Tool Profile Research Articles

Wear mechanisms and failure analysis of a tool used in refill friction stir spot welding of AA6061-T6

Investigating tool wear in refill friction stir spot welding (RFSSW) is essential for understanding its limitations and improving its efficiency. Increasing the tool's service life is important to push the technology's readiness level and transfer the technology from the laboratory to industrial applications. In this study, the quasi-static lap shear performance of AA6061-T6 similar welded spots was investigated and tool wear was continuously monitored until tool failure at 3450 welding cycles. Furthermore, the fundamentals of the wear mechanisms in RFSSW were further elucidated. The investigation shows that it is possible to achieve steady quasi-static lap shear performance of the spot welds over advancing tool wear by adjusting the heat input to compensate for losses in frictional heat generation efficiency (related to tool profile changes by abrasion). A subsequent tool failure case analysis showed the main causes for the continuous wear degradation of the shoulder. Tool wear was driven by plastic deformation of the hot-work tool steel and subsequent break-out of tool steel ridges, introducing big hard particles into the contact region between the moving and rotating tools. In addition, the formation and detachment of Fe-Al intermetallic compounds counteract with the rotating tools and increase tool wear.

Toolpath and Tool Design Innovations in Deformation Machining for Superior AA-7075 T6 Fins

Abstract A hybrid manufacturing process, deformation machining (DM) combines subtractive manufacturing with incremental forming. Monolithic components with complex profiles are created through the hybridization of manufacturing technologies, which also reduces the wastage of raw materials. The properties of geometry and surface quality of the fin made from the aluminum alloy Al-7075 T6 using the DM process’s bending mode was examined in this research, as were the effects of various approaches, toolpath methods, and tool design. To achieve the desired shape for the machined fin, various combinations of arcuate and slanting fin toolpath techniques were explored utilizing both top-down and bottom-up methods. The bottom-up method and the arcuate toolpath strategy were used to investigate various tool profiles. Using the best combination of toolpath strategy and tool profile, named as the T3 tool profile, which has a 0.6 mm nose radius and a circular sector, bottom-to-top (BTT)technique, and arcuate toolpath method, components with better geometrical features and surface roughness (SR) were produced. The analysis of the forming force in the bending approach of the DM progression was further carried out using this optimal combination.

A study on friction stir welding with dissimilar aluminium alloys using various tool profiles

A study on friction stir welding with dissimilar aluminium alloys using various tool profiles

Research on automatic data acquisition scheme of tool profile wear based on B/S structure

Research on automatic data acquisition scheme of tool profile wear based on B/S structure

Experimental optimization of the FSW parameters to weld the dissimilar Al- and Cu-alloys by using additives at their joints

Friction stir welding (FSW) stands as a promising technique for joining materials, offering advantages over conventional methods. This study investigates the influence of tool tilt angle, rotational speed and profile on welded joint characteristics using a design of experiment (DOE) approach. The research objective aims to determine optimal parameter combinations for improved mechanical properties. Methodology entails the systematic variation of tilt angle, rotational speed and tool profile in a DOE setup, with subsequent FSW of samples. Mechanical testing, including tensile, bend and hardness tests, is conducted on 24 samples, with scanning electron microscope (SEM) and microstructure analysis on two specimens. Results reveal that higher tilt angles, rotational speeds and threaded profiles yield increased tensile strength but decreased ductility. Similarly, bend tests show higher fracture loads but reduced deflection before fracture under these conditions. Hardness tests indicate elevated hardness in welded areas, with variations based on input parameters. Main findings highlight the importance of parameter optimization for desired mechanical properties. Lower tilt angles and rotational speeds promote smoother material flow and uniform heating, resulting in consistent microstructure and hardness distribution. In conclusion, this study provides valuable insights for optimizing FSW parameters to achieve desired mechanical properties in welded joints. The combination of a 2° tilt angle, threaded tool profile and 1500 rpm rotational speed demonstrated the highest tensile strength, while a 1° tilt angle, cylindrical tool profile and 1000 rpm rotational speed yielded highest ductility.

Geometric analysis and design of circular form tools

Abstract Supposing serial or quantity production of cylindrical workpieces having complex geometry the application of circular form tool is applicable. This type of cutting tool has complex geometry as a consequence the geometric and the manufacturing design take a lot of time and cost but it is economical since the cutting process is quite fast. In addition, the tool usage is feasible on conventional or CNC controlled machines and the process is independent from the workers’ facility. The tool profile is the conjugated pair of the workpiece profile. This tool geometry has high resharpening area that is advantageous comparing other form tools. The goal of this study is the manufacturing analysis and the geometric design of those tools. The geometric design process will be determined detailedly in constructional and mathematical way. After them a concrete tool generation process including CAD design will be shown.

Tailoring macrostructure and texture in bobbin-tool friction stir weld via manipulation of deformation behaviour of plasticised metal during welding enabled by modifying tool profile

Bobbin-tool friction stir welding is a variant of friction stir welding with high process flexibility that has garnered considerable attention from the community. The reliability of the weld is sensitive to the macrostructure and texture of the stir zone, which must be carefully tailored. The macrostructure of the stir zone is governed by the refill behaviour of the plasticised metal associated with the bobbin-tool; refill occurs preferentially near the upper and lower shoulders, creating a triangular gap at the mid-thickness level that is subsequently closed by the confluence of the layered refilling plasticised metal from the upper and lower levels. Volumetric defects easily develop in this triangular confluence region because the symmetrical confluence of the layered refilling metal has the inherent characteristic of limited intermixing. The visual appearance of the triangular region, featuring limited voiding, was improved by tapering the stirring probe. This modification reduced the volume of displaced metal, leaving a smaller gap to be refilled during welding. Concurrently, the symmetrical confluence pattern was altered to an asymmetrical pattern, which enhanced the intermixing of the layered refilling metal from the upper and lower levels and promoted gap closure. For defect-free welds, macroscopic deformation inhomogeneity under tensile loading was observed due to the presence of a strong basal texture in the stir zone. The texture was scattered by disrupting the regular shear deformation pattern in the stir zone, which was achieved by modifying the tool profile. The activation capability of both basal slip and extension twinning among various local regions across the stir zone was substantially reduced through texture tailoring, resulting in more homogeneous tensile deformation. Consequently, elongation was enhanced by 66 %. This study highlights an easy-to-perform and generic strategy that can improve the quality of bobbin-tool friction stir welds.

Oral health status and oral health-related quality of life: a cross-sectional study of clients in an Australian opioid treatment program.

Background Individuals with opioid dependence often experience poor oral health, including dental decay, periodontal disease and mucosal infection, frequently exacerbated by factors such as smoking, alcohol consumption, inadequate oral hygiene and low utilisation of oral health services. This study aimed to assess oral health status and oral health-related quality of life (OHRQoL) among opioid-dependent individuals and explore their potential associations. Methods Participants enrolled in an opioid treatment program (OTP) at three Australian urban clinics were assessed using the validated Oral Health Assessment Tool (OHAT) and Oral Health Impact Profile (OHIP-14). Results The average age of the 75 participants was 44.7years, with 45% receiving opioid treatment for over 5years. Dental decay and inadequate oral hygiene were prevalent. Mean OHAT and OHIP-14 scores were 6.93 and 20.95 respectively, indicating moderate oral health severity and poor OHRQoL. Physical pain and psychological discomfort significantly impacted participants' quality of life, with the effects being particularly pronounced for those aged 30 and above. An exploratory analysis revealed a strong correlation between OHAT and OHIP-14 severity scores, with a one-point increase in OHAT associated with 1.85times higher odds of a lower OHRQoL (odds ratio=1.85, 95% confidence interval: 1.38-2.49, P = Conclusions These findings underscore the multifaceted impact of oral health on the well-being of OTP clients. Routine dental check-ups, education on oral hygiene practices and timely treatment for oral health problems are crucial recommendations based on this study. Such measures hold the potential to enhance the quality of life for individuals attending OTPs.

VIRTUAL POLE METHOD - ALTERNATIVE METHOD FOR PROFILING RACK TOOLS

This paper presents a variant for determining the enwrapping condition, in the case of rack gear type tools. This variant was called the “virtual pole method”. The position of the virtual pole Pv is defined by the movement angle of the blank together with the centrode associated with the generated profile. The virtual pole method allows translating in the centrodes’ absolute movements, a point on the generated profile, on to the rack tool profile, thus determining the geometric locus representing the generating tool profile. The new method is easier to apply, while remaining scientifically rigorous. By applying the proposed algorithm, it is no longer necessary to write explicitly the relative movements between the tool and the piece, which simplifies the calculation process and eliminates some of the possibilities for errors.

THE VIRTUAL POLE METHOD –AN ALTERNATIVE METHOD FOR PROFILING TOOLS WHICH GENERATE BY ENWRAPPING

In the paper is presented a method for profiling of tools that generate by enwrapping, by the rolling method, curls ordered by surfaces. By the new method is intended to eliminate one of the main disadvantages associated with the processing by generating of parts with radial symmetry, namely the difficulty related to the calculation of generating tool profile. The method allows eliminating the need to determine analytically the relative movement between the tool and the blank, which simplifies the calculation mode.

GEAR-RACK TOOL FOR GENERATING AN INVOLUTE FLANK. VIRTUAL POLE METHOD

In the paper, an approach to the issue of gear-rack type tool profiling is proposed, based on the “virtual pole” method. The proposed issue has also been solved based on complementary fundamental theorems, but the virtual pole method has the advantage of a simplified form of writing the generating movements. This makes it possible to avoid the need to write the relative movements between the tool and the piece.The paper presents the application of the virtual pole method for generating an involute profile.

Multi-weld Quality Optimization of Friction Stir Welding for Aluminium Flange Using the Grey-based Taguchi Method

Friction stir welding (FSW) is gaining traction as a preferred technique due to its potential to reduce heat input and enhance the mechanical properties of welded joints. However, the path to commercializing FSW for flange joints is not without challenges. Two primary obstacles are the complexity of the welding path and the intricate design requirements for the fixtures. These factors contribute to the difficulty in determining the ideal weld settings and process parameters, which are critical for achieving optimal results. The current study addresses these challenges by applying FSW to flange joints using custom-engineered fixtures. These fixtures are meticulously designed to hold the pipes and plates securely during the welding process. The focus of the research is on optimizing the multi-performance characteristics of FSW for Al 6063 flange joints through the hybrid Grey-based Taguchi method. The integrity of the weld joint is assessed by examining various mechanical properties within the weld zone, including rotation speed, travel speed, tool profile, and shoulder diameter. The study identifies the optimal parameter settings for the FSW process: a rotation speed of 3000 rpm, a travel speed of 3 mm/min2, a shoulder diameter of 20 mm, and a conical tool profile. Under these ideal conditions, the welded material exhibited a tensile strength of 170.169 MPa, a hardness of 63.7709 HV, and a corrosion rate of 0.022 mm/year. These findings underscore the effectiveness of the optimized FSW process in producing robust and durable flange joints.

Optimizing Micro Friction Stir Spot Welding (mFSSW) of Aluminum Alloy AA1100 Using Neural Network Model

This study explores the optimization of Micro Friction Stir Spot Welding (mFSSW) by investigating the influence of tool profiles on welding outcomes, using aluminum alloy AA1100 with a 0.42 mm thickness as the specimen material. Monitoring temperature and RPM during welding with thermocouples and tachometers, mechanical properties are assessed through tensile shear tests, microhardness measurements, and macrostructural observations. The findings serve as the basis for developing Neural Network models using Rapidminer software, marking a transformative development that positions Neural Networks as potent tools for optimizing welding processes, potentially leading to achieving optimal weld quality. The investigation also delves into three welding tool configurations – the two-stage pin, one-stage pin, and pinless mFSSW probes – highlighting their distinct impacts on tensile shear test values and overall welding quality. Notably, the two-stage pin configuration emphasizes the significance of larger pin diameters and controlled heat generation for enhanced weld strength, while the one-stage pin configuration underscores the pivotal role of pin diameter and elevated temperatures in improving weld quality. The pinless mFSSW probe configuration, on the other hand, emphasizes the importance of shoulder diameter and temperature control for superior tensile shear test results. Leveraging Neural Network modeling for optimization, this study advances our understanding of parameter interactions and underscores the efficacy of Neural Networks in achieving superior tensile shear test values and welding quality in mFSSW, offering valuable insights for future endeavors in the field..

Research on the Influence of the Material Removal Profile of a Spherical Polishing Tool on the Mid-Spatial Frequency Errors of Optical Surfaces.

Elastic spherical polishing tools effectively conform to the polishing surface and exhibit high efficiency in the removal of materials, so they are extensively used in the sub-aperture polishing stages of optical components. However, their processing is often accompanied by significant mid-spatial frequency (MSF) errors, which critically degrade the performance of optical systems. To suppress the MSF errors generated during polishing with spherical tools, this study investigates the influence factor of MSF errors during the polishing process through an analysis of the convolution effect in material removal. A material removal profile model is established, and a uniform removal simulation is conducted to assess the influence of different shape material removal profiles on MSF errors. Simulation and experimental results show that a Gaussian-like shape material removal profile is more effective in suppressing the MSF errors during polishing compared to the "W" and trapezoidal shape material removal profiles. In addition, based on the characteristics of the RMS decreasing in a serrated trend with the decrease in path spacing, a path spacing optimization method considering the polishing efficiency is proposed to improve the polishing efficiency while controlling the MSF errors, and the effectiveness of the path spacing optimization method is verified by comparing the MSF error at the maximum theoretical path spacing and the path spacing that is less than this. Finally, the path spacing optimization method is used to polish single-crystal silicon to further illustrate its practicality.

Novel Tools for Single Comparative and Unified Evaluation of Qualitative and Quantitative Bioassays: SS/PV-ROC and SS-J/PV-PSI Index-ROC Curves with Integrated Concentration Distributions, and SS-J/PV-PSI Index Cut-Off Diagrams.

Background: This investigation is both a study of potential non-invasive diagnostic approaches for the bladder cancer biomarker UBC® Rapid test and a study including novel comparative methods for bioassay evaluation and comparison that uses bladder cancer as a useful example. The objective of the paper is not to investigate specific data. It is used only for demonstration, partially to compare ROC methodologies and also to show how both sensitivity/specificity and predictive values can be used in clinical diagnostics and decision making. This study includes ROC curves with integrated cut-off distribution curves for a comparison of sensitivity/specificity (SS) and positive/negative predictive values (PPV/NPV or PV), as well as SS-J index/PV-PSI index-ROC curves and SS-J/PV-PSI index cut-off diagrams (J = Youden, PSI = Predictive Summary Index) for the unified direct comparison of SS-J/PV results achieved via quantitative and/or qualitative bioassays and an identification of optimal separate or unified index cut-off points. Patients and Methods: According to the routine diagnostics, there were 91 patients with confirmed bladder cancer and 1152 patients with no evidence of bladder cancer, leading to a prevalence value of 0.073. This study performed a quantitative investigation of used-up test cassettes from the visual UBC® Rapid qualitative point-of-care assay, which had already been applied in routine diagnostics. Using a photometric reader, quantitative data could also be obtained from the test line of the used cassettes. Interrelations between SS and PV values were evaluated using cumulative distribution analysis (CAD), SS/PV-ROC curves, SS-J/PV-PSI index-ROC curves, and the SS-J/PV-PSI index cut-off diagram. The maximum unified SS-J/PV-PSI index value and its corresponding cut-off value were determined and calculated with the SS-J/PV-PSI index cut-off diagram. Results: The use of SS/PV-ROC curves with integrated cut-off concentration distribution curves provides improved diagnostic information compared to "traditional" ROC curves. The threshold distributions integrated as curves into SS/PV-ROC curves and SS-J/PV-PSI index-ROC curves run in opposite directions. In contrast to the SS-ROC curves, the PV-ROC and the novel PV-PSI index-ROC curves had neither an area under the curve (AUC) nor a range from 0% to 100%. The cut-off level of the qualitative assay was 7.5 µg/L, with a sensitivity of 65.9% and a specificity of 63.3%, and the PPV was 12.4% and the NPV was 95.9%, at a threshold value of 12.5 µg/L. Based on these set concentrations, the reader-based evaluation revealed a graphically estimated 5% increase in sensitivity and a 13% increase in specificity, as compared to the visual qualitative POC test. In the case of predictive values, there was a gain of 8% for PPV and 10% for NPV. The index values and cut-offs were as follows: visual SS-J index, 0.328 and 35 µg/L; visual PV-PSI index, 0.083 and 5.4 µg/L; maximal reader Youden index, 0.0558 and 250 µg/L; and maximal PV-PSI index, 0.459 and 250 µg/L, respectively. The maximum unified SS-J/PV-PSI index value was 0.32, and the cut-off was 43 µg/L. The reciprocal SS-J index correctly detected one out of three patients, while the reciprocal PV-PSI index gave one out of twelve patients a correct diagnosis. Conclusions: ROC curves including cut-off distribution curves supplement the information lost in "traditionally plotted" ROC curves. The novel sets of ROC and index-ROC curves and the new SS/PV index cut-off diagrams enable the simultaneous comparison of sensitivity/specificity and predictive value profiles of diagnostic tools and the identification of optimal cut-off values at maximal index values, even in a unifying SS/PV approach. Because the curves within an SS-J/PV-PSI index cut-off diagram are distributed over the complete cut-off range of a quantitative assay, this field is open for special clinical considerations, with the need to vary the mentioned clinical diagnostic parameters. Complete or partial areas over the x-axis (AOX) can be calculated for summarized quantitative or qualitative effectivity evaluations with respect to single and/or unified SS-J and PV-PSI indices and with respect to single, several, or several unified assays. The SS-J/PV-PSI index-AOX approach is a new tool providing additional joint clinical information, and the reciprocal SS-J indices can predict the number of patients with a correct diagnosis and the number of persons who need to be examined in order to correctly predict a diagnosis of the disease. These methods could be used in applications like medical or plant epidemiology, machine learning algorithms, and neural networks.

Effect of tool profile on micro hardness, forming limit, and final thickness in incremental hole flanging process of DC01 steel and AA1050 sheet metals

Effect of tool profile on micro hardness, forming limit, and final thickness in incremental hole flanging process of DC01 steel and AA1050 sheet metals

Models of Cutting Forces in the Matrix Theory of Multitool Machining Accuracy

Two generalized cutting schemes predetermining the machining error formation mechanism are distinguished: contour machining, when the profile of the machined surface is formed by the corresponding tool path - contour machining; profile machining, when the profile of the machined surface is formed by the corresponding tool profile - shaped tool machining. For the trajectory scheme, the known force relations are generalized to a spatial curvilinear trajectory. Generalized dependencies for the cutting force components of form, slotted, cut-off and groove cutters are derived for the profile scheme. The evaluation of the adequacy of the proposed model for cutting force components is carried out on the basis of a specially conducted experimental research of the profile turning process with direct measurement of forces at different levels of varying technological factors. Thus, the developed dependences of the coordinate components of cutting forces on technological factors (parameters of cutting conditions, strength properties of the processed material, deformation properties of the technological system, etc.) allow using them for the practical application of machining error models in the matrix theory of multitool machining accuracy.

Effect of Tool Profile on Mechanical Properties, Temperature, and RPM Using Micro Friction Stir Spot Welding (mFSSW) on Aluminum Alloy AA1100

Micro friction stir spot welding (mFSSW) is a type of solid-state spot welding of nonconsumable tools using friction and force to join material of thickness less than 1 mm. This research aimed to investigate the shape of the tools for best welding results among the proposed tool’s profile. The material specimen was aluminum alloy AA1100, with a thickness of 0.42 mm. This study aims to measure the temperature and RPM of the welding process with thermocouples and tachometers. And then investigate the mechanical properties using the tensile shear test, microhardness, and macrostructural observation to find the welding zone and hook profile. Four tools’ profiles are named tool 1, tool 2, tool 3, and tool 4. The result of this study was that tool 3 (Shoulder 450μm) had the highest temperature, around 428˚ C, and the shear tensile test was 450 N (the highest). The macrostructural observation used to define the zone on the welding result there are stir zone (SZ), thermos-mechanically affected zone (TMAZ), and heat affected zone (HAZ).

Chatter Stability Prediction for Deep-Cavity Turning of a Bent-Blade Cutter.

The bent-blade cutter is widely used in machining typical deep-cavity parts such as turbine discs and disc shafts, but few scholars have studied the dynamics of the turning process. The existing mechanism of regenerative chatter in the metal-cutting process does not consider the influence of bending and torsional vibration, the change of tool profile and the complex machining geometry, so it cannot be directly used to reveal the underlying cause of the chatter phenomena in the deep inner cavity part turning process. This paper attempts to investigate the dynamic problem of the bent-blade cutter turning process. The dynamic model of a bent-blade cutter is proposed by considering the regenerative chatter effect. Based on the extended Timoshenko beam element (E-TBM) theory and finite element method (FEM), the coupling between the bending vibrations and the torsional vibrations, as well as the dynamic cutting forces, are modeled along the turning path. The vibration characteristics of the bending-torsion combination of cutter board and cutter bar, together with the dynamical governing equation, were analyzed theoretically. The chatter stability of a bent-blade cutter with a bending and torsion combination effect is predicted in the turning process. A series of turning experiments are carried out to verify the accuracy and efficiency of the presented model. Furthermore, the influence of cutting parameters on the cutting process is analyzed, and the results can be used to optimize the cutting parameters for suppressing machining vibration and improving machining process stability.

Enhancing Aluminum-Based Composite Manufacturing: Leveraging Si3N4 Reinforcement via Friction Stir Process

In the realm of composite manufacturing, this study delves into the innovative approach of enhancing Aluminum-Based Composite Manufacturing through Si3N4 Reinforcement leveraged via Friction Stir Process (FSP). The FSP technique, executed with precision using a vertical milling machine, intricately fabricates composite materials with unparalleled properties. Meticulously chosen parameters including pin diameter, tool tilt angle, and tool profile, coupled with precise tool traversal and rotation, define the operation. The composite substrate, composed of AA 2024, undergoes stringent cleanliness protocols before Si3N4 powders are strategically placed into a designated groove on the titanium surface for processing. Microscopic examination reveals the uniform dispersion of Si3N4 particles within the aluminum matrix, profoundly enhancing mechanical properties. The tensile strength experiences a remarkable 21.45% improvement, while hardness witnesses a significant enhancement of 36.9%. Additionally, fatigue strength is notably improved by 24.12%, and wear resistance sees a substantial boost of 30.44% following Si3N4 nanoparticle integration via FSP.