2.1. Theoretical framework In a metal cutting operation, a cutting tool deforms the workpiece material until it shears off in the form of chips. The deformation process requires significant energy, and the tool endures a variety of mechanical, thermal, chemical, and tribological loads. These loads eventually cause the tool to deteriorate and wear out or fail. Therefore, the goal for having a good metal cutting application is to balance the energy required to remove metal with the tool’s ability to reliably withstand the load placed on it. Understanding and manipulating correctly cutting parameters, tool geometries, tool materials, and other factors enable machinists to achieve a productive and cost-effective metal cutting process. Mechanical …show more content…
The optimization of cutting parameters during machining is a difficult task as it involves a number of aspects such as knowledge of machining, empirical equations of tool life, cutting forces, power consumed, machining surface finish etc. All these aspects should be considered during machining optimization to develop an effective optimization criterion (Sonmez et el, 1999). Manufacturing industries have long depended on the skill and experience of shop-floor machine-tool operators for optimal selection of cutting conditions and cutting tools. Many authors as early as in the 19th century like Taylor, 1907 have shown the optimization objective as specific cost from the beginning of the researches in this branch when the area of the art of cutting metals was looked on. This was also considered by to some of the most recent work (Liang et el, 2001; wang et el, 2002; Saravanan, 2003 and Cus and Balic, …show more content…
In reality, no matter how experienced he may be or how skilled he maybe, it is still very challenging for him to apply the right input parameters to always attain an optimal output result. The key machining parameters in metal turning operations are its cutting speed, feed rate and depth of cut etc. these needs to be applied optimally before the result output will be the best. As discussed by Palanikumar, et al, the setting of these parameters determines the quality characteristics of the final turned parts. He applied the application of Taguchi method with fuzzy logic to optimize the machining parameters for machining of GFRP (Glass Fiber Reinforced Plastic) composites with multiple characteristics (Palanikumar, et al, 2006). The optimization process was implemented using the multi response performance index (MRPI) as the performance was tailored on the degree of the metal removal rate, surface roughness and tool wear with machine parameters like the work piece’s fibre orientation, feed rate, depth of cut, cutting speed and machining time. Srikanth and kamala (2008) both developed a real coded Genetic Algorithm (RCGA) approach for optimizing the cutting parameters in their turning process. This RCGA approach was quite beneficial in order to attain the minimum surface roughness values and their corresponding optimum cutting parameters, for certain
Noori, S., Feylizadeh, M. R., Bagherpour, M., Zorriassatine, F., & Parkin, R. M. (2008). Optimization of material requirement planning by fuzzy multi-objective linear programming. Proceedings of the Institution of Mechanical Engineers, 222, 887-900. Retrieved from http://search.proquest.com/docview/195144743?accountid=32521
Before a metal piece or metal alloy can be used in any given application, whether it is a construction project or anything else, it might be necessary to cut the material to the right shape and size. One may need to cut metal into pieces of different sizes and shapes according to the end use.
Fabrication at the factory utilizes a mix of robotics and manual labor to produce the body of the V-Rod. Robots that are designed to cut pipe are capable of completing a single operation within 3 seconds. Other fabrication robots utilize 1800 watt lasers that can perform cutting operations at the rate of 100 inches per minute. Where robotics can be used to perform high speed cutting and welding operations, skilled workers are a...
It is thus a thermal erosion process. The sparks are created in a dielectric liquid, generally water or oil, between the work piece and an electrode, which can be considered as the cutting tool. There is no mechanical contact between the electrodes during the whole process. Since erosion produced by electrical discharges, both electrode and work piece have to be electrically conductive. Thus, the machining process consists in successively removing small volumes of work piece material, molten or vaporized during a discharge. The volume removed by a single spark is small, in the range of 10-6-10-4 mm3 but this basic process is repeated typically 10,000 times per
Some four thousand years ago the interest in woodwork was increasing. This created the need for an effective way to quickly and smoothly cut a piece of wood. Around this time the discovery of copper allowed for the invention of a tool, the saw, that could fulfill this need. This saw was designed with a thin piece of copper stuck into a small piece of wood. The copper strip had teeth lined up along one end that allowed the tool to cut a kerf in a small piece of wood. They later replaced the copper with bronze, and the bronze with iron.
Advanced CNC fabrication tools and 3D printing machines have made notable improvements in the construction industry. The benefits of this new approach have been developed over many years to increase...
Forging, one of many manufacturing process, is where metal is pressed, pounded or squeezed under great pressure into high strength parts known as forgings. The process begins with starting stock which is heated to its plastic deformation temperature, then upset between dies to the desired shape and size. It is important to note that the forging process is entirely different from the casting (or foundry) process, as metal used to make forged parts is never melted and poured (as in the casting process). During this hot forging process, coarse grain structure is broken up and replaced by finer grains. Mechanical properties are therefore improved through reduction of cast structure, voids and segregation. Forging also provides means for aligning
Material handling system is an important equipment and in the design of an effective manufacturing design. One of the main tasks in material handling system design is the selection and setup involving apparatus, demanding comprehensive technical understanding along with methodical research. Material handling equipment selection is a very complex and tedious task. The main factors contributing to the complexity of the equipment selection problem is the constraints imposed by the facility and materials, a variety of disagreeing design and style requirements, anxiety inside functional environment, and some of equipment varieties in addition to designs accessible. In recent years, the equipment selection
The use of the computer has had a positive impact on manufacturing engineering in many ways. Engineering is a term applied to the profession in which a knowledge of the mathematical and natural sciences, gained by study, experience and practice, is applied to the efficient use of the materials and forces of nature. The term engineer denotes a person who has received professional training in pure and applied sciences.
Materials engineering and computer engineering are two of the modern examples of industrial engineering. Industrial engineers have the challenge of incorporating today’s leading technological advances with the production of them in manufacturing facilities. Their purpose is to maximize output, while minimizing the costs for materials and production. This is why industrial engineers must have knowledge of product development, materials processing, optimization, queuing theory, production techniques, and engineering economy. Industrial engineers must have adequate skills in computer aided design and computer aided manufacturing.
Metals possess many unique fundamental properties that make them an ideal material for use in a diverse range of applications. Many common place things know today are made from metals; bridges, utensils, vehicles of all modes of transport, contain some form of metal or metallic compound. Properties such as high tensile strength, high fracture toughness, malleability and availability are just some of the many advantages associated with metals. Metals, accompanied by their many compounds and alloys, similar properties, high and low corrosion levels, and affects, whether negative or positive, are a grand force to be reckoned with.
To start, think about what kind of cutting you will be doing and keep it in mind throughout the guide. There are two types of cuts – push cuts and pull cuts. The first is when you push a knife through an object to make a cut, such as slicing a fruit or a vegetable in half. The second is when you have to pull the knife through to finish the separation, such as cutting rope or cutting bread. A paramedic may find themselves doing more of a pull cut, while a handyman uses both due to the variety of tasks at hand. Keeping this in mind helps you narrow down your options of choosing the best pocket knife for your everyday purposes.
Mechanical engineering is a type of engineering which applies principles of physics and material science for the purpose of analyzing, designing, manufacturing and maintaining of mechanical systems (Gorp, 2005). It is involved with the production and usage of mechanical power in the operation of various machines and tools. Mechanical engineering is considered to be the most diverse engineering and has its breadth derived from the need to design tools and manufacture products which range from small individual parts to large systems. Mechanical engineering, as thought of by scholars, is related to Aerospace engineering, Manufacturing and Mechanical engineering (Van et al, 2011).
Fortunately, during under-graduation, I got an opportunity to detect the optimum path of a process through my project “Design and Development of PCB Dual Head Drilling Machine”. Additionally, I became aware of a new subject called Six Sigma which aided me in intertwining new optimization techniques into my project to make the process effective. I optimized the creation...
Manufacturing the process design also faces the same challenge in the optimization of the product (ARAUJO, JOSÉ AUGUSTO DA ROCHA DE; Costa, Reinaldo Pacheco da, 2004, p. 4).