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This master thesis was a part of an ongoing project at Research institutes of Sweden (RISE) and Chalmers University of technology, studying the formation of white layers (WLs) upon hard machining AISI 52100 steel. With a focus on the nanocrystalline microstructure of the machined steel, X-ray diffraction (XRD), white light interferometry (WLI), optical microscopy (LOM) and scanning electron microscopy (SEM) was utilized in the analysis of gathering an in-depth understanding of the WL formation mechanism. By introducing varying cutting parameters as part of the machining process, the effect of cutting speed and tool wear could be observed to directly impact the WL formation and could be linked to the thermomechanical contribution to the formation mechanism. Both thermal and mechanical WLs were observed and could be distinguished by the occurrence of dark layers in thermal WLs. The purpose of this thesis was to observe the influence of retained austenite (RA) on WL formation and from the XRD analysis the residual stress for different RA content could not be concluded. Furthermore, SEM concluded differences in the microstructure where a higher abundance of carbides was observed in the case of lower RA, a phenomenon most likely originating in the heat treatment process. Indications of facilitated mechanical WL formation for lower RA was observed but could not be deemed conclusive. The RA content could not be concluded to have an impact on the surface roughness nor the residual stress where variations were rather linked to the cutting parameters.

This study examined the effects of prenatal sensory and motor experience on the development of spatial orientation and turning bias in bobwhite quail. The theory presented here describes hemispheric specialization as the result of probabilistic events in the developing organism's prenatal environment; in particular, activity and experience in the final stages of prenatal development appear critical. Models and definitions of behavioral asymmetry, hemispheric specialization, and structural lateralization are reviewed. The results of Experiment 1 revealed a left-side turning bias in 85% of unmanipulated chicks. Experiments 2, 3, and 4 demonstrated that prenatal visual experience is a significant facilitator of population level left-side turning biases in bobwhite quail chicks. Experiment 5 investigated a potential underlying neurological basis for the bobwhite turning bias with unilateral injections of cycloheximide. The results of Experiment 5 suggest a left hemispheric specialization for the left-side turning bias. Furthermore, the results of Experiments 2 and 3 suggest that the asymmetrical hatching behaviors of the bobwhite quail are also a significant canalizing influence on the development of turning bias. The findings of this study are discussed in terms of an epigenetic theory of the development of hemispheric specialization and questions are raised as to the efficacy of laterality indexes as a reliable quantification of degree of hemispheric lateralization. / Ph. D.

Effective quality improvement in the manufacturing industry is continually pursued. There is an increasing demand for real-time fault detection, and avoidance of destructive post-process testing. Therefore, it is desirable to employ sensors for in-process monitoring, allowing for real-time quality assurance. Chapter 3 describes the application of sensor based monitoring to additive manufacturing, in which sensors are attached to a desktop model fused deposition modeling machine, to collect data during the manufacturing process. A design of experiments plan is conducted to provide insight into the process, particularly the occurrence of process failure. Subsequently, machine learning classification techniques are applied to detect such failure, and successfully demonstrate the future potential of this platform and methodology. Chapter 4 relates the application of online, image-based quantification of the surface quality of workpieces produced by cylindrical turning. Representative samples of cylindrical shafts, machined by turning under various conditions, are utilized, and an apparatus is constructed for acquiring images while the part remains mounted on a lathe. The surface quality of these specimens is analyzed, employing an algebraic graph theoretic approach, and preliminary regression modeling displays an average surface roughness (Ra) prediction error of less than 8%. Prediction occurs in less than 2 seconds, showing the capability for future application in a real-time, quality control setting. Both of these cases, in additive manufacturing and in turning, are validated using real experimental data and analysis, showing application of sensor-based online process monitoring in multiple manufacturing areas. / Master of Science / Effective quality improvement in the manufacturing industry is continually pursued, and there is an increasing demand for real-time quality monitoring. Therefore, it is desirable to employ sensors for in-process monitoring, allowing for real-time quality assurance. This is explored in two manufacturing areas. The first section of this work is in the area of additive manufacturing (“3D printing”), in which sensors are attached to a desktop model machine, to collect data during the printing process. Experiments are conducted to provide insight into how the process behaves, particularly the occurrence of printing failure. Machine learning classification techniques are then applied to detect such failure, and successfully demonstrate the future potential of this platform and methodology, for real-time monitoring of the process. The second section of this work relates to the conventional machining process of turning, and describes the application of image-based measurement of surface roughness. An apparatus is constructed for acquiring images, while the cylindrically turned shaft remains mounted on the lathe. The surface roughness is measured, and preliminary modeling displays an average surface roughness prediction error of less than 8%. This prediction occurs in less than 2 seconds, showing the capability for future application in a real-time, quality control setting. Both of these cases, in additive manufacturing and in turning, show the application of sensor-based monitoring in various manufacturing areas. This work provides a basis for future research and application, demonstrating how this sensor-based monitoring approach may be used for real-time quality monitoring in manufacturing.

Turning is one of the most widely used processes in machining and is characterized by a cutting tool moving along the axis of a rotating workpiece as it removes material. A detrimental phenomenon to productivity in turning operations is unstable cutting or chatter. This can reduce the life of tooling, dimensional accuracy, and the quality of a part's surface finish because of severe levels of vibration. Ideally, cutting conditions are chosen such that material removal is performed in a stable manner. However, it is sometimes unavoidable because of the geometry of the cutting tool or workpiece. This work seeks to develop a dynamic cutting force model that can be used to predict both the point of chatter instability as well as its amplitude growth over time. Previous chatter models fail to capture the physics of the process from a first-principles point of view because they are oversimplified and rely on various "cutting force coefficients" that must be tuned in order to get a desired correlation with experimental results. The proposed approach models the process in a geometrically rigorous fashion, also giving treatment to the strain, strain rate, and temperature effects encountered in machining. It derives the forces encountered during a turning operation from two sources: forces due to chip formation and forces due to plowing and flank interference. This study consists of a detailed derivation of two new cutting force models. One relies on careful approximations in order to obtain a closed-form solution; the other is more explicit and obtains a solution through numerical methods. The models are validated experimentally by comparing their prediction of the point of instability, the magnitude of vibration in the time and frequency domains, as well as the machined surface topography during chatter.

Manufacturing companies are increasingly compelled to optimize their machining processes for various reasons, such as improved cost effectiveness, tighter regulations and marketing advantages. Increasing energy costs in particular shift the reduction of energy consumption and the cost effectiveness of the production method more into the focus of corporate strategy. This is done by using the example of a turning process for the production of a tapered roller bearing. The main goal of this thesis can be identified as a detailed investigation of the energy consumption of certain turning machine. Further, different optimization approaches regarding energy efficiency are introduced taking under consideration tooling costs and machining time.

Processing completely producting technological documentation for production part “INJECTOR COVER” for firm BM SERVICE (formerly ČKD Hradec Králové), including time schedule production of parts (parts which past welding and machining create demanded component part) and calculation production costs. Solving production process is concepted in two variation (actual and forecast study) for machines which are sorted from existing machinery and from now proposed machines. Estimation is designed for firm conditions introducing to the production with view for qualifications of workers, convention in firm and equipment.

The aim of the master´s thesis is to adjust the technology of machining of a die on the CNC lathe so that the total time for the production of a die could be reduced significantly and in this way also the production costs. The analyse of the technology of the machining of the inner part of the die is carried out and a change in the machining of this part is suggested. The new technology is elaborated in two variants when the CAD/CAM system is used for the creation of a programme in a variant and the machining cycles in the other. The technical and economical evaluation is performed at the end of the thesis.

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.

The safety of a concrete dam is ensured by designing according to failure criteria, for all combinations of loads using safety factors. Today in Sweden, RIDAS, the Swedish power companies’ guidelines for dam safety, is used for the design of dams and is based on BKR, the National Board of Housing, Building and Planning. Swedish dams are designed to resist two global failure modes; sliding and overturning. Combination of failure modes, that should be considered in the design of concrete dams, is however fairly unknown. Since 2009 the Eurocodes was adopted and came into force 2011. The Eurocodes have replaced BKR in the design of most structures in Sweden where the partial factor method is used to ensure safety in the design. The objective of this report was to examine if the design criteria for concrete dams in today’s condition are enough to describe real failure modes. The other objective was to analyse if Eurocode is comparable to RIDAS in dam design. The stated questions were answered by performing a literature study of known dam failures and analytical calculations for different types of concrete gravity dams, with varying geometry and loading conditions. The programs CADAM and BRIGADE were also used as calculation tools to further analyse if failure occurred as expected. The results from the analytical calculations together with the performed FE analysis indicate that limit turning does occur and often generate lower safety factors compared to overturning. Limit turning is similar to overturning failure although it accounts for material failure in the rock. This design criterion is therefore, highly dependent on the quality of the rock and requires investigations of the foundation to be a good estimation of the real behaviour of the dam body. From the compilation of reported failures the conclusion was that the current design criteria are adequate. However, the real challenge lies in ensuring that the construction of dams is correctly performed to fulfil the stated criteria. A transition to Eurocode appears to be reasonable for the stability criterion. A modification of the partial factors is nevertheless necessary to obtain result corresponding to RIDAS, especially for the overturning criteria. / För att uppnå säkra dammkonstruktioner, för alla lastkombinationer, dimensioneras dammar enligt bestämda brottvillkor som ska uppfylla en viss säkerhetsfaktor. Idag används RIDAS, för dimensionering av dammar i Sverige. RIDAS Kraftföretagens riktlinjer för dammsäkerhet, är baserat på BKR, Boverkets konstruktionsregler. I Sverige dimensioneras dammar för att motstå de två globala brottmoderna glidning och stjälpning. Frågan som behöver besvaras är om det finns eller kan finnas några kombinationer av brottmoder som borde beaktas vid dimensionering av dammar. 2009 antogs Eurokoderna och trädde i kraft 2011. Eurokoderna har ersatt BKR vid dimensionering av de flesta konstruktioner i Sverige. I Eurokod används partialkoefficienter för att garantera säkra konstruktioner. Syftet med denna rapport var att undersöka om dagens brottkriterium är tillräckliga för att beskriva hur dammar går till brott. Rapporten behandlar även möjligheten att övergå från att dimensionera dammar enligt RIDAS till att dimensionera enligt Eurokod. För att besvara detta genomfördes en litteraturstudie av rapporterade dammbrott. Dessutom genomfördes analytiska beräkningar för flera olika typer av dammar med varierande geometri och lastfall. Programmen CADAM och BRIGADE användes som ytterligare verktyg för att analysera brottmoderna. Enligt resultat från de analytiska beräkningarna tillsammans med FE-beräkningarna ansågs limit turning inträffa och genererade i högre grad en lägre säkerhetsfaktorer i jämförelse med stjälpning. Limit turning kan förklars som delvis stjälpande och inkluderar brott av bergmassan. Brottmodet är dock beroende av kvalitéten hos berget och det krävs undersökningar av grunden för att kunna göra en god uppskattning av dammens verkliga beteende. Sammanställningen av tidigare brott visade att nu gällande brottkriterier är lämpliga och troligtvis tillräckliga. Utmaningen är istället att säkerställa att konstruktionerna är korrekt utförda och därmed uppfyller dessa brottkriterier. En övergång till Eurokod tycks vara möjlig för de globala brottmoderna, dock är det väsentligt att partialkoefficienterna justeras för att uppnå resultat som överensstämmer med RIDAS, särskilt för stjälpning.