The purpose of work is to provide a manufacturing processes, cutting and machine tools for machining of small parts. The proposals are designed for high volume production with a maximum productivity. The first half is largely nature of the search, which analyzes issue of tools and machines for production of rotary parts. Further proposals are developed manufacturing processes for different types of machines including multi-spindle lathes. The main result of this work is to determine appropriate type of machine for the production of specified parts.

This diploma thesis deals with the design and realization of a detachable joint for transferring a large torque from a drive to a driven member in a vertical forging press. The first part analyzes the disadvantages of production, assembly and disassembly of the original wedge joint of eccentric shaft and gear. The design of a new detachable joint is intended to remove the disadvantages of the original joint. Verification calculations are part of the proposal. The next part deals with the production of joint elements and the modification of the connected components for the designed joint.

Dans les approches numériques pour l'usinage à grande vitesse, le comportement rhéologique des matériaux usinés est généralement décrit par une loi de Johnson Cook et le frottement à l’interface par un coefficient constant de type Coulomb. Une première approche propose de déterminer une loi de frottement à paramètres multiples pour des basses températures combinées à des vitesses de glissement élevées au moyen d'un tribomètre. Les résultats expérimentaux sont comparés à un modèle numérique et une méthode inverse est utilisée pour minimiser l'erreur entre des simulations numériques et expérimentales sur les forces tangentielles et normales. Cette méthode permet de récupérer un coefficient de frottement de type Coulomb qui est associé à la pression locale, la température et la vitesse de glissement. La réalisation de plusieurs essais fournit une loi de frottement à paramètres multiples pour des vitesses de glissement élevées et des basses températures. Une seconde étude est menée sur les phénomènes microstructuraux intervenant à l’interface outil-copeau. De nombreuses études ont montré que les phénomènes de recristallisation dynamique apparaissent lors de l'usinage dans l'interface outil-copeau. La loi de Johnson Cook ne comprend pas de tels phénomènes. Ainsi, les modèles rhéologiques spécifiques basés sur la métallurgie sont introduits pour tenir compte de ces phénomènes de recristallisation dynamique. Un modèle éléments finis de la coupe orthogonale à deux dimensions est développé avec le logiciel Abaqus Explicit en utilisant une formulation ALE. Ce modèle éléments finis peut alors prédire la formation des copeaux, les températures d'interface, les longueurs de contact et les forces de coupe. De nombreux essais spécifiques sont réalisés sur un banc d'essai de coupe orthogonale et un tribomètre grande vitesse sur un acier AISI 1045 et avec un outil en carbure non revêtu. Les résultats expérimentaux sont ensuite comparés aux simulations numériques. Ces deux approches montrent qu’il est nécessaire, afin d’optimiser les modèles de coupe orthogonale, de prendre en compte une loi de frottement à paramètres multiples qui tient compte des pressions, températures et vitesses de glissement locales et d’intégrer une loi de comportement rhéologique à base métallurgique. / In numerical approaches for high speed machining, the rheological behavior of machined materials is generally described by Johnson Cook law and the friction at the interface by a constant coefficient of Coulomb. A first approach proposes to determine a multiparameter friction law for low temperatures in combination with high sliding speeds by means of a tribometer developed by Meresse et Al. [Mer11]. The experimental results are compared to a numerical model and a inverse method is used to minimize the error between the numerical and experimental simulations on tangential and normal forces. This method allows to recover a Coulomb friction coefficient. This one is associated with the local pressure, temperature and sliding velocity. Several tests provide a multiparameter friction law for higher sliding speeds and low temperatures. A second study is conducted on the microstructural phenomena occurring at the tool-chip interface. Numerous studies have shown that the dynamic recrystallisation phenomena appear during machining at the interface. Johnson Cook law excludes such phenomena. Thus, specific rheological models based on metallurgy are introduced to take into account the dynamic recrystallization phenomena. Two empirical models proposed by Kim et al. [Kim03] and Lurdos [Lur08] are studied. A two-dimensional finite element model of the orthogonal cutting is developed with Abaqus Explicit software using an ALE formulation. This finite element model can predict chip formation, interface temperatures, contact lengths and cutting forces. Many specific tests are performed with an orthogonal cutting test bench and with an high speed tribometer on an AISI 1045 steel. The experimental results are then compared with numerical simulations. Both approaches show that it is necessary to optimize the orthogonal cutting model, to take into account a multi-parameter friction law that considers the local pressures, temperatures, and sliding velocities and to integrate a rheological behavior law based on mettalurgy.

<p>Tantalum, niobium, stainless steels, and nickel are corrosion-resistant metals that have become critical in many industrial sectors. Due to the demanding environments and temperatures in which they operate, few materials can serve as substitutes. The advantages of these materials are offset by the difficulties in their machining. Belonging to a group of metals and alloys often referred to as ‘gummy’, their poor machinability or gumminess is manifest as thick chip formation, large cutting forces, and poor finish on cut surface. Hence, machining costs can be prohibitive, and applications limited. The gumminess has been attributed broadly to their high strain-hardening capacity.</p> <p>To examine why these metals are difficult to machine, we used direct <i>in situ</i> observations of the cutting process with a high-speed imaging system, complemented by force measurements. The observations showed that chip formation occurred by repeated large-amplitude folding of the material – sinuous flow – with vortex-like components and extensive redundant deformation. The folding was particularly severe in Ta and Nb. Although Ta and Nb displayed a higher rate of fold nucleation than the Ni and stainless steel, the flow dynamics underlying chip formation across the metals was the same – sinuous flow nucleated by a plastic (buckling-type) flow instability on the workpiece surface just ahead of the advancing tool. The large strains and energy dissipation associated with sinuous flow is the reason for the poor machinability of these metals. </p> <p>Prior work with Cu and Al has shown that sinuous flow can be disrupted and replaced by an energetically more favorable (segmented) flow mode, characterized by quasi-periodic fracture, when suitable chemical media are applied to the initial workpiece surface – a mechanochemical effect. The segmented flow is beneficial for machining processes since it involves much smaller forces and plastic strains. It has been hypothesized that the chemical media influence the flow through their adsorption onto the workpiece surface, thereby altering the surface energy and/or surface stress, and effecting a local embrittlement (ductile-to-brittle transition). </p> <p>We demonstrate similar media (mechanochemical) effects and segmented flow development in cutting of the corrosion-resistant metals, with significant benefits for their machining. These benefits include > 35 percent reduction in the cutting force/energy, and an order of magnitude improvement in cut surface quality (finish, tears and residual strain). Importantly, the experiments with the corrosion-resistant metals provide strong evidence that it is indeed adsorption – not corrosion, as in case of hydrogen embrittlement – that underpins the mechanochemical effect. The experiments used chemical agents well-known for their strong adsorption to metal surfaces, namely green corrosion inhibitors (e.g., plant extracts, propolis) and other natural organic molecules (e.g., dyes, antibacterial drugs, cow’s milk). Lastly, the suitability and application of the mechanochemical effect at industrial cutting speeds is explored in turning experiments with these corrosion-resistant metals. Collectively, our observations, measurements, and analysis show that the gumminess of metals in cutting is due to sinuous flow; the gumminess can be eliminated by use of chemical media; and adsorption is the key to engendering the mechanochemical effect. Implications of the results for industrial processes ranging from machining to particle comminution, and for sustainable manufacturing are discussed.</p> <br>

No description available.

The manufacturing of components with complex internal features, e.g. for automobile industry, aeronautics or medical applications, is a significant challenge. Such components are often machined in temporarily and locally separated stages of production. Due to these separated stages, the form deviations and positioning errors increase, which leads to additional efforts for the quality assurance. The technology that shall be developed within the project SwitchECM is supposed to enable machining of components with differing complex features in one single production stage and shall simultaneously allow for high precision. For this purpose, a multi-cathode system will be developed, in which every single cathode can be switched with specific parameters. The specific switching parameters shall be adjusted according to the requirements of the pre-defined features. For the manufacturing of different pre-defined features with one multi-cathode system the usage of pulsed direct current as well as continuous direct current shall be possible. Hence, removal experiments were carried out on 1.4301 stainless steel using a PEMCenter 8000 with varying feed rates and voltages at a pulsation frequency of 200 Hz. With this comparatively high frequency and a pulse duration of 4 ms pseudo direct current experiments are realized. The results are compared to experiments with a more common pulse frequency of 50 Hz. The mass removal analyses show, in which degree the transferability of experimental results from pulsed current to pseudo direct current or rather direct current is feasible.

No description available.

Sustainability is one of the challenges in today’s world. With limited resources at hand and hazardous impact of manufacturing processes on the environment, there is an increasing need for sustainable manufacturing. Sustainability actually has a broad meaning and is an all-inclusive concept. In this thesis what we are more interested in and focus on, are energy consumption and environmental impacts. Using system dynamics modeling and simulation, we can more easily understand the behavior of processes. Our selected processes are turning, milling and drilling operations in crankshaft machining and using system dynamics concept we model these processes with regards to energy consumption and environmental concerns. The output of this thesis work can be eventually used as a decision support tool to decide how to make processes more sustainable.

Wire Electric Discharge Machining (wire-EDM) is a non-traditional machining process. Controlled electric sparks are successively used to vaporize part of a workpiece along a programmed path in order to machine a desired part. Because there is no tool that comes in direct contact with the workpiece, it is possible to machine thin, delicate parts. This thesis was designed to observe and analyze the differences in cutting capabilities for a conventional wire-EDM machine when cutting thin-walled sections from five commonly used metals utilizing a variation of roughing and finishing passes. The five metals that were used in this study are: Aluminum 6061 T6, Yellow Brass SS360, 420 Stainless Steel, D2 Tool Steel at 25 to 30 RC, and D2 Tool Steel at 60 to 65 RC. The thin-walled sections were constrained on each end by the parent material to which they remained attached, and they ranged in thickness from 0.05 millimeters (0.002 inches) increasing incrementally by 0.05 millimeters (0.002 inches) until they reached a thickness of 0.30 millimeters (0.012 inches). A Sodick AQ325L wire-EDM machine was employed to perform the machining. It was observed that differences exist in the capabilities of cutting thin-walled sections from the five different metals. This could be both observed visually through inspection and statistically through the analysis of each data set obtained by measuring the resultant thickness of each section. It was also observed that differences exist for the same material while utilizing the variations of cutting parameters: a roughing with no finishing passes, a roughing with one finishing pass, and a roughing with three finishing passes. Thus both the material properties and the cutting parameters play a significant role in determining the capability of cutting thin-walled sections with a wire-EDM machine.

This project aims to present machine tool characteristics which may induce limiting factors in terms of flexibility. The aim is also to present a current state description of the machine tools in the production system regarding their characteristics in terms of quantifiable results. This refers to visual presentation in the form of graphs of the distribution of these characteristics among the different machine tools. A literature study was conducted to attain knowledge of machine tools and how the literature defines machine tool flexibility. Based on this, the flexibility parameters were identified. The result illustrates the current state description of the machine tools found in Volvo truck’s factory in Köping. These machine tools are lathe machines, machine centers, gear cutting machines and grinding machines. The result presents a percentage breakdown for each parameter for each of the machine types regarding the number of machines which possess a specific characteristic. The result displayed various cases of data missing. In many cases only a small percentage of data was missing, thus this result should be a sufficient representation of the situation. Meanwhile in other cases more data was missing and it leads to the result being less accurate. Overall, the acquired data in most cases should be sufficient to provide a current state description of the machines in the factory. There is no clear definition of flexibility referenced by the literature, hence it is difficult to conduct a quantitative evaluation. Moreover, there are many parameters presented in this work which emphasizes the multidimensional complexity of the problem. The parameters presented in this project directly influence the type of operations required, geometrical complexity of the workpiece, number of setups and size of workpiece which the machine is capable of handling. The machines have been grouped into the four categories mentioned above. This was done to reduce the complexity of the problem, hence not investigating each sub-category of machine (for example hobbing, skiving, etc.) The work has chosen not to group the machines based on the article they process as this would require additional knowledge of the layout and flow of material in the factory. The chosen approach will provide more of a generic visualization. A method has been developed to present a current state description of a manufacturing system regarding machine tool flexibility and how they can be evaluated. This process includes data collection and documentation of machines tools for the flexibility parameters. Hence, it can be presented how the machines within each machine type possess a specific attribute in terms of numbers or fit within a certain interval. The purpose is to present visual results of the data to illustrate for the reader the distribution of the machine characteristics for each of the machine types and parameters. / Detta projekt har som mål att presentera egenskaper hos bearbetningsmaskiner som kan medföra begränsande faktorer kopplat till flexibilitet. Målet är också att presentera en nulägesbeskrivning av bearbetningsmaskinernas egenskaper i produktionssystemet i form av kvantifierbara resultat. Detta refererar till visuella presentationer i form av grafer angående distribueringen av dessa egenskaper bland de olika bearbetningsmaskinerna. En litteraturstudie har genomförts för att tillhandahålla kunskaper om bearbetningsmaskiner och hur litteraturen definierar flexibilitet hos bearbetningsmaskiner. Resultatet illustrerar nulägesbeskrivningen av bearbetningsmaskinerna som befinner sig i Volvo Trucks fabrik i Köping. Dessa bearbetningsmaskiner är svarvar, fleroperationsmaskiner, kuggbearbetningsmaskiner och slipmaskiner. Resultatet visar en procentuell uppdelning av varje parameter for varje maskintyp, angående antalet maskiner som besitter en viss typ av egenskap. Resultatet visade på olika fall av saknad av data. I många fall saknades endast en liten andel av data, därmed bör detta resultat ge en tillräcklig representation av situationen. I andra fall saknades mer data och det leder till att resultatet blir mindre exakt. Överlag bör den insamlade datan i de flesta fall vara tillräcklig för att presentera en nulägesbeskrivning av maskinerna i fabriken. Det finns ingen tydlig definition av flexibilitet som nämns i litteraturen, därmed medför detta svårigheter att utföra en kvantitativ utvärdering. Dessutom presenteras det många olika parametrar i detta arbete, vilket understryker problemets flerdimensionella komplexitet. Parametrarna presenterade i detta arbete påverkar direkt vilken typ av operation som behövs, geometriska komplexiteten av arbetsstycket, antalet uppspänningar och storleken på arbetsstycket som maskinen kan hantera. Maskinerna har grupperats i fyra olika kategorier som nämndes ovan. Detta gjordes för att minska komplexiteten av problemet, därmed undersöks inte underkategorierna av maskinerna (till exempel hobbing skiving etcetera). Arbetet har valt att inte gruppera maskinerna baserat på vilken artikel de bearbetar, eftersom detta skulle behöva ytterligare kunskaper om layouten och flödet av material i fabriken. Det valda tillvägagångssättet ger en mer generell visualisering. En metod har tagits fram för att presentera en nulägesbeskrivning av ett produktionssystem med avseende på flexibiliteten hos bearbetningsmaskiner och hur de kan utvärderas. Denna process inkluderar datainsamling och dokumentation av flexibilitetsparametrarna hos bearbetningsmaskinerna. Därmed kan det presenteras hur maskinerna inom varje maskintyp besitter en specifik egenskap i form av siffror eller passar inom ett specifikt intervall. Syftet är att presentera visuella resultat av datan för att illustrera för läsaren om distribueringen av maskinegenskaperna för varje maskintyp och parameter.