Reduced Tooling Cost Research Articles

Research on tool remaining useful life prediction algorithm based on machine learning

Tool wear during machining significantly impacts workpiece quality and productivity, making continuous monitoring and accurate prediction essential. In this context, the present study develops an efficient tool wear prediction system to enhance production reliability and reduce tool costs. It is worth noting that conventional methods, including support vector regression, autoencoders, attention mechanisms, CNNs, and RNNs, have limitations in feature extraction and efficiency. Aiming at resolving these limitations, a multiscale convolutional neural network (MDCNN)-based algorithm is proposed for predicting the remaining life of milling cutters. The algorithm uses preprocessing techniques like wavelet transform and principal component analysis for noise reduction and feature extraction. It then extracts temporal data features using convolutional layers of different scales and employs a self-attention mechanism for feature encoding. Validation on the PHM2010 milling cutter wear dataset with 10-fold cross-validation demonstrates that the MDCNN model achieves a wear prediction accuracy of 97%, a recall rate of 98%, and an F1 score of 97%. The MDCNN model effectively processes multi-band data and captures complex temporal features, confirming its efficiency and accuracy in predicting milling cutter wear and remaining service life.

ОБРАБОТКА ТОРЦОВ ЗАГОТОВОК ДЕТАЛЕЙ

The study objective is to increase turn process efficiency of corrosion-resistant stainless hard-to-machine steel 12X18H10T. The task is to reduce tool costs. Research methods are the following: full-field testing and simulation in deform software environment. The novelty of the work: a new approach is formed to increase the durability of a metal-cutting tool for turning the ends of workpieces. This made it possible to find out the most rational coatings for different operating conditions. Research results: recommendations are developed to choose a rational coating for hard alloy of VK8 grade.

Optimized Material Removal and Tool Wear Rates in Milling API 5ST TS-90 Alloy: AI-Driven Optimization and Modelling with ANN, ANFIS, and RSM

One of the performance measures and responses in manufacturing is the optimization of the Material Removal Rate (MRR) and Tool Wear Rate (TWR). This study used the response surface method (RSM) and AI-based models of artificial neural networks (ANNs) and adaptive neuro-fuzzy inference systems (ANFISs) to model and optimize the MRR and TWR for milling API 5ST TS-90 alloys. A ZX6350C milling machine was used to conduct twenty (20) experimental runs using a 10 mm HSS end-mill cutter. The experiment was designed using Central Composite Design (CCD) in Design Expert 14 software. RSM, ANN, and ANFIS models were applied in the predictive modelling of the milling process with a coefficient of determination above 0.85. Comparatively, ANFIS and RSM were marginally better than ANN in the predicted MRR for the milling process. The ANFIS and RSM were slightly better than ANN in the predicted TWR for the milling operation. Generally, ANFIS showed a better predictive capability than RSM and ANN for both MRR and TWR. The optimum process milling parameters for the alloy were a 720-rpm spindle speed, 24 mm/min feed rate and 0.979 mm depth of cut to achieve an optimized predicted MRR of 1272.163 mm3/min and TWR of 0.781 mm/min. The optimum milling process was validated at the suggested experimental conditions by carrying out the milling experiment at those conditions, and the results of 1270.05 mm3/min for MRR and 0.77 mm/min for TWR showed a close correlation between the predicted and validated optimum. The optimum milling parameters from this study would enhance production at reduced tooling costs associated with tool wear.

Impact of Single and Duplex Cryogenic Jets on Mechanical and Physical Characteristics in Turning of Titanium Superalloys

This analyses evaluates the cutting force , surface roughness, chip morphology, chip–tool interface temperature, tool life, and Single use of a coated carbide tool and double liquid nitrogen jets for friendly superalloy that is extremely difficult to cut being turned (Ti-6Al4V). The rake face was the only focus of the single jet, while the rake and flank surfaces were concurrently hit by the duplex jets. Liquid nitrogen jets provided the highest machining quality, reducing cutting force , temp, hardness, and, apparently, tool life. When equated to dry and single jet assist, the double liquid nitrogen jets increased life of the tool by 60% and 30%. In spite of this, chip manufacture has not changed. Using duplex liquid nitrogen jets to extend tool life, reduce tool costs, lower temperatures, improve surface quality, and most importantly, promote machinability of Ti-6Al-4V superalloy has been accepted as a sustainably booster.

Study of Tool Wear Monitoring Using Machine Vision

In order to improve tool utilization and reduce tool costs in milling processing, this paper presented a new approach to monitor tool wear status and replace tool in time by machine vision technology. A tool wear monitoring system was established. The wear images of the tool were obtained by a charge coupled device (CCD) camera, and the wear boundaries were established by image preprocessing, threshold segmentation and edge detection based on Canny operator and sub-pixel, then wear value of the tool was extracted. Milling experiments of GH4169 nickel-based superalloy were carried out. The wear values detected by the monitoring system were compared with that obtained by ultra-depth microscope. The results showed that the wear monitoring system had high detection accuracy and enabled on-machine monitoring of tool wear during milling process.

An Intelligent Milling Tool Wear Monitoring Methodology Based on Convolutional Neural Network with Derived Wavelet Frames Coefficient

Tool wear and breakage are inevitable due to the severe stress and high temperature in the cutting zone. A highly reliable tool condition monitoring system is necessary to increase productivity and quality, reduce tool costs and equipment downtime. Although many studies have been conducted, most of them focused on single-step process or continuous cutting. In this paper, a high robust milling tool wear monitoring methodology based on 2-D convolutional neural network (CNN) and derived wavelet frames (DWFs) is presented. The frequency band of high signal-to-noise ratio is extracted via derived wavelet frames, and the spectrum is further folded into a 2-D matrix to train 2-D CNN. The feature extraction ability of the 2-D CNN is fully utilized, bypassing the complex and low-portability feature engineering. The full life test of the end mill was carried out with S45C steel work piece and multiple sets of cutting conditions. The recognition accuracy of the proposed methodology reaches 98.5%, and the performance of 1-D CNN as well as the beneficial effects of the DWFs are verified.

Economic evaluation of alternative process chains for the large-scale manufacturing of metal-fibre laminates

Hybrid bending plates consisting of fibre-metal laminates (FML) facilitate an individual spring rate at constant component geometry for a wide variety of vehicles, sports equipment and prostheses. The spring rate of such a FML is adjusted by an alternating layer setup of the two materials. Based on the technological potential of hybrid bending plates, this paper evaluates and compares the production costs of hybrid bending plates against composite bending plates in different manufacturing scenarios. For this purpose, the manufacturing processes RTM and prepreg pressing are compared. Three applications scenarios (automotive, sports equipment and running prosthesis), each with different production volumes and number of variants serve the bases for the economic evaluation. The production costs of the resulting process chains are modeled based on the value stream method. While fibre-metal laminates cause reduced tooling costs in all assessed scenarios, higher material costs tend to overcompensate this effect. Material costs seem to have the biggest lever in reducing total costs. Further research hence may be undertaken to investigate the effect of an optimised FML layer structure on the material costs.

Comparison of the Hot Working Behavior of Wrought, Selective Laser Melted and Electron Beam Melted Ti-6Al-4V

The production of high-temperature components is of great importance for the transport and energy sector. Forging of high-temperature alloys often requires expensive dies, multiple forming steps and leads to forged parts with large tolerances that require machining to create the final shape. Additive manufacturing (AM) offers the possibility to print the desired shapes directly as net-shape components. AM could provide the advantage of being more energy-efficient compared to forging if the energy contained in the machining scrap exceeds the energy needed for powder production and laser processing. However, the microstructure and performance of 3D-printed parts will not reach the level of forged material unless further processes such as hot-isostatic pressing are applied. Combining AM and metal forming could pave the way for new process chains with little material waste, reduced tooling costs and increased part performance. This study investigates the hot working properties and microstructure evolution of Ti–6Al–4V pre-forms made by selective laser melting and electron beam melting. The results show that both materials are hot workable in the as-built state. Due to its martensitic microstructure, the SLM material shows a lower activation energy for hot working than EBM and wrought material and a faster globularization during forming, which is beneficial for hot forming since it reduces the forming forces and tool loads.

Optimization of process parameters in laser transmission welding for food packaging applications

Plastics’ joining is used widely in food processing applications for the packaging of increasingly diverse food products. Laser transmission welding is an attractive proposition for such applications as it can significantly reduce tooling costs and potential downtime at product changeovers. In order to fulfil this promise in an industrial environment, an effective means of process parameter prediction is required. In this paper, goal driven optimization is conducted, utilizing numerical simulations as the basis for the prediction of optimal process parameters for the laser transmission welding of polyethylene film to a polypropylene substrate. A key consideration of the optimization process is the requirement for specific, pre-defined bonded track widths.

Effects of Cutting Parameters over Turning of UDIMET® 720 Superalloy in a Broaching Process Simulation

The nickel-based alloy “UDIMET® 720” has been used for several years to manufacture components in turbomachines. Its physical properties allow it to keep high mechanical strength when subjected to high temperatures. However, those properties also cause its low machinability. Turbomachine design requires the use of rotating parts assembled and submitted to high thermo-mechanical stresses. Fir-tree slots machined by broaching are used to create the bond between turbine discs and blades. Currently, the broaches are made from high speed steel which is restricted to low speed and feed hence limiting the productivity. In order to go faster, a solution is to use carbide tools. However, this material is more sensitive to shock and it is then necessary to precisely identify cutting conditions for the optimal design of broaches. Furthermore, cutting phenomena are different and can affect the machined surface integrity for this critical workpiece.A large experimental campaign has been done by turning to reduce tool costs and to highlight the effects of cutting parameters on tool wear and machined surface quality. In order to optimize the productivity, the effect of cutting conditions on cutting forces is taken into account. To determine the broach geometry composed of several teeth, the effects of rake angle, cutting edge preparation and clearance angle are presented. In order to simulate the broaching process, a specific test has been designed on a lathe. This allows us to include specific disturbances like interrupted cut, temperature variation, lubrication discontinuity, and difficulty to liberate the chip.

Impact of chemical finishing on laser-sintered nylon 12 materials

Additive Manufacturing offers many potential benefits including reduced tooling costs and increased geometric freedom. However, the surface quality of the parts is typically below that of conventionally-processed materials. This paper evaluates a new chemical post-processing method to reduce the roughness of laser-sintered Nylon 12 components. This process is called the PUSh™ process. The treatment reduced the surface roughness of sample parts from 18μm to 5μm Ra and largely eliminated roughness with length scales below 500μm. Treatment did not affect the flexural modulus, flexural strength, or dimensions of 3.2mm thick bending specimens, but it did significantly impact the mechanical properties of thin tensile specimens that are one to eight layers thick. The post processing reduced the breaking force of the samples, but it increased the ultimate tensile strength and elongation at break. The impact was largest on the thinnest parts. Significant sample shrinkage (12–20%) and weight gain (3.7–7%) from treatment was also observed in the tensile specimens. The results show that the PUSh™ process dramatically increases surface smoothness and elongation at break in thin specimens. It decreases the surface strength, but effects are negligible in larger samples.

Flexible roll forming process design for variable cross-section profile

Roll forming is a continuous bending operation in which a long strip of sheet metal is passed through sets of rolls mounted on consecutive stands, each set performing only an incremental part of the bend, until the desired cross-section profile is obtained. Roll forming technology has been widely used in the automotive industry due to its various advantages, such as high production speed, reduced tooling cost and improved quality. Recently, flexible roll forming process which allows variable cross sections of profiles by adaptive roll stands was developed. In this study, profile design for the hat-channel has been analytically performed on the basis of established longitudinal strain during the flexible roll forming. The effect of geometrical parameters such as base section width, side wall height and flange width on the longitudinal strain was analyzed. The analytical analysis was experimentally verified by lab-scale flexible roll forming machine. The results show that the profile design method preformed in this study is feasible and the parts with variable cross sections can be successfully fabricated with flexible roll forming process.

가변 롤 성형 공정시 길이방향 변형률에 근거한 제품 형상 설계 기술 개발

The use of roll-formed products increases every year due to its advantages, such as high production rates, reduced tooling cost and improved quality. However, till now, it is limited to part profiles with constant cross section. In recent years, the flexible roll forming process, which allows variable cross sections of profiles by adaptive roll stands, was developed. In this study, an attempt to optimize profile design for the flexible roll forming process was performed. An equation that predicts the longitudinal strain for part geometries with variable cross-sections was proposed. The relationship between geometrical parameters and the longitudinal strain was analyzed and investigations on the optimal profile design were performed. Experiments were conducted with a lab-scale roll forming machine to validate the proposed equation. The results show that the profile design method proposed in this study is feasible and parts with variable cross sections can be successfully fabricated with the flexible roll forming process.

중공품 성형시 삼중관의 액압성형성에 미치는 압력경로의 영향

Tube hydroforming is a technology that utilizes hydraulic pressure to form a tube into desired shapes inside die cavities. Due to its advantages, such as weight reduction, increased strength, improved quality, and reduced tooling cost, single-layered tube hydroforming is widely used in industry. However in some special applications, it is necessary to produce multi-layered tubular components which have corrosion resistance, thermal resistance, conductivity, and abrasion resistance. In this study, a hollow forming process to fabricate a part from multi-layered tubes for structural purposes is proposed. To accomplish a successful hydroforming process, an analytical model that predicts optimal load path for various parameters such as tube material properties, thickness of tubes, diameter of holes and the number of holes was developed. Tubular hydroforming experiments to fabricate a hollow part were performed and the optimal loading path developed by the analytical model was successfully verified. The results show that the proposed hydroforming process can effectively produce hollow parts with multi-layered tube without defects such as wrinkling or fracture.

FMEA for the reliability of hydroformed flanged part for automotive application

Tube hydroforming technology is widely used in the automotive industries due to its advantages such as weight reduction, increased strength, improved quality, and reduced tooling cost compared to conventional manufacturing technology. The hydroformed parts often have to be structurally joined at some point. Therefore, the hydroformed automotive parts which have a localized attachment flange are useful. In many cases, the parts formed by hydroforming process are directly related with structural safety, reliability of hydroformed parts must be considered. In this study, hydroforming process of flanged rectangular parts was designed and process reliability was investigated. Finite element analysis was performed to optimize tool geometry considering process parameters such as die aspect ratio and pressure conditions with Dynaform 5.5. Hydroforming experiments to fabricate a flanged rectangular part were performed with optimized tool geometry. The relationship between process parameters and defect was analyzed by FMEA (failure modes and effects analysis). The result shows that process condition was optimized and reliability of rectangular part was increased.

Process design and experimental verification of hydroforming for flanged tubular part

Tube hydroforming is a technology that utilizes hydraulic pressure to form a tube into desired shapes inside die cavities. It is widely used in the automotive industry because of its various advantages, such as weight reduction, increased strength, improved quality, and reduced tooling cost. Hydroformed automotive parts used as structural components in the vehicle body frame or the subframe must often be structurally joined at certain locations, and it is useful if these parts can be manufactured with a localized attachment flange. This study proposes a flange hydroforming process, which consists of pre-bulging, flange forming, and conform shaping. The numerical process design by finite element (FE) analysis was performed with Dynaform 5.5. To accomplish a successful flange hydroforming process design, investigations on the proper combination of process parameters such as tool geometry, tube diameter, and internal hydraulic pressure were performed. To fabricate a flange of a specific target length on hydroformed tubular parts, an analytical model that predicts the flange length for a given set of process conditions is proposed. Hydroforming experiments to fabricate a flanged tubular part were performed, and the forming characteristics at various pressure conditions were analysed. The results show that the proposed hydroforming process can successfully produce flanged parts of a specific target length.

액압 성형 공정 시 플랜지부 형성을 위한 FE 해석

Hydroforming has attracted a great deal of attention in the manufacturing industries for vehicles and transportation systems. Hydroforming technology contributes to weight reduction, increased strength, improved quality and reduced tooling cost. Hydroformed automotive parts used as structure components in vehichle body frame often have to be structurally joined at some point. Therefore it is useful if the hydroformed automotive parts can be given a localized attachment flange. For a given flange shape, a parting plane for the dies is established relative to which the various surfaces of the flange shape, in cross section, have no significant reverse curvature. In this study, hydroforming process for flange forming was proposed. FE analysis to form flanged circular shape and flanged rectangular shape was preformed with Dynaform 5.5. To accomplish successful hydroforming process design, thorough investigation on proper combination of process parameters such as tool geometry and hydraulic pressure has been performed and optimized. The results show that flanged automotive parts can be successfully produced with tube hydroforming.

Applications of hydroforming processes to automobile parts

Hydroforming process recently draws attention of automotive industries due to its advantages like the increased strength, weight reduction, improved quality and reduced tooling cost. This paper summarizes some of our experiences of tube and sheet hydroforming process design by simulation technique through actual tryout. Parts included in this paper are tie bar, subframe and engine mount bracket. The simulations for the entire hydroforming processes were performed and their results were used to predict and fix the forming failures like the wrinkling and the fracture. Based on this experience, we also suggested necessary improvements in the design procedure.

New developments help composites compete

The use of fibre reinforced plastics, including carbon fibre composites, continues strong in automotive applications. Reducing mass is growing in importance due to increased demand for more fuel-efficient and cleaner cars and trucks. Manufacturers have introduced niche vehicles with innovative styling that would not be economically feasible without the design flexibility and reduced tooling costs possible with composites. New materials and technologies have been developed to improve the surface quality and performance of moulded automotive components while lowering production costs. Richard Stewart reports.

Resin Infusion under Flexible Tooling (RIFT): a review

Increasing legislation to limit styrene emissions (mainly from polyester resin systems) into the work place has been the key factor in promoting new technology in the manufacture of fibre reinforced plastics composites. Styrene emissions can be reduced by the development of: resin systems with low styrene emission; improved ventilation and air filtering systems; closed moulding techniques. It is the final area on which this paper concentrates. RIFT is a variant of vacuum-driven RTM in which one of the solid tool faces is replaced by a flexible polymeric film. The process is known by several acronyms—in this paper it is referred to as RIFT (Resin Infusion under Flexible Tooling). Potentially a very clean and economical composites manufacturing method, the process draws resin into a dry reinforcement on an evacuated vacuum bagged tool using only the partial vacuum to drive the resin. It reduces worker contact with liquid resin whilst increasing component mechanical properties and fibre content by reducing voidage compared to hand lay-up. For higher performance composites, RIFT offers the potential for reduced tooling costs where matched tooling (RTM or compression moulding) is currently used. This paper reviews the progress of RIFT from its first development as the Marco method in 1950 to the Seemann Composites Resin Infusion Manufacture Process (SCRIMP) today. Development of the process has been slow (compared to RTM) and generally lacking in scientific rigour. Current research is reviewed and the potential for scientific development is discussed.