Mechanical Machining Research Articles

Modify the Injection Machine Mechanism to Enhance the Recycling of Plastic Waste Mixed with MHD Nanoparticles

Recycling plastic waste (RPW) benefits the ecological footprint. Therefore, the authors test its mixing by magnetic hydrodynamic MHD nanofluid materials such as alumina in two sizes (βcore, βskin) prepared into a new device called the incubator installed in the desktop injection machine to enhance its solubility by taking advantage of the mixture’s heat via defining the oblique stagnation-point slip flow (OSPSF) of a nanofluid in two dimensions. The paper has been innovative in mathematically identifying the operating parameters’ values for the injection flow mechanism (IFM) via controlling in Riga magnetic field and piston orifice pressure using a meta-heuristic algorithm called WSA. The proposed (IFM) is used to experimentally enhance the mixture properties via parameters’ control to meet the output quality and predict the control equation for the Riga plate. IFM controls the amount of pushed nanoparticles in the mixture with a ratio of plastic to aluminum approximate by 96.1%: 3.9%. The defects were reduced by approximately 23.21%, with an increasing system performance of 70.98%.

Experiments and Evaluation of a Container Migration Data-Auditing System on Edge Computing Environment

With the proliferation of IoT sensors and devices, storing collected data in the cloud has become common. A wide variety of data with different purposes and forms are not directly stored in the cloud but are sent to the cloud via edge servers. At the edge server, applications are running in containers and virtual machines to collect data. However, the current deployment and movement mechanisms for containers and virtual machines do not consider any conventions or regulations for the applications and the data it contains. Therefore, it is easy to deploy and migrate containers and virtual machines. However, the problem arises when it is deployed or migrated, which may violate the licensing terms of the contained applications, the rules of the organization, or the laws and regulations of the concerned country. We have already proposed a data-audit control mechanism for the migration of virtual machines. The proposed mechanism successfully controls the unintentional and malicious migration of virtual machines. We expect similar problems with containers to occur as the number of edge servers increases. Therefore, we propose a policy-based data-audit control system for container migration. The proposed system was verified in the implemented edge computing environment and the results showed that adding the proposed data-audit control mechanism had a minimal impact on migration time and that the system was practical enough. In the future, we intend to conduct verification not in a very compact and short-range environment such as this one but on an existing wide-area network.

Single well virtual metering research and application based on hybrid modeling of machine learning and mechanism model

As a supplement or alternative metering method for physical metering devices, Virtual Flow Metering (VFM) is more and more widely used in the upstream metering scenario of oil and gas fields. To enhance the accuracy of single well VFM system and improve the system maintenance convenience, a new VFM method based on “hybrid model” which combines mechanism model and data model is proposed on the basis of the traditional mechanism model of dynamic multi-phase flow, the interactive logic between machine learning model of big data on single well production condition and mechanism model is established. The new VFM system architecture can realize the stable and accurate operation of the new “hybrid model” VFM system driven by real-time measurement data. The research show that: (1) machine learning model of big data on single well production condition can realize the second index output of three-phase flow under real-time measurement data input; (2) The field data are used to evaluate the accuracy of new VFM results, shows the average errors of liquid flow and gas flow are less than 5% and 3% respectively, and the metering accuracy is improved to a certain extent compared with traditional VFM method; (3) Compared with virtual metering based on the traditional mechanism model, the new VFM system is more convenient in later model maintenance and only adjust few model setting according WC and GOR changing in field data.

Meso-scale cracks initiation of Nomex honeycomb composites in orthogonal cutting with a straight blade cutter

Cracks generated in micro and meso-scales pose a potential threat to the full product. Numerous reports on microscale voids and cracks in Nomex honeycomb composites (NHCs) have focused on the process of co-curing and co-bond. Practically, substantial meso-scale cracks were introduced in the machining without sufficient attention. To fill this gap, the study explored a new phenomenon (i.e., transverse and longitudinal cracks) in meso-scales, with a special focus on formation mechanism and evolution. A meso-scale numerical model of NHCs was developed for the analysis of fracture inducing mechanisms in ultrasonic vibration machining (i.e., multi-source loading conditions). During model establishment and validation, not only the friction model of the cutter and NHCs was amended, but also the cutting force system was evaluated and compensated. Analytical and experimental validation indicated that the cell deformation and the peak value of the cutting force showed a reasonable agreement with the numerical results. Further understanding based on the numerical model can obtain the cracks initiation mechanisms that: (i) Transverse cracks are induced by longitudinal tensile stress, which is generated by tool vibration, while (ii) longitudinal cracks are induced by transverse tensile stress, which is caused by tool feed. The findings of meso-scale cracks not only enhance the significance of curing-induced microcracks and voids, but also provide theoretical guidance for the evolution of macroscopic defects after machining.

Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper.

In this paper, the responses of machined surface roughness and milling tool cutting forces under the different milling processing parameters (cutting speed v, feed rate f, and axial cutting depth ap) are experimentally investigated to meet the increasing requirements for the mechanical machining of T2 pure copper. The effects of different milling processing parameters on cutting force and tool displacement acceleration are studied based on orthogonal and single-factor milling experiments. The three-dimensional morphologies of the workpieces are observed, and a white-light topography instrument measures the surface roughness. The results show that the degree of influence on Sa (surface arithmetic mean deviation) and Sq (surface root mean square deviation) from high to low level is the v, the f, and the ap. When v = 600 m/min, ap = 0.5 mm, f = 0.1 mm/r, Sa and Sq are 1.80 μm and 2.25 μm, respectively. The cutting forces in the three directions negatively correlate with increased cutting speed; when v = 600 m/min, Fx reaches its lowest value. In contrast, an increase in the feed rate and the axial cutting depth significantly increases Fx. The tool displacement acceleration amplitudes demonstrate a positive relationship. Variation of the tool displacement acceleration states leads to the different microstructure of the machined surfaces. Therefore, selecting the appropriate milling processing parameters has a positive effect on reducing the tool displacement acceleration, improving the machined surface quality of T2 pure copper, and extending the tool's life. The optimal milling processing parameters in this paper are the v = 600 m/min, ap = 0.5 mm, and f = 0.1 mm/r.

Nomograms in the History and Education of Machine Mechanics

Computing formulae and solving equations are essential elements of scientific analysis. While today digital tools are almost always applied, analog computing is a rich part of the larger history of science and technology. Graphical methods are an integral element of computing history and still find some use today. This paper presents the history of nomograms, a historically-relevant tool for solving mathematical problems in various branches of science and engineering; in particular, we consider their role in mechanical engineering, especially for education, and discuss their mathematical properties. Each nomogram is a graphical description of a specific mathematical equation, designed such that the solution can be found through a simple geometric construction that can be performed with a straightedge. By design, using nomograms requires little skills and can be done even in adverse environments; a solution of sufficient accuracy for most purposes can then be found in a very short time. Another important advantage of nomograms is that they offer clear insight on the relationships between the variables, an insight which can be lost by looking at a complex equation. First introduced in the late $$19^{\textrm{th}}$$ century, nomograms were used by engineers and scientists due to their speed with respect to manual calculations, before being superseded by computers. While now mostly obsolete in practice, nomograms can still prove useful in workshops and teaching classes: we thus also discuss their educational applications and present a few original examples.

Topology Optimization of Package Sealer Jaw Chassis of Automatic Packaging Machine

After the Covid-19 epidemic, the need to reach hygienic and sealed packaged food products has gained importance and the packaging machinery sector has become an important sector. In this context, the need for special packaging machines has increased. The jaw mechanism of the packaging machine developed within the scope of the study performs the package closing function by opening and closing 200 times per minute, and the jaw chassis carrying the jaw mechanism is exposed to the same series of movements. The design of the jaw chassis should be as light as possible so that no additional load is placed on the motors that provide the movement, while its strength should be high since it carries the entire load from the jaw plates to the motors. To solve this problem, a structural optimization solution called topology optimization, which regulates the distribution of the elements in the design volume within the framework of the determined constraints, is used. With the performed topology optimization study, it has been determined that the new solid model, which continues to provide sufficient strength when exposed to 5000 N force, provides 11% weight gain. This work has been a pioneer for new research to obtain lightweight designs.

TOPOLOGY OPTIMIZATION OF PACKAGE SEALER JAW CHASSIS OF AUTOMATIC PACKAGING MACHINE

After the Covid-19 epidemic, the need to reach hygienic and sealed packaged food products has gained importance and the packaging machinery sector has become an important sector. In this context, the need for special packaging machines has increased. The jaw mechanism of the packaging machine developed within the scope of the study performs the package closing function by opening and closing 200 times per minute, and the jaw chassis carrying the jaw mechanism is exposed to the same series of movements. The design of the jaw chassis should be as light as possible so that no additional load is placed on the motors that provide the movement, while its strength should be high since it carries the entire load from the jaw plates to the motors. To solve this problem, a structural optimization solution called topology optimization, which regulates the distribution of the elements in the design volume within the framework of the determined constraints, is used. With the performed topology optimization study, it has been determined that the new solid model, which continues to provide sufficient strength when exposed to 5000 N force, provides 11% weight gain. This work has been a pioneer for new research to obtain lightweight designs.

The relevance of the use of an intelligent mechanism in the drive of modern agricultural machines

The article analyzes theoretical and experimental studies of intelligent mechanism designs, considers the advantages of using intelligent mechanisms for agricultural machines in comparison with traditional structural schemes. The principle of operation of an intelligent mechanism presented in the form of two differential drives for agricultural machines is considered. Planetary mechanisms of this type are systems with two or more degrees of freedom in terms of the number of structural connections, therefore, with one leading link, the movement of their driven links is determined by additional external links that may have different physical origins. The paper presents a description and also considers the main advantages of using the developed kinematic scheme of an intelligent mechanism for agricultural machines, which allows for automatic regulation in a wide range of movement speed depending on the load on the working body, the weight of grain on the conveyor belt, the type of soil on which the agricultural machine moves, etc., overload protection, increased productivity due to full engine load. The proposed intelligent mechanism for agricultural machines allows the distribution of torque from a single engine, and there is also no need to install a set of sensors and a control unit.

RESEARCH OF VARIABLE PARAMETERS OF NEEDLE THREAD TAKE-UP MECHANISMS AND DEVELOPMENT OF RECOMMENDATIONS FOR ADJUSTING MULTI-THREAD CHAIN STITCH SEWING MACHINES

The purpose of this research is to develop specific recommendations for optimizing the adjustment of the thread take-up mechanisms of typical chain stitch sewing machines based on the analysis of the thread take-up process. These recommendations are intended to help manufacturers and machine operators achieve maximum productivity and increased product quality, while taking into account the specific technological parameters of the operations performed on these machines. The research is aimed at increasing the efficiency of the sewing process, reducing machine setup time, and improving the overall result of the technological process in the sewing industry. The research uses an analytical method of determining and investigating functions of the actual thread take-up as the instantaneous sum of sections of the take-up contour when adjustable parameters of the mechanisms are changed, taking into account accepted assumptions. In the research, an analytical method was used to determine functions of the actual thread take-up as the instantaneous sum of sections of the take-up contour, taking into account the change in regulated parameters of the mechanisms. At the same time, assumptions were made that has simplified analysis and modelling of this process with sufficient accuracy of calculation results. The scientific novelty of this research lies in discovery of new relationships and establishment of regularities that determine influence of adjustable parameters on the nature and scope of the thread take-up function in chain stitch machines. Further re-search in this area can be aimed to the development of more efficient methods of adjustment and optimization of needle thread take-up mechanisms, as well as to the implementation of new technologies in pro-duction to improve productivity and quality of sewing operations. The obtained results became basis for the development of nomograms for determining the optimal values of adjustable parameters for needle thread take-up mechanisms of typical flat chain stitch machines, taking into account technological parameters of specific operations. These nomograms allow operators and manufacturers of sewing machines significantly simplify adjustment of these mechanisms when using operational equipment or when switching to other technological operations. The obtained results can be applied directly in production during adjustment or repairing of specified ma-chines to increase their productivity by reducing adjustment time and for improving the quality of the technological process.

Surface and subsurface formation mechanism of SiCp/Al composites under ultrasonic scratching

Rotary ultrasonic machining (RUM) is an effective method of high-quality and high-efficiency machining for advanced composites. However, the machining mechanism and kinematic characteristics of ultrasonic machining of SiC particles-reinforced aluminum matrix (SiC p /Al) composites are yet unclear, limiting the applications of RUM in composites machining. In this study, a rotary ultrasonic vibration-assisted scratch (RUVAS) test was designed for the high-volume fraction of SiC p /Al composites. The kinematic and scratch force model of RUVAS was developed to describe the scratch process of SiC p /Al. Both RUVAS and conventional scratch (CS) tests were performed under various scratch speeds on SiC p /Al. The scratch trajectory was divided into three modes: continuous, semi-continuous, and intermittent. We observed the formation of different surface morphology under different modes. The scratch force difference between RUVAS and CS was insignificant when the scratch speed is high, which indicated that the effect of ultrasonic vibration diminished at a high speed when the ultrasonic frequency was fixed. When assisted by ultrasonic vibration, the scratch morphology of SiC p /Al indicated that the matrix has undergone significant plastic deformation. While the hard SiC particles tended to be ruptured and pressed into the plastic matrix, this mechanism can effectively suppress the initiation and propagation of cracks, which is beneficial to reducing the stress influence zone, healing the surface defects, and improving the surface integrity. The subsurface morphology indicates that the subsurface damage under CS and RUVAS mainly includes particle cracking, matrix tearing, and interface failure. Our experimental result shows that ultrasonic vibration can effectively reduce the subsurface damage of SiC p /Al composites, bringing insight into fundamental mechanisms of ultrasonic machining and providing guidance for the vibration-assisted processing of SiC p /Al composites.

The effect of roller pressure and feed rate on hides squeezing

The article presents the results of experimental studies of the process of extracting excess liquid from a water-saturated hide. The experiments were conducted in two options: using a rigid base plate and a cermet base plate for the feed mechanism of the roller machine. In the study, samples of a wet hide on rigid and cermet base plates were pulled between rotating squeezing rollers using conveyor chains. Mathematical dependences of the amount of liquid removed from a wet hide on its feed rate and the pressure of the squeezing rollers were obtained for two special options. The experimental results showed a significant increase in the efficiency of the squeezing process of a wet hide due to the use of a cermet base plate in comparison with a rigid base plate.

Optimization of the operation of the mechanism of the cross planer

The subject of the research is the optimization of the mechanism of the cross planer. In the article, on the basis of the condition of closed contours, the equations of the projection of the links on the corresponding coordinate axes are compiled. A functional relationship has been established between the kinematic parameters characterizing the movement of the input and output links of the mechanism. The obtained numerical calculations are presented in the form of graphic dependences. The aim of the work is the optimal metric synthesis of the mechanism of a cross-planer, with parametric restrictions. The conclusions obtained in the article can be used to improve and design modern technological equipment with mechanisms similar to the mechanism of a cross-cutting machine.

Review on Removal Mechanism and Process Modeling in Machining of Metal Matrix Composites

Review on Removal Mechanism and Process Modeling in Machining of Metal Matrix Composites

Non-Traditional Machining Techniques in Manufacturing Industries – An Overview

This comprehensive study provides an in-depth analysis of non-traditional machining techniques in the manufacturing industry. Focusing on mechanical, electrochemical, chemical, and thermal machining processes, the research explores recent advancements and their implications. The study adopts the action research method to gain a deeper understanding of the challenges associated with these techniques. Through a thorough examination of the machining processes, this work delves into various concepts, including the operations involved in each process and their corresponding outcomes. The analysis sheds light on the significance of non-traditional machining in the manufacturing industry, highlighting its potential for producing complex components and meeting design requirements that traditional machining methods may struggle to achieve. By exploring recent developments in non-traditional machining, this study aims to provide an overview of the advancements made in this field. It emphasizes the importance of understanding these techniques to unlock their full potential and enhance manufacturing capabilities. The findings of this research contribute to the existing knowledge base and serve as a valuable resource for professionals and researchers in the field of non-traditional machining.

Plasma Coatings for Protection Against Hydroabrasive and Cavitation Wear

The results of research work on the application of coatings designed to protect the working surfaces of machine parts and mechanisms operating under conditions of hydroabrasive and cavitation wear are presented. Coatings were produced by supersonic atmospheric plasma spraying of powder materials using air as a plasma gas. The experimental list of materials was chosen taking into account the experience of the authors in protecting the details of the propulsion and steering complex of river vessels using coatings applied by subsonic thermal plasma flows.

Design and methods for calculating the parameters of a machine for cleaning wool from vegetable impurities

The article presents an effective scheme and principle of operation of the device, working bodies, drive mechanisms of machines for cleaning wool from vegetable impurities. Theory - experimental studies have obtained the laws of motion of the peg feeder, saw cylinder, impact roller, take-off drum, motor shaft, the main parameters of the device for cleaning wool from plant impurities are substantiated. Based on the results of comparative production tests, recommendations were developed for introducing the developed machine into production.

Influence of the process of reserving filled containers of the cotton picker on the completeness of the cotton harvest

The technology and technical means for collecting cotton in elastic cylindrical containers, loading them and transporting them to cotton processing enterprises have been developed, allowing to increase the productivity of the complex of machines and preserve the quality of the grown crop. The design of a cotton harvesting machine is proposed, analytical studies are carried out to ensure the stable operation of the machine mechanisms in accordance with agrotechnical requirements. It is assumed that the reserve device with the support wheel will have a damping effect on the harvesters not only in the process of reservation, but also in the process of picking cotton with a reserved container. To do this, it is necessary to conduct comparative experimental studies to determine the effect of the reserve device on the course stability and agro technical indicators of the cotton picker for wheeled and wheel less schemes of reserve devices.

Dynamic model and machining mechanism of wire sawing

During the wire sawing process, the wire usually undergoes large deformation, which leads to changes in the sawing force and the contact state between wire and workpiece, and in turn affects the material removal rate (MRR) and the workpiece quality. This paper presents a general dynamic model for the wire sawing. The model aims to describe the coupling relations among the contact state of wire and workpiece, the sawing force and the material removal. An iterative simulation flow was designed by the proposed model. The experiment of wire sawing with rocking and reciprocating (WSRR) was carried out to validate the proposed model. The comparison results indicated that the proposed model replicated the entire sawing experiment well. On this basis, the influences of wire speed, feed rate, rocking angle, preload force, guide rollers distance and workpiece size on sawing force, contact length and MRR were systematically analyzed. The results show that the wire reciprocating is the root cause of saw marks. Workpiece rocking causes the wire bow angle to change periodically and significantly reduces the contact length. Wire speed and feed rate has great influence on the value of normal force. The force fluctuation is affected by the maximum rocking angle and wire preloading force. MRR is mainly determined by the feed speed. The feed rate, maximum wire speed, maximum rocking angle, and preloading force could influence on the fluctuation range of the MRR. This work provides a general model for a better understanding of the wire sawing.

Thermo-hydraulic analysis of melt pool dynamics and material removal on anode in electrical discharge machining

The melt pool dynamics and material removal mechanism in electrical discharge machining (EDM) is not clear yet. In this study, a thermo-hydraulic coupling simulation model considering practical boundary conditions was proposed to investigate the melt pool evolution and material removal on the anode in EDM, with the simulated results directly verified by the high-speed observation of the discharge process. Discharge currents of 5–15 A, a discharge duration of 10 µs, and workpieces of zinc and steel were used in the model, with the forces acting on the melt pool comprehensively integrated and their effects on the melt pool dynamics and material removal analyzed. The simulation results show that on the anode the evaporation recoil pressure is one of the dominant factors that drive the melt flow and cause the molten material removal. The increase of discharge current results in larger evaporation recoil pressure, and thus larger volume of the molten material is removed. Under the effect of evaporation, obvious fluctuation of the melt pool will occur. Meanwhile, the evaporation recoil pressure oscillates with the melt pool fluctuation, which may induce a wave-like motion of the molten material and promote the generation of debris particles. Novel high-speed observation methods were proposed to observe the melt pool evolution and the material removal, with the observed melt pool behavior consistent with the simulated results. The observation also shows that the intermittent removal of the molten material occurs in the case of long discharge duration, which is considered to be caused by the intermittent increase of the evaporation recoil pressure during the melt pool fluctuation.