between the different parameters affecting the useful life of the abrasive is proposed

Technological evolution in machining processes with CNC machines in the context of the concept of Industry 4.0

Dissertação de mestrado em Industrial EngineeringThe work related to the project of this dissertation will consist of an analysis of the technological evolution of the machining processes with CNC (Computer Numerical Control) machines regarding the new concept of Industry 4.0. The concept fits into the current transformation process for the fourth industrial revolution, such as integrated Cyber-Physical Systems (CPS) within the manufacturing processes using the Internet of Things (IoT) in industrial processes. Faced with technological advances, the processes of Industrial Engineering in machining using CNC machines must undergo adaptations, aiming at substantial increases in the operational effectiveness. Thus, an approach will be made to understand how current processes can adapt to the concept under study when analyzing the evolution of the machining tools for CNC machines in the face of new processes. A thorough study will be done to adapt the methodology of Industry 4.0 applying it to the machining processes in CNC Machines. Thereby, a proposal for future applications will be given on the topics studied. The methodology will be based entirely on a documental analysis research strategy. The virtual technology in machining tools is still a subject in development, being one of the main factors to be understood in this dissertation. In this study, it will be possible to analyze the main factors that can influence directly or indirectly the production processes of a factory with CNC machines. It will be explored and studied the types of machining processes for CNC machines and the types of machining tools developed with virtual technology. When we are talking about virtual technology, we are usually addressing the need for software. In CNC machining operations, there is a CAM (Computer Aided Manufacturing) software that performs machining simulations for CNC machines. Thus, a study and analysis of a production system involving a CAM software, a tool with virtual technology and CNC machines will be done to verify how this set can work encompassed and what changes this production model introduces. In the sequence of this study, an idea of a new production system will be proposed, allowing for a better understanding of the possibilities for application of new approaches in the future.O trabalho relacionado ao projeto desta dissertação de mestrado consistirá de uma análise da evolução tecnológica dos processos de usinagem com as máquinas CNC (Comando Numérico Computacional) em relação ao novo conceito da Indústria 4.0. O conceito se enquadra no atual processo de transformação da quarta revolução industrial, com os Sistemas Ciber-Físicos integrados (CPS) dentro dos processos de fabricação que utilizam a Internet das Coisas (IoT) em processos industriais. Diante dos avanços tecnológicos, os processos de Engenharia Industrial em usinagem utilizando máquinas CNC devem sofrer adaptações, visando um aumento substancial na eficácia operacional. Assim, uma abordagem será feita para entender como os processos atuais podem se adaptar ao conceito em estudo, visando também uma análise da evolução das ferramentas de usinagem para máquinas CNC em face de novos processos. Um estudo minucioso será feito para adaptar a metodologia da Indústria 4.0, aplicando-a aos processos de usinagem em máquinas CNC. Com isso, algumas proposta para aplicações futuras serão apresentadas para os tópicos estudados. A metodologia será totalmente baseada em uma estratégia de investigação documental. A tecnologia virtual em ferramentas de usinagem ainda é um assunto em desenvolvimento, sendo um dos principais fatores a serem compreendidos na realização deste trabalho. Neste estudo, será possível analisar os principais fatores que podem influenciar direta ou indiretamente nos processos de produção de uma fábrica com máquinas CNC. Serão explorados e estudados os tipos de processos de usinagem para máquinas CNC e os tipos de ferramentas de usinagem desenvolvidas com tecnologia virtual. Quando abordamos o assunto sobre tecnologia virtual, geralmente estamos a lidar com a necessidade de um software. Nas operações de usinagem CNC, existe um software CAM (Manufatura Assistida por Computador) que realiza simulações de usinagem para máquinas CNC. Assim, um estudo e análise do sistema de produção envolvendo um software CAM, uma ferramenta com tecnologia virtual e máquinas CNC será feito para verificar como este conjunto pode trabalhar englobado e quais as mudanças para esse modelo de produção. Na sequência dessa análise, será proposta uma ideia de um novo sistema de produção, que permite uma melhor compreensão das possibilidades de aplicação no futuro das novas abordagens