Tool life of TiAlN PVD coated carbide tool in high-speed end milling of untreated inconel 718 under minimum quantity lubrication condition

This paper presents the tool life of the end milled Inconel 718, which is part of a material that is difficult to be machined. Previous researchers found that tool life in machining aged Inconel 718 is shorter compared with other materials. However, this observation required further investigation. Thus, a raw grade Inconel was proposed in this experiment. The experiments were performed using TiAlN-coated carbide. The studied milling parameters were the cutting speed, Vc, from 90 to 150 m/min; feed rate, fz, from 0.15 to 0.25 mm/rev; depth of cut, ap, from 0.3 to 0.5 mm; and radial depth of cut, ae=1 mm. The application of the cutting fluid used in this experiment was a minimum quantity lubricant, which had the advantage of cooling effectiveness and low consumption of cutting fluid. The results showed that the feed rate, fz, was the primary factor controlling the tool life. The combination of Vc=115 m/min, fz=0.15 mm/tooth, as well as ap=0.5 mm and ae=0.15 mm gave the longest tool life that served 95.38 min in operation

Radiation beam scanning for leaky wave antenna by using slots

This paper provides an insight of a new, microstrip leaky wave antenna. It holds the ability to continue steer its beam at a swapping frequency. This is done with acceptable impedance matching while scanning and very little gain variation. Investigation is carried out on LWAs’ control radiation pattern in steps at a band frequency via vertical and horizontal slots. The enhancement is realized by etching horizontal and vertical slots on the radiation element. This study also presents a novel half-width microstrip leaky wave antenna (LWA). The antenna is made up of the following basic structures group’s vertical and horizontal slots. The reactance profile at the microstrip’s free edge and thus the main beam direction is changed once the control-cell states are changed. The radiation pattern direction changes by sweeping the operating frequency between 4 GHz to 6 GHz.The main beam may be directed by the antenna between 15o and 55o. C band achieved the measured peak gain of the antenna of 10 dBi at 4.3 GHz beam scanning range

Optimization of Drill Geometry Design to Minimize Thermal Necrosis in Surgical Bone Drilling

During the orthopedic bone drilling surgery procedures, the friction between the drill and bones surface leads to a localized temperature increase results in thermal necrosis on the soft tissue surrounding the hole. The magnitudes of the friction energy are greatly dependent with the drill geometry design. Recognizing the importance on studying this phenomenon, this paper aim to investigate the effects of drill geometry on temperatures during the bone drilling procedure. Totals of 17 drills were design and tested with different geometry namely point angle, helix angle and web thickness on different penetration angle (0⁰, 15⁰, and 30⁰) to mimic the manually control penetration by the surgeon. From the conducted investigation, the most significant parameter that affects the temperature rise was the penetration angle followed by the point angle. In addition, the interaction between helix angle and web thickness also controlled the drilling temperature. From the result, the optimum drill-bit design geometry was 21.8% web thickness, 126.92° point angle and 36.53° helix angle which produces the minimum drilling temperature

The Effect of Surface Finish by Varying Machining Strategies of Five-Axis Flank Milling for Curvy Angled Convex Profile

The main aim of this research is to identify the best machining strategy on the five-axis flank machining curvy angled shapes using various machining approaches or strategies offered by CATIA V5 software. In machining of curvy angled shapes, the most important factor is to obtain the exact shape or machined part in certain acceptable tolerance with good surface finish. Hence, applying the right and the best machining strategy in Computer Aided Manufacturing (CAM) process is the most vital phase. The machining strategies that have been applied were Tanto Fan, Combin Tanto and Combin Parelm. In this study, only convex shape is analyzed throughout the study. Each of every machining part has been gone through a thorough analysis of surface finish by using Mitotuyo Surf-tester to determine the effect of the surface finish. Meanwhile, the parts chosen to be machined was modified aero-structural component part using the same aerospace standard material, Aluminum A6063. Based on the analysis carried out, the best machining strategy for the sample chosen part was Combin Parelm according to the mean Ra values. Factors contributed to the results obtained are further discussed in this paper

Parametric Study on Parameter Effects in Hybrid Micro Wire Electrical Discharge Turning

In this paper, a comprehensive parametric study on the effects of operating parameters in wire electrical discharge turning (WEDT) process was conducted. Total of eleven operating parameters were considered against the machined surface quality. The research focuses on the micro-turning of Ti6Al4V materials using Taguchi’s L12 orthogonal array at two level experimental designs. Analysis of variance (ANOVA) and signal-to-noise (S/N) ratio were used as statistical tools to evaluate the significances of the parameters. It was found that among the eleven operating parameters, only four parameters dominated and have statistical significant effects on the surface roughness values as discovered by ANOVA. The operating parameters were the rotational spindle speed (28.34%) as the most dominating factor, followed by intensity of pulse (24.18%), wire tension (20.57%) and stabilizer E (11.97%)

EFFECT OF PARAMETER CONDITION ON SURFACE ROUGHNESS FOR MACHINING AISI D2 HARDENED TOOL STEEL

Hardened steel such as AISI D2 is often used in mould and die industry. Some of the application required to have good surface quality profile and sophisticated free-form shape simultaneously. In current industry practice, manual polishing and grinding is often performed to achieve the required machining tolerance which tends to lower the productivity and difficulty in ensuring the component accuracy. Machining surface roughness is directly affected by the milling parameter and should be methodically analyzed. Thus, this paper aims to study the effect of milling parameter on surface roughness of AISI D2 tool steel. Response Surface Methodology (RSM) technique was used to evaluate the influence of milling parameter namely cutting speed, feed rate and depth of cut on machined surface. From the conducted study, based on the statistical analysis result it is found that feed rate is the main factor that influence the surface roughness followed by milling speed and depth of cut. In addition, the machined surface roughness observed was between 1.5 to 4.5 μm Ra

A Study on Surface Roughness During Fused Deposition Modelling: A Review

Rapid Prototyping (RP) is technology used to produce a physical model or prototype directly from three-dimensional Computer-Aided-Design (3D CAD) data in a very short time. Fused Deposition Modelling (FDM) is a process for developing RP objects from plastic material by laying tracks of semi molten plastic filament on to a platform in precise layers from bottom to top. RP has been extensively used by manufacturers from different backgrounds to accelerate their product development and cycle time without neglecting product quality. In the RP process, surface finish is an important criterion as it can influence the part precision, post-handling expenses and functionality of the part. This paper presents a review of current studies on surface roughness using FDM. This paper also highlights design of experiments (DOE) and its association with surface finish

MULTI-RESPONSE OPTIMIZATION OF PLASTIC INJECTION MOULDING PROCESS USING GREY RELATIONAL ANALYSIS BASED IN TAGUCHI METHOD

This project investigates the multi-response optimization using grey relational analysis based in Taguchi method of plastic injection mould. Four input process parameters selected are mould temperature, melting temperature, injection time and cooling time. The responses investigated were part weight, shrinkage, warpage, ultimate tensile strength, tensile modulus and percentage of elongation. It is found that the optimum setting parameter generated from multi-response optimization is at run number 4 that are mould temperature at 56oC, melting temperature at 250oC, injection time at 0.7s and cooling time at 15.4s. Result of run number 4 for multi-response optimization for part weight, warpage, shrinkage, tensile ultimate strength, tensile modulus and percentage of elongation are 6.9807g, 0.087mm, 1.73%, 24.732MPa, 981.76MPa and 31.37%, respectively. Multi-response optimization results show that all response results are not higher or lower than experimental results. This is because multi-response optimization normalized all response value. Thus, by implemented multi-response optimization process, the materials characteristics value of plastic part can be predicted

HELICAL MICRO-HOLE DRILLING OF CHEMICALLY STRENGTHENED GLASS USING CAPSULE-SHAPED ELECTROPLATED DIAMOND TOOL

This study investigates the micro-hole drilling performance of chemically strengthened glass plate by using a capsule-shaped electroplated diamond tool and the helical drilling method. Three different helical pitch conditions were tested to drill holes with a diameter of 1 mm. The number of drilled holes, grinding force, and maximum crack size were measured along with the observation of the drilled holes to evaluate the performance of the micro-hole drilling. From the experimental results, it was found that as the size of helical pitch decreased, the number of drilled holes increases where the average grinding force generated becomes smaller. By using small helical pitch condition, 43 holes could be drilled but the maximum crack size generated at the outlet side of the drilled hole is not able to achieve the high-grade quality compared to the inlet side. The resultant grinding force generated when the tool tip nearing the outlet side of the glass plate has caused the large crack at a certain position on the outlet side

A PROPOSAL OF MUDA INDICATOR AGENT TO ESTIMATE LEAN MANUFACTURING VERIFICATION

Lean Manufacturing (LM) is the philosophy to improve productivity of manufacturing system by eliminating wastes. LM tools have been implemented as software tools in order to implement this philosophy. However, implementing LM in factories does not always succeed because of several reasons; insufficient expertise and knowledge on LM practitioners, dynamic feature of complicated manufacturing processes, difficulty in quantifying the benefits of LM implementation, and etc. Simulation-based approaches have been proposed to support LM implementation, and their effectiveness has been reported in several papers. However, they are not suitable for LM practitioners who are not familiar with simulation software. Therefore, some appropriate niche techniques to bridge the gap between LM practitioners and simulation-based approaches are expected to achieve successful LM implementation. This research proposes an agent-based approach to LM implementation using Muda Indicator (MI) agent to narrow the gap. This paper presents the overview of MI agent, defines quartile calculation to determine Muda level, explains MI indication by MI agent, and shows the feasibility of MI agent using a manufacturing process model. The feasibility study showed how MI agent presents transition of quantifying wastes during simulation in a dynamic manner