Adaptive control optimization in micro-milling of hardened steels-evaluation of optimization approaches

Nowadays, the miniaturization of many consumer products is extending the use of micro-milling operations with high-quality requirements. However, the impacts of cutting-tool wear on part dimensions, form and surface integrity are not negligible and part quality assurance for a minimum production cost is a challenging task. In fact, industrial practices usually set conservative cutting parameters and early cutting replacement policies in order to minimize the impact of cutting-tool wear on part quality. Although these practices may ensure part integrity, the production cost is far away to be minimized, especially in highly tool-consuming operations like mold and die micro-manufacturing. In this paper, an adaptive control optimization (ACO) system is proposed to estimate cutting-tool wear in terms of part quality and adapt the cutting conditions accordingly in order to minimize the production cost, ensuring quality specifications in hardened steel micro-parts. The ACO system is based on: (1) a monitoring sensor system composed of a dynamometer, (2) an estimation module with Artificial Neural Networks models, (3) an optimization module with evolutionary optimization algorithms, and (4) a CNC interface module. In order to operate in a nearly real-time basis and facilitate the implementation of the ACO system, different evolutionary optimization algorithms are evaluated such as particle swarm optimization (PSO), genetic algorithms (GA), and simulated annealing (SA) in terms of accuracy, precision, and robustness. The results for a given micro-milling operation showed that PSO algorithm performs better than GA and SA algorithms under computing time constraints. Furthermore, the implementation of the final ACO system reported a decrease in the production cost of 12.3 and 29 % in comparison with conservative and high-production strategies, respectively

Multi-objective optimisation of product quality in the manufacture of Ti-6AI-4V prostheses

[EN] This paper presents a multi-objective optimisation procedure for optimising the quality of prostheses and manufacturing productivity. The aim of this procedure is to develop machining performance models through a minimal and progressive Design of Experiment (DoE), which models the variables of interest by linear regressions or Surface Response Models (SRMs). The multi-objective optimisation is based on desirability functions, which are defined according to the relative importance of each variable of interest. The procedure was implemented to optimise a process of manufacturing spherical turned components for Ti-6Al-4V hip prostheses with special requirements as regards surface roughness Ra, Rz and geometrical form toleranceThis work has been partially supported by Fundació Caixa-Castelló Bancaixa under the research project INV-2009-39. The authors are grateful to Miguel Angel Aymerich and Arcadi Sanz, who assisted in the experimental part. The authors extend their acknowledgements to Lafitt Company for its collaboration. Additional support was provided by Tecnológico de Monterrey through the research group in Mechatronics and Intelligent Machines.Abellán Nebot, JV.; Siller Carrillo, HR.; Vila, C.; Rodríguez González, CA. (2010). Multi-objective optimisation of product quality in the manufacture of Ti-6AI-4V prostheses. Journal of Manufacturing Technology Research. 5(3):353-369. https://doi.org/10.1504/IJMR.2010.033471S3533695

Micro-injection Moulding of Polymer Locking Ligation Systems

AbstractIn recent years, there has been an increment on micro-components for medical purposes, diseases treatment and surgical equipment, requiring biocompatible materials such as some engineering polymers. Nonetheless, the micro size of these parts impose challenges for fabrication using high production processes, like polymer injection moulding submitted to high cooling rates and variability of the process, in addition to the complex design of precise mould micro-cavities. This paper presents the development of a complete mould for a polymer locking ligation system fabrication, a medical device selected as a case study for micro-injection moulding tooling. This development includes the prediction of appropriate injection parameters and process conditions using computer simulations and a comparison with real values of pressure and temperature during the process, due to data acquisition with piezoelectric sensors. The results show a moderate error between experimental and simulated results, in terms of pressure (0.05% prediction error) and average cycle temperature at the sensor location (13% prediction error), which proves that the proposed approach can be used for precision micro-injection moulding applications

Fiber Laser Microcutting of AISI 316L Stainless Steel Tubes- influence of Pulse Energy and Spot Overlap on Back Wall Dross

AbstractThe design of coronary stents imposes high demands in terms of dimensional tolerance and surface finish. These devices are manufactured by laser microcutting of miniature tubes in materials such as stainless steel, cobalt chromium alloys and Nitinol. The work presented here is focused on fiber laser microcutting for coronary struts in AISI 316L stainless steel. This work studies the influence of gases such compressed air and argon passing through the tube in order to drag molten material while laser microcutting is performed. The experimental work studies the influence of beam spot overlap and pulse energy on back wall dross and average surface roughness, using response surface methodology. The results indicate that the introduction of compressed air or argon gas is a relevant method to reduce the amount of dross adhered in the back wall of the miniature tube

Efecto de adicionar ácido ascórbico al medio de vitrificación de folículos preantrales bovinos

The aim of this study was to evaluate the effect of adding ascorbic acid (AA) to the vitrification medium of bovine preantral follicles (PFs) subjected previously to cooling at 4 °C for 4 h or 24 h. Ovaries were collected from Nelore heifers at 14 months of age. In the laboratory, ovarian fragments were removed from the cortical region and distributed to fragments as fresh control (C0h), and fragments to cooling at 4 ºC for 4 and 24 hours in TCM-199 plus HEPES and antibiotics. Of the cooled fragments, two were fixed as controls for each cooling time (C4h, C24h), and the remaining fragments were distributed in four vitrification treatments, using the TCM-199 medium associated with ethylene glycol and dimethyl sulfoxide (V), sucrose (VSUC) or ascorbic acid (VAA), and the treatment with ethylene glycol, dimethyl sulfoxide, sucrose and AA (VSUC+AA). After 72 h, fragments were warmed and fixed for histological analysis and mechanical follicular isolation. No difference (p>0.05) between C0h and C4h for morphologically normal PFs was detected (99.3 and 96.0%, respectively). Vitrification reduced the morphological integrity and follicular viability in all treatments compared to C0h; nevertheless, VAA treatment maintained the follicular viability like C24h (p>0.05). It is concluded that bovine PFs were conserved efficiently at 4 °C during 4 h, and the addition of ascorbic acid to the vitrification medium improved survival rates and kept the morphological integrity of the follicles.El objetivo del estudio fue evaluar el efecto de la adición de ácido ascórbico (AA) al medio de vitrificación de folículos preantrales (FPs) bovinos previamente enfriados a 4 °C durante 4 o 24 h. Se recolectaron ovarios de novillas Nelore a los 14 meses de edad. En el laboratorio se extrajeron fragmentos de ovario de la región cortical y se distribuyeron a fragmentos para control fresco (C0h), y fragmentos para refrigeración a 4 ºC por 4 y 24 horas en TCM-199 más HEPES y antibióticos. De los fragmentos enfriados, dos se fijaron como controles para cada tiempo de enfriamiento (C4h, C24h), y los restantes se distribuyeron en cuatro tratamientos de vitrificación, utilizando el medio TCM-199 asociado con etilenglicol y dimetilsulfóxido (V), sacarosa (VSUC) o ácido ascórbico (VAA), y el tratamiento con etilenglicol, dimetilsulfóxido, sacarosa y AA (VSUC+AA). Después de 72 h, los fragmentos se calentaron y fijaron para el análisis histológico y el aislamiento folicular mecánico. No se detectó diferencia (p>0.05) entre C0h y C4h para FPs morfológicamente normales (99.3 y 96.0%, respectivamente). La vitrificación redujo la integridad morfológica y la viabilidad folicular en todos los tratamientos en comparación con C0h; sin embargo, el tratamiento VAA mantuvo la viabilidad folicular similar a C24h (p>0.05). Se concluye que los FAs bovinos se conservaron eficientemente a 4 °C durante 4 h, y la adición de ácido ascórbico al medio de vitrificación mejoró las tasas de supervivencia y mantuvo la integridad morfológica folicular

Design Concepts of Polycarbonate-Based Intervertebral Lumbar Cages: Finite Element Analysis and Compression Testing

This work explores the viability of 3D printed intervertebral lumbar cages based on biocompatible polycarbonate (PC-ISO® material). Several design concepts are proposed for the generation of patient-specific intervertebral lumbar cages. The 3D printed material achieved compressive yield strength of 55 MPa under a specific combination of manufacturing parameters. The literature recommends a reference load of 4,000 N for design of intervertebral lumbar cages. Under compression testing conditions, the proposed design concepts withstand between 7,500 and 10,000 N of load before showing yielding. Although some stress concentration regions were found during analysis, the overall viability of the proposed design concepts was validated

Stress-Softening and Residual Strain Effects in Suture Materials

This work focuses on the experimental characterization of suture material samples of MonoPlus, Monosyn, polyglycolic acid, polydioxanone 2–0, polydioxanone 4–0, poly(glycolide-co-epsilon-caprolactone), nylon, and polypropylene when subjected to cyclic loading and unloading conditions. It is found that all tested suture materials exhibit stress-softening and residual strain effects related to the microstructural material damage upon deformation from the natural, undistorted state of the virgin suture material. To predict experimental observations, a new constitutive material model that takes into account stress-softening and residual strain effects is developed. The basis of this model is the inclusion of a phenomenological nonmonotonous softening function that depends on the strain intensity between loading and unloading cycles. The theory is illustrated by modifying the non-Gaussian average-stretch, full-network model to capture stress-softening and residual strains by using pseudoelasticity concepts. It is shown that results obtained from theoretical simulations compare well with suture material experimental data

TNFA-863 polymorphism is associated with a reduced risk of chronic obstructive pulmonary disease: a replication study

We replicated the previously reported association between the TNFA -863 SNP and COPD. TNFA -863A allele may confer a protective effect to the susceptibility to the disease in the Spanish populatio

TNFA-863 polymorphism is associated with a reduced risk of Chronic Obstructive Pulmonary Disease: A replication study

<p/> <p>Background</p> <p>TNF-α mediated inflammation is thought to play a key role in the respiratory and systemic features of Chronic Obstructive Pulmonary Disease. The aim of the present study was to replicate and extend recent findings in Taiwanese and Caucasian populations of associations between COPD susceptibility and variants of the <it>TNFA </it>gene in a Spanish cohort.</p> <p>Methods</p> <p>The 3 reported SNPs were complemented with nine tag single nucleotide polymorphisms (SNP) of the <it>TNFA </it>and <it>LTA </it>genes and genotyped in 724 individuals (202 COPD patients, 90 smokers without COPD and 432 healthy controls). Pulmonary function parameters and serum inflammatory markers were also measured in COPD patients.</p> <p>Results</p> <p>The <it>TNFA </it>rs1800630 (-863C/A) SNP was associated with a lower COPD susceptibility (ORadj = 0.50, 95% CI = 0.33-0.77, p = 0.001). The -863A allele was also associated with less severe forms of the disease (GOLD stages I and II) (ORadj = 0.303, 95%CI = 0.14-0.65, p = 0.014) and with lower scores of the BODE index (< 2) (ORadj = 0.40, 95%CI = 0.17-0.94, p = 0.037). Moreover, the -863A carrier genotype was associated with a better FEV₁percent predicted (p = 0.004) and a lower BODE index (p = 0.003) over a 2 yrs follow-up period. None of the <it>TNFA </it>or <it>LTA </it>gene variants correlated with the serum inflammatory markers in COPD patients (p > 0.05).</p> <p>Conclusions</p> <p>We replicated the previously reported association between the <it>TNFA </it>-863 SNP and COPD. <it>TNFA </it>-863A allele may confer a protective effect to the susceptibility to the disease in the Spanish population.</p