Che Hassan Che Haron

Online tool wear prediction system in the turning process using an adaptive neuro-fuzzy inference system

Tool wear is a detrimental factor that affects the quality and tolerance of machined parts. Having an accurate prediction of tool wear is important for machining industries to maintain the machined surface quality and can consequently reduce inspection costs and increase productivity. Online and real-time tool wear prediction is possible due to developments in sensor technology. Recently, various sensors and methods have been proposed for the development of tool wear monitoring systems. In this study, an online tool wear monitoring system was proposed using a strain gauge-type sensor due to its simplicity and low cost. A model, based on the adaptive network-based fuzzy inference system (ANFIS), and a new statistical signal analysis method, the I-kaz method, were used to predict tool wear during a turning process. In order to develop the ANFIS model, the cutting speed, depth of cut, feed rate and I-kaz coefficient from the signals of each turning process were taken as inputs, and the flank wear value for the cutting edge was an output of the model. It was found that the prediction usually accurate if the correlation of coefficients and the average errors were in the range of 0.989-0.995 and 2.30-5.08% respectively for the developed model. The proposed model is efficient and low-cost which can be used in the machining industry for online prediction of the cutting tool wear progression, but the accuracy of the model depends upon the training and testing data.

Online Cutting Tool Wear Monitoring Using I-Kaz Method and New Regression Model

This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals using the regression model and I-kaz method. The detection of tool wear was done automatically using the in-house developed regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out on a CNC turning machine Colchester Master Tornado T4 in dry cutting condition, and Kistler 9255B dynamometer was used to measure the cutting force signals, which then stored and displayed in the DasyLab software. The progression of the cutting tool flank wear land (VB) was indicated by the amount of the cutting force generated. Later, the I-kaz was used to analyze all the cutting force signals from beginning of the cut until the rejection stage of the cutting tool. Results of the I-Kaz analysis were represented by various characteristic of I-kaz 3D coefficient and 3D graphic presentation. The I-kaz 3D coefficient number decreases as the tool wear increases. This method can be used for real time tool wear monitoring.

Tool Wear Mechanism in Continuous Cutting of Difficult-to-Cut Material under Dry Machining

Wear mechanism on the flank of a cutting tool is caused by friction between newly machined surface and the cutting tool, which plays predominant role in determining tool life. Detailed study on wear mechanism at the cutting edge of carbide tools were carried out at cutting speed of 55 – 95 m/min, feed rate of 0.15 – 0.35 mm/rev and depth of cut of 0.10 – 0.20 mm. The wear on the cutting tools was occurred predominantly on the nose radius, as effect of lower feedrate and nose radius selected. Various wear observed on both coated and uncoated cutting tool such as abrasive wear, adhesive wear, adhering chip on the cutting edge, flaking, chipping, coating delamination of coated tool, crack and fracture. The abrasive wear predominantly occurred on the flank face while the flaking on the rake face. Abrasive wear occurred at nose radius due to the depth of cut selected was low therefore, the contact area between the cutting tool and the workpiece material was small. Adhesion or welded titanium alloy onto the flank and rake faces demonstrated a strong bond at the workpiece-tool interface. The adhesion wear takes place after the coating has worn out or coating delamination has been occurred. The crack occurred possibly due to machining at high cutting speed and high depth of cut. Cutting at high cutting speed caused more heat generated at the cutting edge and at high depth of cut caused more cutting forces on the insert.

Disassembly time evaluation for enhancing the reusability of automotive components

Recovery of products including reuse, remanufacture and recycle is now emerging as an important strategy for reducing wastes to the environment. Among others, the automotive industry is the leading industry in this environmental consciousness manufacture. Research and development on automotive component design and manufacture as well as tools and methods to facilitate reuse are under way in several countries. To enable reuse, the determinant factors must be studied including the disasssemblability of the product. This study focuses on disassembly time evaluation of a locally produced car door using MOST Measurement System method. The existing design of the car door was evaluated and design changes were proposed to improve the ease of disassembly design of the car door. Significant improvements to the design and disassembly time is presented and discussed in this paper.

Comparison of oil press for jatropha oil - A review

Siregar A.N., Ghani J.A., Haron C.H.C., Rizal M., Yaakob Z., Kamarudin S.K. (2015): Comparison of oil press for jatropha oil – a review. Res. Agr. Eng., 61: 1–13. As petrol will soon be exhausted in the near future, Jatropha is going to be one of the substitute candidates for future biodiesel production. Countries of South-East Asia, such as Malaysia, they are going to start the establishment of Jatropha plantations assuming that Jatropha will be the main resource for biodiesel production. A press is commonly used to extract oils from Jatropha. An oil press can be manually driven or engine-powered. In this paper, we will review some available advances focused on mechanical extraction techniques, covering three types of press for Jatropha oil extraction. We have found that major points like operating principles, oil extraction levels, advantages and disadvantages of each press and important factors to increase oil recovery. Based on the study, three types of press are: ram press, which is ineffective; strainer press, which is able to produce more oil than others and cylinder-hole press, which is the best due to its capacity in extracting oil from Jatropha seeds for about 89.4% of oil yields.

Determination of sensor location for cutting tool deflection using finite element method simulation

The aim of this study was to determine the the optimum locations to mount the sensor for measuring the cutting tool deflection during turning process using finite element method simulation. In this study, stress analysis had been conducted using Autodesk Inventor Professional 2010 integrated with ANSYS software. The simulation results were validated using a strain gauge as the sensor for the detection of cutting force signal during the turning of hardened plain carbon steel JIS S45C using carbide tool. Two strain gauges were mounted on the tool holder at two defined locations I and II, at distances of 37 and 47 mm, respectively, from the cutting point. Only one set of cutting parameters was conducted at spindle speed, N = 1000 rpm, feed, f = 0.25 mm/rev and depth of cut, d = 0.80 mm. The turning process was stopped and the insert discarded when the average flank wear, VBm, reached 0.30 mm. The main cutting force, Fy, and the feed force, Fx, for each machining run were measured, collected and analysed at locations I and II. It was found that when strain gauges were placed at a distance of approximately 43 mm from the cutting point, it was the optimum location for sensing the cutting force signals.

Comparison of Dry and Cryogenic Machining on Chip Formation and Coefficient of Friction in Turning AISI 4340 Alloy Steel

Application of cutting fluid that provides both coolant and lubrication properties in manufacturing operations such as turning, milling, grinding and other processes has been proven to improve the machining output in many aspects. In cryogenic machining, liquid nitrogen (LN2) is used as cutting fluid to reduce the temperature generated at the cutting zone. However, there is still an issue being raised on whether LN2 also functions as a good lubricant as it does as an excellent coolant. Therefore, an intensive study on the chip formation during dry and cryogenic turning of AISI 4340 alloy steel has been conducted to examine the effect of LN2 cutting fluid on the reduction of friction between the chip and the tool. Results from calculation of coefficient of friction indicate that application of LN2 during turning is able to help the friction reduction up to 73%. Smaller value of coefficient of friction indicates that the shear angle is larger which results in smaller shear plane area that provides benefits of lower cutting force needed to shear off the chips and lower cutting temperature being generated during the machining process.

Cutting Performances of Coated PVD in High Speed End Milling of Aged Inconel 718

Inconel 718 is a material exhibiting characteristic that are able to maintain strength and integrity at elevated temperatures, but it is well known as a material with poor machinability. This paper presents a study of the performance in high speed machining of TiAlN/AlCrN nanomultilayer PVD coated Inconel 718 with minimum lubrication. Investigations have been made into the effects of cutting speed, feed rate and depth of cut (DOC) on the tool life. A toolmakers microscope and a scanning electron microscope (SEM) were used to examine the tool wear and chemical attrition, respectively, on the cutting tool during machining. In the machining of aged Inconel 718, the cutting tool experienced attrition, abrasion and notch wear throughout the experiment. Notch wear was found to be the dominant failure mode during milling; this wear appeared severe when localized flank wear reached the critical zone. The influence of radial depth despite the cutting speed, well known as having the most significant effect on tool life, is also discussed.

Tool Wear and Surface Roughness when Machining AlSi/AlN Metal Matrix Composite Using Uncoated Carbide Cutting Tool

Aluminium silicon alloy (AlSic) matrix composite reinforced with aluminium nitride (AlN) particle is a new generation material for automotive and aerospace application. This material has low density, light weight, high strength, high hardness and stiffness. Metal Matrix Composit (MMC) material is one of the advanced materials which have good future prospects. This paper presents the study of tool wear and surface roughness investigation when milling AlSi/AlN Metal Matrix Composite using uncoated carbide cutting tool. The volume of AlN reinforced particle was 10%. The milling process was carried out under dry cutting condition. The uncoated carbide insert parameters used were cutting speed of (250-750 m/min), while feed rate and depth of cut were kept constant at 0.15 mm/tooth of 0.3mm respectively. The Sometech SV-35 video microscope system and Mitutoyo surface roughness tester were used for tool wear measurements and surface roughness respectively. The results revealed that the tool wear increases with cutting speed (450 m/min). While at high cutting speed, the surface finish improves. It was found that the cutting speed of 750m/min was optimum condition for obtaining smooth finish and longer tool life. Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, and surface roughness, uncoated cemented carbide tool

Performance of PVD-Coated Carbide Tools When Turning Inconel 718 in Dry Machining

Inconel 718 has found its niche in many industries, owing to its unique properties such as high oxidation resistance and corrosion resistance even at very high temperatures. Coated carbide tool with hard layer of PVD TiAlN is used to turn Inconel 718. Taguchi method with the orthogonal array L9 is applied in this experiment with the parameter cutting speed of 60–80 m/min, feed rate of 0.2–0.3 mm/rev, and depth of cut of 0.3–0.5 mm. The results show that depth of cut is a significant influence to the tool life. Cutting speed of 60 m/min, feed rate of 0.2 mm/rev, and depth of cut of 0.3 mm are the optimum parameters. The flank wear, crater wear, notch wear, and nose wear are the wear mechanisms on the carbide tool. Through the SEM, abrasion, attrition, and adhesion are the wear mechanisms which can be seen on the cutting tool.