MINIMIZATION OF DEFLECTION ERROR IN FIVE AXIS MILLING OF IMPELLER BLADES

The 5-axis CNC machine tools are used for manufacturing free form surfaces of sophisticated parts such as turbine blades, airfoils, impellers, and aircraft components. The virtual machining systems can be used in order to analyze and modify the 5-axis CNC machine tools operations. Cutting forces and cutting temperatures induce deflection errors in thin-walled structures such as impeller blades through machining operations. Thin-walled impeller blades' flexibility can result in machining errors such as overcutting or undercutting. So, decreasing the deflection error during machining operations of impeller blades can achieve the desired accuracy in produced parts. Optimized machining parameters can be obtained to minimize the deflection of machined impeller blades. In terms of precision and efficiency enhancement in component production processes, a virtual machining system is developed to predict and minimize deflection errors of 5-axis milling operations of impeller blades. The deflection error in machined impeller blades is calculated by using finite element analysis. The optimization methodology based on the genetic algorithm is applied to minimize the deflection error of impeller blades in machining operations. To validate the integrated virtual machining system in the study, the impeller is milled by using a 5-axis CNC machine tool. The CMM machine is used in order to measure and analyze deflection error in the machined impeller blades. As a result, by using the developed virtual machining system in the study, accuracy and efficiency in 5-axis milling operations of impellers can be increased

EXPLORING THE EFFECT OF ORGANIC ADDITIVES ON PHYSICAL PROPERTIES OF BITUMEN

Warm additives had wide popularity in recent years due to saving in energy and lowering emissions dealt with asphalt mixture production. Warm Mix Asphalt (WMA) is produced by using foaming technology or reducing -viscosity additives of binder to enhance the rheological properties. In this study, organic-based additives (Asphaltan A and Asphaltan B) are used to investigate their effect to minimize the viscosity and lower the temperature of asphalt mixture production. Bitumen is mixed with three doses of each additive: 1, 2, and 3% of its weight. The binder viscosity was measured by rotational viscometer with and without the additives at three different temperatures. The study showed that the organic additives have a positive impact on the behavior of the binder in terms of viscosity reduction and made enhancements in terms of bitumen properties. This result could be useful in the reduction of production temperature and quantity of odour emissions

Smart manufacturing for industry 4.0 using Radio Frequency Identification (RFID) technology

Industry 4.0 (I4.0) presents a unique challenge of efficiently transforming traditional manufacturing to smart and autonomous systems.Integrating manufacturing systems, materials, machinery, operators, products and consumers, improve interconnectivity and traceability across the entire product life cycle in order to ensure the horizontal and vertical integration of networked Smart Manufacturing (SM) systems. Manufacturing functions of Material Handling (MH)-control, storage, protection and transport of raw materials, work in process (WIP) and finished products- throughout a manufacturing and distribution process will need a revamp in ways they are currently being carried in order to transition them into the SM era. Radio Frequency Identification (RFID), an Automated Identification Data Capture (AIDC) technology increasingly being used to enhance MH functions in the (SM) industry, due to opportunities it presents for item tracking, out of sight data capturing, navigation and space mapping abilities. The technology readiness level of RFID has presented many implementation challenges as progress is being made to fully integrate the technology into the preexisting MH functions. Recently, many researchers in academia and industry have described various methods of using RFID for improving and efficiently carrying out MH functions as a gradual transition is being made into I4.0 era. This paper reviews and categorize research finding regarding RFID application developments according to various MH functions in SM, tabulates how various I4.0 enablers are needed to transform various traditional manufacturing functions into SM. It aims to let more experts know the current research status of RFID technology and provide some guidance for future research

Recent developments in tensile properties of friction welding of carbon fiber-reinforced composite: A review

In this review article, the joining of carbon fiber-reinforced polymer composite with metallic materials by using friction welding techniques was discussed and the effects of process parameters on the weld properties were evaluated. Major parameters involved in this process were plunge depth (PD), dwell time, joining time, and tool rotational speed. A successful friction joint of carbon fiber-reinforced poly composite laminate (CF-PPS)-metal was formed with an interlayer film of additional polyphenylene sulfide. In addition, a detailed overview of the friction techniques was discussed, such as friction stir spot welding (FSSW), friction stir welding (FSW), and refill friction stir spot welding (RFSSW). In this current work, we had focused on the parameters, process, and their development during friction welding of similar and dissimilar metals with CFRP joint. Regarding the FSSW review, the best tensile shear load was 7.1 kN obtained from AA5182 and CFRP at a rotational speed of 3,000 rpm and 5 s welding time. The thickness for AA5182 and CFRP are 1.2 and 3 mm, respectively. The most efficient parameters are rotational speed, PD, dwell time, and shoulder penetration depth. In addition, the heat generated during the process parameters, its influence on mechanical and microstructure properties along with the possible defects and internal cracks of the similar and dissimilar welded joints will be reviewed and discussed

FREE VIBRATION INVESTIGATION ON RVE OF PROPOSED HONEYCOMB SANDWICH BEAM AND MATERIAL SELECTION OPTIMIZATION

In this paper, free vibration, modal and stress state analyses of honeycomb sandwich structures with different boundary conditions was investigated and major factors affecting the sandwich frequencies and stiffness due to material or parameter changes were determined. The representative volume element (RVE) method used in this work were analytically and numerically validated by comparing the obtained results to those available in literature. Firstly, unit cell method was used to capture the entire effects of different parameters on the free vibration of honeycomb sandwich structure in ANSYS. This study analyzed the natural frequencies of honeycomb sandwich structures with different core materials combination. The effects of foil thickness, boundary conditions, materials selection, density and presence of crack on sandwich structure were taken into consideration and examined. The proposed core had an inbuilt shaped reinforcement with different materials for effective resonance, fatigue and deformation resistance at much higher frequency

Effect of combined Ce and Er Addition on Solidification, Microstructure of the Al-7Si-alloy

This paper highlights the effects of the additions of two rare earth elements (REEs) (Ce and Er) on microstructure and to investigate the characteristic temperatures during solidification of the modified alloy. Five changes of Al-7Si alloys with xEr+xCe additions (x=0.15, 0.25, 0.4, 0.5 and 0.75) were produced by casting technique via the solidification parameters examined using computer-aided cooling curve thermal analysis (CA-CCTA). The thermal analysis tests were carried out for each one by using a thermal analysis system that includes (K-type Thermocouple, EPAD-TH8-K, EPAD-Baes2 and Laptop with Dewesoft-7.5-Lt). To estimate the change in microstructure and solidification as a result of adding (Ce+Er) additions, the obtained result showed that the growth TG Al-Phase and nucleation TN Al-Phase temperatures decreased to lower temperatures 614.7°C and 615.5°C respectively as the amount Ce, Er increased

Lost foam casting of LM6-Al-Si cast alloy

In the present research, experimental investigation of an investigation of lost foam casting of LM6-Al-Si cast alloy has been conducted. The investigation has as main objectives to investigate the effect of pouring temperature and melt treatment by addition of grain refiner on the microstructure and mechanical properties of lost foam castings of the LA-Si alloy. Castings in the shape of step-like with five sections were produced mainly using a foam density of 20 kg/m³ and pouring was made at five different temperatures of 700,720,740,760,780oC with and without the presence of AlTiB grain refiner in the melt. The different pouring temperatures would permit obtaining castings at different cooling rates. The results obtained showed that pouring temperature has a significant influence on the quality as well as microstructure of lost foam casting of LM6- Al-Si alloy. Lower pouring temperature provides finer microstructure and high hardness and that faster cooling rate produced either by lower pouring temperature or thinner section would results in enhanced hardness. However, the addition of AlTiB as grain refiner did not affect the castings produced significantly whether in terms casting quality or microstructure

A review on recent achievements and challenges in electrochemical machining of tungsten carbide

Electrochemical machining (ECM) is a modern, unconventional manufacturing technique that uses the electrochemical dissolution of metal to produce pieces with a predetermined shape, dimensions, and surface polish. Tungsten carbide (WC) is used in many fields and applications due to its high wear resistance and hardness. WC is used in cutting tools, mining and drilling equipment, wear parts, industrial machinery, aerospace and defence components, and medical equipment. It gives a workpiece a particular shape and number of boreholes, removes a damaged outer coat, and eliminates surface roughness. Though the ECM of WC is fraught with difficulties and obstacles, altering the electrolytes and refining the technological equipment and process of the ECM of WC can help improve machining accuracy and stability. In the current study, we examined the ECM of WC and compiled a reliable database from reliable sources using the keywords "electrochemical machining" and "tungsten carbide". Research papers constitute the majority of these publications. It was discussed how WC behaves anodically as it applies to ECM, which experiments were conducted with various electrolytes, and how they performed. Several ECM modes have been considered, and each mode has been evaluated in detail for challenges and gaps