High Speed Cutting of Carbon Fibre Reinforced Plastics

The effects of high speed cutting (HSC) on metallic workpiece materials have been widely studied and the benefits are commonly employed in the machining industry. However, in the machining of composite materials, these effects have not yet been a focus of significant research work and core questions such as what impact HSC cutting parameters have on tool wear, process forces and workpiece quality remain open. As such, the work described in this paper shall focus on the use of HSC cutting parameters with spindle speeds up to 60000 rpm for the machining of carbon fibre reinforced composites. Workpiece quality and tool wear are quantified in dependence of cutting speed and feed rate and the known phenomena of reduced cutting forces at high cutting speeds are examined in the case of CFRP machining

Artificial neural networks for controlling the temperature of internally cooled turning tools

Copyright @ 2013 Scientific Research PublishingBy eliminating the need for externally applied coolant, internally cooled turning tools offer potential health, safety and cost benefits in many types of machining operation. As coolant flow is completely controlled, tool temperature mea- surement becomes a practical proposition and can be used to find and maintain the optimum machining conditions. This also requires an intelligent control system in the sense that it must be adaptable to different tool designs, work piece materials and machining conditions. In this paper, artificial neural networks (ANN) are assessed for their suitability to perform such a control function. Experimental data for both conventional tools used for dry machining and internally cooled tools is obtained and used to optimise the design of an ANN. A key finding is that both experimental scatter characteristic of turning and the range of machining conditions for which ANN control is required have a large effect on the optimum ANN design and the amount of data needed for its training. In this investigation, predictions of tool tem- perature with an optimised ANN were found to be within 5°C of measured values for operating temperatures of up to 258°C. It is therefore concluded that ANN’s are a viable option for in-process control of turning processes using inter- nally controlled tools.This study is funded by the European Commission

Substitution of Coolant by Using a Closed Internally Cooled Milling Tool

The saving of raw materials plays a major role in industry and is becoming increasingly important. In the field of cutting technology, the aim is to maximise practices such as the substitution of coolant and the steady increase of tool life in order to make an effective contribution towards environmental protection. Concerning the saving of coolant and to enhance the performance in dry machining a milling tool with a closed internally cooled system was developed. Heatpipes are applied which ensure improved heat dissipation from the cutting edge because of their excellent thermal conductivity. The dissipated heat is subsequently delivered to the surroundings via a heat sink. This contribution describes how the performance of a standard tool can be enhanced by the integration of a closed internally cooled system. Simulations of the heat distribution in the tool have been conducted to design and optimise the prototype. Hence, milling tests on duplex steel and temperature measurements in the cutting process have been carried out to verify and further optimise these simulation results

Steigerung der Nutzungspotenziale von CVD-diamantbeschichteten Werkzeugen

Die Gasphasenabscheidung (engl. chemical vapour deposition, CVD) erlaubt es, Diamantschichten kostengünstig direkt auf Werkzeugsubstraten abzuscheiden und öffnet somit zahlreiche Anwendungsgebiete für Diamantschneidstoffe. Eine oftmals unzureichende Schichthaftung sowie fehlende Kenntnisse in Bezug auf den Einsatz dieser Werkzeuge führen jedoch dazu, dass das hohe Potenzial CVD-diamantbeschichteter Werkzeuge derzeit noch nicht ausgenutzt wird. Im Rahmen dieser Arbeit werden neue Kenntnisse erarbeitet, die zu einer Steigerung der Nutzung dieser aussichtsreichen Werkzeuggruppe führen sollen. So werden am Beispiel von Aluminium-Legierungen die Einflüsse der System- und Stellgrößen erarbeitet und industrielle Hinweis für den Einsatz gegeben. Der Einfluss der Substrat- und Schichteigenspannungen auf die Schichthaftung und das Einsatzverhalten wird umfangreich charakterisiert und die Ergebnisse in einem Eigenspannungsmodell zusammengefasst. Letztlich kommt das Strömungsschleifen als Vor- und Nachbearbeitungsmethode zum Einsatz, um eine Werkzeugoptimierung zu ermöglichen. Die Nachbehandlung der CVD-diamantbeschichteten Werkzeuge führt zu einer Erhöhung der Schichthaftung und zeigt damit aussichtsreiche Ergebnisse. Im Rahmen der Arbeit wird ein Beitrag zur Erweiterung der Einsatzmöglichkeiten von CVD-diamantbeschichteten Werkzeugen geleistet

Solutions for Sustainability-Driven Development of Manufacturing Technologies. Pt.II. Foreword

Sustainability imposes an unprecedented challenge on society and has become the driving force of an urgent search for innovative solutions in all branches of economy. Manufacturing plays a key role in many areas of human living, and it is both part of the problem and of the solution. This book offers an overview of the broad field of research on sustainability in manufacturing with a particular focus on manufacturing technology and management. It summarizes the current challenges, describes best in class methods for development of sustainable manufacturing solutions and offers implementation perspectives. This volume covers areas of research such as production processes, product development, business model and corporate development, macro economy and education. The target audience primarily comprises research experts and practitioners in the field of manufacturing, but the book may also be beneficial for graduate students

First Approach in Analysis of Tool Wear When Milling Additive Manufacturing (AM) Parts

Wire arc additive manufacturing (WAAM) and laser-based powder bed fusion (L-PBF) are additive manufacturing (AM) processes that allow the manufacturing of complex part geometries. The manufacturing of AM parts does not result in high-quality functional surfaces; therefore, postprocessing such as milling is usually required. For L-PBF parts, the support structures and, for WAAM parts, the undulating surface are usually removed after AM processes. These two application-related cases are investigated in this work, with the conclusion that support structure milling and the milling of the surface of WAAM parts lead to the dimensionally increased wear of milling tools in comparison to milling of solid material