Cutting tool edges are honed to an edge radius of about 15-30 micrometers for enhancing tool performance. During honing, defects left by prior manufacturing processes such as grinding and pressing are removed to achieve a higher quality edge. Recently, researchers have shown that tailoring the edge microgeometry to comprise an asymmetric shape and/or a gradient edge microgeometry is beneficial. Conventional edge honing processes such as brush honing and abrasive micro-blasting are limited in terms of reliably generating such geometries in a productive manner. To this end, this research explored the application of non-Newtonian aqueous suspensions of cornstarch and abrasives, for the edge honing of cutting tools. This thesis details the science, technology, characteristics and capabilities of this innovative process. / Thesis / Master of Applied Science (MASc)

This thesis describes a tool that facilitates rapid modeling of devices from informal documents. The ModelMaker tool facilitates the construction of models by analyzing the source specification document and presenting it based on the modeler's need. ModelMaker analyzes and indexes the source document for the noun phrases and identifiers it contains. When the modeler specifies the name of a pin or device that the modeler is working on, ModelMaker will recover any behavioral or structural information about the particular pin or device. ModelMaker can return this information based on the order of how relevant the information is to the model that the modeler is trying to build. The modeling language that can be used for this tool is VHDL. The initial VHDL model is derived from a block diagram of the source document using a schematic capture tool. This VHDL model can be edited inside ModelMaker to add behavioral code and to insert source document fragments as comments. / Master of Science

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The thesis presents an approach to adaptive decision making strategies to reduce bottlenecks in a drilling operation and to extend tool life. It is an attempt to portray the real drilling system in a typical Flexible Manufacturing System (FMS) layout. The system designed serves as back end intelligence to drilling machines (INTELLIDRILL) in a Flexible Manufacturing System for making dynamic and real time decisions. INTELLIDRILL uses mathematical and adaptive tool reliability models to simulate the machining conditions and tool availability for an operation based on history of tool failures. The results are used to compute the machining parameters and the tools required for an operation. INTELLIDRILL can devise strategies for different tool materials to operate on batches of different materials. INTELLIDRILL decisions could lead to significant savings in tooling costs and reduction in flow line bottlenecks.

Miniaturized devices are the key producing next-generation microelectro-mechanical products. The applications extend to many fields that demand high-level tolerances from microproducts and component functional and structural integrity. Silicon-based products are limited because silicon is brittle. Products can be made from other engineering materials and need to be machined in microscale. This research deals with predicting microtool failure by studying spindle runout and tool deflection effects on the tool, and by measuring the cutting force that would fail the tool during microend-milling. End-milling was performed using a tungsten carbide (Ø1.016 mm dia., 2 flute) tool on SS-316L material. Tool runout measured using a laser was found to be less than 1 µm and tool deflection at 25000 rpm was 20 µm. Finite element analysis (FEA) predicts tool failure due to static bending for a deflection greater than 99% of tool diameter. Threshold values of chipload and cutting force resulting in tool failure were found using workdone by tool. Threshold values to predict tool failure were suggested for axial depth of cut in between 17.25% - 34.5% of cutter length. For a chipload greater than 20% of cutter diameter, the microtool fails instantly for any radial depth of cut.

The thesis presents an approach to adaptive decision making strategies to reduce bottlenecks in a drilling operation and to extend tool life. It is an attempt to portray the real drilling system in a typical Flexible Manufacturing System (FMS) layout. The system designed serves as back end intelligence to drilling machines (INTELLIDRILL) in a Flexible Manufacturing System for making dynamic and real time decisions. INTELLIDRILL uses mathematical and adaptive tool reliability models to simulate the machining conditions and tool availability for an operation based on history of tool failures. The results are used to compute the machining parameters and the tools required for an operation. INTELLIDRILL can devise strategies for different tool materials to operate on batches of different materials. INTELLIDRILL decisions could lead to significant savings in tooling costs and reduction in flow line bottlenecks.

The aim of this work is to design tools to the manipulator, unspecified metal-working machine. The proposal consists of a selection of the optimal design nodes and their functional calculations. The work also includes structural model in 3D view created in Autodesk Inventor 2010. All calculations and procedures are in accordance with current standards.

The thesis focuses on the design technology of the tooth gap mills. The theoretical part summarizes issues of material, milling and CAM technology. The practical part of the design process for the production of variants using CAM system. Parts are finally produced on 5-axis milling machine. At the end there is technical-economic evaluation of production.

Municipalities tend to develop their stormwater management policy by examining those of their neighboring communities, chosen out of convenience and perception of similarity rather than a purposeful, directed search. Alternatively, having a policy that is backed by science creates regulations that policy makers can confidently support. To address this issue, the model used in this study incorporates local rainfall and development data to analyze stormwater runoff volumes for various storm events using one year of development data from Chattanooga, Tennessee. The runoff values are used to analyze several policy combinations based on simplified policies, model policies, and customizable policies. Outputs of the tool include project count, impervious area managed, runoff managed, and runoff cleaned. This study indicates that stormwater managers can use the outputs of this tool to choose the policy that best meets their city’s unique goals.