Browse Topic: Machining processes

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Tolerances Titanium and Titanium Alloy Extruded Bars, Rods, and Shapes AMS2245D (Current)12/09/2025
This specification covers established manufacturing tolerances applicable to titanium and titanium alloy extruded bars, rods, and shapes. These tolerances apply to all conditions, unless otherwise noted. The term "excl" applies only to the higher figure of the specified range.
AMS G Titanium and Refractory Metals Committee
Core, Honeycomb, Aluminum Alloy, Corrosion Inhibited For Sandwich Construction, 5052, 350 (177)AMS4348F (Current)11/21/2025
This specification covers bonded honeycomb core made of aluminum alloy and supplied in the form of blocks, slices, or other configurations as ordered.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extruded Wide Panel Profiles (7150-T77511), 6.4Zn - 2.4Mg - 2.2Cu - 0.12Zr, Solution Heat Treated, Stress-Relieved, Straightened and OveragedAMS4325B (Current)11/21/2025
AMS4325A prohibits unauthorized exceptions (3.7), revises condition (3.2), properties (3.4.5), quality (3.5.1), reports (4.4.1), and identification (5.1.1), and results from a Five-Year Review and update of this specification.
AMS D Nonferrous Alloys Committee
Development of Higher Clarity Injection Molded Windscreen for Motorcycles2024-32-004004/18/2025
The windscreen is one of the key elements to enhance passenger comfort of touring motorcycle. The clarity through the windscreen should not discomfort the rider. The discomfort we discuss here mainly refers to three factors: the “distortion,” the “blur,” and the “transparency.” Introduced in this paper is the technical measures to achieve sufficient clarity by the injection molding method. Firstly, with respect to the “distortion,” we determined the main cause was local unevenness of plate thickness. As the uneven thickness were related to the accuracy of the die, we clarified the tolerable zone and carried out higher precision machining of the die to satisfy the requirements. Regarding the “blur,” we analyzed the refractive power of the windscreen and found the main cause of blur is the microscopic roughness on the surface. As the microscopic roughness were attributable to the die surface, we clarified the tolerable zone and established the polishing conditions satisfactory for the
Yamada, Atsushi, Endo, Sakae
Characterization and Aluminum Recovery from Chemical Milling Sludge in Aerospace Industry2025-01-501603/21/2025
The chemical milling process used in the aerospace industry generates substantial metallic residue in the etching bath, referred to as chemical milling sludge (CMS). The direct disposal of CMS into the environment leads to ecological deterioration and economic losses. This study focused on the recovery of aluminum from the aerospace industry CMS, aiming to mitigate environmental harm and enhance resource efficiency. The energy-dispersive X-ray (EDX) analysis revealed that the aluminum content in extracted CMS increased significantly to 95.86%, compared to 28.98% in non-extracted sludge. The XRD analysis of the CMS extracted samples also revealed the presence of increased Al2O3. The surface morphology study suggested the irregularly shaped particles with large chunks, and fine granules were observed on CMS. The yield of Al2O3 was observed to be 35.9% (wt) prior to the calcination process followed by 12.1% (wt) after calcination. The phytotoxicity study indicated that the CMS inhibited
Prasad, Jag, Sonwani, Ravi Kumar
3D-PRINTING IMPACTS ON SYSTEMS ENGINEERING IN DEFENSE INDUSTRY2024-01-352711/15/2024
ABSTRACT Today’s combat vehicle designs are largely constrained by traditional manufacturing processes, such as machining, welding, casting, and forging. Recent advancements in 3D-Printing technology offer tremendous potential to provide economical, optimized components by eliminating fundamental process limitations. The ability to re-design suitable components for 3D-printing has potential to significantly reduce cost, weight, and lead-time in a variety of Defense & Aerospace applications. 3D-printing will not completely replace traditional processes, but instead represents a new tool in our toolbox - from both a design and a manufacturing standpoint.
Deters, Jason
On-Line Pose Measurement and Adjustment of End Effector Based on Laser Tracker for Robotic Drilling System2023-01-098203/07/2023
Tang, Yue, Zheng, Jinhui, Zhang, Mao
Development of Predictive Models and Prediction of Process Parameters for Wire Electrical Discharge Machining of Monel 4002022-28-049111/18/2022
The numerous applications and desirable attributes of Monel 400 urge many researchers to undertake multiple systematic evaluation studies for diverse manufacturing operations. Because of their exceptional mechanical qualities and great corrosion resistance, nickel-based alloys, particularly Monel 400, are increasing in popularity in a variety of applications. Because of their tendency for rapid work hardening and low thermal conductivity, these materials are particularly difficult to machine using traditional manufacturing techniques. Advanced material removal methodologies have been applied to eliminate such drawbacks and are regarded as a suitable alternative approach to traditional machining processes. Based on the Electrical Discharge Machining technique, Wire Electrical Discharge Machining was developed, which a sophisticated machining technology is used to machine hard materials with complex forms in any electrically conducting materials. The machinability performance of Monel
Natarajan, Manikandan, Pasupuleti, Thejasree
An Effective Design of Micro Tesla Valve as a Passive Mixer in Microfluidics Channels 2022-26-117805/26/2022
Mixing fluids is one of the major challenges in microfluidics. Normally, the mixing process is done by diffusion rather than turbulence, which makes it very slow due to low Reynolds number (Re) flow in the range of 0.1 to1. Owing to this behaviour, ineffective mixing occurs when two miscible liquids are mixed purely by diffusion which requires longer striation lengths and therefore longer microfluidic channels along with lengthy mixing time. Homogeneous mixing of solute and solvent is important for providing consistent chemical and biological reactions in µTAS.In this study, we develop a passive mixer that provides efficient mixing using micro tesla valves which allows the flow of liquids in the forward and reverse directions to analyse the formed vortices, turbulent intense areas, Reynolds number, and pressure using Ansys fluent workbench. An optimum design has been arrived by varying the number of cells from 1 to 5 in series and realization is done by excimer laser micromachining.
Singh, Deepak, Sankar PhD, Ravi
Novel study on Elastic recuperation of Titanium (grade 5) alloy during machining2022-26-116705/26/2022
Machining is the process of removing material from a workpiece, in the form of chips, to obtain the final part in its desired shape and size. Various aerospace materials such as Aluminum, Steel, Titanium etc. can be mainly shaped through machining process. Titanium alloys also find larger adoption in areas like Bio-medical and Automotive mainly because of their inherent high specific strength and consistent corrosion resistance. Machining Ti-6Al-4V (grade 5) has been difficult due to a number of its characteristics like poor conductivity of heat, strong and undesirable chemical reactivity with cutting tool materials at operating/ cutting temperature, it’s work hardening characteristics and very low modulus of elasticity. Due to low modulus of elasticity, the elastic recovery or recuperation of thin-walled Titanium grade 5 parts that occur after machining is an important topic/issue to be addressed since it has greater effect on the work piece surface quality, cutting tool wear and the
Acharya, Nishanth R.
Machinability Studies on Wire Electrical Discharge Machining (WEDM) of AA2014 alloy using Taguchi Grey Approach2021-28-026410/01/2021
AA 2014 is a copper based aluminium alloy which is having exceptional mechanical characteristics such as better strength, ductility and lesser fatigue. AA 2014 is most generally employed in various engineering applications such as fabrication of structural components, defense applications and manufacturing of aerospace components. Also, this material possess better resistant to corrosion which makes this material best suitable for numerous engineering applications. Unconventional methods of machining have been evolved for producing intricate shapes in electrically conductive components. Wire Electrical Discharge Machining (WEDM) is one among the unconventional machining method which is used for making intricate shape on any electrically conductive work material. In this work, an experimentation has been carried out on WEDM of AA 2014 alloy, employing Taguchi’s technique. The experimental runs have been conducted by taking into account, the process variables such as pulse-on-time, pulse
Navya, C., Chandra Sekhara Reddy PhD, M
Experimental Analysis on Wire Electrical Discharge Machining of Nickel Alloy Using Taguchi based Grey Relational Analysis2021-28-027310/01/2021
Nickel is one of the difficult to machine materials and exclusively employed in high temperature environments. This alloy possesses better strength and lesser thermal coefficient which makes the poor machining performance in conventional methods of machining. For overcoming such kind of demerits, nontraditional machining methods have been identified. Wire Electrical Discharge Machining (WEDM) is one among the advanced methods that is developed from the concept of Electrical Discharge Machining process that is predominantly engaged for machining of harder materials and also for producing intricate shapes. This present exploration deals about an experimental study on WEDM of nickel alloy and also mainly concentrating on the optimization of process variables using Taguchi based grey approach. The experimental trials are devised by Taguchi’s experimental design approach and process variables are analyzed by Taguchi’s single response analysis. Pulse on time, pulse off time and peak current
N, MANIKANDAN, Joseph Selvi, Binoj, KRISHNAMACHARY, P.C, Thejasree, P
Application of Taguchi approach on Wire Electrical Discharge Machining of SS3042021-28-027110/01/2021
SS304 (Stainless Steel 304) is a nickel- chromium based alloy, that is extensively used for the applications like cryogenic vessels, valves, refrigerator equipment and evaporators because of its high corrosion resistance, ductility and ability to remain as solid up to a temperature of 14000 C. SS304 is one of the tough to machine materials by conventional methods of machining. Wire Electrical Discharge Machining (WEDM) facilitates the ease of machining complicated cuts with hard to machine, conductive materials where high surface finish is required. In this investigation, a study has been done on WEDM of SS304 and mainly to optimize the process parameters during the machining of SS304 by using Taguchi’s analysis. Taguchi’s DoE approach is used to plan the experimental runs and by considering the process parameters such as pulse on time, pulse off time and peak current at three different levels the experiments were conducted. The performance measures considered in present analysis are
Thejasree, P., N, Manikandan, Krishnamachary, PC, Varaprasad, K C, Joseph Selvi, Binoj
Development of a Non-Parametric Robot Calibration Method to Improve Drilling Accuracy2021-01-000303/02/2021
The drilling of large quantities of repetitive holes during the manufacture of large aerospace components is often considered a key limiting factor with regards to production efficiency. Whilst the desire within aerospace is to use relatively cheap six axis robot arms with drilling end effector units, their poor accuracy remains an obstacle. Robot calibration presents a way of improving robot accuracy such that aerospace drilling tolerances can be met, without permanently committing metrology equipment to an automation cell during production. Extensive research has been conducted into robot calibration by correcting the kinematic model, known as parametric calibration. This method is highly complex, and calibrates the robot across the entire working volume. This is often not required in industrial drilling applications, as drilling routines are often contained within a smaller volume of the robot reach. In this paper, a non-parametric method of robot calibration is proposed. This
Scraggs, Chris, Smith, Thomas, Sawyer, Daniela, Davis, Matthew
A Novel Approach to Dynamic Contact Analysis in the Course of Aircraft Assembly Simulation2021-01-000403/02/2021
A new numerical approach is proposed for studying possible vibrations caused by drilling during the assembly of aircraft structures. It is based on modelling of the stress-strain state of assembled structures by solving the corresponding transient contact problem. This approach is intended for fast dynamic analysis of the structure in the drilling area. It includes a time discretization algorithm, a special reduction technique and a reformulation of contact problem in terms of quadratic programming. The high speed of the algorithm allows one to combine the non-stationary calculations with variation analysis in order to check the possible deviations in the shape of assembled parts. The proposed approach is validated by commercial software and it is also applied for analysis of a test problem.
Vasiliev, Alexey, Minevich, Olga, Lapina, Evgeniia, Shinder, Julia, Lupuleac, Sergey, Barboule, Joel
Innovation on a Larger Scale: Robotic Fiber Placement and 3D PrintingTBMG-3850602/01/2021
Washington, DC
Simple Robot Vision Tools Support Complex ApplicationsTBMG-3780810/01/2020
A new wave of easy-to-use robot vision systems allows companies with no automation experience to enjoy the benefits of vision-powered production. But can these no-fuss, low-cost systems support complex tasks like quality inspection?
An Inside Look at Maximizing Throughput, Speed, and Efficiency with Robotics in Medical Device ManufacturingTBMG-3768309/01/2020
Recently I entered our stainless-steel tube processing area, which looks completely different from the way it did 10 years ago. The entire room used to be filled with people who were running machines, inspecting components, and working on changeovers. The company was a different place back then and was only starting to embrace automated work cells. Fast forward to today. When I walked into that room, I was greeted by one of our setup technicians sitting on a chair in the corner. I joked with him, “Don’t you have any work to do?” He replied, “Take a look around, you see all those green lights? If they are green, then I am doing my job.” There was no one else in the room but us, yet all of the machines were running. That was a powerful moment for me, and it was then that I realized we had transitioned almost every processing machine in that room to some form of automation.
Metal Injection Molding Offers OEMs Edge and Safety with DisposablesTBMG-3711706/01/2020
Medical instruments used in surgery today often require more elaborate features and added functionality than they did in the past, largely due to the growth in minimally invasive surgery. For this reason, greater attention to detail is critical in product design and development. To meet the demand for small, complex, lightweight surgical products, medical device original equipment manufacturers (OEMs) are increasingly opting for disposable surgical tools and product offerings, which provide flexible, off-the-shelf single-use sterile solutions to surgeons and hospitals.
Tesla casts a new strategy for lightweight structures20AUTP06_0106/01/2020
The EV maker boldly invests in the world's largest aluminum die-casting machine to manufacture entire rear underbody structures. Aluminum is synonymous with “weight-saving” in most contemporary automotive-engineering reference points. But apart from a few applications - most notably Ford's F-Series pickups - aluminum largely is deployed where steel can be readily displaced without performance loss or for comparatively small components that deliver comparatively small weight or process savings. Electric-vehicle maker Tesla is readying the next step in aluminum use, however - one that effectively matches Ford's “big gain” approach by specifying a massive piece of structural die-cast aluminum for the rear underbody of the recently launched Model Y crossover. According to Tesla CEO Elon Musk, this new aluminum application represents a radical step for its design and manufacturing advantages and its light-weighting potential. Musk is renowned for outsized promises, but in the case of the
Visnic, Bill
Micromolding: Achieving Exacting Medical Device Manufacturing RequirementsTBMG-3692905/01/2020
It is undoubtedly fair to say that one of the key sectors driving innovation in the area of micromolding is the medical device industry. Demand for minimally invasive curative and diagnostic procedures is growing exponentially, and because of this, medical device manufacturers have been designing (and seeking to manufacture) smaller and smaller components, with thinner walls, and complex and miniature features. Couple this with the overarching demand from patients and healthcare providers to rationalize the costs associated with medical treatment, and medical device OEMs are constantly on the lookout for cost-effective and efficient manufacturing processes.
Aluminum Alloy, Extruded Rod, Bar, and Profiles (7055-T76511) 8.0Zn - 2.3Cu - 2.0Mg - 0.16Zr Solution Heat Treated, Stress-Relieved, and OveragedAMS4336B (Historical)04/28/2020
This specification covers an aluminum alloy procured in the form of extruded bars, rods, and profiles (shapes) with nominal thickness up to 3.000 inch (76.20 mm), inclusive, and having a cross-sectional area of 12 square inches (77 square centimeters) maximum and circle size of 10 inches (254 mm) maximum (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extruded Rod, Bar, and Profiles (7055-T76511) 8.0Zn - 2.3Cu - 2.0Mg - 0.16Zr Solution Heat Treated, Stress-Relieved, and OveragedAMS4336B-TEST-REC (Historical)04/28/2020
This specification covers an aluminum alloy procured in the form of extruded bars, rods, and profiles (shapes) with nominal thickness up to 3.000 inch (76.20 mm), inclusive, and having a cross-sectional area of 12 square inches (77 square centimeters) maximum and circle size of 10 inches (254 mm) maximum (see 8.6).
AMS D Nonferrous Alloys Committee
PLCs Directly Access Internet InformationTBMG-3639204/01/2020
Programmable logic controllers (PLCs) are a workhorse of industrial automation for monitoring and controlling equipment and they typically are standalone or networked locally on a site. Some have gained extensive networking and communication abilities and newer PLCs can programmatically obtain Internet-sourced information like weather conditions or energy prices that can be used to optimize operations.
Case Study on the Challenges and Responses of a Large Turnkey Assembly Line for the C919 Wing2020-01-001003/10/2020
Design and production of an assembly system for a major aircraft component is a complex undertaking, which demands a large-scale system view. Electroimpact has completed a turnkey assembly line for producing the wing, flap, and aileron structures for the COMAC C919 aircraft in Xi’an, China. The project scope includes assembly process design, material handling design, equipment design, manufacture, installation, and first article production support. Inputs to the assembly line are individual component parts and small subassemblies. The assembly line output is a structurally completed set of wing box, flaps, and ailerons, for delivery to the Final Assembly Line in Shanghai. There is a trend toward defining an assembly line procurement contract by production capacity, versus a list of components, which implies that an equipment supplier must become an owner of production processes. The most significant challenge faced was the amount of front end engineering work required to develop
Forbes, Mark
In-Process Hole and Fastener Inspection Using a High-Accuracy Laser Sensor2020-01-001503/10/2020
Electroimpact has produced a new in-process inspection system for use on drilling and fastening systems. The system uses a high-accuracy, non-contact, laser system to measure the flushness of installed fasteners. The system is also capable of measuring part normality and providing feedback to the machine for correction. One drawback to many automatic inspection systems is measurement error. Many sources of measurement error exist in a production environment, including drilling chips, lubrication, and fastener head markings. Electroimpact’s latest system can create a visualization of the measured fastener for the operator to interpret. This allows the operator to determine the cause of a failed measurement, thus reducing machine downtime due to false negatives.
Luker, Zachary, Stansbury, Erin
Advances in Drilling with PCD (Polycrystalline Diamond)2020-01-003503/10/2020
PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.
Bunting, Jeremy, Bunting, John
Tool Wear Analysis on Drilling Process of Inconel 718 Superalloy2020-01-003403/10/2020
The Inconel 718 is an alloy based on nickel of high thermal and mechanical resistance, which allows its wide application in the aerospace industry, being generally implemented in aircraft tail cone and engine components. On the other hand, these features become a recurring problem when the machining of this material is performed. For example, in the drilling process of this superalloy, the cutting tools used exhibit excessive wear due to the high temperature and pressure at the cutting edge. However, there are numerous parameters that can influence the cutting tool life, and when analyzed and well defined, determine the types of modifications needed to enable less wear, and consequently an increase of its useful life in service. Given this context and knowing that the study of tool life in the Inconel 718 drilling process is extremely relevant in the aerospace sector, this paper presents a wear study in order to evaluate the behavior of different types of cutting tools used to drill
Barros, Pedro Cabegi, Barbosa, Gustavo Franco, Ventura, Carlos Eiji Hirata, Santos, Gustavo Roberto
Advances in Drilling with PCD (Polycrystalline Diamond)2020-01-003503/10/2020
PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.
Bunting, Jeremy, Bunting, John
Ultrasound Helps Make 3D Printed Alloys StrongerTBMG-3627103/01/2020
A new study shows that high-frequency sound waves can have a significant impact on the inner micro-structure of 3D printed alloys, making them more consistent and stronger than those printed conventionally.
Marubeni Citizen-Cincom Opens New Technical CenterTBMG-3627303/01/2020
Marubeni Citizen-Cincom Inc. (MCC) has opened a new technical center in Agawam, MA. The company is holding a ribbon cutting and grand opening celebration March 9. An open house will follow to introduce the company’s new L12 Type X and the new 12 mm laser cutting and welding machine. A variety of Cincom sliding headstock and Miyano fixed headstock lathes will be on display as well. The event will also include technical seminars presented by Sandvik, Esprit, and Gen Swiss.
Smart Manufacturing ControlTBMG-3599702/01/2020
The manufacturing process of today involves many challenges, from mass production down to a lot size of one. The CNC controls in factories have to master this market trend without an adequate amount of skilled labor in the US manufacturing world. In essence, manufacturing is facing a renaissance in the CNC control technology shift.
Cutting Edge - Double Bevel Cross SectionsJ738_202001 (Current)01/15/2020
This standard is for cutting edge sections typically used in earth-moving machinery defined in SAE J1116 and ISO 6165: a Scrapers as defined in ISO 7133. b Dozers as described in ISO 6747. c Loaders as described in ISO 7131. d Graders as described in ISO 7134. Hole spacing is defined ISO 7129. Hole conformation is defined in SAE J740.
MTC1, Earthmoving Machinery
Design Treatment for Advanced Metals Enables Easier MachiningTBMG-3580201/01/2020
Exotic and advanced metals are used in aircraft, orthopedic components, medical instruments, cars, solar panels, military equipment, and other applications. They are referred to as advanced or exotic because they are more difficult to find and more costly to use in manufacturing.
NASA's Thirst for Water on Mars Quenched by Student InnovatorsTBMG-3579401/01/2020
Protolabs Maple Plain, MN
Collaborative Automation: It's More Than Just the CobotTBMG-3560812/01/2019
Collaborative robots, often called “cobots,” offer opportunities for companies of almost any size to cost-effectively automate processes that were previously out of reach. Cobots are available in a wide range of sizes, payloads, and capabilities but they all share attributes that define the term “collaborative.” The aspect that most people think of first is safety — the ability for cobots to work alongside human workers without bulky, expensive guarding. Cobots include a number of built-in safety mechanisms including rounded edges and softer materials as well as power-and force-limiting technologies that avoid injury and minimize discomfort in case of contact, and sensors that automatically slow or stop the robot arm if a human enters its workspace.
Reducing the High Cost Of Titanium19AERP12_0312/01/2019
Titanium is neither a precious metal nor rare, yet among industrial metals it has the reputation for being very expensive. It's the fourth most abundant metallic element and the ninth most abundant of all the elements in the earth's crust. Its commercially useful oxide ore occurs in the minerals rutile and ilmenite and numerous iron ores, and exploitable ore deposits are liberally scattered around the world in Australia, Canada, India, Malaysia, Norway, Russia, South Africa and the U.S. But due to its properties and high cost it has often been referred to as unobtanium. With such great abundance why is titanium so expensive?
Vision Based Surface Roughness Characterization of Flat Surfaces Machined with EDM2019-28-014810/11/2019
Surface roughness measurement is an important one in any manufacturing next to dimensions. In this investigation, a vision system and image processing tools were used to develop reliable surface roughness characterization technique for Electrical Discharge Machined surfaces. A CMOS camera with red LED light source were used for capturing images of EDMed surfaces. A separate signal vector generated for all the images from its image pixel intensity matrices. The mean, skewness and kurtosis were obtained from the signal vector. The mean, skewness and kurtosis of the images signal vector correlates very well with the stylus measured hybrid roughness parameters Rda and Rdq. Hence the technique may be preferred for online surface roughness characterization of Electrical Discharge Machined (EDMed) surfaces.
Ali, Mahashar, Jailani, Siddhi, Mariappan, Murugan, Anandan, Mangalnath, Pavithran, Vignesh
Investigation of Machinability Characteristics on Turning of Nimonic 90A Using Al 2 O 3 and CNT Nanoparticle in Groundnut Oil2019-28-007210/11/2019
Nimonic 90A alloy is a nickel-chromium-cobalt alloy and found as a potential material for turbine blades, discs, forgings, a ring section, and hot-working tools. This paper presents the effect of concentration along with cutting speed and feed rate on Fz: cutting force, Ra: surface roughness and Vba: tool wear with the application of two different nanofluids (NFS) on turning of Nimonic 90A by TiAlN PVD carbide cutting inserts. The nanoparticles suspended in oil taken for present investigation are nAl2O3, nCNT, and groundnut oil. The Taguchi L9 orthogonal array and derringer’s desirability response surface has been employed for parameter design and optimal search. 3D surface plots, factor effect plots, Taguchi S/N, and variance tests are used to study the effect of concentration on the machining performance of Nimonic 90A. The statistical analysis revealed % concentration for nCNT and cutting speed for nAl2O3 are found as an influenced parameter on performance characteristics. From the
Kannan, Venkatesan, Sundararajan, Devendiran
Fault Detection in Single Stage Helical Planetary Gearbox Using Artificial Neural Networks (ANN) and Decision Tree with Histogram Features2019-28-015110/11/2019
Drive train failures are most common in wind turbines. Lots of effort has been made to improve the reliability of the gearbox but the truth is that these efforts do not provide a lifetime solution. Majority of failures are caused by bearing and gearbox. It also states that wind turbine gearbox failure causes the highest downtime as the repair has to be done at Original Equipment Manufacturer [OEM]. This work aims to predict the failures in planetary gearbox using fault diagnosis technique and machine learning algorithms. In the proposed method the failing parts of the planetary gearbox are monitored with the help of accelerometer sensor mounted on the planetary gearbox casing which will record the vibrations. A prototype has been fabricated as a miniature of single stage planetary gearbox. The vibrations of the healthy gearbox, sun defect, planet defect and ring defect under loaded conditions are obtained. The signals show the performance characteristics of the gearbox condition. These
Shaul Hameed, Syed, Vaithiyanathan, Muralidharan, Kesavan, Mahendran
Multi Response Optimization on Machining Titanium Alloy Using Taguchi-DEAR Analysis in Abrasive Water Jet Cutting2019-28-007010/11/2019
Abrasive water jet cutting has been proven to be an effective technology for processing various engineering materials. This paper investigated the effects of process parameters on depth of cut in abrasive water jet cutting of titanium alloy. Four different process parameters were undertaken for this study; water pressure, nozzle traverse speed, abrasive mass flow rate and standoff distance. The influence of these process parameters on depth of cut, surface roughness and MRR has been investigated and analyzed. An empirical model for the prediction of depth of cut in abrasive water jet cutting of cast iron has been developed using regression analysis. The approach is based on Taguchi-DEAR method to optimize the AWJM process parameter for effective machining. It has been found that the stand-off-distance has highest impact on performance measures among all process parameters.
Thangaraj, Muthuramalingam, Loganathan, Ganesh Babu, Atif, Akhtar, Palanisamy, Srinivasan
Application of Response Surface Method to Optimize Waterjet Cutting Process Parameter of Glass Fiber Reinforced Polymer Matrix Laminates2019-28-015310/11/2019
Waterjet machining is a widely used advanced machining technique because of its versatility in removal of material for a wider range of materials. Waterjet machining is particularly advantageous in the precise cutting of advanced materials like Fiber Reinforced Polymers (FRPs) comparative to conventional machining methods. The conventional machining methods result in the release of high amount of glass fiber dust which leaves the work environment unsafe for the workers. The material dust if inhaled can lead to acute respiratory diseases. In this work an analysis was done on the cutting performance of Waterjet machining and is presented based on an experimental investigation on fabricated fiberglass reinforced laminates. It is shown that with a good combination of cutting parameters such as nozzle traverse speed, waterjet pressure, and Stand-off distance a cutting performance can be achieved. Plausible trends of kerf quality and machining time with respect to the waterjet pressure
Aulakh, Savitoj Singh, Patil, Dhanush, Elsen, Renold, Aggarwal, Sangeet
Optimization of Machining Process Parameters for Minimizing the Waste Stream Response through Multi-Objective Optimization2019-28-006210/11/2019
During the delivering of an item, any material created moreover to a definitive item will be named as waste. The waste produced in light of machining could be a notable conservation worry for creators. The shape and condition of waste streams created, and their transportation components divergence with the strategy utilized and also shift among the technique. The effect in view of each waste stream differs as well. This examination reports a machining strategy includes the procedure of material to give a completed or a semi-completed item. This is frequently done by misapplication tools, totaling, machines and distinctive data sources that are appropriate to the strategy. The procedures thought of for the point of this work includes machining of material manipulation devices to give parts and items. The yield of the technique incorporates the item and increase the waste streams. The waste streams will be in the form of Chips, Energy usage, and Worn cutting tools and Operating time
Sivam Sundarlingam Paramasivam, Sundar Singh, Loganathan, Ganesh Babu, Saravanan, Krishnaswamy, Kumaran, Durai, Rajendran, Raj, Sriram, Harish
Value Engineering Applied to Micro ComponentsTBMG-3533710/01/2019
Value engineering (VE) is an organized/systematic approach directed at analyzing the function of systems, equipment, facilities, services, and supplies for the purpose of achieving their essential functions at the lowest life-cycle cost consistent with required performance, reliability, quality, and safety.1 The implementation of the VE process on a problem typically increases performance, reliability, quality, safety, durability, effectiveness, or other desirable characteristics.
NIST Research Sparks New Insights on Laser WeldingTBMG-3537310/01/2019
On its surface, the work is deceptively simple: Shoot a high-power laser beam onto a piece of metal for a fraction of a second and see what happens. But researchers say the physics of laser welding is surprisingly complex. A better understanding of the interaction between laser and metal could give industry more control over laser welding, a technology that is becoming increasingly popular in manufacturing.
Assessing Viscosity in Hydro-Erosive Grinding Process via Refractometry04-12-03-001208/22/2019
The manufacturing of diesel injector nozzles requires precision processing to produce multiple micro-holes. An abrasive fluid containing a mixture of mineral oil and hard particles is used for rounding them, ensuring the hydrodynamics of the injection. As verified in a previous investigation, the viscosity of the fluid undergoes uncontrolled changes during hydro-erosive (HE) grinding. Such undesired viscosity changes are detrimental to the process and difficult to assess. The current investigation aims to study the possibility of using the refractive index of the oils used in the HE grinding for assessing their viscosities. A calibration curve correlating the refractive index and viscosity was obtained from the analysis of samples produced by mixing two distinct mineral oils in different proportions. The determined calibration curve was tested with 45 samples of filtered oil, collected directly from the tanks during the HE grinding. The results showed that refractometry is a potential
Heidemann, Bárbara R., Scherpinski, Gustavo, Fabris, Luís, Muller, Marcia, Fabris, José L., Pintaude, Giuseppe
Machining Capabilities Enhance Space-Related ProgramsTBMG-3473607/01/2019
Insaco Quakertown, PA
Groove Design - Metal Face SealAIR1108A (Current)06/06/2019
Groove designs presented herein are applicable for use with machined or formed metal seals which are similar in configuration to those shown in figure 3, which operate under internal pressure or in vacuum service and which have been specifically qualified or recommended by the purchaser or the manufacturer for use with this AIR. They are also applicable for use with metal o-rings (e.g., MS9142, MS202 thru MS9205) where interchangeability with machined or formed metal seals is desired. For metal o-ring groove designs where inter-changeability is not a requirement refer to ARP 674.
E-25 General Standards for Aerospace and Propulsion Systems
Machining Titanium Aero-FramesTBMG-3454306/01/2019
The rise of titanium for aerospace applications has been well documented in recent years. Equally, the challenges associated with the efficient, productive and high-quality machining of this popular material, have also been a topic of debate and scrutiny. Of course, every machine shop wants optimized performance from its cutters when milling titanium, but this can prove less than straightforward without the right technology and know-how in place. Today, however, thanks to a breakthrough in this area, things are beginning to change.
Cross-Training Made Possible by Common Control PlatformTBMG-3457906/01/2019
EMAG L.L.C. is the U.S. subsidiary of a major German machine tool builder that specializes in machine tools for the production of automotive, off-highway, agricultural, and oil field components. The company’s equipment ranges from basic round part turning centers to large-workpiece, five-axis machining centers; gear hobbing machines; and alternative equipment such as laser welding and electrochemical machining centers. This wide variety of machine tools requires an assortment of control technologies to power and manage the motion. For one customer requirement where a major agricultural equipment builder needed grinding, turning, and turn-grind machines, EMAG looked to Siemens for a standardized CNC solution.
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