Tool Forces Research Articles

The influence of crescent texture parameters on the axial force when drilling bone

In order to reduce bone tissue damage, the effect of crescent texture parameters on the axial force during bone drilling was investigated. The biomimetism micro-texture shape was selected from a bionic point of view. A laser marking machine was used to process biomimetism crescent texture on the rake face of the drill bit, and then a theoretical model of axial force is established to determine the relationship between axial force and texture parameters according to actual chip-tool contact area. A test platform for drilling bone was built to prove the theoretical model. The novelty of the study involved predicting the change of the axial force according to the true chip-tool contact area. The experimental results showed that a biomimetism crescent texture on the rake face of a drilling tool significant reduced the axial force during bone drilling compared with that of a non-textured tool. Within the range of the experiment data, during the stage of drill entry and stabilization, the measured axial force of a micro-textured tool was more stable and the fluctuation in stress was lower, compared to the response from a conventional drilling tool.

Causes of residual stresses during machining of workpiece surfaces

The basic data about residual stresses are considered, and the classification of residual stresses that occur in the surface layer of parts is provided. At the moment, it is customary to divide residual stresses by the volume of balancing into macro-stresses, micro-stresses and submicron stresses, and by the sign — compressive and tensile. The main causes of residual stresses are analyzed, and the factors influencing their occurrence are identified. There are three main causes of residual stresses: uneven plastic deformations in the cutting zone, as a result of the force of the tool on the workpiece, high temperatures accompanying the cutting process, and structural and phase transformations occurring on the surface of the workpiece.

Two-Point Incremental Forming of Metal–Polymer Three-Layer Sheets

Incremental forming process is a manufacturing process with many advantages, so it has received attention by many researchers, while further investigation is required for incremental forming of sandwich panels. In this study, the response surface method is employed to perform a series of experiments, and the effects of parameters, including vertical step down size, tool diameter, tool rotation speed and polymer type (as the core material) on incremental forming of metal–polymer three-layer sheets are studied. The results are used to evaluate the average tool force and uniformity of sheet thickness distribution. The results of variance analysis of the average tool force show that the vertical step size, tool diameter, polymer type and tool rotation speed have, respectively, the greatest effects on the average tool force. Moreover, the interactions between the pairs of vertical step size/tool rotation speed, vertical step size/tool diameter, vertical step size/polymer type and the tool rotational speed/tool diameter affect the average tool force. From the results of variance analysis of maximum thickness variation, it can be concluded that the vertical step size, polymer type, tool rotation speed and tool diameter have, respectively, the greatest effects on the maximum thickness variation; moreover, the interaction between vertical step size and polymer type also affects the maximum thickness variation. It is shown that the vertical tool force in incremental forming of a metal–polymer three-layer sheets is approximately 50% that of a single-layer aluminum sheet with similar bending moment.

Prediction of Tool Force in Two Point Incremental Forming by Slab Analysis

Two-Point Incremental Forming (TPIF) method is a novel technique for producing free form shell parts. The main purpose of this study is to analyze the TPIF process, and, by approximate calculation, to find the force applied to the tool. One of the limitations of an incremental forming process is that during this process force applied to the tool is born by the machine. In this research, an equation for approximate prediction of the force applied to the tool is presented using the values of the yield stress of the sheet, friction coefficient, tool radius and thickness of the sheet; hence, the applied force can be calculated. By increasing the forming angle, the amount of the created local strain increases and the change in thickness and the force applied to the tool is enhanced. However, by increasing the angle of punch wall, less compressive stress is applied to the metal sheet due to the reduction in contact between the surface of the tool and punch wall. Analytical equations presented are validated by the results from experimental tests.

Fitrah dalam Pendidikan Islam Menurut Hasan Langgulung

This research examines Hasan Langgulung 's perspective of Fitrah in Islamic education. This research is intended to analyze Hasan Langgulung 's essence of Islamic education and analyze the growth of Fitrah potentials from Hasan Langgulung 's perspective on Islamic Education. This research is a research library utilizing content analysis.
 The results of the research revealed that 1) According to Hasan Langgulung, Fitrah is the original power buried in humans from birth, which will become a driving force and determinant of personality and service tools. 2) The potential of Fitrah in Islamic education from Hasan Langgulung 's perspective is an interaction between potential and culture, the possibility of religion that complements humans from birth, promoting the establishment of Islamic civilization. 3) The capacity of Fitrah and Gharizah requires humans to continually learn from their surroundings and the ability to think and choose (good and bad) to decide their course of life. This research shows that improving Fitrah 's potential can be an Islamic education model that can see students' different potential paths. It may also establish formal and informal education. The growth of the capacity of Fitrah by students, teachers, and parents, therefore, seeks to instill good behavior because nature does not evolve by itself. The principle of Fitrah also demands that Islamic education strive to guide instruction for a healthy human connection with God.

Simulation Analysis of the Influence of Micro-texture Parameters on Tool Strength Based on ANSYS

In this paper, the influence of the micro-texture parameters of the tool surface on the tool strength is studied, and the texture parameters with less influence are selected.Firstly, the cutting force of the PCBN tool in the actual cutting process is measured by the dynamometer, and then the 3D model of the tool is imported through the finite element analysis software ANSYS. After the mesh is divided, certain constraints and the measured cutting force are applied, and finally get the deformation and equivalent stress of the tool for analysis.The results show that when designing the micro-texture, the width of the micro-texture should be between 90-110μm, the spacing of the micro-texture should be between 110-120μm, and the margin between the micro-texture and the cutting edge should be between 160-180μm. The depth of the micro-texture should be between 30-40μm, so that it can not only play the role of micro-texture on the cutting tool, but also reduce its impact on the strength of the tool.

Система управления качеством кромки при финишной обработке эластичными полимерно-абразивными инструментами и ее анализ. Часть 1

The purpose of the paper is to create a control system of edge quality under finishing machining of parts by elastic polymer abrasive tools, which are effective in surface conditioning and rounding of part edges. The principle of the system approach is used for a formalized description of the system characterized by the mutual interaction between the subsystems that form it. Consideration is given to the control system of these finishing operations design in order to ensure the required quality (in terms of surface roughness, size and geometric accuracy of edges) and optimal process performance under a large variety of tool designs and shapes of the processed surfaces and their mutual arrangement. The system includes input parameters, state space (subroutines) and output data. The input parameters of the system include equipment, workpiece and tool. The state space includes subsystems of mathematical interaction models of tool and surface and forces on the basis of which the mathematical models of material removal, roughness formation, power consumption, tool wear, and cutting zone temperature operate. The information from these subsystems is transmitted to the subsystem for optimizing finishing operation parameters. An algorithm for designing finishing technological operations is presented. It consists of source data input to the system, analysis of operation functional capability, decisions on the possibility of changes in the input data, control action formation, designing of operation, organization of preparation for operation execution, control of operation execution results for the compliance with the requirements of normative and technical documentation and finishing operation implementation in mass production. The developed system provides optimal tools and processing modes as a result of fulfillment of its functions. When this information is implemented in the manufacturing process of parts, the required quality indicators (surface roughness, size and geometric accuracy of edges) are provided as well as the optimal process performance.

Investigation of tool forces, weld bead micro-hardness and surface roughness during friction stir welding of Aluminium 6063 alloy

ABSTRACT From last decade, Friction Stir Welding (FSW) process finds increasing applications in industry as the process is environment-friendly and offers inherent advantages in mechanical and metallurgical properties of welded joints. FSW employs a non-consumable rotating tool, which generates frictional heat and plastic deformation at the welding location while the material is in solid state. In this paper, mechanical behaviour of Aluminium 6063 alloy (AA6063) FSW joints in terms of tool forces, weld bead micro-hardness and surface roughness was investigated varying the welding parameters, namely the welding speed and feed which were varied in the range of 385–960 rpm and 18–45 mm/min, respectively. It has been observed that tool forces and hence, the surface roughness decreases with increase in welding speed and feed. Lower tool forces at higher values of welding speed and feed can be attributed to increase in temperature at weld bead resulted in softening of the material at higher welding parameters. Micro-hardness of the weld bead has been observed little affected within the domain of the weld parameters selected in the present study.

Utilization of ultrasonically forced pulsating water jet decaying for bone cement removal

Ultrasonic pulsating water jet for non-thermal and selective removal of acrylic bone cement is studied. Variation of acoustic chamber length is used for tuning of the ultrasonic system into the resonance regime to gain maximum power transmission. The study investigates the minimal technological conditions such as nozzle traverse speed and supply water pressure required to generate disintegration grooves in bone cement mantle. It also proposes the safe standoff distance range, which is essential for its potential application during the extraction of bone cement without compromising host bone. Palacos R+G bone cement was used for the experiments. Generated groove depths were measured using MicroProf FRT and analyzed using SPIP software. Depth values showed an increasing trend with an increase in acoustic chamber length, decrease in traverse speed, and increase in supply pressure values. From the entire experimental domain, a maximum depth of 615 μm was obtained at 22-mm chamber length, 0.5-mm/s traverse speed, 10-MPa pressure, and a standoff distance of 4 mm. Brittle fractured surface features like material chipping, micro-pits, cracks, and sheared material layers were observed in the SEM images. Disintegrated debris, diameter 21–37 μm, conceived from pit diameters can be used to design a suction unit. Real-time control of the disintegration process using accelerometer sensors was shown. The results support the idea of using pulsating water jet for bone cement removal in a single blind hole. Minimal technological parameters reduce reaction force of the hand tool, allowing bone cement removal without bone fracture or perforation.

Numerical Analysis of Multi-pass Cold Spinning of Superalloy of Cylindrical Part

In view of the poor plasticity and easy cracking of superalloy at room temperature, the multi-pass cold spinning of cylindrical part was studied. Firstly, the tensile test of superalloy GH3030 is carried out, and the true stress-strain curve is obtained. Then, the numerical models of 250 and 87.5 diameter-thickness ratio blank are established, and the stress and strain field, wall thickness distribution and tool force distribution of the cylindrical part are analyzed and compared. The wrinkle model of 250 diameter-thickness ratio blank was analyzed, and the experiment of 87.5 diameter-thickness ratio blank was carried out. The results show that the wall thickness of the cylindrical part has metal accumulation at the flange, and the thickness of the waist is very small, which is easy to crack under the repeated forming of the roller; the wall thickness distribution of the large diameter-thickness cylindrical part is more uniform, but it has a great challenge to the equipment force and the equipment stiffness. The main reason for the flange wrinkle is staggered distribution of the tangential tensile and compressive stress of the whole flange.

Surface Plastic Deformation of Commutator Plates in Electric-Motor Repair

A smoothing tool is developed for commutator plates in electric motors. The dependence of the surface roughness on the applied tool force is established.

A Comparative Study of Friction Self-Piercing Riveting and Self-Piercing Riveting of Aluminum Alloy AA5182-O

In this paper, self-piercing riveting (SPR) and friction self-piercing riveting (F-SPR) processes were employed to join aluminum alloy AA5182-O sheets. Parallel studies were carried out to compare the two processes in terms of joint macrogeometry, tooling force, microhardness, quasi-static mechanical performance, and fatigue behavior. The results indicate that the F-SPR process formed both rivet–sheet interlocking and sheet–sheet solid-state bonding, whereas the SPR process only contained rivet–sheet interlocking. For the same rivet flaring, the F-SPR process required 63% less tooling force than the SPR process because of the softening effect of frictional heat and the lower rivet hardness of F-SPR. The decrease in the switch depth of the F-SPR resulted in more hardening of the aluminum alloy surrounding the rivet. The higher hardness of aluminum and formation of solid-state bonding enhanced the F-SPR joint stiffness under lap-shear loading, which contributed to the higher quasi-static lap-shear strength and longer fatigue life compared to those of the SPR joints.

A two-stage observer for the compensation of actuator-induced disturbances in tool-force sensors

In this paper, a novel two-stage observer strategy for improving the measurement of tool forces is presented. The mass-spring-damper system which inevitably occurs when a tool and a (compliant) force sensor are combined is studied and its adverse influence on the measurement signal is analyzed. The proposed observer consists of two stages. The first stage captures the input-output characteristics from the control input to the tool force by a recursive least-squares estimation algorithm. The estimated tool characteristics are used in a second stage to suppress the oscillations in the measurement signal, which mainly occur due to the mass-spring-damper nature of the tool-sensor combination. In a tailored experimental test rig, which mimics the conditions in magnetic levitation, magnetic bearings, or magnetic strip positioning devices in hot-dip galvanizing lines, the efficacy and the high estimation accuracy of the developed observer strategy are demonstrated.

A modified analytical cutting force prediction model under the tool crater wear effect in end milling Ti6Al4V with solid carbide tool

This paper presents a study of the relationship between cutting force and tool crater wear of solid carbide tool during milling Ti6Al4V. The cutting force model in milling considering tool crater wear is discussed, which shows that for given the cutting conditions, tool geometries, and workpiece material, cutting force under the tool crater wear effect could be predicted easily and conveniently. The tool wear condition in milling Ti6Al4V is obtained by finite element simulation method. In addition, the experimental work of end milling Ti6Al4V with solid carbide tool is developed. Comparisons among experiment results, mathematical model results, and finite element simulation model results, including cutting force and tool wear, are discussed. The results show that the proposed mathematical model could predict cutting force under the tool crater wear effect with higher accuracy.

Enhanced carbide tool life by the electromagnetic coupling field for sustainable manufacturing

The effective extension of tool life while maintaining machining quality is an important research topic in advanced machining and sustainable manufacturing. Cemented carbide is widely used as the tool material in different manufacturing processes, and it has various forms and work ranges. However, the internal flaw in the tool material can induce a micro-crack which could result in the decrease of tool strength and toughness, and affect the tool life. Improving the tool cutting performance, slowing down the tool wear, and enhancing production efficiency are the eternal themes of cutting tool research. This research focused on a P10 cemented carbide tool. The influences of the electromagnetic coupling field (TEMCP) on the carbide tool life and the maximum of tool force are investigated. The correlation analysis between the TEMCP parameters and the tool life index is conducted using SPSS. The experiment proves that the TEMCP can significantly prolong the cemented carbide tool life, and that the magnetic intensity is a dominant factor. The TEMCP enriches the field technology theory and provides technical support for the sustainable manufacturing and research and development of a high-performance tool with important scientific meaning and research potential.

Modeling the interaction of soil and a vibrating subsoiler using the discrete element method

A vibrating subsoiler can effectively reduce the draft force compared to a rigid one. Several theoretical and experimental methods have been developed to study the interaction of soil and vibrating tools, enabling the exploration of the mechanism of a vibrating subsoiler to reduce the draft force. However, these methods are unable to predict the dynamic force of tools and soil behavior because of nonlinear soil properties. This paper employs the discrete element method (DEM) to simulate vibrating tillage. The aim is to clearly understand the dynamic force of vibrating tools and soil behavior. Three different types of representative vibrating subsoilers and one rigid one were selected for this study. These subsoilers varied in their tines and vibrating structures. The DEM model of soil and subsoilers was established. Results showed that the draft and vertical dynamic forces of the vibrating tines periodically changed and had distinct peak and valley phases in one period. The value of the draft and vertical forces in the valley phase of a vibrating subsoiler was much less than that of the rigid one, which led to the decrease of mean draft force. The soil disturbance widths, velocities, and horizontal and vertical forces of soil particles also periodically changed. Soil ruptures mainly occurred when a tine vibrated in the forward direction. Compared with a rigid tine, a vibrating tine had more time to disturb soil particles and thus to achieve better soil fracture. The DEM model was validated by comparing it with an actual soil bin test. The errors of the simulation model in predicting the soil disturbance and forces were less than 13.23% and 9.65%, respectively, indicating that the model is a useful tool to simulate the dynamic interaction of soil and a vibrating subsoiler.

Enhanced wear performance of laser machined tools in dry turning of hardened steels

Polycrystalline boron nitride cutting tools are currently used for precision machining of automotive components made of hardened steel due to their high wear resistance and long durability, however adhesion of workpiece to the cutting tool can reduce cutting tool lifetime. Laser surface engineering of polycrystalline boron nitride single point cutting tools using a nanosecond fibre laser is proposed to improve their wear properties and extend tool life in turning of continuous hardened steel components. The effect of different designs on the wear properties was investigated in turning tests under dry conditions and compared to benchmark cutting tools made of the same material. Condition monitoring of machining forces revealed a 20% reduction of cutting force and 30% reduction of feed force for tools with crosshatch design and grooves perpendicular to chip flow direction, when benchmarked to commercial cutting tools. The number of grooves in contact with the forming chip contributed to the creation of three distinguished interfacial secondary deformation areas. Texturing the chamfer proved to alter the dynamic of chip formation in the secondary deformation zone, while engineering the formation of laser-induced solid lubricant h-BN improved the heat dissipation rate in the secondary and tertiary deformation areas.To the best of authors’ knowledge, this paper reports for the first time the possibility of simultaneously engineer geometry and chemistry of PcBN cutting tools so to enhance their service life by up to 20%.

Magnetic Field Analysis of Polishing Tools in Permanent Magnetic Field Polishing Device

In order to achieve the polishing of the inner wall of the workpiece with a complex internal cavity structure. In this paper, a planar polishing machine is used as an example to design a polishing device platform. The permanent magnet is used as a magnetic field to drive the polishing tool to polish the inner surface of the workpiece. In this paper, a magnetic field internal polishing analysis method is proposed, which mainly uses the matlab to qualitatively analyze the magnetic force and magnetic moment of the polishing tool, and then qualitatively analyze its motion stability.

A Novel Method for Tool Identification and Wear Condition Assessment Based on Multi-Sensor Data

The development of industry 4.0 has put forward higher requirements for modern milling technology. Monitoring the degree of milling tool wear during machine tool processing can improve product quality and reduce production losses. In the machining process of machine tools, many kinds of tools are usually used, and the signal characteristics of various sensors of different tools are different. Therefore, before the tool wear assessment, this paper identified the tool type according to the spindle current data. After the tool type recognition, this paper evaluates the tool wear degree according to the tool force data, vibration data, acoustic emission signal, and other multi-sensor data. Firstly, the Elman neural network and Adaboost algorithm are combined to construct the Elman_Adaboost strong predictor. Then, the variance and mean of seven sensor data were selected as the characteristic quantities to input the strong predictor. Finally, three wear quantities were obtained to measure the wear degree of the tool. The method proposed in this paper is implemented by Matlab, and the validity of this method is verified using the competition data provided by PHM (Prognostics and Health Management) Society. The results show that the average evaluation accuracy of the same tool wear is more than 92%, and that of the similar tool wear is more than 85%.

Prediction of subsurface damage depth in rotary ultrasonic machining of glass BK7 with probability statistics

Subsurface damage (SSD) generated in rotary ultrasonic machining (RUM) process significantly deteriorates the technological and structural performance of the optical components. However, the invisibility of subsurface cracks underneath the machined surface makes it difficult to accurately and online evaluate the SSD depth. In the present research, incorporated with the probability statistics of the abrasive heights and the indentation fracture mechanics of the brittle material, a theoretical prediction model was established by investigating the inherent correlation between the measured cutting force of the diamond tool and the maximum depth of the subsurface cracks. Utilizing this predictive method, the SSD depth could be rapidly and precisely calculated through the mechanical properties of the material, the cutting force of the diamond tool, and the geometrical characteristics of the abrasives. To validate the feasibility of prediction technique, the experimental measurements of the maximum SSD depths were compared with the predicted results, revealing the acceptable consistency in their values.