Tool Angle Research Articles

An Analysis of the Effect of Skew Rolling Parameters on the Surface Quality of C60 Steel Parts Using Classification Models

This paper presents the experimental and numerical results of a study on producing axisymmetric parts made of the C60-grade steel by skew rolling. The experimental part of this study involved conducting the skew rolling process with varying parameters, including the forming angle α, tool angle θ, chuck velocity Vu, and reduction ratio δ. Their effect on the quality of produced parts was examined and described by the roughness parameter Ra. Numerical calculations involved the use of machine learning models to predict the quality class of produced parts. The highest prediction accuracy of the results was obtained with the random forest and logistic regression models. Metrics such as precision, recall and accuracy were used to evaluate the performance of individual models. Confusion matrices and ROC curves were also employed to illustrate the performance of the classification models. The results of this study will make it possible to prevent the formation of spiral grooves on the circumference of steel parts during the rolling process.

Simulation Optimization and Experimental Validation of Hydraulic Impact in Pruning Machines

Abstract This study addresses the instability caused by hydraulic shocks in fruit tree pruning machines during operation and proposes an optimization scheme that combines simulation with experimentation. We investigated the mechanisms of load shock in the hydraulic system through mathematical modeling and LS-DYNA simulation analysis. The optimal operating parameters were determined using mechanical and orthogonal analyses: a forward speed of 4 km/h, a pruning tool angle of 60°, and a saw blade rotation speed of 1200 r/min.Additionally, we employed AMESim simulation to optimize the hydraulic system of the pruning machine by designing a dual accumulator configuration to effectively suppress hydraulic shocks.We validated the optimized system through simulations and experimental tests, demonstrating significant reductions in pressure fluctuations, with cutting efficiency improved by 30% and pressure fluctuations reduced by 26.7%.This study not only presents an innovative dual accumulator design but also validates its effectiveness in pruning machines through simulations and experiments, thereby enhancing the operational efficiency and stability of agricultural machinery.

Post-processing algorithm of five-axis CNC machine tool under rotation angle optimization

During the operation of 5-axis CNC machine tools, the angle deviation of the rotation axis greatly affects the tool path control. Therefore, a post-processing algorithm of five-axis CNC machine tool with optimized rotation angle was proposed. Firstly, the basic The structure of the machine tool was analyzed, the Hausdoff distance was used to obtain the matching error between the actual machined surface and the difference surface, and the error compensation method was used to compensate the obtained error, and the rotation axis angle of the machine tool was completed according to the processing result. Based on the optimization results, the machine tool coordinate system was established, and the machine tool post-processor was developed through the coordinate transformation results and integrated into the relevant software to realize the post-processing of the machine tool. The experimental results show that the proposed method achieves better processing results when used for post processing of machine tools.

Experimental and statistical damage analysis in milling of S2‐glass fiber/epoxy and basalt fiber/epoxy composites

AbstractS2‐glass fiber reinforced plastics (S2‐GFRP) and basalt fiber reinforced plastics (BFRP) have emerged as crucial materials due to their exceptional mechanical properties, and milling of composite materials plays an important role in achieving desired properties. However, they have proven challenges due to relative inhomogeneity compared with metals, resulting unpredictability in quality of milling operations. The objective of this work is to investigate the effect of cutting parameters, tool geometry and tool surface materials on the surface quality of composites using burrs as a metric. S2‐GFRP and BFRP composites were produced by the vacuum infusion method. Helical and straight flute end mills were manufactured from high‐speed steel (HSS) and carbide rounds, and half of them were coated with titanium nitride using reactive magnetron sputtering technique. Taguchi L18 orthogonal array is used to determine the effect of tool material, tool angle, coating, cutting direction, spindle speed, and feed rate on the machining quality of S2‐GFRPs and BFRPs with respect to burr formations. Milling experiments were conducted under dry conditions and then the burrs were imaged to calculate the total area and length. Statistical analysis was also performed to optimize the machining parameters and tool type for ensuring the structural integrity and performance of the final composite parts. The results showed that the selection of tool material has the most significant impact on the burr area and length of the machined surface. The novel image analysis allows to analyze the extent of the burr size with a desirable operation speed for industrial applications.Highlights Aerospace grade S2‐Glass (S2‐GFRP) and basalt fiber reinforced plastics (BFRP) were manufactured. Carbide and HSS end mills were fabricated and coated with titanium nitride protective layer. FRPs were machined at various process parameters designed by Taguchi method. Distinctive image processing was firstly used to compute milling induced Burr area and length. Statistical analysis was performed to quantify the contribution of parameters and optimize milling.

Optimization of tool wear and surface roughness in ST-37 steel turning process with varying tool angles and machining parameters

The process of cutting low carbon steel (ST-37) typically utilizes High-Speed Steel (HSS) tools owing to their high hardness, affordability, and ease of shaping tool geometry. In machining, tool geometry plays a crucial role in the material cutting process and determines the quality of the final product, particularly surface roughness. The objective of this research is to achieve optimal surface roughness by varying the tool geometry and nose radius. This study employed an experimental approach using ST-37 and HSS tools. The variations in tool geometry include side rake angles of 12°, 15°, and 18°; side cutting edge angles of 85°, 80°, and 75°; and nose radii of 0 mm, 0.4 mm, and 0.8 mm. The machining parameters applied consist of a cutting depth of 1 mm and 2 mm, spindle rotation speeds of 185 rpm, 425 rpm, and 624 rpm, and a feed rate of 0.05 mm/rev, 0.075 mm/rev, and 0.1 mm/rev. Tool wear measurements were captured using a USB camera, whereas the surface roughness was assessed using a surface roughness tester. The impact of the tool geometry on the surface roughness was analyzed using the Taguchi-Grey Relational Analysis (Taguchi-GRA) and ANOVA methods. The optimal combination for ST-37 lathe machining with a sharpening tool is: A1 (cutting depth 1 mm), B1 (cutting speed 17.42 m/min), C3 (feed 0.05 mm/rev), D1 (corner radius 0 mm), E3 (side rake angle γ 18°), and F3 (side cutting edge angle γ 75°). According to the Analysis of Variance (ANOVA), three factors—cutting speed, tool tip angle, and chip angle—should be considered to achieve minimal tool wear and desirable surface roughness during machining

Development and performance of additively manufactured Tungsten carbide tool insert: An application of additive manufacturing towards flexible and customized machining

Carbide tool manufacturing is proposed by Additive Manufacturing to introduce flexibility and customization in machining industries. Development and performance of the additively manufactured (AM) tool is reported. Crack-free deposition of 88 wt%WC was obtained at 800 °C substrate-preheat temperature. An insert was dimensioned and progressive turning of Aluminium 6061-T6 alloy was performed upto 65 min at various cutting speeds. Cutting force, chip-reduction-coefficient, shear angle, built-up-edge, flank wear, crater wear and tool life of AM tool were analysed. The flank wear of AM tool was observed as 0.219 and 0.314 µm respectively at cutting speeds of 120 and 140 m/min after 65 min of machining. The cutting performance of the AM tool was then compared with that of K20 conventional cutting tool insert.

Optimization of Process Parameters in Under Water Friction Stir Welded AA2014 and AA6082 joints.

This work focuses on optimizing process parameters in underwater friction stir welding to study their impact on the mechanical characteristics of aluminum 2014 T6 and 6082 T6 joints. The aluminum plates are precisely machined to provide the necessary polish for the underwater friction stir welding process (UFSW). Experiments are designed using Taguchi L-9 orthogonal array, considering three process parameters: speed, transverse speed, and tool angles at three levels each. The aluminum plates of series 2014-T6 and 6082-T6 are securely installed in the machine. The plates will be welded using the UFSW process using a taper pin tool. The welded plates are next subjected to tests to assess their mechanical qualities. Tests for tensile strength, hardness, and impact strength are conducted on the welded area of the plate to determine its mechanical qualities. An ANOVA was conducted to determine the significant influence of each variable. The optimal values achieved are Tensile Strength of 185.592 N/mm2, Hardness of 75.1 (BHN), and Impact Strength of 21.236 Joules at a speed of 1120 rpm, transverse speed of 80 mm/min, and tilt angle of 2 degrees.

Influence of tool nose angle on cutting performance in hot machining of Inconel 718

Superalloy Inconel718 is an important material for aircraft preparation because of its excellent performance at high temperatures. However, when cutting Inconel718, a large amount of cutting heat will be generated, resulting in excessive tool temperature and serious wear, which accelerates the tool failure. In order to solve this problem, the influence of tool angle on the process of thermal aided machining was studied by simulation model combined with thermal aided machining technology. During the cutting process, the workpiece preheating temperature rises from room temperature 20° C to 500° C, the front tool angle range is − 5° to 10°, and the rear tool angle range is 4° to 16°. By analyzing various parameters, it was found that a smaller tool rake angle can effectively reduce the tool temperature. Additionally, a flank angle of around 12° was found to decrease the maximum wear area of the tool by approximately 10.5%. Moreover, it was observed that implementing heat-assisted machining can result in a significant reduction of tool temperature by 11.1%, as well as a decrease in cutting force ranging from 18 to 22%, particularly at temperatures exceeding 500 °C.

Analysis of the Influence of Changes In Workpiece Rotation and High Speed Steel Lathe Tool Angles on the Surface Roughness of ST37 Workpieces

Analysis of the Influence of Changes In Workpiece Rotation and High Speed Steel Lathe Tool Angles on the Surface Roughness of ST37 Workpieces

Investigation of Furrow Formation by Rotary Tillage Tools with an Active Drive

Power driven rotary tillage tools are widely used in agriculture. However, the process of furrow formation by these tillage tools remains insufficiently studied. (Research purpose) To study the process of furrow formation by the actuating elements of rotary working bodies with an active drive. (Materials and methods) The experiments were carried out on a laboratory setup in a soil bin filled with sandy soil. The attack angle of the working elements ranged from 30 to 90 degrees, and the kinematic parameter varied from 0.8 to 2.2. The actuating element of the investigated rotary tillage tools was made in both circular and elliptical blade forms with the least curvature line (the major semi-axis of the ellipse). The actuating element with an elliptical blade has the ability to adjust the angle of inclination relative to the axis of rotation of the of the tillage tool. (Results and discussion) Rotary tillage tools with a circular blade form a furrow parallel to the travel direction. It has been established that an increase in the attack angle of the tillage tool from 30 to 90 degrees results in a twofold increase in the width of the furrow. The actuating element, made along the elliptical line of the blade, forms a furrow having the shape of a parallelogram when viewed from above. At a small angle of attack, this actuating element forms a short, narrow furrow deviating from the unit’s travel direction within the boundaries of the furrow width of the rotary tillage tool. (Conclusions) The results obtained make it possible to choose the parameters for the studied rotary tillage tools, which will ensure the formation of optimal furrows. This will increase the evenness of the furrow bottom and the degree of weed destruction, i.e. improved soil quality.

Assessment of the tolerance angle for pedicle screw insertion.

Cannulation process intervenes before implantation of pedicle screw and depends on the surgeon's experience. A reliable experimental protocol has been developed for the characterization of the slipping behavior of the surgical tool on the cortical shell simulated by synthetic materials. Three types of synthetic foam samples with three different densities were tested using an MTS Acumen 3 A/T electrodynamic device with a tri-axis 3 kN Kistler load cell mounted on a surgical tool, moving at a constant rotational speed of 10° mm-1 and performing a three-step cannulation test. Cannulation angle varied between 10° and 30°. Synthetic samples were scanned after each tests, and cannulation coefficient associated to each perforation section was computed. Reproducibility tests resulted in an ICC for Sawbone samples of 0.979 (p < 0.001) and of 0.909 (p < 0.001) for Creaplast and Sawbone samples. Cannulation coefficient and maximum force in Z-axis are found the best descriptors of the perforation. Angular threshold for perforation prediction was found to be 17.5° with an area under the curve of the Receiver Operating Characteristic of 89.5%. This protocol characterizes the cannulation process before pedicle screw insertion and identifies the perforation tool angle until which the surgical tool slips on the cortical shell depending on bone quality.

Advancements in Friction Stir Welding: A Comprehensive Review of Process Variables and Emerging Developments

Friction stir welding (FSW) is a solid-state welding technique widely employed to join materials such as Aluminum (Al), Copper (Cu), Magnesium (Mg), and their respective alloys. These materials find extensive use in industries like transportation, where lightweight materials with superior mechanical properties are in demand due to their reduced mass. Conventional fusion welding methods can adversely affect the mechanical properties of these welds.Over the last two decades, FSW has emerged as a specific and significant advancement in welding technology. Various parameters, including shoulder diameter, shoulder profile, pin length, pin diameter, tool angle, rotating speed, feed rate, and weld speed, play crucial roles in determining weld strength, quality, heat generation, and material mixing.The current research focuses on investigating the process variables that influence the characteristics of welded products. Furthermore, it includes an in-depth exploration of FSW fundamentals, recent advancements, and comprehensive literature reviews.

The impact of the grinding angle of the soil dredging tool on its performance

This investigation explores the optimization of the backhoe blade's entry angle, addressing its crucial role in enhancing energy efficiency and operational effectiveness in subsoil manipulation - a fundamental aspect of agricultural tillage technologies. Utilizing an integrated approach that combines detailed field experiments with robust theoretical simulations, the study methodically quantifies the effects of angular variations on energy demands and mechanical performance during soil dredging. Our results reveal precise angular configurations that offer optimal reductions in energy use while significantly improving the disruption and aeration of the subsoil layer. This optimization contributes directly to the development of advanced, precision-engineered agricultural implements aimed at boosting sustainability and productivity in farming practices. Furthermore, the outcomes of this research provide pivotal insights into soil health management strategies, potentially influencing crop yield through improved root penetration and water absorption. These findings are expected to serve as a benchmark for future innovations in agricultural machinery design, aligning with global trends towards more sustainable agricultural practices and enhanced food security. This study sets a new standard for agricultural tool engineering, paving the way for transformative changes in the sector.

A Two-degree-of-freedom Tool-holder Mechanism for Real-time Adjustment of Tool Angles in Turning Process

A Two-degree-of-freedom Tool-holder Mechanism for Real-time Adjustment of Tool Angles in Turning Process

Simulative optimization of continuous bevel gear manufacturing with special regard to effective tool angles

In recent years, extensive research has been carried out on the influence of tool and process design on tool wear for bevel gear cutting. However, due to the complex interactions between tool, gear and process design, an analytical analysis of the cutting process has proven difficult. In this paper, the influence of the tool design on tool wear in continuous bevel gear manufacturing is analyzed using both simulations and cutting trials. Initially, a theoretical analysis is performed using a manufacturing simulation and a method is derived to calculate the effective tool angles. Subsequently, the results of cutting trials using the same tool designs are presented and compared to the simulation results.

Enhancing lithic analysis: Introducing 3D-EdgeAngle as a semi-automated 3D digital method to systematically quantify stone tool edge angle and design.

In stone tool studies, the analysis of different technological and typological features is known to provide distinct but interrelated information on the design and use of artefacts. The selection of these features can potentially influence the understanding and reconstruction of past human technological behaviour across time. One feature frequently part of a standard lithic analysis is the measurement of edge angles. The angle of an edge, unmodified or shaped by retouch and an integral part of the overall tool design, is certainly a parameter that influences the interpretation of an artefact. The acuteness of an edge angle is often linked to aspects such as cutting, carving, or scraping efficiency and durability and thus, tool performance. Knowing the actual edge angle of a stone tool can therefore have important implications for its interpretation. In the case of edge angle analyses, manual measuring techniques have been established for many years in lithic studies. Here, we introduce a new method for accurate and precise edge angle measurements based on 3D data (hereafter 3D-EdgeAngle). 3D-EdgeAngle consists of a script-based, semi-automated edge angle measuring method applicable to 3D models. Unlike other methods, 3D-EdgeAngle illustrates an objective way of measuring the edge angle at cross sections along the entire tool edge in defined steps and, moreover, allows measurements at different distances perpendicular to the edge by controlling three involved parameters. Thus, with this method, the edge angle can be measured at any point in a high resolution and scale of analysis. Compared to measurements taken manually, with this method random and systematic errors can be reduced significantly. Additionally, all data are reproducible and statistically evaluable. We introduce 3D-EdgeAngle as a standard method to calculate edge angles with a highly accurate and systematic approach. With this method, we aim to improve the process of studying lithics and thus to increase the understanding of past human tool design.

Sliding on cortical shell: Biomechanical characterization of the vertebral cannulation for pedicle screw insertion

BackgroundPedicular screws pull-out has been well studied unlike their insertion. A need for characterizing cannulation before pedicle screw implantation is highlighted in literature and offers promising prospects for future intra-operation instrumentation. A reliable cannulation protocol for ex-vivo testing in swine and cadaver vertebrae is presented in this work to predict extra pedicular perforation. MethodsAn MTS Acumen 3 A/T electrodynamic device, with a tri-axis 3 kN Kistler load cell mounted on a surgical tool was used to reproduce surgeon's gesture by moving at a constant rotational speed of 10°/mm and performing a three-section test. Perforation of the pedicle's cortical shell was planned through a design of experiment on the surgical tool angle at the entry point. Samples were scanned before and after mechanical tests and reproducibility of the protocol was tested on synthetic foam. Computation of the angle between cannulation tool and pedicle cortical shell was performed as well as cannulation coefficient of each perforation section. FindingsA total of 68 pedicles were tested: 19 perforated and 21 non-perforated human pedicles, 17 perforated and 16 non-perforated swine pedicles. The reproducibility of the protocol for cannulation coefficient computation resulted in an intraclass correlation coefficient of 0.979. Cannulation coefficients results presented variability within spinal levels as well as between swine and human model. Correlation between bone density and cannulation coefficient was found significant (p < 0.005). Torque measurement was found to be the best predictor of perforation. Threshold of angle for prediction of perforation was found to be 21.7°. InterpretationCharacterizing pedicle cannulation enables to predict extra pedicular perforation. Influence of bone mineral density and patient-specific morphology on pedicle cannulation has been highlighted together with a comparison of swine and cadaver models.

Design and application of a fault diagnosis system for machine tool angle heads based on Boolean matrix filtering and an optimized BP neural network

In this paper, a fault diagnosis method based on Boolean matrix filtering and optimizing backpropagation (BP) neural networks is proposed for angle heads of computer numerical control (CNC) machine tools. The matrix filtering is first carried out with the fault case database and the fault cause symptom Boolean matrix according to the fault types and characteristics of the machine tool angle head. On the basis of the combination of multiple fault causes obtained from the initial filtering, the Euclidean distance method is used to narrow the results of fault cause filtering. The BP neural network model with weight vector is established and optimized to perform an accurate diagnosis. Finally, the fault diagnosis and management system of the angle head of a CNC machine tool, integrating with the Boolean matrix filtering method, Euclidean distance method, and BP neural network model, is developed and implemented with the Python language and QT development framework.

Optimization of drilling parameters in vertical machining centre drilling on magnesium AZ91D alloy under dry condition with Taguchi design

Drilling using a Vertical Machining Centre (VMC) remains a prevalent machining technique, even if current metal cutting processes have improved. Drilling settings on a VMC are optimized using the Taguchi technique to minimize surface roughness, hole diameter, and circularity error roundness test in this experimental investigation. In order to obtain the optimum process parameters in the VMC drilling on Magnesium AZ91D Alloys, L16 orthogonal arrays was formed by changing the four different speed, feed and end point angle. In the trials, an AZ91D alloy was employed and a variety of process factors, like drilling speed (250, 350, 450 and 550 rpm), feed rate 0.025, 0.05, 0.075 and 0.1 mm/rev), and end point angle (55, 75, 95 and 118°) were examined. Experimental results shows that a combination of slow speed (250 rpm), higher feed (0.1 mm/rev), and a medium end point angle (75°) resulted in the lowest roughness average value. It was possible to achieve the hole diameter accuracy by using the parameter at higher speed (450 rpm), higher feed (0.1 rev/min) and an end point angle of 118°. The lowest possible cylindricity error was perceived at 250 rpm speed, 0.01 mm/rev feed and 118° end point angle respectively. The lowest possible roundness error was perceived at 250 rpm speed, 0.05 mm/rev feed and 118° end point angle respectively. It was noticed from this experimental study and Taguchi technique, the surface roughness of the drilled hole is greatly affected by speed, feed and end point angle of the drill bit tool. Lower magnitude of drill tool speed and lower end point angles cause the good surface roughness values rather than the higher magnitude. The drilled hole’s diameter accuracy is significantly influenced by lower tool speed, higher feed rate and higher end point angle of the drill bit tool. The lower tool speed and higher end point angle of the drill bit tool are the two major factors, which are influenced the minimum cylindricity and roundness errors. It was observed from this experimental study, the lower drill bit tool speeds, higher tool feeds and higher end point angles are the important factors, which are significantly affected the quality of the drill holes during the machining of Magnesium AZ91D alloy in Vertical Machining Centre ((VMC) under dry conditions.

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling.

This study aimed to investigate the effect of the clearance angle of the milling tool on wear, cutting forces, machined edge roughness, and delamination during non-contiguous milling of carbon-fiber-reinforced plastic (CFRP) composite panels with a twill weave and 90° fiber orientation. To achieve the objective of the study, it was first necessary to design suitable tools (6 mm diameter sintered carbide shank milling cutters) with a variety of clearance angles (8.4°, 12.4°, and 16.4°) and all the machinery and measuring equipment for the research to be carried out. Furthermore, measurement and evaluation methods for cutting tool wear, cutting forces, machined edge roughness, and delamination were developed. Last but not least, the results obtained during the research were summarized and evaluated. From the experiments conducted in this study, it was found that the tool clearance angle has a significant effect on tool wear, roughness of the machined surface, and delamination of the carbon fiber composite board. The tool with a clearance angle of 8.4° wore faster than the tool with a clearance angle of 16.4°. The same trend was observed for cutting force, machined surface roughness, and delamination. In this context, it was also shown that the cutting force increased as the tool wear increased, which in turn increased surface roughness and delamination. These results are of practical significance, not only in terms of the quality of the machined surface but also in terms of time, cost, and energy savings when machining CFRP composite materials.