This thesis presents models and algorithms necessary to simulate the five-axis flank milling of jet-engine impellers in a virtual environment. The impellers are used in the compression stage of the engine and are costly, difficult to machine, and time-consuming to manufacture. To improve the productivity of the flank milling operations, a procedure to predict and optimize the cutting process is proposed. The contributions of the thesis include a novel cutter-workpiece engagement calculation algorithm, a five-axis flank milling cutting mechanics model, two methods of optimizing feed rates for impeller machining tool paths and a new five-axis chatter stability algorithm. A semi-discrete, solid-modeling-based method of obtaining cutter-workpiece engagement (CWE) maps for five-axis flank milling with tapered ball-end mills is developed. It is compared against a benchmark z-buffer CWE calculation method, and is found to generate more accurate maps. A cutting force prediction model for five-axis flank milling is developed. This model is able to incorporate five-axis motion, serrated, variable-pitch, tapered, helical ball-end mills and irregular cutter-workpiece engagement maps. Simulated cutting forces are compared against experimental data collected with a rotating dynamometer. Predicted X and Y forces and cutting torque are found to have a reasonable agreement with the measured values. Two offline methods of optimizing the linear and angular feeds for the five-axis flank milling of impellers are developed. Both offer a systematic means of finding the highest feed possible, while respecting multiple constraints on the process outputs. In the thesis, application of these algorithms is shown to reduce the machining time for an impeller roughing tool path. Finally, a chatter stability algorithm is introduced that can be used to predict the stability of five-axis flank milling operations with general cutter geometry and irregular cutter-workpiece engagement maps. Currently, the new algorithm gives chatter stability predictions suitable for high speed five-axis flank milling. However, for low-speed impeller machining, these predictions are not accurate, due to the process damping that occurs in the physical system. At the time, this effect is difficult to model and is beyond the scope of the thesis.

The effect of particle size, velocity, and angle of attack was investigated on the roughness and erosion rate of unmasked channels machined in borosilicate glass using abrasive jet micro-machining (AJM). Single impact experiments were conducted to quantify the damage due to the individual alumina particles. Based on these observations, an analytical model from the literature was modified and used to predict the roughness and erosion rate. A numerical model was then developed to simulate the brittle erosion process leading to the creation of unmasked channels as a function of particle size, velocity, dose, impact angle and target material properties. For the first time, erosion was simulated using models of two damage mechanisms: crater removal due to the formation and growth of lateral cracks, and edge chipping. Accuracy was further enhanced by simulating the actual relationship between particle size, velocity and radial location within the jet using distributions measured with high-speed laser shadowgraphy. The process of post-blasting AJM channels with abrasive particles at a relatively low kinetic energy was also investigated in the present work by measuring the roughness reduction of a reference unmasked channel in borosilicate glass as a function of post-blasting particle size, velocity, dose, and impact angle. The numerical model was modified and used to simulate the post-blasting process leading to the creation of smooth channels as a function of particle size, velocity, dose, impact angle, and target material properties. Finally, the effect of alumina particle kinetic energy and jet impact angle on the roughness and erosion rate of channels machined in borosilicate glass using abrasive slurry jet micro-machining (ASJM) was investigated. The analytical and numerical models derived for AJM, were found to predict reasonably well the roughness and the erosion rate of ASJM channels, despite the large differences in the fluid media, flow patterns, and particle trajectories in AJM and ASJM.

The effect of particle size, velocity, and angle of attack was investigated on the roughness and erosion rate of unmasked channels machined in borosilicate glass using abrasive jet micro-machining (AJM). Single impact experiments were conducted to quantify the damage due to the individual alumina particles. Based on these observations, an analytical model from the literature was modified and used to predict the roughness and erosion rate. A numerical model was then developed to simulate the brittle erosion process leading to the creation of unmasked channels as a function of particle size, velocity, dose, impact angle and target material properties. For the first time, erosion was simulated using models of two damage mechanisms: crater removal due to the formation and growth of lateral cracks, and edge chipping. Accuracy was further enhanced by simulating the actual relationship between particle size, velocity and radial location within the jet using distributions measured with high-speed laser shadowgraphy. The process of post-blasting AJM channels with abrasive particles at a relatively low kinetic energy was also investigated in the present work by measuring the roughness reduction of a reference unmasked channel in borosilicate glass as a function of post-blasting particle size, velocity, dose, and impact angle. The numerical model was modified and used to simulate the post-blasting process leading to the creation of smooth channels as a function of particle size, velocity, dose, impact angle, and target material properties. Finally, the effect of alumina particle kinetic energy and jet impact angle on the roughness and erosion rate of channels machined in borosilicate glass using abrasive slurry jet micro-machining (ASJM) was investigated. The analytical and numerical models derived for AJM, were found to predict reasonably well the roughness and the erosion rate of ASJM channels, despite the large differences in the fluid media, flow patterns, and particle trajectories in AJM and ASJM.

No description available.

No description available.

Using a Panasonic MG-72 Micro Electro-Discharge Machine, techniques and procedures are developed to fabricate complex microstructures in conductive materials and engineered ceramics.

The present day manufacturing environment has forced manufacturing systems to be flexible and adaptable to be able to match the product demands and frequent introduction of new products and technologies. This research forms part of a greater research initiative that looks at the development of the reconfigurable manufacturing paradigm. Previous research has shown that the lack of development of a Modular Reconfigurable Manufacturing Tools (MRMT) and Open Architecture Control System (OACS) is currently a key limiting factor to the establishment of Reconfigurable Manufacturing Systems (RMS), which has been the primary motivation for this research. Open Architecture (OA) systems aim to bring the ideas of RMS to control systems for machining systems. An OA system incorporates vendor neutrality, portability, extendibility, scalability and modularity. The research has proposed, designed and developed a novel solution that incorporates these core principles allowing the system to be flexible in mechanical and control architectures. In doing so, the system can be reconfigured at any time to match the specific manufacturing functionality required at that time thereby prolonging the lifecycle of the machine via multiple reconfigurations over time, in addition to decreasing the cost of system modifications due to a well-defined modular system. The reconfiguration and machining variance is achieved by the introduction of mechanical and control modules that extend the Degrees of Freedom (DOF’s) available to the system. The OACS has been developed as a modular solution that links closely to the existing mechanical modularity on the RMT to maximize the reconfigurability of the system. The aim was to create a one to one link between mechanical and electronic hardware and the software system. This has been achieved by the addition of microcontroller based distributed modules which acts as the interface between the electro-mechanical machine axes via hardwired signals and the host PC via the CAN bus communication interface. The distributed modules have been developed on different microcontrollers, which have successfully demonstrated the openness and customizability of the system. On the host PC, the user is presented with a GUI that allows the user to configure the control system based on the MRMT physical configuration. The underlying software algorithms such as, text Interpretation, linear interpolation, PID or PI controllers and determination of kinematic viability are part of the OACS and are used at run time for machine operation. The machining and control performance of the system is evaluated on the previously developed MRMT. The performance evaluation also covers the analysis of the reconfigurability and scalability of the system. The research is concluded with a presentation based on conclusions drawn from the research covering the challenges, limitations and problems that OA and RMS can face before MRMT become readily available for industry. / M.Sc.Eng. University of KwaZulu-Natal, Durban 2013.

This thesis presents models and algorithms necessary to simulate the five-axis flank milling of jet-engine impellers in a virtual environment. The impellers are used in the compression stage of the engine and are costly, difficult to machine, and time-consuming to manufacture. To improve the productivity of the flank milling operations, a procedure to predict and optimize the cutting process is proposed. The contributions of the thesis include a novel cutter-workpiece engagement calculation algorithm, a five-axis flank milling cutting mechanics model, two methods of optimizing feed rates for impeller machining tool paths and a new five-axis chatter stability algorithm. A semi-discrete, solid-modeling-based method of obtaining cutter-workpiece engagement (CWE) maps for five-axis flank milling with tapered ball-end mills is developed. It is compared against a benchmark z-buffer CWE calculation method, and is found to generate more accurate maps. A cutting force prediction model for five-axis flank milling is developed. This model is able to incorporate five-axis motion, serrated, variable-pitch, tapered, helical ball-end mills and irregular cutter-workpiece engagement maps. Simulated cutting forces are compared against experimental data collected with a rotating dynamometer. Predicted X and Y forces and cutting torque are found to have a reasonable agreement with the measured values. Two offline methods of optimizing the linear and angular feeds for the five-axis flank milling of impellers are developed. Both offer a systematic means of finding the highest feed possible, while respecting multiple constraints on the process outputs. In the thesis, application of these algorithms is shown to reduce the machining time for an impeller roughing tool path. Finally, a chatter stability algorithm is introduced that can be used to predict the stability of five-axis flank milling operations with general cutter geometry and irregular cutter-workpiece engagement maps. Currently, the new algorithm gives chatter stability predictions suitable for high speed five-axis flank milling. However, for low-speed impeller machining, these predictions are not accurate, due to the process damping that occurs in the physical system. At the time, this effect is difficult to model and is beyond the scope of the thesis.

Doctor of Philosophy / This research aimed to develop new cooling methods to replace, or at least minimise, the use of currently used grinding coolants which are known to be harmful to the environment. The methods used involved the application of a cold air and vegetable oil mist mixture (CAOM), and the use of liquid nitrogen as cooling media. Allied research focused on the development of a segmented grinding wheel equipped with a coolant chamber. The feasibility of a grinding system using CAOM was assessed on the surface grinding of plain carbon steel 1045. It was found that at low material removal rates, ground surfaces were obtained with a quality comparable to that from grinding with a conventional coolant in association with a reduction of grinding forces. There was no significant difference in the subsurface hardness of the components using CAOM, although the latter method showed a stronger dependence of surface residual stresses on the depth of cut due to the limit in cooling capacity of CAOM. The effects of using liquid nitrogen as a cooling medium on the microstructure of quenchable steel were explored. It was found that a martensite layer was induced on the ground surface. The microstructure featured a dispersion of very fine carbides within the martensite lattice, resulting in a remarkable increase in hardness and high compressive residual stresses within the layer. The topography of the ground surfaces indicated that the material was predominantly removed by brittle fracture. Furthermore surface oxidisation was suppressed. In the interest of coolant minimisation, a segmented wheel equipped with a pressurized coolant chamber was developed. A higher quality ground surface was obtained in conjunction with a coolant saving of up to 70%. In addition, the adhesion of ground chips on the wheel surface largely disappeared. Furthermore, surface tensile residual stresses caused by thermal deformation were minimised. The mechanism of coolant disintegration to form mists using this type of wheel system was studied. The Weber theory for Newtonian jet instability was applied to quantitatively determine the contribution of coolant flow rate to mist and ligament modes. A semi-analytical model was then developed to predict the mist flow rate by taking into account both grinding parameters and coolant properties. The model prediction was in agreement with experimental measurements. Based on the principles of fluid motion and the mechanisms of spin-off and splash, analytical models for both conventional and segmented wheels were established to provide a physical understanding of the mechanisms of coolant penetration into the grinding zone. Coolant minimisation was evident using the segmented wheel where the coolant pumping power into the grinding zone increased with wheel speed, but for the conventional wheel it decreased. A quantitative analysis was developed that accounted for the coolant properties and system design characteristics governing the penetration mechanism revealed by the theory established above. In conjunction with the mist formation analysis, the developed model offers a practical guideline for the optimal use of grinding coolants in achieving a balance between the demands of productivity and care for the environment.

Thesis (Ph.D.) -- McMaster University, 1998. / Includes bibliographical references (p. 295-305). Also available via World Wide Web.