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Article
Publication date: 13 January 2022

Jun Zhang, Yixuan Ma, Zongjin Ren, Tao Bai, Peikai Hu and Zunhao Wang

The purpose of this paper is to improve the reliability of the force measurement system by determining the reliable test range of dynamometer.

Abstract

Purpose

The purpose of this paper is to improve the reliability of the force measurement system by determining the reliable test range of dynamometer.

Design/methodology/approach

Based on the principle of leverage and moment balance, a general force distribution model is applicable in where the test point is located either inside or outside the support region of four three-component force links of dynamometer is established. After corroborating the correctness of the model through verification experiments, the boundary conditions that each three-component force link should satisfy are analyzed by considering the characteristic of the dynamometer components comprehensively. Furthermore, the reliable test range of dynamometer is determined, followed by a calibration experiment to verify its rationality.

Findings

The relationships between the reliable test range and the tested force, the bolt pre-tightening force and the bearing capacity of quartz wafers are clarified. Further, the experimental calibration results show that when the test point is within the reliable test range, the three-directional output voltage of dynamometer has excellent linearity and repeatability. The nonlinearity and repeatability in X-, Y- and Z-directions are all less than 1.1%.

Originality/value

A general mathematical model of force distribution of four three-component force links is constructed, which provides a theoretical basic for the mechanical analysis of multi-sensors’ dynamometer. Comprehensively considering the performance of dynamometer components, the value of measured force and the pre-tightening force, the simultaneous equations of reliable test range are deduced, which limits the boundary of allowable test position of piezoelectric dynamometer.

Details

Sensor Review, vol. 42 no. 2
Type: Research Article
ISSN: 0260-2288

Keywords

Article
Publication date: 9 March 2020

Qingbing Chang, Jun Zhang and Zongjin Ren

The purpose of this paper is to solve the problem that the relationship between loading forces, which were applied at different positions on a plane, and output values of…

Abstract

Purpose

The purpose of this paper is to solve the problem that the relationship between loading forces, which were applied at different positions on a plane, and output values of load-sharing dynamometer is non-linear.

Design/methodology/approach

First, the analytical model of ISPM (isodynamic surface proportional mapping method) method, which is used to calibrate dynamometer, was established. Then, a series of axial force calibration tests were performed on a load-sharing dynamometer at different loading positions. Finally, according to output values, calibration forces at different loading positions were calculated by ISPM method, and corresponding distribution histogram of calibration force error was generated.

Findings

The largest error between calculated force and standard force is 2.92 per cent, and the probability of calculated force error within 1 per cent is 91.03 per cent, which verify that the ISPM method is reliable for non-linear calibration of dynamometers.

Originality/value

The proposed ISPM method can achieve non-linear calibration between measured force and output signal of load-sharing dynamometer at different positions. In addition, ISPM method can also solve some complex non-linear problems, such as prediction of plane cutting force under the influence of multiple parameters, the force measurement of multi-degree-of-freedom platform and so on.

Article
Publication date: 12 December 2017

Yu Tian, Jun Zhang, Zongjin Ren, Wei Liu, Zhenyuan Jia and Qingbing Chang

This paper aims to improve calibration and force measurement accuracy of multi-sensors’ piezoelectric dynamometer used in thrust measurement of rocket/air vehicle engine.

Abstract

Purpose

This paper aims to improve calibration and force measurement accuracy of multi-sensors’ piezoelectric dynamometer used in thrust measurement of rocket/air vehicle engine.

Design/methodology/approach

This paper presents a mapping solution method of sensors’ outputs based on the Kirchhoff thin plate theory, builds force-deformation differential equations with specific boundary conditions, uses finite difference (FD) method to solve the equations and analyzes outputs in offset loading forces in four-sensor square layout in main direction. The resultant force deviations calculated by the Kirchhoff theory are optimized with sequence quadratic program (SQP) method, and a calibration method of multiple loading points (MLP) based on the Kirchhoff theory is presented. Experiments of static calibration and verification are complemented to contrast the novel and single loading point (SLP) calibration method.

Findings

Experiments of static calibration and its verification show that at a loading force of 5,000N, the average resultant force deviations with MLP is 17.87N (0.35% FS) compared with single loading point method 26.45N (0.53% FS), improving calibration and measurement precision.

Originality value

A novel calibration method with MLP is presented. Force distributions of multiple sensors of main direction in piezoelectric dynamometer with offset loading force are solved with the Kirchhoff theory. The resultant force deviations calculated by Kirchhoff theory are optimized with the SQP method.

Article
Publication date: 5 June 2017

Quentin Cosson-Coche, Olivier Cahuc, Philippe Darnis, Raynald Laheurte, Denis Teissandier and Didier Chabirand

The purpose of this paper is to understand the impact of the cutting forces on the quality of pieces in industrial cutting of multi-ply textile material. It also tries to…

Abstract

Purpose

The purpose of this paper is to understand the impact of the cutting forces on the quality of pieces in industrial cutting of multi-ply textile material. It also tries to establish a cutting model that can simulate the cutting forces in order to understand the behaviour of the blade.

Design/methodology/approach

Working on an industrial machine, a cutting head with an oscillating knife is instrumented with different sensors. Using this equipment, cutting forces can be analysed experimentally while the fabric is being cut along a straight line.

Findings

A model of the physical phenomena of the cutting forces is proposed, taking different parameters into account such as the geometry of the blade, the properties of the material being cut and the parameters of the cut. The simulated forces and the monitored forces are compared and parameters for minimising the cutting forces of fabrics are deduced.

Research limitations/implications

Due to the wide diversity of fabrics, all with different mechanical characteristics, this research only began with the study of denim in a straight cut.

Originality/value

This paper describes an instrumentation of automatic cutting head for textile. It manages to simulate the action of the fabrics on the blade through effort monitoring and help in the understanding of the multi-ply cutting process.

Details

International Journal of Clothing Science and Technology, vol. 29 no. 3
Type: Research Article
ISSN: 0955-6222

Keywords

Article
Publication date: 1 September 2006

O.C. Mendes, R.F. Ávila, A.M. Abrão, Pedro Reis and J. Paulo Davim

The knowledge over the performance of cutting fluids when applied under different machining conditions (such as distinct work material and cutting parameters) is critical in order…

1147

Abstract

Purpose

The knowledge over the performance of cutting fluids when applied under different machining conditions (such as distinct work material and cutting parameters) is critical in order to improve the efficiency of most machining operations. This paper is concerned with the performance of cutting fluids employed under two distinct machining operations involving aluminium alloys: drilling of AA 1050‐O aluminium applying cutting fluid as a mist and turning of AA 6262‐T6 aluminium alloy using cutting fluids (as a flood) with distinct extreme pressure additives (chlorine, sulphur and phosphor).

Design/methodology/approach

This work reports on a experimental study of the performance of cutting fluids when machining aluminium alloys.

Findings

The results indicated an increase in the flow rate of the mist led to lower feed forces but higher torque, power consumption and specific cutting pressure in the drilling operation (AA 1050‐O aluminium). The surface finish was not drastically affected by the cutting fluid flow rate. When turning AA 6162‐T6 aluminium alloy, in general, best results were observed using 10 per cent fluid concentration applied at the tool‐workpiece interface. The cutting fluid containing chlorine as extreme pressure additive produced lower cutting forces and better surface finish at high cutting speed and low feed rate and depth of cut.

Originality/value

The novel element of this paper is the use of minimal lubrication (drilling) and cutting fluids with distinct extreme pressure (turning).

Details

Industrial Lubrication and Tribology, vol. 58 no. 5
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 8 March 2024

Çağın Bolat, Nuri Özdoğan, Sarp Çoban, Berkay Ergene, İsmail Cem Akgün and Ali Gökşenli

This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the…

Abstract

Purpose

This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the literature. The main goal of this endeavor is to create a casting machining-neural network modeling flow-line for real-time foam manufacturing in the industry.

Design/methodology/approach

Samples were manufactured via an industry-based die-casting technology. For the slot milling tests performed with different cutting speeds, depth of cut and lubrication conditions, a 3-axis computer numerical control (CNC) machine was used and the force data were collected through a digital dynamometer. These signals were used as input parameters in neural network modelings.

Findings

Among the algorithms, the scaled-conjugated-gradient (SCG) methodology was the weakest average results, whereas the Levenberg–Marquard (LM) approach was highly successful in foreseeing the cutting forces. As for the input variables, an increase in the depth of cut entailed the cutting forces, and this circumstance was more obvious at the higher cutting speeds.

Research limitations/implications

The effect of milling parameters on the cutting forces of low-cost clay-filled metallic syntactics was examined, and the correct detection of these impacts is considerably prominent in this paper. On the other side, tool life and wear analyses can be studied in future investigations.

Practical implications

It was indicated that the milling forces of the clay-added AA7075 syntactic foams, depending on the cutting parameters, can be anticipated through artificial neural network modeling.

Social implications

It is hoped that analyzing the influence of the cutting parameters using neural network models on the slot milling forces of metallic syntactic foams (MSFs) will be notably useful for research and development (R&D) researchers and design engineers.

Originality/value

This work is the first investigation that focuses on the estimation of slot milling forces of the expanded clay-added AA7075 syntactic foams by using different artificial neural network modeling approaches.

Details

Multidiscipline Modeling in Materials and Structures, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 18 August 2022

Shailendra Chauhan, Rajeev Trehan and Ravi Pratap Singh

This work aims to describe the face milling analysis on Inconel X-750 superalloy using coated carbides. The formed chips and tool wear were further analyzed at different cutting…

Abstract

Purpose

This work aims to describe the face milling analysis on Inconel X-750 superalloy using coated carbides. The formed chips and tool wear were further analyzed at different cutting parameters. The various impact of cutting parameters on chip morphology was also analyzed. Superalloys, often referred to as heat-resistant alloys, have exceptional tensile, ductile and creep strength at high operating temperatures and good fatigue strength, and often better corrosion and oxidation resistance at extreme heat. Because of these qualities, these alloys account for more than half of the weight of sophisticated aviation, biomedical and thermal power plants today. Inconel X-750 is a high-temperature nickel-based superalloy that is hard to machine because of its extensive properties. At last, the discussion regarding the tool wear mechanism was analyzed and discussed in this article.

Design/methodology/approach

The machining parameters for the study are cutting speed, feed rate and depth of cut. One factor at a time approach was implemented to investigate the effect of cutting parameters on the cutting forces, surface roughness and material removal rate. The scatter plot was plotted between cutting parameters and target functions (cutting forces, surface roughness and material removal rate). The six levels of cutting speed, feed rate and depth of cut were taken as cutting parameters.

Findings

The cutting forces are primarily affected by the cutting parameters, tool geometry, work material etc. The maximum forces Fx were encountered at 10 mm/min cutting speed, 0.15 mm/rev feed rate and 0.4 mm depth of cut, further maximum forces Fy were attained at 10 mm/min cutting speed, 0.25 mm/rev feed rate and 0.4 mm depth of cut and maximum forces Fz were attained at 50 mm/min cutting speed, 0.05 mm/rev feed rate and 0.4 mm depth of cut. The maximum surface roughness value was observed at 40 mm/min cutting speed, 0.15 mm/rev feed rate and 0.5 mm depth of cut.

Originality/value

The effect of machining parameters on cutting forces, surface roughness, chip morphology and tool wear for milling of Inconel X-750 high-temperature superalloy is being less researched in the present literature. Therefore, this research paper will give a direction for researchers for further studies to be carried out in the domain of high-temperature superalloys. Furthermore, the different tool wear mechanisms at separate experimental trials have been explored to evaluate and validate the process performance by conducting scanning electron microscopy analysis. Chip morphology has also been evaluated and analyzed under the variation of selected process inputs at different levels.

Details

World Journal of Engineering, vol. 21 no. 1
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 7 October 2014

Amrinder Pal Singh, Manu Sharma and Inderdeep Singh

Damage induced during drilling of polymer matrix composites depends upon torque during drilling. Modeling of torque with feed rate and its control becomes imminent for damage free…

Abstract

Purpose

Damage induced during drilling of polymer matrix composites depends upon torque during drilling. Modeling of torque with feed rate and its control becomes imminent for damage free drilling of composite laminates. Therefore, the purpose of this paper is to construct a transfer function between drilling torque and feed rate based upon experiments. Thereafter, the torque is controlled by using PID controller.

Design/methodology/approach

This paper presents step-by-step procedure to capture complex drilling dynamics of polymer matrix composites in a mathematical model. A glass fiber reinforced plastic (GFRP) composite laminate is drilled at constant feed rate during experimentation. The corresponding time response of torque is recorded. First order, second order and third order transfer functions between torque and feed rate are identified using system identification toolbox of Matlab®. These transfer functions are then converted into state-space models. Experimental verification is performed on GFRP composite laminate. PID controller is designed using Simulink® to track a given reference torque during drilling of polymer matrix composite. The controller is then validated using different reference torque trajectories.

Findings

Good match is observed between torque response from state-space models and experiments. Error analysis based on integral absolute error and integral squared error on experimental and simulated response show that third-order system represents the complex drilling dynamics in a better way than first and second-order systems. PID controller effectively tracks given reference trajectories.

Originality/value

Third-order model between torque and feed rate for drilling of composites not available in literature has been presented. PID controller has previously been applied successfully for drilling of conventional materials, this paper extends implementation of PID torque control for drilling of composites.

Details

Multidiscipline Modeling in Materials and Structures, vol. 10 no. 3
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 24 May 2022

Arun Kumar Bambam, Anil Dhanola and Kishor Kumar Gajrani

Nowadays, ionic liquids (ILs) are used as lubricant additives because of their ability to improve tribological characteristics. However, majority of the ILs contains halogen-based…

Abstract

Purpose

Nowadays, ionic liquids (ILs) are used as lubricant additives because of their ability to improve tribological characteristics. However, majority of the ILs contains halogen-based anions. They are extremely sensitive to moisture and produce detrimental halides and halogen acids when reacted with moisture and water. These halides and halogen acids are harmful to the health and environment of the operator’s. This paper aims to study four different lubricants including two halogen-based ILs blended in canola oil and two phosphonium-based halogen-free ILs blended in canola oil and in pure canola oil.

Design/methodology/approach

Viscosity and contact angle were measured by using rheometer and contact angle goniometer, respectively. Machining experiments were performed using turning centre with four different lubricants at two different cutting speeds and temperatures, and the machining forces, tool morphology and roughness of the machined surface were analysed.

Findings

The results showed that the inclusion of 1% phosphonium-based halogen-free ILs blended in canola oil increased the viscosity by 44.8% and reduced the cutting and thrust force by 21.7% and 26.8%, respectively, compared to pure canola oil lubricant. Microscopic analysis of tool showed lower adhesive and abrasive wear when machined with phosphonium-based halogen-free ILs blended in canola oil. The workpiece surface roughness reduced by 32% for phosphonium-based halogen-free ILs blended in canola oil compared with pure canola oil.

Originality/value

Halogen-free ILs are possible green lubricants, as they do not contain harmful elements such as F, S, B and Cl like halogen-based ILs. To the best of the authors’ knowledge, this is presumably the first work which shows machining performance of halogen-free ILs as lubricant additives.

Details

Industrial Lubrication and Tribology, vol. 74 no. 6
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 7 October 2021

Amrita Maddamasetty, Kamesh Bodduru, Siva Bevara, Rukmini Srikant Revuru and Sanjay Kumar

Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply…

Abstract

Purpose

Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply of a small quantity of specialized coolant to the machining zone or use of a solid lubricant is a possible solution. The purpose of the present work is to improve machinability of Inconel718 using graphene nanoplatelets.

Design/methodology/approach

In the present study, graphene is used in the machining of Inconel 718 alloy. Graphene is applied in the following two forms: as a solid lubricant and as an inclusion in cutting fluid. Graphene-based self-lubricating tool and graphene added nanofluids are prepared and applied to turning of Inconel 718 at varying cutting velocities. Performances are compared by measuring cutting forces, cutting temperature, tool wear and surface roughness.

Findings

Graphene, in both forms, showed superior performance compared to dry machining. In total, 0.3 Wt.% graphene added nanofluids showed the lowest cutting tool temperature and flank wear with 44.95% and 83.37% decrease, respectively, compared to dry machining and lowest surface roughness, 0.424 times compared to dry machining at 87 m/min.

Originality/value

Graphene could improve the machinability of Inconel 718 when used in tools as a solid lubricant and also when used as a dispersant in cutting fluid. Graphene used as a dispersant in cutting fluid is found to be more effective.

Details

World Journal of Engineering, vol. 19 no. 4
Type: Research Article
ISSN: 1708-5284

Keywords

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