Tool Profile Research Articles

Research on the profile modification of power skiving tool for internal gears

Power skiving provides an effective solution and considerable machining efficiency for the machining of internal gears. The tool profile design and the reusability after resharpening is crucial in gear manufacturing. In this paper, a novel method of tool profile correction based on the inverse error-complement of involute profile is proposed. Firstly, the mathematical model of involute cutter with rake angle and relief angle is established. The profile error relative to the target gear is calculated by the mathematical model. Then, the distribution of the gear profile errors is fitted by a fifth-order multinomial. The fitted multinomial function is attached to the cutter profile. The maximum theoretical error of the target gear profile is in 10e-7 mm order of magnitude through the calculation of fewer iterations. Finally, the distribution of the multinomial coefficients along the resharpening direction is obtained by linear programming. The result shows that the cutter designed by the proposed method possess almost negligible error to the gear profile and good repeatability of resharpening.

EXPERIMENTAL INVESTIGATION ON THE EFFECT PROCESS PARAMETERS OF FRICTION STIR WELDED AL & MG ALLOYS

Friction Stir Welding is done on the Al alloy AA 5083 as well as magnesium alloy AZ31B with dimensions of 150X100X6 mm. The tool profiles used in this work are Square, Conical, Cylindrical threaded, Tapered threaded, and Hexagonal; Tool profiles are made up to certain specifications, and H13 steel is used as a tool material.The FSW tools were hardened to improve their characteristics. Tool profile plays an important role in improving welding. This study explains the essential welding parameters used in the process. Employed characteristics include traverse speed, tool rotational speed, and tool pin profile.Welded joints' mechanical characteristics were examined by conducting various tests such as tensile strength test, Impact test, Microstructure Analysis, and bending test. Following welding, the welded aluminum alloy and magnesium alloy were machined using an EDM machine following ASTM standards.At last, the test results are compared between both the aluminum and magnesium alloys

Performance Evaluation of Low-Cost Vibration Sensors in Industrial IoT Applications

The recent development of low-cost accelerometers, driven by the Industrial Internet of Things (IIoT) revolution, provides an opportunity for their application in precision manufacturing. Sensor data is often of the highest consideration in any precision machining process. While high-cost vibration sensors have traditionally been employed for vibration measurements in industrial manufacturing, the measurement uncertainty affecting the accuracy of low-cost vibration sensors has not been explored and requires performance evaluation. This research focuses on the characterization of measurements from low-cost tri-axial micro electro-mechanical systems (MEMS) accelerometers in terms of identifying the parameters that induce uncertainties in measured data. Static and dynamic calibration was conducted on a calibration test bench using a range of frequencies while establishing traceability according to the ISO 16063 series and the IEEE-STD-1293-2018 standards. Moreover, comparison tests were performed by installing the sensors on machine tools for reliability evaluation in terms of digital transmission of recorded data. Both tests further established the relationship between the baseline errors originating from the sensors and their influence on the data obtained during the dynamic performance profile of the machine tools. The outcomes of this research will foresee the viability offered by such low-cost sensors in metrological applications enabling Industry 4.0.

Experimental Investigation of the Friction Stir Welded Dissimilar Aluminium Alloys

Abstract: Friction stir welding is the solid-state welding method that is used to weld mostly aluminium alloys. A cylindrical tool with a shoulder and pin rotates at high rpm is penetrated at the interface between two materials to be welded. The high rotational speed causes the material to flow plastically and the joint is formed with the traverse movement of the tool. The tool profile, material nature, rpm of tool, traverse speed are the major factors that affect the weld quality. In this research Al 1100 and Al 6061-T6 aluminium alloys were used and the joint is made using Friction Stir Welding. The joint is then tested for the impact strength, tensile strength and microhardness. The tensile test done on Universal Testing Machine and the highest strength was 202.56Mpa found at 1000 rpm and 12mm/min traverse speed. In the impact Charpy test the highest strength found is 0.1494 kj/mm2. The micro hardness test gives the highest value of 52hv at the weld zone at 100 rpm and 12mm/min weld speed. Keywords: Friction Stir Welding, Aluminium alloys, tensile strength, impact strength, Micro hardness.

Thermal Stress Analysis and Optimization of FSW Process on UHMWPE by Using Triangular Tool Profile

Abstract: The use of polymeric materials has grown widely in various sectors such as packaging, building, electronic, automotive, and aerospace industries. Particularly, Ultra-High Molecular Weight Polyethylene has wide engineering applications and is used in large quantities in automotive oil pans, gears, slides, cams, bearings, fluid reservoirs, and the sports industry. Friction Stir Welding (FSW) is a solid-state process in joining thermoplastic materials. In this investigation, FSW process must be applied to join a UHMWPE plate of 10 mm thickness with specially designed triangular tool pin profile. The aim of this study is to examine the effect of main friction stir welding (FSW) parameters on the quality of UHMWPE plate welds. FSW machine, using a tool with a stationary shoulder and no external heating system. The welding parameters studied were the tool rotational speed which varied between 1300 and 1500 (rpm); the traverse speed which varied between 15 and 25 (mm/min), and the axial force ranging from 8 to 10 (KN). Good quality welds are achieved without using external heating, when the tool rotational speed and axial force are above a certain threshold. For high rotational speed and axial force welds have poor material mixing at the retreating side and mild voids at the nugget, tensile strength also obtained very poor. The hardness angle distortion and bead geometry also evaluated. Taguchi design optimum parameters and ANNOVA were found. Keywords: FSW, Tool Profile, Taguchi, HRM, Polyethylene

The Influence of Process Parameters on the Mechanical Properties of Friction Stir-Welded Dissimilar Aluminium Alloys AA2219 and AA7068

A practical solution is friction stir welding (FSW) of heterogeneous alloys in industrial applications. The welded joint’s mechanical strength has been improved by combining two different alloys (AA2219 and AA7068). The focus of this study was on friction stir-welded heterogeneous metals’ microhardness and material properties. It is possible to work with either hot or cold aluminium alloy, as it is heat treatable. Revitalizing and precipitation hardening follow the heat treatment. The welded joints’ hardness was assessed in several locations. Different joints’ tensile characteristics are compared. According to the stress-strain curve, the FSW settings’ mechanical properties were spread throughout the material flow. In terms of tool profiles, the cylindrical threaded profile is critical. One-third of the efficiency is due to it. A 195 MPa strength was reached in the cylindrical threaded pin profiled tool. In a new study, researchers discovered that cylindrical threads have faster rotary motion, transversal, and D/d speeds. The cylindrical threaded tool provided the highest tensile strength and was superior to other materials. This phase of the material characterization included measurements of tensile strength and hardness.

Effectiveness of Breast Massage on Amount of Milk Production in Mothers who are not Actively Breast Feeding Preterm Babies

ontext: Breastfeeding to premature baby is often challenging for the postnatal mothers. In case of preterm labour milk synthesis is poor due to insufficient sucking reflex and poor mother baby bonding, if baby is admitted in neonatal unit. Breast massage is a technique to improve milk production in lactating mothers. Aims: To assess the effectiveness of breast massage on amount of milk production in mothers who are not actively breast feeding preterm babies. Settings and Design: Setting was postnatal ward Queen Mary Hospital, Lucknow. Research design was quasiexperimental (time series one group pre test post test). Methods and Material: Data were collected with the help of demographic profile and assessment of breast milk tool from 26 samples using purposive sampling technique who met the inclusion criteria. The pretest data collected before intervention and post test data collected after each intervention consecutively for 3 days. Statistical Analysis used: Mean, mean difference, standard deviation, t-test and chi-square. Results: The result revealed that on day 1, the post intervention milk production was found to be more (12.34±3.83) than pre intervention (3.03±1.98), t =16.68. On day 2, the post intervention milk production was found to be more (60.61±20.52), than pre intervention (17.07±6.73), t= 15.62 . On day 3, the pre intervention milk production was 25.15±7.13, which increased to 81.92±21.10 after intervention, t=20.16 at 0.05 level of significance. Conclusions: The findings of the study conclude that breast massage was found to be effective in increasing the amount of milk production among mothers who are not actively breast feeding preterm babies.

Corrective profiling method for tools that generate by enwrapping

There are known methods of corrective profiling of tools, which can predict the quality of parts generating obtained with cutting tools that process by enwrapping. The purpose of this profiling is to avoid errors caused by improper profiles of generating tools, using the so-called method of "reverse generation", which is based on the reproduction of the relative movement between the tool and the part, but in which the tool profile is known, and the goal is determining the part’s profile. The method presented in this paper uses the "virtual pole" method to profile the tools generating by enwrapping, by the rolling method and avoids the need to explicitly write the enveloping condition. This paper demonstrates the possibility of applying this method to the profiling of gear-shaped tools and presents the application of the proposed algorithm for a tool whose profile was determined directly by measurement. The numerical application developed demonstrates the ability of the method to simply solve the problems related to the corrective profiling of the tools that generate by rolling.

Influence of tool pin profiles in the strength enhancement of friction stir welded AA5083 and AA5754 alloys

Friction stir welding (FSW) is a well-known technology for joining similar and dissimilar materials. The quality of the weld in FSW is affected by the various process parameters such as tool rotational speed (TRS), tool transverse speed (TTS) and tool pin profiles. This study aims to investigate the effect of three different tool pin profiles on the variation of microstructure and mechanical strength of friction stir welded AA5083 and AA5754 alloys joints. Both of these alloys combinations offer excellent corrosion resistance and formability. As a result, they’re commonly seen in tanks, pressure vessels, shipyards, and trucks. In this work, the FSW methodology focused on varying the TRS of 750, 1000, 1250 and 1500 rpm and TTS as 20, 30, 40 and 50 mm min−1. The surface microstructures of the weldments were analyzed using an optical microscope and scanning electron microscope. Tensile and Microhardness tests were carried out on the weldments to determine the weld strength. Three variety of tool pins, namely straight square, threaded cylinder, and straight cylinder were used for this study. The microstructural and the mechanical properties analysis of the welded samples proved that the straight square tool pin profile is suitable for joining AA5083 and AA5754 alloys. The weldments prepared using a straight square pin profile exhibited good material stream behaviour, uniform spreading of plastic deformation in the weld zone and aided in the reduction of formation of macroscopic defects on the welded zone. Among the process parameters, it was detected that the pin profile displays more impact on tensile strength followed by tool rotation speed and welding speed. According to the findings, the dissimilar weld joint formed at the optimum process parameters had the highest tensile strength of 212 MPa and hardness of 88 HV were: Square Tool Profile, 1250 rpm TRS, and 40 mm min−1 TTS.

Optimization of process parameters of friction stir welding using desirability function analysis

The latest generation of Aluminum–Lithium alloy (Al–Li) is majorly used in aerospace industries due to its low density and high strength. Friction stir welding is a preferred joining method for the joining of Al–Li alloy due to its low heat input. The quality of the weld is majorly influenced by the process parameters. In the present work, FSW is conducted on Al-Li based alloy AA2099 T8 and studied the effect of process parameters. The objective of this article is to optimize the process parameters for maximizing the tensile strength at a minimum tool wear rate. The process parameters are optimized by the composite desirability analysis coupled with Taguchi L16 orthogonal array. The rotational speed, welding speed, tool profile, and welding condition are considered as the input process parameters. Mathematical models are developed for tensile strength, tool wear rate, and composite desirability, and the accuracy of the model is found at 95.94, 91.04, and 98.23%, respectively. Furthermore, it is observed that the improvement in composite desirability is 11.01% at optimum parameters. Moreover, the improvement in tensile strength and wear rate of the tool at optimum parameter (rotational speed 1500 rpm, welding speed 90 mm/min, tool profile cylindrical, and welding condition 80 preheated) was observed at 5.32 and 1.65%, respectively.

Geometric definition, rapid prototyping, and cutting force analysis of cylindrical milling tools with arbitrary helix angle variations

In this work, a method is developed for geometric definition and analysis of cylindrical milling tools having various free-form variations of helix angle. The method is based on replicating a position vector on each cutting edge to generate a point set for the whole tool envelope using piece-wise rotation and magnification matrices which are varied according to mathematical laws describing the intended variable shape of the tool. The computed point sets are applied in additive manufacturing of samples of such tools having non-conventional shape features by transforming the point sets to stereolithography formats that are sliced to guide the 3D-printing processes. This manufacturing route that simplifies the realization of arbitrary helix profiles on milling tools is a major contribution of this work since such tools are gaining popularity for their passive damping of vibrations and reduction of cutting forces but are notoriously difficult to manufacture, limiting their exploitation. Analyses are shown about the effects of the considered variable profiles on milling cutting force. These suggest that cutting forces can be greatly suppressed by the proposed free-form helix angle variations. For example, relative to a conventional fixed helix tool of same mean helix angle, the innovative tools recorded 40.33%–84.42% and 60.53%–67.81% force reductions at axial depths of cut of 1 and 5 mm. This demonstrates that innovative variable tool profiles which can be realized through the simplified rapid prototyping technique are promising for advanced sustainable manufacturing of parts with preferred surface conditions.

Digital generating method for cylindrical helical gear based on indexable disk milling cutter

To solve the problem of low efficiency in digital generating machining for producing small or medium batches of helical gears, a method to improve the machining efficiency with an indexable disk milling cutter is presented in this paper. First, the mathematical model of the tooth profile and the indexable disk milling cutter are established. Second, according to the spatial free-form envelope theory, the overall planning scheme of the tool path is given; the relative position and the relative transformation matrix of the tool and tooth profile during digital generating machining using the indexable disk milling cutter are solved, the simulation cutting and actual cutting experiments are conducted, and the cutting efficiency per unit time and cutting simulation time of the two tools under the same deformation conditions is obtained through a finite element analysis experiment. The results show that the cutting efficiency of the indexable disk milling tool was 2–3 times higher than that of the end mill cutter.

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.

Tool profile modification of hypoid gear machined by the duplex helical method

To avoid edge contact and stress concentration on the tooth surface of hypoid gear pairs machined by the duplex helical method for the drive axle of heavy-duty vehicles, a four-segment tool profile was designed for the simultaneous modification of the concave and convex surfaces of the pinion. First, a geometric model of the four-segment tool profile was established. Second, a mathematical model of the duplex helical method based on the four-segment tool profile was established, and a method for solving the tooth surface generated by the connecting points of the four-segment tool profile was presented. Finally, loaded tooth contact analysis based on finite element method was used to analyse the meshing performance of the gear pair obtained by the four-segment tool profile modification. The results of the original and modified gear pairs were compared. The tooth surface modification inhibited edge contact, improved the stress distribution, and decreased the maximum contact stress of the tooth surfaces, thereby improving the fatigue and wear life of the gear pair.

Review on Study Methods for Reciprocally Enwrapping Surfaces

The processing of the piece surfaces involves the transformation of the blank into a piece, the defining characteristics of the surfaces (the form, dimensions, deviations, etc.), depending to a large extent on the parameters of the generated processes of the surfaces. Generating surfaces by enveloping represents a complex problem, this mode of generating being a constant concern of researchers due to its advantages. A very important issue is the cutting edge profiling of the future tool, which will generate the wanted profile of the piece. Throughout time, researchers have studied the problems of enveloping surfaces and stated theorems related to them, based on which practical solutions have been conceive to determine the generating and generated surfaces form. The paper presents an overview on study methods for reciprocally enwrapping surfaces, as well as methods for profiling tools for generating helical surfaces by the kinematic method and by the method of decomposing the helical movement. This review can represent a basis for future research articles and projects.

Design of tool employed in dissimilar micro-friction stir welding

Friction Stir Welding is a unique way of welding similar or dissimilar materials, utilizing the friction created between the spinning tool and workpiece. This work focus on improving the weld quality obtained from micro-FSW of dissimilar materials. The tool profile used is vital in generating the frictional heat, and its failure degrades the actual process. So, the need for selecting or designing a best tool for the process is important. Design methodology is used to make this process more efficient. Several design concepts have been utilized; including Mind Map, Morphological chart, and the best tool profile was assessed using a Pugh matrix. Finite Element Analysis (FEA) was carried out using different tool profile subjected to heat generation. Based on the temperature distribution and minimum deflection criteria, the best tool design is selected and compared with the tool profile obtained based on design methodology. The best conceivable concept has been the tool pin with a triangular profile. Based on the study High Carbon High Chromium tool steel is selected as tool material, considering the mechanical properties and cost of tooling.

Optimization of FSW parameters of AA6061-6 wt.% SiC composite plates

AA6061-SiC composites are the most preferred materials for applications in the automobile and aerospace sector due to their superior properties. The FSW process is one of the novel solid states joining processes that overcome almost all the difficulties of the fusion welding process because the process that operates well below the melting point of the metals to be joined, consumes less energy, environment-friendly, and versatile, no shielding gas or filler metal is used. The welding parameters such as tool rotational speed, axial force, and tool pin profile play a major role in deciding the joint strength and hardness of the weld zone. Taguchi method was employed in this study to scrutinize the impact of welding processing factors, including rotational, speed, axial load, and pin profile on ultimate tensile strength, microhardness of weld zone. The results reveal that the welded joints produced at 750 rpm of tool rotational speed, the axial load of 6 kN using a square pin tool profile that exhibits higher UTS. The Vickers's hardness of AA6061-6 wt.% SiC composites was found to be superior at tool rotational speed of 900 rpm, the axial force of 6kN using cylindrical tool pin. The ANOVA Findings based on Vickers's hardness are tool profile: 53.84%, tool rotational speed: 20.16%, and axial force: 21.32%.

Educational Data Mining to Identify the Patterns of Use made by the University Professors of the Moodle Platform

Due to the events caused by the COVID-19 pandemic and social distancing measures, learning management systems have gained importance, preserving quality standards, they can be used to implement remote education or as support for face-to-face education. Consequently, it is important to know how teachers and students use them. In this work, clustering techniques are used to analyze the use, made by university professors, of the resources and activities of the Moodle platform. The CRISP-DM methodology was applied to implement a data mining process, based on the Simple K-Means algorithm; to identify associated groups of teachers it was necessary to categorize the data obtained from the platform. The Apriori algorithm was applied to identify associations in the use of resources and activities. Performance scales were established in the use of Moodle functionalities, the results show the use made by teachers was very low. Rules were generated to identify the associations between activities and resources. As a result the functionalities that need to be enhanced in the teacher training processes were identified. Having identified the patterns of use of the Moodle platform, it is concluded that it was necessary to use a Likert scale to transform the frequency of use of activities and resources and identify the rules of association that establish profiles of teachers and tools that should be promoted in future training actions.

Influence of Straight Cylindrical and Straight Threaded Tool Profile in the Friction Stir Welding of AA 6061 Aluminum Alloy

Influence of Straight Cylindrical and Straight Threaded Tool Profile in the Friction Stir Welding of AA 6061 Aluminum Alloy

A holistic approach for gear skiving design enabling tool load homogenization

Gear skiving is a highly productive manufacturing process for internal gears. Due to its challenging cutting conditions often insufficient tool life is achieved and localized wear occurs. There is a lack of tool parameters in process design that allow for an uniform and comparable characterization of the process kinematics and tool geometry. In this paper, a new method for calculating process kinematics and tool profile based on parameters of profile-shifted conical gears and an approach for tool load homogenization are presented. The high potential of the methods is demonstrated by comparative tool life tests with an improvement of 300%.