Advanced Composite Materials and Structures

Composite materials are used to produce multi-objective structures such as fluid reservoirs, transmission pipes, heat exchangers, pressure vessels due to high strength and stiffness to density ratios and improved corrosion resistance. The mathematical concepts can be used to simulate and analyze the generated mechanical and thermal properties of composite materials regarding to the desired performances in actual working conditions.  To solve and obtain the exact solution of the developed nonlinear differential equations in the composite materials, analytical methods can be applied. Mechanical and thermal analysis of complex composite structures can be numerically analyzed using the Finite Element Method (FEM) to increase performances of composite structures in different working conditions. To decrease failure rate and increase performances of composite structures under complex loading system, thermal stress and effects of static and dynamic loads on the designed shapes of composite structures can be analytically investigated. The stresses and deformation of the composite materials under the complex applied loads can be calculated by using the FEM method in order to be used in terms of safety enhancement of composite structures. To increase the safety level as well as performances of the composite structures in different working conditions, crack development in elastic composites can be simulated and analyzed. To develop and optimize the process of composite deigning in terms of mechanical as well as thermal properties under different mechanical and thermal loading conditions, the advanced machine learning systems can be applied. A review in recent development of composite materials and structures is presented in the study and future research works are also suggested. Thus, to increase performances of composite materials and structures under complex loading systems, advanced methodology of composite designing and modification procedures can be provided by reviewing and assessing recent achievements in the published papers

Advanced Composite Materials and Structures

Composite materials are used to produce multi-objective structures such as fluid reservoirs, transmission pipes, heat exchangers, pressure vessels due to high strength and stiffness to density ratios and improved corrosion resistance. The mathematical concepts can be used to simulate and analyze the generated mechanical and thermal properties of composite materials regarding to the desired performances in actual working conditions.  To solve and obtain the exact solution of the developed nonlinear differential equations in the composite materials, analytical methods can be applied. Mechanical and thermal analysis of complex composite structures can be numerically analyzed using the Finite Element Method (FEM) to increase performances of composite structures in different working conditions. To decrease failure rate and increase performances of composite structures under complex loading system, thermal stress and effects of static and dynamic loads on the designed shapes of composite structures can be analytically investigated. The stresses and deformation of the composite materials under the complex applied loads can be calculated by using the FEM method in order to be used in terms of safety enhancement of composite structures. To increase the safety level as well as performances of the composite structures in different working conditions, crack development in elastic composites can be simulated and analyzed. To develop and optimize the process of composite deigning in terms of mechanical as well as thermal properties under different mechanical and thermal loading conditions, the advanced machine learning systems can be applied. A review in recent development of composite materials and structures is presented in the study and future research works are also suggested. Thus, to increase performances of composite materials and structures under complex loading systems, advanced methodology of composite designing and modification procedures can be provided by reviewing and assessing recent achievements in the published papers

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

Virtual Machining

Virtual machining systems apply computers and different types of software in manufacturing and production in order to simulate and model the behavior and errors of a real environment in virtual reality systems. This can provide useful means for products to be manufactured without the need of physical testing on the shop floor. As a result, the time and cost of part production can be decreased

Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines

Virtual manufacturing systems can provide useful means for products to be manufactured without the need of physical testing on the shop floor. As a result, the time and cost of part production can be decreased. There are different error sources in machine tools such as tool deflection, geometrical deviations of moving axis and thermal distortions of machine tool structures. Some of these errors can be decreased by controlling the machining process and environmental parameters. However other errors like tool deflection and geometrical errors which have a big portion of the total error, need more attention. This paper presents a virtual machining system in order to enforce dimensional, geometrical and tool deflection errors in three-axis milling operations. The system receives 21 dimensional and geometrical errors of a machine tool and machining codes of a specific part as input. The output of the system is the modified codes which will produce actual machined part in the virtual environment

Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines

Virtual manufacturing systems can provide useful means for products to be manufactured without the need of physical testing on the shop floor. As a result, the time and cost of part production can be decreased. There are different error sources in machine tools such as tool deflection, geometrical deviations of moving axis and thermal distortions of machine tool structures. Some of these errors can be decreased by controlling the machining process and environmental parameters. However other errors like tool deflection and geometrical errors which have a big portion of the total error, need more attention. This paper presents a virtual machining system in order to enforce dimensional, geometrical and tool deflection errors in three-axis milling operations. The system receives 21 dimensional and geometrical errors of a machine tool and machining codes of a specific part as input. The output of the system is the modified codes which will produce actual machined part in the virtual environment

Residual Stress Prediction in Turbine Blade Machining Operations Using a Virtual Machining System

Part manufacturing process using machining operations is along with residual stress due to friction, chip formation and generated heat in cutting zone. The performance of produced parts in working conditions such as fatigue life, corrosion resistance and part distortion is under the influence of residual stress which should be analyzed and minimized. To produce compressor section blades of gas turbines, machining operations can be used. The process is always with complexities and challenges. However it can be analyzed and modified in virtual environments. Residual stress due to machining operations of gas turbine blades can also be analyzed in virtual environments in order to be minimized. In the present research work, application of a virtual machining system to predict residual stress in milling operations of turbine blades is presented. Finite element analysis is implemented in order to calculate residual stress as well as strain of blades in machining operations. In order to validate the research work, experimental results are compared with the finite element results obtained from the virtual machining system. The present research work can replace the costly experimental tests by predicting the residual stress in a virtual machining environment

Advanced Composite Materials and Structures

Composite materials are used to produce multi-objective structures such as fluid reservoirs, transmission pipes, heat exchangers, pressure vessels due to high strength and stiffness to density ratios and improved corrosion resistance. The mathematical concepts can be used to simulate and analyze the generated mechanical and thermal properties of composite materials regarding to the desired performances in actual working conditions.  To solve and obtain the exact solution of the developed nonlinear differential equations in the composite materials, analytical methods can be applied. Mechanical and thermal analysis of complex composite structures can be numerically analyzed using the Finite Element Method (FEM) to increase performances of composite structures in different working conditions. To decrease failure rate and increase performances of composite structures under complex loading system, thermal stress and effects of static and dynamic loads on the designed shapes of composite structures can be analytically investigated. The stresses and deformation of the composite materials under the complex applied loads can be calculated by using the FEM method in order to be used in terms of safety enhancement of composite structures. To increase the safety level as well as performances of the composite structures in different working conditions, crack development in elastic composites can be simulated and analyzed. To develop and optimize the process of composite deigning in terms of mechanical as well as thermal properties under different mechanical and thermal loading conditions, the advanced machine learning systems can be applied. A review in recent development of composite materials and structures is presented in the study and future research works are also suggested. Thus, to increase performances of composite materials and structures under complex loading systems, advanced methodology of composite designing and modification procedures can be provided by reviewing and assessing recent achievements in the published papers

Radio Frequency Identification (RFID) based wireless manufacturing systems, a review

Radio frequency identification (RFID) is one of the most promising technological innovations in order to track and trace products as well as material flow in manufacturing systems. High Frequency (HF) and Ultra High Frequency (UHF) RFID systems can track a wide range of products in the part production process via radio waves with level of accuracy and reliability.   As a result, quality and transparency of data across the supply chain can be accurately obtained in order to decrease time and cost of part production. Also, process planning and part production scheduling can be modified using the advanced RFID systems in part manufacturing process. Moreover, to decrease the cost of produced parts, material handling systems in the advanced assembly lines can be analyzed and developed by using the RFID. Smart storage systems can increase efficiency in part production systems by providing accurate information from the stored raw materials and products for the production planning systems. To increase efficiency of energy consumption in production processes, energy management systems can be developed by using the RFID-sensor networks. Therefore, smart factories and intelligent manufacturing systems as industry 4.0 can be introduced by using the developed RFID systems in order to provide new generation of part production systems. In this paper, a review of RFID based wireless manufacturing systems is presented and future research works are also suggested. It has been observed that the research filed can be moved forward by reviewing and analyzing recent achievements in the published papers