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For several years, research work has been carried out at the University of Canterbury aimed at the development of a rapid prototyping and manufacturing process referred to as Robotic Foam Sculpting (RFS). This system uses a six-axis industrial robot and electrically-heated hot-wire and hot-blade tools to sculpt desired parts from blocks of polystyrene foam. The vision for this system is that it will be able to rapidly create large volume foam models at low cost, for a range of potential applications. Parts produced by the RFS system can potentially be used as investment casting patterns, cores for sculptures and architectural details, demonstration and testing models, wind tunnel test models, and many other potential applications. At the beginning of the work reported in this thesis, there was very little understanding of the nature of the surfaces produced by hot-tool cutting of foam, very little knowledge of the range of input cutting conditions that affected the surface quality, and almost no understanding of the relationships between the cutting strategy and the nature of the surfaces being produced. In addition, there was little evidence of published work on these subjects that was sufficiently robust to be applicable to the RFS system. This research was concerned with rectifying this gap in the existing knowledge. There were a number of different focal areas for this research. These included the surface texture of surfaces cut with hot tools, the effects of cutting strategy on the surface quality in single-pass cutting of foam, the effects of cutting strategy on the surface quality in multi-pass cutting, and the application of a current-control system to control the surface quality in real time during a cut. In each of the focal areas the goal was to develop a detailed understanding of the nature of the different aspects of surface quality, to map the factor interactions and dependencies that controlled these aspects of surface quality, to develop methods for predicting the expected surface quality based on cutting strategy (and vice versa) and to develop techniques for minimising the surface errors. The detailed investigation of the surface texture of surfaces produced with hot-tool cutting is presented in Chapter 4. This chapter explores the characteristic nature of foam surfaces, presents the development of a method of measuring the surface texture of foam, and investigates the usefulness of a range of standard texture parameters for assessing foam surface quality. It is concluded in this chapter that common texture parameters based on the relative heights of surface features are not capable of reliably discriminating between different foam surfaces, so a new texture parameter (the 10%-Height Contiguous Diameter) is developed and implemented. Using this parameter, it is possible to reliably predict the surface texture to be expected for a given set of cutting conditions. Investigations of the cutting strategy in single-pass cutting are presented in Chapter 5. This chapter identifies the two key aspects of surface quality in single-pass cutting, the kerfwidth and the surface barrelling. Experimental work is carried out to investigate the relationships between these errors and the cutting strategy, and the factors that influence each of them are identified. In addition, statistical models are developed for the kerf along the length of a cut so that the kerf can be predicted based on cutting conditions. This chapter also includes a study of the cutting force in single-pass cutting, and develops models that allow the prediction of the expected cutting force for a given cutting strategy. A detailed study of the cutting strategy for multi-pass cutting is presented in Chapter 6. This study identifies the most significant surface errors in multi-pass cutting and determines the causes of each of these errors and the factor interactions and dependencies that have to be considered when developing a multi-pass cutting strategy. Once again, statistical models that allow the prediction of these surface errors based on cutting strategy, or the evaluation of cutting strategy parameters to achieve a desired surface quality, are developed. The models for cutting force in single-pass cutting are applied to multi-pass cutting, and it is found that these models can accurately predict the force in multi-pass cutting as well. The characterisation of the acoustic output in hot-tool cutting forms the subject matter of Chapter 7. This study establishes that the magnitude of the acoustic output is proportional to the cutting force experienced during the cut, and is therefore potentially suitable for use as a trigger signal for feedback current control. This would allow an acoustic signal to be used instead of the current force signal, which has a number of drawbacks that will be discussed in Chapter 2, the Background Material chapter. The specific trigger signal identified as being of most use is the acoustic output in the 4 – 12 kHz band, where the presence of any non-zero acoustic output above background noise is a reliable and repeatable indicator of the presence of thermomechanical cutting. The work presented in this thesis provides a detailed, quantitative, evidence-based and reliable understanding of the nature of the cutting strategy in hot-tool cutting of foam. The key cutting strategy parameters and the important aspects of surface quality for different cutting types are identified, the relationships between all these parameters are mapped, and quantitative models are developed that allow the output metrics like the surface quality or the cutting force to be predicted with a high degree of accuracy based on the input cutting strategy conditions. Armed with this understanding, it is possible to determine the most suitable cutting strategy for sculpting a given part, and to assess whether a given part can be sculpted with the RFS system. As such, the research problem posed at the start of this thesis has been largely solved, and the stage is set for further research to optimise the cutting strategy for sculpting different parts and to correct the remaining drawbacks of the RFS system to complete the development of a commercially-useful manufacturing system.

The Industrial Laser is firmly established in metalcutting as the tool of choice for many applications. The elevator division of Montgomery KONE Inc., in an effort to move towards quality, ontime, complete deliveries and 100% customer satisfaction, decided to invest in new equipment to improve manufacturing processes. A huge investment is proposed for a laser-cutting machine. It is the responsibility of Manufacturing Engineering to direct the management by justifying its benefits, which includes payback time and financial gains. Factors such as common line cutting, automated material handling system and cutting time were involved in justification of the initial cost of a laser-cutting machine. Comparative statistics on appropriate factors accurately determine and justify the initial cost of a laser-cutting machine.

The vision of this thesis is to improve the machinability of workpiece steels. Workpiece material frequently transfers to the cutting tools during machining, and the transfer layers then forming on the tools may give both good and bad effects on machining performance and tool life. The objective of this work is to understand the effects of alloying element additions to workpiece steels on material transfer and the roles of the formed transfer layers on friction characteristics and wear of tools. To isolate and study the influence of the individual alloying elements, model steels are specifically designed. These steels include one reference with C as the only alloying element and others alloyed also with single additions or combined additions of 1 mass% Si, Mn, Cr and Al. The experiments are performed using both a sliding test, simulating the material transfer in milling, and a turning test. In a sliding contact, the mode of transfer is strongly dependent on the normal load and sliding speed. Material transfer initiates extremely fast, in less than 0.025 s, and characteristic transfer layers develop during the first few seconds. The different steel compositions result in the formation of different types of oxides in the transfer layers. At the workpiece/tool interface where the conditions involve high temperature, high pressure and low oxygen supply, easily oxidized alloying elements in the steel are preferentially transferred, enriched and form a stable oxide on the tool surface. The degree of enrichment of the alloying elements in the oxides is strongly related to their tendencies to become oxidized. The difference in melting temperature of the oxides, and thus the tendency to soften during sliding, explains the difference in the resulting friction coefficient. The widest differences in friction coefficients are found between the Si and Al additions. A Si containing oxide shows the lowest friction and an Al containing oxide the highest. The damage mechanism of coated tools is chiefly influenced by the form and shear strength of the transferred material. Absence of transfer layer or non-continuous transferred material leads to continuous wear of the coating. Contrastingly, continuous transfer layers protect it from wear. However, transfer layers with very high shear strength result in high friction heat and a large amount of steel transfer. This leads to rapid coating cracking or adhesive wear.

A dissertation submitted to the Faculty of Engineering and the Built Environment, University of the Witwatersrand, Johannesburg, in fulfilment of the requirements for the degree of Masters of Science in Engineering. Johannesburg, 2017 / This dissertation presents the zinc recycling of tool grade cemented tungsten scrap material generated during commercial production at Pilot Tools Pty Ltd (South Africa), production of powders and alloys from the zinc recycled materials, and evaluation of the properties of the recycled and un-recycled powders and alloys. Tool grade cemented tungsten carbide inserts were subjected to the zinc recycled process under controlled conditions. Tungsten carbide, cubic (TiC, TaC, NbC, TiCN) carbides and Co were recovered from the recycled scrap material. Two recycled alloys, R and RA, and two un-recycled alloys NS and N were produced following the conventional powder metallurgy route. Alloy R was made from 100 % zinc recycled powder with stoichiometric adjustment of C only, and alloy RA was made from 100% zinc recycled powder with stoichiometric adjustment of C and Co. Alloy N was produced under the same conditions as the recycled alloys R and RA, while alloy NS was produced at commercial level at Pilot Tools Pty Ltd (South Africa) using un-recycled powders. The alloy properties were evaluated following standard procedures for hardmetals. When the zinc recycled material was mechanically disintegrated, about 70 % of the recycled material was recovered as fine powder, while 30% was recovered as coarse oversize particles. The oversize particles were quite tough due to a high Co content, and it was difficult to disintegrate them through milling or repeated zinc recycling. The recycled powders took twice as much time to mill to the desired size as the new un-recycled powders, and had predominantly angular particles, while the new powders had smaller more rounded particles. A cubic free layer (CFL) was formed in all the alloys during sintering, although the recycled alloys R and RA had a narrower CFL compared to the new alloys NS and N. The recycled alloys R and RA had carbide grain size, carbide contiguity, binder mean free path, hardness, fracture toughness and wear rate which were generally within the same ranges as the new un-recycled alloys. / MT2018

O handebol é um esporte onde há mistura de velocidade, potência, resistência e, principalmente, de mudanças rápidas de direção, mudanças essas que são responsáveis por um número elevado de lesões. A ruptura do ligamento cruzado anterior (LCA) é frequente em atletas e pode ocorrer de duas maneiras: com ou sem contato direto. As lesões no LCA sem contato direto (LCASC) representam de 70 a 85% das lesões em atletas, normalmente em mudanças de direção denominadas \"sidestep\" (SID). Entender os fatores de risco e os mecanismos das lesões são algumas das etapas do processo de prevenção. O presente estudo tem como objetivo analisar as variáveis biomecânicas na articulação do joelho durante a mudança de direção seguida de um arremesso em atletas profissionais e universitárias de handebol com e sem informação visual. Participaram do estudo 14 atletas de nível profissional (GP = 21,5 ± 2.58) e 15 de nível universitário (GU = 22,4 ± 2,63), do sexo feminino. Foram posicionados 25 marcadores refletivos no tronco e membros inferiores da participante além de 10 eletrodos posicionados em: glúteo médio, bíceps femoral, reto femoral, gastrocnêmio e tibial anterior. Os valores angulares foram calculados pelos ângulos de Euler e a velocidade angular foi calculada pelos quatérnions. As participantes realizaram o sidestep cutting SID, sidestep cutting com bola (SIDB), sidestep cutting com luz (SIDluz) e sidestep cutting com bola e luz (SIDBluz). Foram encontrados maiores valores de flexão nos momentos CI e 40ms para GU em SID, SIBD e SIBluz. GP apresentou maiores valores de rotação em 100ms após o CI na maioria dos testes. GP apresentou maiores valores de velocidade angular (quatérnions) em 100ms em SID, SIDluz e SIDBluz. GP também apresentou maiores velocidade angulares na execução dos testes: SIDlu, SIDB e SIBluz. GU apresentou. GP apresentou melhor razão de co-contração (CC) quando comparado GU no SIDluz, e GU apresentou melhor CC em SID. GP apresentou maior tempo de contato (TC) SIDluz, SIDBluz e SID. Conclui-se que atletas universitários e profissionais apresentam padrões cinemáticos diferentes durante a execução de tarefas de mudanças de direção / Handball is a sport where there is mixture of speed, power, resistance, and especially the fast changes of direction. These changes are responsible for a high incidence of injuries in handball players. The rupture of the anterior cruciate ligament (ACL) is common in athletes and can occur in two different ways: with contact and non-contact. The ACL injuries non-contact (LCASC) represent 70 to 85% of injuries in athletes typically in the change of direction called \"sidestep\" (SID). Understand the risk factors and mechanisms of injury are some of the steps to prevent them. This study aims to analyze the biomechanical variables in the knee joint during the change of direction then a pitch in professional and college athletes of handball with and without visual information. All participants were female, 14 professional athletes (GP = 21.5 ± 2:58) and 15 the college athletes (GU = 22.4 ± 2.63). In total, 25 reflective markers were positioned on the trunk and lower limbs of the participant along with 10 electrodes placed on: gluteus medius, biceps femoris, rectus femoris, gastrocnemius and tibialis anterior. The angles were calculated by Euler angles and the angular velocity were calculated from the quaternions. The participants performed the SID, sidestep cutting Ball (SIDB), sidestep cutting with light (SIDluz) and sidestep cutting with ball and light (SIDBluz). We found greater flexion values in the CI and 40ms moments for GU in SID, SIDB and SIDBluz. GP has higher rotation values in 100ms after the IC in most tests. GP pointed high values of angular velocity (quaternions) in 100ms in SID, SIDluz and SIDBluz. GP also had higher angular speed in carrying out the tests: SIDluz, SIDB and SIDBluz. GU presented better rate of cocontraction (CC) compared GP in SIDluz, and GU pointed better CC in SID. GP presented greater contact time (TC) in SIDluz, SIDBluz and SID. Concludes that college and professional athletes have different kinematic patterns during the execution in changes of direction tasks

Thesis (Ph.D.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1979. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING / Vita. / Includes bibliographical references. / by Bruce M. Kramer. / Ph.D.

Vita. / Digitized by Kansas Correctional Industries

Laser cutting is one of the most important applications of laser in manufacturing industry; it is mainly used for sheet metal cutting. In laser cutting, performing real-time evaluation of laser cut quality is very important to the advancement of this process in industry. However, due to the dynamic nature of the laser cutting process specially when cutting ferrous alloys using oxygen as an assist gas, laser cut quality cannot be easily predicted; therefore, the quality inspection of the laser cut is performed by off line inspections of the edges of the metal by skilled operators. This methodology is carried out after the process and thus cannot maintain a good quality if the process performance is out of control. Therefore, the objective of the research project is to qualify and develop a sensor system that ensure fault recognition online and can automatically control the laser metal cutting process to achieve good quality cut. For the realization of this objective the following has been done: - study the relationship between process parameters and cut quality characteristics; - identify the best sensors that can be used to monitor the process; - design and develop an experimental setup to test the proposed sensors; - collect and analyze data from the proposed sensors and correlate them to specific cut quality characteristics (process state variables); - develop direct relationships between the process signals and cut quality; - develop appropriate strategy for process control; - design and develop an integrated monitoring and control system; - test and evaluate the proposed system using simulation. In this study, a new technique for the determination of cut quality of sheet steels under the CO2 laser cutting process has been established. It is based on on-line detection and post-processing analysis of light radiation and acoustic emissions from the cut kerf. Determination of machining quality during cutting is best done through the measurement of surface roughness and kerf widths, as these are the two parameters that vary in successful through cuts. These two quality parameters can further be correlated to the two dominant process parameters of laser power and cutting speed. This study presents an analysis of acoustic emissions and reflected light for CO2 laser cutting of steel plates, and discusses their use for the estimation of cut quality parameters of kerf width and striation frequency for mild steel plates of 3mm, 5mm, 8mm, and 10mm thicknesses. Airborne acoustic and light signals are acquired with a microphone and a photodiode respectively, and recorded with a PC based data acquisition system in real time. The signals are then analyzed to establish a correlation between the signals obtained and the cut quality achieved. Experimental evidence shows that the energy levels of acoustic emission signals (RMS analysis) can be used to maintain the cutting process under steady state condition. On the other hand, the light intensity signal fluctuates with a frequency that corresponds to the frequency of striations formed on the cut surface; therefore it can be used to regulate cutting speed and laser power to obtain an optimum cutting condition and best cut quality. The validity of the proposed control strategy was tested experimentally by simulating the variations of cutting speed and examining their effect on the signals. So far, the prototype used for experimentation has been successful in providing correct information about cut quality in terms of striation frequency, and also about the state of the process where the microphone signal was successful in determining system failure or improper cutting conditions. A microprocessor based control system utilizing the PID control algorithm is recommended for the implementation of the control strategy. The implementation requirements of the proposed system for industrial use are then discussed. A new setup for the coaxial monitoring of CO2 laser cutting using a photodiode is proposed to enhance the quality of the signal and also to protect the photodiode from the harsh cutting environment. It is also proposed that an open control architecture platform is needed to enhance the integration of the proposed process control functions. Conclusions and future research directions towards the achievement of Autonomous Production Cell (APC) for the laser cutting process are then given.

Thesis--Auburn University, 2009. / Abstract. Includes bibliographic references (p.83-85).