Cincinnati, OH, United States
Cincinnati, OH, United States

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Patent
Foundation University and Techsolve Inc. | Date: 2013-02-28

In one embodiment, a system for extending cutting tool life includes a vise, a jig provided in the vise adapted to hold or support a magnetic cutting tool insert, a magnet holder positioned above the jig that can be rotated, a magnet held in proximity to the jig by the magnet holder, and a mixture including abrasive particles that extends between the magnet and the jig, the mixture being supported by a magnetic field generated by the magnet, wherein when the magnet holder rotates, the magnet and the mixture of magnetic and abrasive particles rotate to finish a surface of the tool insert.


Yamaguchi H.,University of Florida | Srivastava A.K.,TechSolve Inc. | Tan M.A.,University of Florida | Riveros R.E.,University of Florida | Hashimoto F.,Technology Center
CIRP Annals - Manufacturing Technology | Year: 2012

Uncoated carbide tool surfaces are conditioned using magnetic abrasive finishing (MAF) to improve the tool wear characteristics by reducing friction between the tool and chip. The configuration of the magnetic particle chains that drive the abrasives plays an important role in surface finishing with minimal damage to the tool cutting edges. Roughnesses of less than 25 nm Ra on the flank and nose and less than 50 nm Ra on the rake can be achieved. In turning of Ti-6Al-4V alloy rods (at 100 m/min cutting speed), MAF-processed tools exhibited tool lives of up to twice as long as unprocessed tools. © 2012 CIRP.


Ozel T.,Rutgers University | Sima M.,Rutgers University | Srivastava A.K.,TechSolve Inc. | Kaftanoglu B.,Atilim University
CIRP Annals - Manufacturing Technology | Year: 2010

This paper presents investigations on turning Ti-6Al-4V alloy with multi-layer coated inserts. Turning of Ti-6Al-4V using uncoated, TiAlN coated, and TiAlN + cBN coated single and multi-layer coated tungsten carbide inserts is conducted, forces and tool wear are measured. 3D finite element modelling is utilized to predict chip formation, forces, temperatures and tool wear on these inserts. Modified material models with strain softening effect are developed to simulate chip formation with finite element analysis and investigate temperature fields for coated inserts. Predicted forces and tool wear contours are compared with experiments. The temperature distributions and tool wear contours demonstrate some advantages of coated insert designs. © 2010 CIRP.


Ozel T.,Rutgers University | Sima M.,Rutgers University | Srivastava A.K.,TechSolve Inc.
Transactions of the North American Manufacturing Research Institution of SME | Year: 2010

Titanium alloys present superior properties such as high strength-to-weight ratio and resistance to corrosion but posses poor machinability. Finite element simulations can be used to study the influence of process parameters. In this work, constitutive material models are modified to simulate serrated chip formation which can be extended to other materials. In modified models, strain (flow) softening, strain hardening and thermal softening effects are coupled. The predictions are compared with orthogonal cutting tests and found to be in agreement.


Siegel D.,Intelligent Maintenance | Al-Atat H.,Intelligent Maintenance | Shauche V.,Intelligent Maintenance | Liao L.,Intelligent Maintenance | And 2 more authors.
Mechanical Systems and Signal Processing | Year: 2012

The assessment and diagnosis of bearing health using vibration data has been a research topic of interest for many years and includes developments in an assortment of signal processing methods and classification algorithms. This paper investigates detecting bearing degradation at different levels of damage, in that estimating the bearing health at the various stages of degradation is important for predicting failure as well as making maintenance decisions. The proposed technique does not require a measure of the rotational shaft speed or bearing cage speed, which makes it very suitable in certain applications in which it is very difficult or not cost effective to measure the rotational speed. To effectively estimate the bearing health state, a novel tachometer-less synchronously averaged envelope (TLSAE) signal processing and feature extraction technique for rolling element bearing is proposed. The Tachometer-Less Synchronous Averaged Envelope (TLSAE) method consists of first using a narrow band pass filter around a calculated bearing fault frequency of interest and using the derivative of the phase of the Hilbert Transform of this narrow band signal to generate a synthesized tachometer signal that is representative of the impact due to a bearing defect. This synthesized tachometer signal is combined with the high frequency envelope method to perform synchronous averaging on the envelope signal, resulting in a defect synchronous envelope spectrum in which the frequency content is in terms of the fault frequency orders. The proposed method is further compared and evaluated with other existing methods, in particular to the traditional Fourier Transform technique, the bearing envelope analysis technique, and the empirical mode decomposition signal processing methods on the basis of whether each method provides an enhanced level of indication that can determine the health of rolling element bearings. Data from a bearing test-rig is used to facilitate the comparison and evaluation of the signal processing methods. Vibration data was collected from the test-rig for bearings with different levels of degradation. The calculated vibration features from the tachometer-less synchronously averaged envelope (TLSAE) technique are compared to the other feature extraction techniques; with the synchronous average method providing a set of bearing vibration features that can distinguish all three levels of damage on the outer race of the rolling element bearing. Future work looks to further investigate this proposed technique for data collected during a run to failure test in order to consider its merits for early detection of incipient bearing damage and whether it provides a consistent monotonic trend from spall initiation to bearing failure. © 2012 Elsevier Ltd.


Atluru S.,University of Cincinnati | Huang S.H.,University of Cincinnati | Snyder J.P.,Techsolve Inc
International Journal of Advanced Manufacturing Technology | Year: 2012

Machine tools and machining systems have gone through significant improvements in the past several decades. Recent advance in information technology made it possible to collect and analyze a large amount of data in real time. This brings about the concept of a smart machine tool, enabled by process monitoring and control technologies, to produce the first and all subsequent parts correctly. This paper presents a system framework for a smart machine supervisory system. The supervisory system integrates individual technologies and makes overall intelligent decisions to improve machining performance. The communication mechanism of the supervisory system is discussed in detail. Its decision-making mechanism is illustrated through an example that integrates process planning, health maintenance, and tool condition monitoring. © 2011 Springer-Verlag London Limited.


Deshpande A.,TechSolve Inc
International Journal of Advanced Manufacturing Technology | Year: 2013

Purchasing the correct machine tool can have strategic implications for manufacturers, because incorrect selection will eventually lead to quality and productivity losses. Prior research has concentrated on developing an analytical decision support system to select and compare machine tools based on machine functionality - not capability. Machine tool selection decision analyses concentrate on machine specifications and characteristics, which disregard the actual machine accuracy and dynamic performance. In this paper, the need to include machine accuracy and performance in terms of cycle time, tool wear, and surface finish is described with a case study of manufacturing a typical aerospace component using three different production methodologies on three computer numeric controller milling machines. Even though the three selected machine tools have similar technical specifications, which are adequate to manufacture the sample aerospace part, the machine accuracy and dynamic machining performance of the machines is significantly different. We conclude that it is necessary to include machine tool performance and production readiness attributes and not solely rely on the specifications when considering machine tool selection and purchasing. © 2012 Springer-Verlag London Limited.


Deshpande A.,TechSolve Inc. | Pieper R.,TechSolve Inc.
ASME 2011 International Manufacturing Science and Engineering Conference, MSEC 2011 | Year: 2011

A typical manufacturing job shop comprises of legacy machine tools, new (modern) machine tools, material handling devices, and peripheral manufacturing equipments. Automated monitoring of legacy machine tools has been a long-standing issue for the manufacturing industry primarily because of the computer numeric controller (CNC) closed architecture and limited external communication functionality. This paper describes a non-invasive methodology and development of a software application to monitor real-time machine status, energy usage, and other machining parameters for a legacy machine tool using power signal analysis. State machine algorithm is implemented to detect tool changes and part count. The system architecture, implementation, benefits, limitations, and future work needed for the legacy machine tool monitoring application is explained in detail. Copyright © 2011 by ASME.


Cong W.L.,Kansas State University | Pei Z.J.,Kansas State University | Deines T.W.,Kansas State University | Srivastava A.,TechSolve Inc. | And 2 more authors.
Ultrasonics | Year: 2012

Carbon fiber reinforced plastic (CFRP) composites are very difficult to machine. A large number of holes need to be drilled in CFRP for many applications. Therefore, it is important to develop cost-effective drilling processes. CFRP has been drilled by rotary ultrasonic machining (RUM) successfully. The literature has reports about the effects of input variables on output variables (including cutting force, torque, surface roughness, tool wear, and workpiece delamination) in RUM of CFRP. However, there are no reports on power consumption in RUM of CFRP. This paper reports the first study on power consumption in RUM of CFRP. It reports an experimental investigation on effects of input variables (ultrasonic power, tool rotation speed, feedrate, and type of CFRP) on power consumption of each component (including ultrasonic power supply, spindle motor, coolant pump, and air compressor) and the entire RUM system. © 2012 Elsevier B.V. All rights reserved.


Grant
Agency: NSF | Branch: Standard Grant | Program: | Phase: Manufacturing Machines & Equip | Award Amount: 200.00K | Year: 2012

The collaborative research to be conducted under this award is directed toward a more fundamental understanding of an atomized-based cutting fluid and carbon dioxide spray cooling and lubrication application system for machining of titanium alloys. The specific objectives are to: (i) establish an understanding of the film formation behavior on a stationary surface from the atomized cutting fluids, and its penetration characteristics at the cutting interface during titanium machining; (ii) better understand the temperature distribution and the heat removal characteristics throughout the cutting interface; (iii) study the effects of spray parameters, spray unit orientation angle, and fluid properties (for example, surface tension and viscosity) and the application of carbon dioxide as a droplet carrier gas on the machining performances including tool wear, cutting temperature, and chip formation. These objectives will be realized through the execution of three principal tasks: (1) model the film formation behavior of the atomized cutting fluid droplets and their penetration to the tool-chip interface; (2) predict the temperature distribution at the cutting interface under the atomized cutting fluid spray conditions; and (3) develop a process plan for an effective lubrication and cooling application during machining of titanium alloys. The validation of model predictions of the fluid film characteristics including film thickness and film pressure will be accomplished by employing the probe pressure sensors, and a high resolution camera. A hardware testbed will be developed at the site of collaborative partner, TechSolve, Inc., for the technology capability testing and evaluation.

The enhanced understanding of the tribological behavior of the atomized droplets at the tool/chip/work-piece interfaces will drive advances in tool design and manufacturing and improvement in other processes such as minimum quantity lubricant in grinding, machining and rolling. As the atomized-based cutting fluid spray system uses significantly small amount of electrical energy, this cooling system will help in saving electrical energy for those existing cooling techniques that operate a large fluid pump. Further, the use of carbon dioxide in this cutting fluid spray system can lead to developing many environmentally-friendly manufacturing processes. Efforts will be made to boost the participation of members from under-represented groups in this research by proactively participating in several on-campus/off-campus programs, including Women in Engineering Program and Minority Engineering Program.

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