Process For Production Of Parts Research Articles

COMBINED FIRMWARE OF DEEP CHANNELS OF VARIABLE CROSS-SECTION

Variants of manufacturing deep channels of different cross-sections in typical details of modern equipment are considered. Most of the methods were created with the participation of the authors of the article and are protected by Russian patents. The results of the research are implemented in production at enterprises of various branches of mechanical engineering. Information is given about the original methods of piercing deep holes with a depth-to-diameter ratio of more than 25:1 by using combined processes with the imposition of high-frequency vibrations and the possibility of obtaining holes of variable cross-section in pressed ceramic and metal workpieces. The production of mating surfaces from small cross-section channels and narrow grooves is considered,which allowed us to offer an original technological process for the erosive chemical production of precision parts. This technology has been used in the manufacture of parts whose traditional processing methods are poorly understood or not feasible.In particular, a new application of combined firmware for obtaining deep holes of small cross-section in metal workpieces obtained by pressing is shown.Typical parts containing deep channels are given, the combined processing of which is the most technologically advanced and allows for a high economic effect.

An Analytic Approach to the Cox Proportional Hazards Model for Estimating the Lifespan of Cutting Tools

The machining industry raises an ever-growing concern for the significant cost of cutting tools in the production process of mechanical parts, with a focus on the replacement policy of these inserts. While an early maintenance induces lower tool return on investment, scraps and inherent costs stem from late replacement. The framework of this paper is the attempt to predict the tool inserts Mean Up Time, based solely on the value of a cutting parameter (the cutting speed in this particular turning application). More specifically, the use of the Cox Proportional Hazards (PH) Model for this prediction is demonstrated. The main contribution of this paper is the analytic approach that was conducted about the relevance on data transformation prior to using the Cox PH Model. It is shown that the logarithm of the cutting speed is analytically much more relevant in the prediction of the Mean Up Time through the Cox PH model than the raw cutting speed value. The paper also covers a numerical validation designed to show and discuss the benefits of this data transformation and the overall interest of the Cox PH model for the lifetime prognosis. This methodology, however, necessitates the knowledge of an analytical law linking the covariate to the Mean Up Time. It also shows how the necessary data for the numerical experiment was obtained through a gamma process simulating the degradation of cutting inserts. The results of this paper are expected to help manufacturers in the assessment of tool lifespan.

ПЕРСПЕКТИВИ РОСТУ ВИКОРИСТАННЯ ТЕРМОПЛАСТИЧНИХ КОМПОЗИЦІЙНИХ МАТЕРІАЛІВ У СВІТОВОМУ АВІАБУДУВАННІ

It is shown that in the complex problem of permanent increase in the competitiveness of aircraft, a special role is played by the increasing use of polymer composite materials in aircraft structures of the transport category every year. An important role is played not only by the rational choice of structural and technological solutions of their units and assemblies, but also by the use of new composite materials to reduce the cost and production time of aircraft structures, which greatly contributes to the implementation of high flight technological and economic characteristics of competitive aircraft in the global market for sales and services. A review and analysis of the development of new composite materials and technologies for their processing into products, discussed at the annual international exhibition Sampe 2019. From an analysis of the results of the materials of the exhibition and conferences held within its framework, it follows that the global aviation industry is paying more and more attention to the study of structural thermoplastics and the development of new technological processes associated with these materials, in particular, welding. In the field of aircraft manufacturing, various companies and institutes are working to optimize and reduce the cost of production processes for parts from polymer composite materials, especially in the direction of autoclave-free production technologies. New developments of leading aircraft manufacturers, in particular AIRBUS, for the creation of large-sized responsible high-load structural elements of aircraft from polymer composite materials with a thermoplastic matrix are presented. Of particular note is 3D printing technology, which aircraft manufacturers have successfully begun to use for the manufacture of aircraft parts. It is noted that this technology allows not only to reduce the production cycle of manufacturing parts, but also significantly reduce the energy intensity of processes, which positively affects the cost of products. During a visit to the AIRBUS factory in Nantes, a high level of automation of production processes for manufacturing parts from polymer composite materials with a large number of laying, winding machines, CNC machines, robots was noted, which is due to a significant production program for the A350XWB and A400M aircraft with a high degree of automation of production processes, and also a very high level of safety and labor protection.

Selection of technological process for production of parts made of iron-based powders, providing their strength

Large-scale production of parts from powders and powder steels, in which parts are shaped in presses is considered. The three processes for production of the parts are analyzed. At two of them preforms are formed from the powder, they are sintered and the parts are punched from the sintered preforms. In the first process is used hot forging, in the second process used cold forging. The advantage of cold forging is demonstrated. The durability of the tool during cold forming is not sufficient to produce of parts from powder steels. The ways to reduce of stresses in the tool are described. The third process comprises forming from powder of the final shape parts and their sintering. Such process is applied for parts from powder steels. However in this process the parts have large porosity, which reduces their strength and reduces the efficiency of heat treatment. The method for reducing of the parts porosity as they are formed is described.

Comparison of different titanium alloys welded by Yb:YAG fibre laser for thin sheet applications used for T-ducts in bleed air systems

Research in aerospace applications includes the replacement of well-known materials by newly developed alloys or by new manufacturing methods for the existing materials. In the frame of TiB-Air project funded by the German Federal Ministry for Economic Affairs and Energy (BMWi) the development of a process chain consisting of deep drawing at elevated temperatures, chemical milling, contour machining by laser cutting and laser beam welding to produce pneumatic T-ducts used in bleed air systems is in focus. This production process of sheet metal parts could lower costs in terms of the process itself and the used materials: low alloyed Ti-alloys. Commercially pure titanium alloy (cp-Ti) is commonly used for these structures because of its balanced mechanical properties regarding tensile strength, yield strength, plastic strain and fatigue strength as well as good resistance against corrosion and oxidation. The possibility to substitute cp-Ti by low-alloyed Ti-alloys is examined in this work, by the comparison of two different low alloyed Ti-alloys, namely KS1.2ASN and Ti XT, with a cp-Ti alloy (Grade 4). Mechanical properties of the base materials, their weldability and the mechanical assessment of the laser beam welded butt joints in terms of static, cyclic and fracture mechanical behaviour is compared for sheet materials, with a thickness of 0.9 mm. Defect-free welding according to EN13919 acceptance criteria B was possible for all three alloys, no porosity problems occurred. The low strength alloy KS1.2ASN exhibited mechanical anisotropy between longitudinal direction and transverse direction in the tensile test, welded specimens of this alloy broke in the base material. Due to the tensile properties, both weld and base material of KS1.2ASN showed the least values for the fatigue strength and endurance limit strength. Ti XT and Grade 4 showed similar mechanical anisotropy and fractured in the base material, too. Fatigue strength of Ti XT is below Grade 4, but for the 50%-percentile the endurance limit strength is equal. Fracture mechanical testing showed that KS1.2ASN is a very promising alloy in the welded condition.

高周波誘導加熱エネルギー入出力の線形性に着目した「機能性評価法」による汎用モーター部品生産プロセスの最適化

高周波誘導加熱エネルギー入出力の線形性に着目した「機能性評価法」による汎用モーター部品生産プロセスの最適化

Intelligent integrated monitoring system for lathe equipment

During the production process of the components of precision machines, a stable quality is the key consideration of the vendors. During the production process of metal parts, a thermal expansion error of the spindle will occur due to long time operations, which causes machining errors during the production process. The chatter phenomenon that occurs during the production of components causes knife marks on the processing surface. Thus, chatter is also a major factor that affects the stability of quality. The occurrence of chatter phenomenon not only affects the quality of metal components, it also causes severe wear of the blade surface and shortens the life of the knife tool, and makes the cutting quality more difficult to control. Therefore, this paper uses the lathe machine to simulate the production process in the factory, to collect signals of the thermal expansion error of the spindle phenomenon and the coexistence of chatter, for timely compensation of the thermal expansion error and the development of the chatter suppression system, while spending extra efforts to implement real-time dynamic detection with the Lorenz chaotic system and applying spindle speed selection to control the chatter phenomenon, thus enhancing the processing quality and lengthening the longevity of the knife tool. As for the compensation of temperature, the system applies multi-regression analysis to detect the front and rear bearings of the spindle and room temperature and to compensate the error of the spindle in real time. The system takes real-time control of the chatter phenomenon and compensation of long-time thermal expansion error as its core architecture, while the secondary architecture combines the Internet of Things with Skymars to enable the machine to stabilize communication and to combine with heterogeneous machines such as robotic arm, milling machine, and grinding machine. It is a framework with horizontal development and establishes a database to record the critical value of the occurrence of chatter and implement two-time quality detection, achieving management of the production line, improvement of quality, and cloud information storage.

Reducing Waste in Spare Part Production Process with Lean Manufacturing Approach

In the current era of globalization, competition in the industrial world is increasingly competitive, and then the manufacturing industry must be able to optimize its ability to compete. PT. ABC is a battery production manufacturing company that also produces engine parts for use on the company’s production floor. The inability to meet the punch needs to be used on the battery production floor is one of the problems faced by the company. In the punch production process, some activities are not needed such as operators looking for irregularly located support devices and operators repeatedly measuring the results of object feeding in the manual turning process because there is no standard measurement, which causes the grace period to belong. This study aims to reduce waste in a series of production processes or not valuable adding activities and shortening the total waiting time using the Value Stream Mapping tool. To identify waste, you must first know which activities are of added value and not value added. One method proposed to fix this problem is Lean Manufacturing. The result of using the Lean Manufacturing method is the proposed improvement is to eliminate activities that are less efficient and can reduce production time by 2897 seconds and reduce production activities with 17 events so that the production process is more efficient than before. It can be concluded that the waste that occurs is over processing and movement caused by work methods and machinery.

Environmental life cycle assessment of remanufactured engines with advanced restoring technologies

Abstract Several restoring technologies are employed in engine remanufacturing, such as brush electroplating, arc spraying and laser cladding, which could improve the quality and performance of the remanufactured product and the efficiency of remanufacturing processes. The primary objective of the present study is to analyze the environmental benefits of remanufacturing employing advanced restoring technologies (Scenario 3) in comparison to newly manufacturing (Scenario 1) and remanufacturing without using advanced restoring technologies (Scenario 2) based on Life Cycle Assessment (LCA) methodology. Resource and energy consumptions of each manufacturing and remanufacturing processes were collected along the production line and then the results of seven selected environmental impact categories are calculated. The results show that engine remanufacturing with advanced restoring technologies will achieve large environmental benefits. By using advanced restoring technologies, engine remanufacturing could be able to restore more damaged components and reduce the environmental impacts through reduced consumption of raw materials production and manufacturing process of production replacement parts.

Injection Mold Analysis Based on Moldex3D Car dashboard back cover Casting System

This paper is the injection mold design of the car dashboard back cover casting system. Two different types of gating systems for cold and hot are analysed and processed for mold structure design and problems that may arise during the production process of plastic parts. Moldex3D mold flow analysis software was used for simulation, and two different types of gating systems were analysed and compared. It is found that the advantages and disadvantages of different casting systems exist and the optimal design scheme is selected to improve the mold structure design and improve the production qualification rate of plastic parts.

DEVELOPING AGENT BASED HEURISTIC OPTIMISATION SYSTEM FOR COMPLEX FLOW SHOPS WITH CUSTOMER-IMPOSED PRODUCTION DISRUPTIONS

The study of complex manufacturing flow-shops has seen a number of approaches and frameworks proposed to tackle various production-associated problems. However, unpredictable disruptions, such as change in sequence of order, order cancellation and change in production delivery due time, imposed by customers on flow-shops that impact production processes and inventory control call for a more adaptive approach capable of responding to these changes. In this research work, a new adaptive framework and agent-based heuristic optimization system was developed to investigate the disruption consequences and recovery strategy. A case study using an Original Equipment Manufacturer (OEM) production process of automotive parts and components was adopted to justify the proposed system. The results of the experiment revealed significant improvement in terms of total number of late orders, order delivery time, number of setups and resources utilization, which provide useful information for manufacturer’s decision-making policies.

Rigidity and Damage Evolution of Long Fibre Reinforced Polypropylene Made by Direct Processing Route (LFT-D)

In order to reduce fuel consumption due to environmental aspects, weight of automotive components has to be reduced. Fibre reinforced polymers have high potential to contribute to this aim as they feature a high ratio of stiffness to weight. The direct processing route for long fibre reinforced polymers is a potential process for the net shape series production of automotive parts. To retain safety and comfort, the material properties of polymers processed in such a way have to be investi-gated thoroughly implementing a deeper understanding of elastic response and damage mechanisms. This work deals with glass fibre reinforced polypropylene manufactured by a direct LFT processing route (D-LFT). After introducing basic properties, studies to determine damage evolution are presented. In this regard, the decrease of stiffness with increasing strain was analyzed using tensile tests featuring loading-unloading cycles. The materials properties have been correlated to fibre orientation measurements from X-ray computed tomography. The stiffness decrease is compared to stiffness measurements carried out by ultrasonic phase spectroscopy (UPS) tests, carried out on juvenile, undamaged specimens. This method is used in this study for the first time to describe the elastic properties of long fibre reinforced thermoplastics.

One Step Production of High-performance Sandwich Components

The combined PU spray and wet pressing process allows the manufacture of parts with high lightweight potential. The process can be used for the production of sandwich parts with compact continuous fiber reinforced PU outer layers and a process integrated formation of the foam core. Compared with established production processes for structural sandwich parts, the integration of the foam core formation in a wet pressing process is highly efficient and economical especially for complex structural parts.

Investigation of the coating thickness of plasma-transferred arc deposition welded and cross wedge rolled hybrid parts

Most of today’s technical parts and components are made of monolithic materials. These mono-material components produced in established production processes reach their limits due to their respective material characteristics. Thus, a significant increase in production quality and efficiency can only be achieved by combining different materials in one part. Bulk forming of previously joined semi-finished products to net shape hybrid components that consist of two different materials is a promising method to produce parts with locally optimized characteristics. This new production process chain offers a number of advantages compared to conventional manufacturing technologies. Examples are the production of specific load-adapted forged parts with a high level of material utilization, an improvement of the joining zone caused by the following forming process and an easy to implement joining process due to the simple geometries of the semi-finished products. This paper describes the production process of hybrid steel parts, produced by combining a plasma-transferred arc deposition welding process with a subsequent cross wedge rolling process. This innovative process chain enables the production of hybrid parts. To evaluate the developed process chain, coating thickness of the billet is analysed before and after cross wedge rolling. It could be shown, that the forming process leads to an improvement of the coating, meaning a more homogeneous distribution along the main axis.

Deformation behavior of haynes230 superalloy during backward flow forming

Flow forming manufacturing technique has a unique advantage in producing thin-walled cylindrical parts, witnessing a growing demand in defense, aerospace and other fields. However, some of mechanisms of flow forming have not been deeply understood yet. Aiming at easily appearing problems of the crack and expanding, a finite element model with implicit code has been developed to simulate backward flow forming process for production of thin-walled superalloy tubular parts. The material displacement and stressstrain field distribution were obtained, impact of material displacement to dimensional accuracy and residual stress of spun part was analyzed; distribution of strain vector along thickness of spun part and its influence on the occurrence of fracture was analyzed. The results indicate that inhomogeneous distribution of material displacement in thickness brings about residual tensile stress in outer layer and residual compressive stress in inner layer of spun part; plastic deformation occurs mainly in the outer layer; shear plastic strain on the outer surface is much larger than the inner, which may lead to fracture on the outer surface. Above research can play an active role in understanding the mechanism of backward flow forming and deepening the understanding of fracture and the optimization of the process parameters.

Recursive estimation of the parts production process quality indicator

Consideration is given to a mathematical representation for manufacturing of batch parts on a metal-cutting machine tool. Linear dimensions of machined parts are assumed to be the major quality indicator, deviation from these dimensions is determined by size setting of machine tool and ensemble of random factors. It is allowed to have absolutely precise pre-setting of machine tool, effects from setup level offsetting due to deformation in process equipment on the specified indicator are disregarded. Consideration is given to factors which affect the tool wear, with two definitions of tool wear being provided. Reasons for development of random error in processing, dependence of measurement results on error as well as distribution laws and some parameters of random values are provided. To evaluate deviation of size setting value in each cycle, it is proposed to apply a recursive algorithm in description of investigated dynamic discrete process in the space state. Kalman filter equations are used in description of process model by means of first-order difference equations. The algorithm of recursive estimation is implemented in the mathematical software Maple. Simulation results which prove effectiveness of algorithm application to investigate the given dynamic system are provided. Variants of algorithm application and opportunities of further research are proposed.

Simulating operational control of production in lumber house building businesses

Substantial reserves for higher operation efficiency in wooden house building businesses exist in improvements of production control system through methods of simulation and optimization. This report presents analysis of key factors of lumber house building processes that influence approaches to production control simulation. The need to factor in interconnection and dependence of lumber and house part production processes is highly difficult for operational control of the production system in question. The optimization mathematical models that we developed will help to solve the tasks of operational scheduling at all stages of wooden house manufacturing, from log cutting to production of finished assembly sets.

Robot and Plant Simulation for Automotive Part Production Process Design: A Case Study

Robot and Plant Simulation for Automotive Part Production Process Design: A Case Study

Overview of Additive Manufacturing Informatics: “A Digital Thread”

Additive Manufacturing (AM) has huge promise for manufacturing parts with improved cost and performance compared to traditional subtractive manufacturing methods. But scale-up from prototyping operations and optimization of parts across this range of processes entails understanding complex and varied interactions between part design, materials, production processes, and part performance. To this end, significant investments are being made in R&D programs to manufacture high-performance AM parts, researching new designs and new materials. These programs generate huge amounts of data on materials, process parameters, tests, and part qualification. In parallel, many large companies are responding to competitive pressures by “digitizing” their supply chain, manufacturing processes, parts, and in-service data. Data is captured throughout the product lifecycle and analyzed for opportunities to drive down tooling costs and lead times and improve efficiencies and innovation. The phrase, “Digital Thread,” is commonly used to describe this process. AM represents an ideal opportunity to apply Digital Thread (DT) technology, since 3D printing relies on new digitally - driven technologies. Success requires that data be made available to integrated discovery, data mining, and physics-based simulation tools, enabling timely evaluation of manufactured parts and ensuring a fluid response to the in-process variability that can affect part quality. This can make the difference between parts that can be reliably reproduced to the level of required fidelity (and, hence, are certifiable), as well as reducing costs of physical testing, repair, and in-service liability. Collectively, we call this AM Informatics—the science of managing AM data across its lifecycle with full maintenance of the complex relationship between the part geometry, material, and individual processes used to create the final part. This report provides an overview of the current state of AM Informatics—how data from AM is being captured and utilized to enhance supply chain and production processes, shortening development times and enhancing the reproducibility and quality of part production in support of qualification objectives.

Application of low-melting alloy in the fixture for machining aeronautical thin-walled component

In the production process of aeronautical thin-walled parts, under the influence of cutting force, clamping force, cutting chatter, and other factors, thin-walled parts are particularly prone to vibration and instability phenomena. Thus, it is hard to guarantee machining accuracy. In this paper, a special fixture using low-shrinkage of low-melting-point alloy to clamp thin-walled parts was designed. The physical properties of low-melting-point alloy were studied. The experimental results showed that the alloy with melting point of 70 °C is suitable for clamping the thin-walled part. A typical aeronautical thin-walled part was selected, and the corresponding milling process was adopted. Then, the overall structural design of the fixture is accomplished. The machining experiment results showed that the workpiece milled with this special fixture has high accuracy and low removal rate.