Tool Face Research Articles

A wireless and passive tool holder for online measurement of milling temperature

Abstract The measurement of cutting temperature is very important in monitoring the manufacturing process and greatly impacts tool wear and the workpiece surface quality. Milling temperature measurement is particularly difficult due to high-speed rotation. This paper uses an intelligent and wireless passive tool-holder system for milling temperature sensing, with a resolution of 0.25°C, a range of 0~700°C, and an update speed of 10 Hz. Thermocouple is pre-embedded in the machined groove near the cutting edge on the flank face of the milling tool, and signal acquisition circuits and wireless transmission module are integrated into the tool holder system for online signal processing. Based on electromagnetic induction, the self-power supply scheme is designed by converting the rotating kinetic energy of the spindle to electricity, and hierarchical energy regulation is achieved to realize a stable and constant power supply. With a temperature-sensing intelligent tool holder, cutting experiments on different processing parameters are carried out to verify the feasibility of the measurement system.

Assisting Directional Drilling by Calculating a Safe Operating Envelope

Summary Nowadays, complex 3D trajectories are executed with a succession of circular arcs (CAs). Although they have constant curvature, their tool face is not constant. Consequently, directional drillers must adjust the tool face regularly to reach the target entry within its tolerances. This paper investigates the use of the constant curvature and constant tool face (CTC in short) curve as an alternative to the CA to assist the directional drilling work to reach the target entry within its boundaries. The problem is addressed by calculating a safe operating envelope (SOE) to reach the boundaries of the target entry and provide a tolerance window for the curvature and tool face to support directional drilling decisions. The target entry tolerance is discretized as a polygon. From the current bit position and its direction, the possible choices of curvatures and tool faces are obtained to reach the edges of the target entry shape. The SOE can be calculated with the CA or with the CTC curve. It is, therefore, possible to compare the advantages and disadvantages of both types of curves to attain the target entry and stay within its boundaries. The CA is shorter than the CTC curve. However, it requires adjusting the tool face during the navigation, which is not the case with the CTC curve. As a result, the directional driller can control the bottomhole assembly (BHA) direction such that the well lands within the target entry limits by using set points for tool face and curvature inside the calculated SOE. Furthermore, a new way to represent the SOE is introduced. It makes use of a 3D cylindrical representation where the curvature is mapped as the height of a cylinder, while the tool face corresponds to the azimuth in the cylindrical coordinate system, and the length is linked to the radial distance. This provides a visual aid to understand the SOE. Moreover, this visualization helps to appreciate the relationship between the initial bit location and direction in the construction of the SOE and how the margins increase in a particular manner as the bit approaches the target entry polygon. The CTC curve is the natural one followed by directional positive displacement motors (PDMs) or rotary steerable systems (RSS). Potentially, the CTC curve may be a more straightforward solution to automated directional drilling control because it is easier to be followed by both PDM and RSS.

An Analysis of Drilling Projection Uncertainty and Implications for Collision Avoidance Management Systems

Summary During well planning, specifying the separation that must be maintained from offset wellbores is critical to ensuring safe operations. Recent efforts on API RP 78, an upcoming American Petroleum Institute recommended practice for wellbore placement, have provided guidelines for calculating safe separation distances and engineering considerations for those calculations. A major milestone was the publication of a separation rule (Sawaryn et al. 2019) standardizing a formula for separation factor (SF), which in turn defines the minimum allowable separation distance (MASD) between two wellbores and the allowable deviation from plan (ADP) for a wellbore being drilled. One element of this formula, σpa, describes the accuracy with which a future wellpath can be predicted. Prior guidance provides a suggested value for σpa (1.6 ft or 0.5 m at 1-sigma) based on heuristics. A more rigorous approach for estimating this value is presented, where the design of the drilling program can be considered. A framework is proposed for modeling deviation from a projected path using a planned trajectory, bottomhole assembly (BHA) properties, and survey practices. The method identifies where a deviation is detected through survey measurements and estimates a planned recovery operation. Equations are provided for estimating the distance from plan at deviation detection along with the maximum expected deviation during recovery. Common drilling scenarios are analyzed for sensitivity to operational parameters such as survey course length, sensor offset, tool face control, and BHA performance. The impact of varying σpa is explored across prototypical collision avoidance cases. A discussion of the relationships between the σpa value and the common collision avoidance calculations, such as SF, MASD, and ADP, is included along with considerations for the design of a risk management policy. Survey course length, survey sensor offset, and uncertainty in directional performance are all shown to have a significant impact on the potential maximum deviation from plan. An additional factor considered is the aggressiveness expected when performing recovery operations. An analysis of common drilling scenarios suggests the previously provided guidance of 1.6 ft at 1-sigma appears suitable for cases where the directional behavior of the BHA is well characterized and the combination of course length and survey sensor offset is kept to 150 ft or less. Longer survey course lengths, larger sensor offsets, or uncertainty in directional performance of the BHA can produce larger σpa values, in some scenarios causing a significant impact on the MASD and ADP. Previous work has called attention to the uncertainty in drilling to a projection, but up to now, there has not been a rigorous method for estimating that quantity. With the methods outlined in this paper, well planners and drilling engineers can make more informed decisions on how to ensure safe separation practices in their own operations.

Optimization of Sustainable Production Processes in C45 Steel Machining Using a Confocal Chromatic Sensor

Metal machining production faces a myriad of demands encompassing ecology, automation, product control, and cost reduction. Within this framework, an exploration into employing a direct inspection of the machined area within the work zone of a given machine through a confocal chromatic sensor was undertaken. In the turning process, parameters including cutting speed (A), feed (B), depth of cut (C), workpiece length from clamping (D), and cutting edge radius (E) were designated as input variables. Roundness deviation (Rd) and tool face wear (KM) parameters were identified as output factors for assessing process performance. The experimental phase adhered to the Taguchi Orthogonal Array L27. Confirmatory tests revealed that optimizing process parameters according to the Taguchi method could enhance the turning performance of C45 steel. ANOVA results underscored the significant impact of cutting speed (A), feed (B), depth of cut (C), and workpiece length from clamping (D) on turning performance concerning Rd and KM. Furthermore, initial regression models were formulated to forecast roundness variation and tool face wear. The proposed parameters were found to not only influence the machined surface but also affect confocal sensor measurements. Consequently, we advocate for the adoption of these optimal cutting conditions in product production to bolster turning performance when machining C45 steel.

Analysis of the influence of dies geometry on the process extrusion force and properties of the extrudate obtained in the process of cold extrusion of 7075 aluminum alloy by the KOBO method

Abstract The KOBO extrusion process is an unconventional method of extrusion based on the phenomenon of superplasticity as an effect of a special state caused by the oscillatory motion of the die at a certain angle a certain frequency. It significantly lowers the extrusion force and makes it possible to extrude lightweight metals and alloys (e.g. aluminum and magnesium alloys) in cold extrusion with high extrusion ratios compared to conventional hot extrusion. This work studies the influence of the tool (die) geometry on process realization parameters and the properties of the extrudate. Experimental studies of cold KOBO extrusion were performed using dies with different face portion geometry. The obtained extrudate obtained from EN-AW 7075 aluminum billets was examined for mechanical properties and macro/microstructure, showing that, with adequate modifications to the tool face part geometry, it is possible to lower the extrusion force and obtain extrudate with desired properties.

Face and content validity of a mobile delirium screening tool adapted for use in the medical setting (eDIS-MED): Welcome to the machine.

Following a user-centred redesign and refinement process of an electronic delirium screening tool (eDIS-MED), further accuracy assessment was performed prior to anticipated testing in the clinical setting. Content validity of each of the existing questions was evaluated by an expert group in the domains of clarity, relevance and importance. Questions with a Content Validity Index (CVI) <0.80 were reviewed by the development group for potential revision. Items with CVI <0.70 were discarded. Next, face validity of the entirety of the tests was conducted and readability measured. A panel of five clinical experts evaluated the test battery comprising eDIS-MED. The content validity process endorsed 61 items. The overall scale CVI was 0.92. Eighty-eight per cent of the responses with regard to question relevancy, usefulness and appropriateness were positive. The questions were deemed fifth grade level and very easy to read. A revised electronic screening tool was shown to be accurate according to an expert group. A clinical validation study is planned.

An FSCEEMD method for downhole weak SNR signal extraction of near-bit attitude parameters

In practice, the near-bit drilling tool confronts with strong vibrations and high-speed rotation. Therein the original signal amplitude of the tool attitude measurements is relatively feeble, and the signal-to-noise ratio (SNR) is exceptionally low. To handle this issue, this paper proposes a weak SNR signal extraction method, frequency selecting complementary ensemble empirical mode decomposition, which is based on ensemble empirical mode decomposition combining with complementary noise and frequency selecting. This method firstly adds different positive and negative pairs of auxiliary white noise to the original near-bit weak SNR signal, secondly adopts empirical mode decomposition on each pair of noise-added signals, then performs ensemble averaging on the obtained multiple sets of intrinsic mode function (IMF) to output more stable IMF of each order and set suitable weights according to designed frequency threshold, and finally reconstructs the original useful signal through weighted summing IMFs. Simulation results show that the extraction accuracy of well inclination angle ranges about ± 0.51°, and the extraction accuracy of tool face angle ranges about ± 1.35°, and meanwhile experimental results are provided compared with other advanced methods, which verifies the effectiveness of our method.

Study on the atomic removal behavior and damage formation mechanism of nano cutting copper–nickel alloy with diamond tool

The effects of tool rake angle and cutting depth on cutting temperature, cutting force, friction coefficient of rake tool face, atomic accumulation of chip flow and removal, surface quality, sub-surface damage layer thickness, atomic stress, and dislocation evolution were studied by molecular dynamics simulations. The results showed that the cutting temperature was concentrated on the chip, and the chip was easy to flow out with the increase of the tool rake angle, which weakens the extrusion and shearing action of the workpiece, resulting in the gradual reduction of tangential force. The tool rake angle of 10° is beneficial to improve the surface/subsurface quality of the workpiece. The minimum root-mean-square roughness obtained was 0.73 Å. The atomic stress of the workpiece was mainly concentrated around the area of interaction with the tool, and the atoms on the finished surface underwent elastic recovery, so the atomic stress was not significant. The 1/6<112> (Shockley) dislocation density had always been in the leading position, and 1/6<112> (Shockley) dislocation was continuously synthesized and decomposed during the nano-cutting process. With the increase of cutting depth, the number of atoms removed increases rapidly, and the width of chip side flow increases, but the symmetry is weakened. The contour line map even shows deep wave valleys caused by the absence of atoms, which increases the surface roughness. Moreover, the area and depth of the atomic stress distribution in the subsurface layer increase, and the number of amorphous atoms and dislocation density increase.

Integrated design and fabricate of high sensitivity built-in thin-film thermocouple temperature measurement tool

Abstract Cutting temperature is playing a key role in evaluating the cutting process, which significantly affects the tool wear and the quality of the workpiece. Aiming at the problems of low precision, low aging, and poor stability of cutting temperature measurement on the front tool face, an integrated design and production scheme of a high sensitivity built-in wireless temperature measurement tool was proposed. The temperature distribution position on the front tool face was analyzed with 3D finite element simulation software, and the thermal contact position of the main and secondary film thermocouples was determined. SiO2 insulated films and NiCr/NiSi film thermocouples were prepared on the front tool surface by femtosecond laser micromachining, electrolyte-plasma polishing, plasma enhanced chemical vapor deposition and magnetron sputtering, and a static calibration experiment system for sensitivity and accuracy of the temperature measuring tool for the film thermocouple was established, and Seebeck coefficient of the film thermocouple was obtained. According to the actual cutting conditions, the wireless temperature measuring system of the thin film thermocouple tool was built and the field cutting test was carried out to obtain the influence law of different cutting parameters on the cutting temperature, and further verify the feasibility of the thin film temperature measuring sensor. The research results show that: Seebeck coefficients of the two kinds of thermocouples prepared by the NiCr/NiSi thin film thermocouple temperature measuring tool are 34.97 μV/°C and 34.96 μV/°C, and the slope of the temperature data fitting curve is 1.00398 and 0.997475, respectively. The linear correlation coefficient R2 is close to 1, which is close to the standard K-type thermocouple, which shows good sensitivity and accuracy. At the same time, the temperature measurement results are close to the commercial standard K thermocouple, and the error is less than 5%, indicating that the developed film thermocouple has a high measurement accuracy and can meet the needs of temperature measurement. Actual cutting test is carried out with developed wireless temperature measuring device of thin film thermocouple, which shows this device can meet the requirements of tool temperature measurement, and the feasibility of thin film temperature measuring sensor is further verified. The research provide technical reference for industrial intelligent manufacturing in order to realize the wireless measurement of cutting area temperature of tool front.

Uncertainty analysis method for the output force vector control on the rib of the orienter in coiled tubing drilling

This work addresses the uncertainty associated with downhole parameters in coiled tubing drilling and proposes a new method for controlling the output force vector on the ribs of the orienter, enabling more precise control of the actual wellbore trajectory. Based on the principles of longitudinal and transverse bending beams, we construct a 3D mechanical model of the Bottom Hole Assembly (BHA) used in coiled tubing drilling. We then analyze the spatial geometry relating the force direction on the orienter's rib and the tool face angle, establishing a comprehensive steering resultant force vector model. Applying the principle of minimum energy, we explore traditional control schemes for the output force on each rib and reveal its intricate variation patterns. We conduct a statistical analysis to investigate the randomness distribution state and sensitivity of the experimental parameters, allowing us to derive the probability density and cumulative probability functions for the two-dimensional random variables linked to the output force on the ribs. Confidence interval models are constructed to predict the output forces with a predetermined level of certainty. Finally, we experimentally verify the proposed uncertainty control method in real-world coiled tubing drilling. Our results show that the randomness of weight on bit (WOB) and the tool face angle of rib 1# are the main factors influencing the uncertainty of the output force control. When the output forces vector on the ribs exceeds the uncertainty confidence interval, the actual wellbore trajectory significantly deviates from the designed one. Conversely, when the output forces vector falls within the confidence interval, the error between the actual and designed wellbore trajectories is significantly smaller. This validates the rationality and effectiveness of the proposed uncertainty analysis method, providing valuable guidance for implementing wellbore trajectory control in coiled tubing drilling.

Precision tailoring of laser beam propagation in a single crystalline diamond tool for in situ laser-assisted diamond turning.

The characteristics of laser beam propagation within a diamond tool critically influence the applied thermal softening capability of in situ laser-assisted diamond turning (In-LAT). In the present work, we perform optical geometric analysis, optical simulation and experimental validation to propose a novel diamond tool configuration for precisely tailoring laser beam propagation in In-LAT. First, the characteristics of laser beam propagation in the current In-LAT diamond tool are theoretically and experimentally explored. Second, according to the issues discovered in the current In-LAT diamond tool, an improved tool configuration based on the total internal reflection of a laser beam within the diamond tool is proposed, aiming for promoting refraction of the laser beam from the rake face of the diamond tool as well as eliminating the reflection of laser beam to tool holder. Finally, the optimization of laser beam incident position is carried out for achieving the superior profile and intensity of the emitted laser spot. Current work provides rational laser beam propagation for improving the thermal-softening capability of an In-LAT diamond tool.

Performance Evaluation of Micro-Textured Inserts Coupled With Solid Lubricants During the Sustainable Dry Machining of Inconel 825

Abstract In this research work, the turning of Inconel 825 has been carried out using uncoated and coated laser-textured hard tungsten carbide (WC) cutting inserts. The efficacy of uncoated textured inserts has been tried to improve by impregnating them with micro-sized MoS2 and nano-TiC powder paste. The results of coated and uncoated textured inserts have been compared with the plain uncoated tungsten carbide insert. The use of solid lubricant-impregnated textured tools and coated textured tools has significantly reduced the cutting forces and chip–tool interface friction as compared to plain and normal textured tools. Upon the SEM analysis, high adhesion over the rake face of the plain tool has been observed. The excessive adhesion over the rake surface has been observed over the normal textured tool due to the derivative cutting phenomena. The use of MoS2 and nano-TiC-impregnated textured tools has significantly reduced the material adhesion over the rake surface by eliminating the derivative cutting effect. The use of AlTiSiN-coated textured tools has also restricted the extent of work material adhesion over the rake surface of the cutting insert.

Modelling of the damage initiation at WC/WC and WC/Co boundaries in WC-Co tool material at the microstructure scale: Application to the tool/chip contact

In machining process, the wear of tungsten‑cobalt carbide cutting tools (WC-Co) is the result of different wear mechanisms such as abrasion, adhesion and diffusion. At the microstructure scale, the presence of microcracks in the carbide grain boundaries can be observed of the tool and in the WC/Co interfaces on the cutting surface. These microcracks are the cause of the WC-Co pull-out clusters from the cutting tool face. In this work, simulations were set up to evaluate the number of WC/WC and WC/Co interfaces that are likely to be damaged first. The behaviour of each phase was modelled by thermo-elasto-plastic behaviour and cohesive interfaces of zero thickness were used to simulate the behaviour of WC/WC and WC/Co interfaces. Different quasi-realistic microstructures were generated by an algorithm to evaluate the dispersion of the results. These microstructures are surrounded on three sides by an assumed homogeneous WC-Co embedding. The microstructure and the embedding form a part of the cutting tool with one side rubbing against a rigid chip to locally reproduce the chip/tool contact. The results of this study show the influence of the cobalt content, temperature, friction coefficient and orientation of the interfaces on the number of interfaces likely to be damaged first.

Attitude Control of Stabilized Platform Based on Deep Deterministic Policy Gradient with Disturbance Observer

A rotary steerable drilling system is an advanced drilling technology, with stabilized platform tool face attitude control being a critical component. Due to a multitude of downhole interference factors, coupled with nonlinearities and uncertainties, challenges arise in model establishment and attitude control. Furthermore, considering that stabilized platform tool face attitude determines the drilling direction of the entire drill bit, the effectiveness of tool face attitude control and nonlinear disturbances, such as friction interference, will directly impact the precision and success of drilling tool guidance. In this study, a mathematical model and a friction model of the stabilized platform are established, and a Disturbance-Observer-Based Deep Deterministic Policy Gradient (DDPG_DOB) control algorithm is proposed to address the friction nonlinearity problem existing in the rotary steering drilling stabilized platform. The numerical simulation results illustrate that the stabilized platform attitude control system based on DDPG_DOB can effectively suppress friction interference, improve non-linear hysteresis, and demonstrate strong anti-interference capability and good robustness.

Analysis of Tool Wear and Chip Morphology during Turning of AZ31B Magnesium Alloy under Dry Environment

The present research investigated the turning of AZ31B magnesium alloy in a dry environment using carbide tool inserts coated with tungsten carbonitride (TiCn) and thin alumina (Al2O3). A Box–Behnken design based on fifteen experiments showed a proportional increasing trend of flank wear with all three machining parameters, i.e., cutting speed, feed rate, and depth of cut. The most influential parameter is the cutting speed. A maximum flank wear of 299.34 µm due to excessive adhesion of work material on the tool face was observed at a high cutting speed. Machining at low speed resulted in a significant reduction in tool wear due to less chipping. The tool wear and chip morphology study confirmed the results.

Discrete wavelet transforms analysis of vibration signals for correlating tool wear in diamond turning of additive manufactured Ti-6Al-4V alloy

Ultra-precision machining (UPM) of Ti-6Al-4V alloy is widely regarded as a challenging material processing due to excessive tool wear and chemical reactivity of the tool and workpiece. Tool wear has a significant influence on the surface quality and also causes damage to the substrate. Therefore, it is critical to consider the tool condition during diamond turning, especially as precision machining moves toward intelligent systems. Consequently, there is a need for effective ways for in-process tool wear monitoring in UPM. This study aims to monitor the diamond tool wear using time-frequency-based wavelet analysis on vibrational signals acquired during the machining of Additively Manufactured (AM) Ti6Al4V alloy. The analysis employed Daubechies wavelet (db4, level 8) to establish a correlation between the Standard Deviation (SD) of the magnitude in the decomposed vibrational signal obtained from both the fresh and used tools. The analysis revealed that at a feed rate of 1 mm/min, the change in SD is 32.3% whereas at a feed rate of 5 mm/min, the change in SD is 8.4%. Furthermore, the flank wear and microfractures are observed using a scanning electron microscope on the respective flank and rake face of the diamond tool.

Infrared thermography as a non-invasive method for evaluating stress in lactating dairy cows during isolation challenges.

The overall objective of the current data report was to evaluate and test the feasibility of using infrared thermography (IRT) as a non-invasive method for measuring stress signs in lactating dairy cows during short negative challenges, such as visual isolation from herd-mates. The study was carried out at the Experimental Farm of the Research and Development Institute for Bovine Romania, on 20 Holstein-Friesian lactating multiparous dairy cows, between August and September 2022. Cows were housed in two identical tied stanchion barns (170/85 cm), and were isolated individually from the herd for 240 min post-morning milking. Our results shown significant (p ≤ 0.05) rises for both orbital and nasal IRT temperatures following the isolation challenge, suggesting that such approaches could represent adequate tools for assessing social stress in cattle. Overall, current results are in accordance with previous studies which validated both eye and nasal regions as IRT thermal windows for studying the effects of painful and negative contexts on stress response in farmed ruminants, while considering the stress-induced hyperthermia as an integral part of the physiological response to negative stimuli, as well as the current limitations that this tool faces.

Tool anisotropic wear prediction and its influence on surface topography in diamond turning of oxygen-free copper

Oxygen-free copper components are widely used in high energy physics engineering, which are usually fabricated by the diamond machining process for achieving low roughness surface. However, the wear of diamond tool heavily affects the surface quality. In this work, the wear law of diamond tool in machining of oxygen-free copper is studied with consideration of the anisotropy of diamond strength. Firstly, the stress distribution on the tool face in machining is calculated. The results show that the cutting stress near the flank face is larger than that near the rake face. Secondly, the strength distribution of tool cutting edge is modeled. The theoretical prediction reveals that the anisotropy of diamond crystal leads to the great differences in the strength of cutting edge at different positions, and further affects the cutting edge wear resistance. Thirdly, the wear model of diamond tool is established with consideration of cutting stress distribution and tool edge strength, in which the mechanical wear is the dominant wear process. Finally, the variation of the surface roughness is analyzed on the basis of the tool wear through the cutting experiments. The experiment results indicate that the surface material deformation is closely related to the tool cutting edge wear transition area and results in different values of surface roughness. The obtained results can improve the understanding of the diamond tool wear law and estimate the diamond tool wear in machining of oxygen-free copper.

Vaccination Mandates—An Old Public Health Tool Faces New Challenges

This Viewpoint discusses how federal vaccine requirements have helped thwart vaccine-preventable diseases as well as how growing public resistance to vaccines and judicial and legislative limits to vaccination mandates may change that.

Evaluating Psychometric Properties of the Sultan Bin Abdulaziz Humanitarian City (SBAHC) Nurses' Electronic Handover Tool.

Handover is crucial during the transfer of patient care between healthcare professionals.Successful handover maintains patients' safety and high-quality care. The electronic handover of patients' information is achievable, feasible, and potentially improves the quality of patient care. However, the introduction of the electronic handover is relatively recent and challenging for healthcare providers, especially nurses. Since Sultan Bin Abdulaziz Humanitarian City (SBAHC)has recently implemented an electronic handover system among nurses, the main aim of the current study was to develop a tool to assess the perception and barriers to electronic handover systems among nurses working at SBAHC and evaluate its psychometric properties. The tool content and face validity were assessed by the content validity ratio (CVR). Exploratory and confirmatory factor analysis were used as validity methods, while the test-retest and inter-item consistency were used as reliability measures. The sample size was planned as five times the number of questions and a total of 200 nurses participated in the study. The criteria required for factor analysis were met as indicated by the results of the Kaiser-Mayer-Olkin test and Bartlett's test of sphericity. The reliability results showed a Cronbach's alpha coefficient ranging from 0.858 to 0.910 for the perception subscale and from 0.564 to 0.789 for the barrier subscale, and an overall interclass correlation of 0.986, p<0.001. The developed SBAHC electronic handover tool was valid and reliable, and it is advisable to consider it at the initial stages of implanting an electronic handover system to identify obstacles that are faced by the staff to be considered and addressed by the higher management.