List of articles (by subject) traditional and nontraditional manufacturing
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Open Access Article
1 - Investigating the Effect of Cutting Condition on the Plastic Energy in Turning Process of AISI 1050
Mohammad Meghdad Fallah Seyyed Reza HamzelooReducing energy consumption is a demanding issue considering the limited available energy resources and increasing environmental pollution. On the other hand, industry consumes a huge amount of energy, and manufacturing processes are the most energy consuming portions o MoreReducing energy consumption is a demanding issue considering the limited available energy resources and increasing environmental pollution. On the other hand, industry consumes a huge amount of energy, and manufacturing processes are the most energy consuming portions of the industry. Machining issues including cutting tool geometry and process parameters affect the cutting forces and also production consuming energy. By increasing cutting forces, the tool life would be reduced and therewith cost of machining process increases. In this work, the effect of machining condition on cutting force and energy consumption studied in turning process during validated FE analysis using ALE method. So, the effect of rake angle, tool edge radius and cutting speed was investigated on the cutting force, plastic strain and plastic consuming energy. Results proved that these parameters are effective on plastic energy consumption in turning process among them cutting speed has more effect on the plastic energy. By increasing the cutting speed, the plastic energy decreases considerably. Rake angle is also effective on process energy consumption and the combination of increasing the rake angle and cutting speed, and choosing the optimal edge radius leads to the minimized plastic energy. Manuscript profile -
Open Access Article
2 - Effects of Abrasive Media on Surface Roughness in Barrel Finishing Process
Ali Vakili Sohrforozani Masoud Farahnakian Mohammad Sajjad Mahdieh Amir Masoud Behagh Omid BehaghBarrel finishing is a common technique for surface finishing of industrial parts. Many factors such as working time, abrasive media, initial roughness and machining parameters of rotary barrel affect the final surface roughness of workpieces. Analysing these input param MoreBarrel finishing is a common technique for surface finishing of industrial parts. Many factors such as working time, abrasive media, initial roughness and machining parameters of rotary barrel affect the final surface roughness of workpieces. Analysing these input parameters in order to obtain the least surface roughness as well as the least working time for barrel finishing of the specific samples, is not possible except by applying Design of Experiments method. Thus, the aim of the present paper is to improve the surface quality of the steel alloy CK45 samples in barrel finishing process, by investigating different combination of three abrasive particles including ceramics, steel balls and aluminium oxide as the abrasive media through design of experiments method. Initial roughness, working time and the combination of abrasive media are the input factors in the designed experiments, while the surface roughness is the output factor. Results show that the best surface roughness and working time have been achieved with the specific combination of steel balls and aluminium oxide particles as the abrasive media. Manuscript profile -
Open Access Article
3 - Numerical Simulation of Ultrasonic Assisted Indentation Tube Forming
Saeid Dashti Masih Paknejad Amir Abdullah Abbas PakIndentation forming is an internal tube forming process in which a mandrel with a diameter slightly larger than that of the tube is pressed inside the tube and in so doing, creates the internal profile. Forming forces have a significant effect on the spring back, residu MoreIndentation forming is an internal tube forming process in which a mandrel with a diameter slightly larger than that of the tube is pressed inside the tube and in so doing, creates the internal profile. Forming forces have a significant effect on the spring back, residual stress, quality of the inner surface, quality of tube dimensions, and tool wear. In this study, the forming process of CK45 steel tube by carbide tungsten tool in the presence of ultrasonic vibration has been simulated and the effect of ultrasonic on the forming mechanism has been investigated by introducing two regimes according to the forming conditions. The effects of tool feed-speed and amplitude of vibration on forming force reduction have been investigated. According to the simulation results, the main reason for the force reduction in the presence of longitudinal tube ultrasonic vibration is the intermittent phenomenon which is the continuous or impulsive regime. The critical amplitude which determines the borderline of continuous and impulsive regimes is obtained 38µm by the simulation of the process. The maximum force reduction obtained in continuous regime is 64.2% at the critical amplitude. The simulation results are consistent well with the previous experimental data. Manuscript profile -
Open Access Article
4 - Evaluation of Fatigue Behavior and Surface Characteristics of Novel Machining Process: Rotary Chemical Machining (RCM)
Pooya Bahrami Ali Khoshanjam Abdolhamid AziziIn this study, Rotational Chemical Machining (RCM) as a novel machining process is introduced. The properties such as surface roughness and residual stress as well as fatigue strength of the RCM process are evaluated, discussed and compared to the conventional turning p MoreIn this study, Rotational Chemical Machining (RCM) as a novel machining process is introduced. The properties such as surface roughness and residual stress as well as fatigue strength of the RCM process are evaluated, discussed and compared to the conventional turning process. In this sense, Scanning Electron Microscope (SEM) and Atomic Force Microscope (AFM) were utilized. The results show the superiority of the RCM method over the conventional method and eliminate limits of process such as low surface quality and improve fatigue strength. The Amplitude Distribution Curve has a balanced Gaussian shape in RCM indicating the balanced distribution of peaks and valleys on machined surface. Due to the absence of machining force in the RCM process, in comparison to the turning process, maximum residual stress is significantly decreased from 363Mpa to 71Mpa; surface roughness reduced from 3.1µm to 1.5 µm as well as the fatigue strength improved 20% approximately. Manuscript profile