Tool Design Method Research Articles

Prototype of Water Level and Rainfall Detection System as Flood Warning Based On Blynk Iot Application

Rainfall in the rainy season can last for about six months, resulting in continuous rain and increasing the amount of water that causes flooding. The community does not directly get information or be informed when it rains. To anticipate these problems, the Prototype of Water Level and Rainfall Detection System as a Flood Warning Based on the Blynk IoT Application is considered effective for developing a rainfall and water level monitoring system. By using the tool design method, flowchart, system analysis (SDLC), and testing using the black box testing method. The system detects the distance between the sensor and the water surface. If the distance to the water level is close to the sensor, the system will report a flood and then switch to the Blynk software. The mobile will display a message and the system can enter all distances into the program.

A cylindrical skiving tool design method based on a conjugate surface for internal gear manufacture

Power skiving is a highly productive method for manufacturing gears, especially internal gears. However, due to the resharpening errors of the conical skiving tool, the insufficient tool life hinders the large-scale applications of power skiving. This work proposes a novel design method of the cylindrical skiving tool based on deriving the mathematical model of two-parameters conjugate tooth surface of an internal gear. The error-free cutting-edge of the skiving tool is obtained from the intersection curve of the conjugate tooth surface and the rake face with an offset along the tool axis. In the present study, a helical internal gear with 97 teeth, module of 1.5875 mm and helix angle of 23.5° is used for the design of a cylindrical skiving tool with 37 teeth. The numerical analysis results show that the tool axial offset zoff, crossed shaft angle Σ and geometric rake angle of tool γ0 result in the asymmetrical tool profile and the uneven clearance angles on both flanks. However, the change of the tool helix angle by 0.7° can obtain an even clearance angles on both flanks when zoff is −30 mm. The noninterference height of the cylindrical tool is 48 % more than the conical tool when machining the same workpiece, which means the cylindrical tool is expected to be a longer tool life. Experiments are conducted on a Profilator Type H skiving machine by using the cylindrical skiving tool by the accuracy of DIN 3. The results show the tool design method is effective and applicable to machine a gear by the accuracy of ISO1328-1 level 7.

Profile design and simulation verification of hard whirling tool for ZC1 worm machining

The profile of the hard whirling tool for ZC1 worm machining is challenging to design precisely. An inaccurate tool profile results in irreversible overcutting or additional machining allowance. This study aimed to develop an accurate tool profile design method and digital verification approach to enhance the quality of ZC1 worms. The precise measurement and axial section data acquisition of the worm are conducted. A tool profile design method is proposed based on the envelope of the equidistant axial section. The motion law of whirling is studied, and a 3D model generation procedure for worm teeth is developed. The effect of the tool profile design is verified, and the impact of cutting parameters on worm tooth profile error is analyzed. The results show that the presented tool design method can effectively avoid overcutting. The employed modeling approach of worm teeth provides an intuitive verification means for tool profile design. Variable cutting parameters lead to different machining errors, and the maximum error is less than 3 μm. Changing the cutting parameters will not induce macro profile error but will impact the micromorphology. These findings should be valuable for designing envelope machining tools with complex motion and realizing the superior performance of hard whirling for ZC1 worm machining.

Machining principle and cutter design of face gear skiving

Current processing methods of face gear are mainly limited to gear shaping, gear hobbing, and other processes. In order to achieve high-precision and high-efficiency machining of face gear, this paper proposed the cutting technology and tool design of face gear skiving. Solving the tooth surface of the skiving cutter according to the meshing principle, and fitted by NURBS surface. Intersecting the rake and conjugate face to obtain cutting edge data, and import it into the CAD software to build the skiving cutter model, the tooth surface enveloped by the cutting edge of the skiving tool is solved according to the envelope principle. This paper proposed the machining principle and tool design method of face gear skiving and analyzed the influence of tool tooth profile error and installation error on the face gear tooth surface deviation, which provides a reference for improving the machining accuracy and efficiency of face gears and further improving the gear skiving process.

Research on the Cutting Principle and Tool Design of Gear Skiving Based on the Theory of Conjugate Surface

Tool design is one of the key factors that restrict the development of gear skiving technology since the design principle does not correspond to the cutting principle. The existing skiving tool cannot achieve ideal machining accuracy and reasonable cutting angles. In view of this, some research has been done in this paper. Firstly, the skiving principle is investigated essentially according to the skiving motions. Then, the principle of tool design is analyzed based on the theory of conjugate surface, and a new tool design method is proposed to match the skiving principle. For this, all the skiving patterns for various kinds of workpieces are enumerated and summarized to abstract a normalized skiving model. Based on this, the mathematical model of the conjugate surface is then derived to lay the foundation for tool design. Then, the design methods of cutting edge, rake face, and flank face are proposed. An example is presented at last, and the cutting simulation is conducted. The result proves that the proposed methods are correct and valid. The theoretical research in this paper could promote the improvement of skiving tools.

Design, Performance Evaluation and Field Test of a Water Jet Tool for ROV Trencher

ROV trencher is a kind of ROV which trenches the sea floor using a specifically designed tool and buries the subsea cables and pipelines. According to the soil conditions, this trenching method can have two different types, one is mechanical cutting and the other one is water jetting. In this paper, we present a water jet tool design method for a 2500 m depth-rated ROV trencher. A series of CFD simulations and laboratory tests with one nozzle, and a ground test using 1:6 scale jetting arm model were carried out to derive and demonstrate the jetting tool design parameters. In October 2018, the constructed ROV trencher was put into the sea trial in the East Sea of Korea to evaluate its final performances. In addition, in December 2019, the trencher was applied in a construction site to bury subsea water pipelines near the Yogji Island in the Korea. Through these two field tests and operation, the trencher was demonstrated for both its operational capability and trenching performance. The main contribution of this paper is that it presents the entire design procedures of water jet tools, including CFD simulations, laboratory tests, field test with 1:6 scaled jetting tool, and the final prototype tool design. These consecutive procedures are carried out in order for us to set up sort of relationship between jetting angle, trench depth, trench speed, and jetting power, from which we can predict and evaluate the trenching performance of the prototype jetting tool.

Design and Experiment of a Teaching Tool for Oval Gears with Variable Transmission Ratio

The basic theory of oval gear is studied. The teaching tool with variable transmission ratio of oval gear is designed. On the premise that the center distance remains unchanged, the parameter law of oval gear is clarified, and finally oval gear mechanism parameters of meeting the constraint conditions of box body are obtained. The effectiveness of the teaching tool design method is verified by experiments, which facilitates the standardized design and application of oval gear.

Optimized Design of Precision EDM Machine Tool based on CAE Simulation and Modal Testing Technology

For precision EDM equipment, in addition to the static stiffness of the body of the machine, the dynamic characteristics of the body and the ambient temperature are also the key factors that affect the machining accuracy of the workpieces. In this paper, through the modal simulation analysis of the machine tool that with the sheet metal shell, the weak points of the EDM machine tool are determined. Through thermal stress simulation analysis, the thermal deformation law of the workpieces mounting table is determined, and a solution to reduce thermal deformation is proposed. Through machine tool ODS (operating deflection shapes) test and analysis, the weak links of the machine tool's body in actual processing are determined. Through the above optimization analysis, the foundation has been laid for improving the dynamic and static accuracy of the precision machine tool. The research method in this paper makes up for the deficiency of the machine tool design method based on static stiffness.

PEMBUATAN LAMPU LED CELUP UNTUK PERIKANAN BUBU DI PERAIRAN LHOK BUBON KABUPATEN ACEH BARAT

The activity of exploiting the potential of capture fisheries in the waters of West Aceh still depends a lot on the simple fishing technology. Common types of fishing gear used in West Aceh are beach seines, fishing rods, gill nets and traps. One of the success factors for fishing with traps is bait. Many previous researchers have examined traps regarding the different types of bait used. Therefore, the researcher has an idea about trap arresting devices, making renewable innovations by utilizing the light placed in the traps to lure fish to gather and enter the trap. Light is a tool to collect fish into catchable areas. The type of lamp used in this study is underwater lamps. This LED lamp is a type of lamp that is durable, energy efficient, environmentally friendly, efficient and inexpensive. The purpose of this study is to get a construction and determine the effectiveness of underwater lamps that are designed and get more catches. The research method used in this activity is a tool design method. This research was initiated by designing, making and testing tools in the laboratory and field. Data collection was carried out using descriptive methods and statistical analysis. The type of data needed in this study are primary data and secondary data. Primary data is collected by making direct measurements with related parameters such as measurements of light illumination, bubu construction, operational costs, fishing time and the type and composition of fish catches. Whereas secondary data collection by means of literature study. Data analysis used is descriptive method using data tabulation and graphical methods based on the results obtained.

Design Optimization Approach of a Large-Scale Moving Framework for a Large 5-Axis Machining Center

The traditional machine tool design method with metal materials makes large-scale moving structures very heavy, which seriously impacts dynamic performance and results in significant energy consumption. Using sandwich structures of composite materials to replace metal materials is an important strategy for lightweight large-scale moving structures. However, this kind of substitution is generally believed to be difficult because foam-filled sandwich structures usually show nonlinear characteristics and must balance the moving mass, material costs, and structural stiffness. In the present study, we proposed a design optimization approach for a large-scale moving framework in a large 5-axis machining center (L5AMC) considering large dimensions in the x, y, and z work space and high machining speed with the aim of minimizing the displacements of the milling head. An improved approach, named the 3-step design optimization, was executed to obtain the optimum framework structures to solve the contradiction between the moving mass, material costs, and structural stiffness. This approach was based on multi-objective optimization and finite element analysis. The structural stiffness of the framework after optimization increased by 89% compared with before optimization although the mass increased by 6% and the material costs increased by 9%. A finite element simulation under four given operational loads showed that the displacements of the milling head were all less than the design requirement of 0.25 mm. The results indicated that the proposed 3-step design optimization approach for the optimal design of a large-scale moving framework was feasible and successful. A 40 m × 6 m × 4 m L5AMC prototype was manufactured, and the actual verification results indicated that the large-scale moving framework fully met the design requirements of the L5AMC and reduced energy consumption.

A Four-Roll Squeeze Pointing Machine for a Shape-Drawing Process

A pointing process is a pre-work operation to facilitate the feeding of a rod to pass through a drawing die. After performing the pointing process, the drawing material is inserted into the drawing die and the jaw pulls the end of the material. A bar pointing turning machine, which is universally used for the pointing process, causes a breaking of drawing material easily in the shape-drawing process. Because a shape-drawing process requires a higher drawing load and a smaller cross-sectional area of the pointed zone of drawing material, a pointing process which is to prevent the breaking of the drawing material through a work-hardening effect at an early stage of the drawing process is necessary. In this study, a four-roll squeeze pointing machine (RSPM) as a new automatic pointing machine is introduced. RSPM has been developed to improve the productivity of the pointing process as well as the shape-drawing process by preventing the breaking of the drawing material. The ductile fracture criterion based on Cockcroft–Latham’s theory was used to predict the breaking of drawing material and any defects during the pointing process. A tool design method for the RSPM and a feasible pointing size for the conventional pointing machine are proposed. In addition, the drawing materials manufactured using a conventional pointing machine and the RSPM are compared through finite element (FE) simulations and experiments.

MONITORING LOCATION TRACKER UNTUK KENDARAAN BERBASIS RASPBERY Pi

Learning from the development of new technologies using the Internet as a monitoring medium, it can be ascertained that gps can be applied in various fields. These gps systems offer efficient improvements in vehicle monitoring and obtaining accurate and real time data. That with thedevelopment of new technologies that can be done that was the work-manual work using a computer that is Raspberry Pi. Data collection method is done by observation method, interview method and literature study, tool design method is done by using Fritzing application as a tool to design the system to be made and design of prototype to be built. But so far some are still local (Intranet), such as Infrared, Bluetooth and Wireless LAN. With the latest technology changing the local paradigm (Intranet) into IoT / Internet Protocol Based. In designing this tool required Raspberry Pi as Gps media as well as vehicle monitoring media using GPS, equipped with GPS module as a monitoring medium with ease. The creation of this tool may make it easy for vehicle owners to monitor vehicles remotely and provide reports in realtime.

Downhole Tool Design for Conditional Monitoring of Electrical Submersible Motors in Oil Field Facilities

The electrical submersible pump (ESP) systems rely on downhole tools to monitor the operation of electrical submersible motors and pumps. The monitored parameters include temperature and vibration of the motor, and the pump intake pressure. Transmitting these parameters successfully and reliably through a downhole tool from downhole to surface under various ESP system operating conditions is critical for production optimization and equipment safety. In this paper, a new downhole tool design method using a phase-to-neutral communication scheme is proposed, which can overcome issues of current downhole tool products installed in the field. In this design, an effective signal communication path is formed by external impedance on the wellhead connecting one phase to the ground combined with a controlled thyristor at downhole connecting the neutral of an electrical submersible motor to the ground. Extensive analytical calculation and PSCAD simulation of the proposed method are demonstrated in the paper. Two case studies are conducted using a real ESP system under normal and single-line-to-ground fault conditions. A sensitivity study is performed to evaluate the influence of various factors on the signal strength for signal communication purpose. A lab testing further provides proof of concept. The proposed method in this paper will result in a reliable and effective downhole tool design for an ESP system operation.

Development of a Tool Design Method in Cross Wedge Rolling: Description and Applications

Till now, the definition of cross wedge rolling dies requires know-how and important expertise from the designers. A decision-making methodology is being developed to provide sequential and logical steps to draw easier and faster the tool geometry. This methodology is based on designing rules found in literature that link the geometrical parameters of the desired rolled part and the geometrical parameters of the tool. Nevertheless, in the literature, the rules are not always consistent because the admissible domain for a parameter can differ from one author to another. In order to take into account this variability, a stability index is associated to each rule and to the designed tool. The methodology allows updating of the existing rules and the implementation of new rules. The set of parameters defining the geometry of the tool can be exported in the CAD/CAM software and FEM software. A case-study is presented to illustrate and validate the methodology.

Novel Tool Design Method for Orbiting EDM -A 2nd Approach on Design Automation Developed in CAD-

Tool design for orbiting EDM process often encounters some difficulties to adjust for EDM orbit and machining overcut concurrently. In orbiting process, the tool sweeps out some extra volume due to the additional orbit motion. Hence, it is compulsory to adjust tool geometry based on the chosen orbit cycle to avoid dimension distortion on the final product. Currently, tool correction is done manually since there is no CAD package which provides a specific assistance to adjust the tool geometry for orbital motion. Therefore, design process becomes lengthy and more prone to error due to manual correction process. The authors have proposed a tool design principle for orbiting purposes. Presented in the paper is continuation of the previous work, which emphasizes an automation strategy of tool design developed inside CAD system. The tool is compensated automatically for overcut and EDM orbit, and checked for its validity. The developed CAD system has been tested for a few EDM applications with complex shapes and proven effective to cut tool design time and human-related failures which are commonly found during manual design processes. Experimental validation for a complex part was executed with a promising result.

Using an artificial neural network to assist roll design in cold roll-forming processes

Cold roll-forming is a highly efficient and economical method for the production of sheet metal products, compared to rival processes. It has a major difficulty, however, because it frequently experiences quality problems such as longitudinal curvature. The tool design method is largely subjective and often involves a trial and error procedure where rolls are tested in the workshop. This paper develops a technique using an artificial neural network to assist in the design of roll-forming tools.