Proceedings of the 36th International MATADOR Conference (eBook)

Srichand Hinduja and Lin Li both work in the School of Mechanical, Aerospace and Civil Engineering at The University of Manchester, Manchester, UK.

Organising Committee 5
International Scientific Committee 6
Foreword 7
Contents 8
PART 1 - Bio- and Nanotechnolgy 17
1-1 Robust Control Strategy of Fluid Dispensing Process for Solid Freeform Fabrication of Tissue Engineered Hydrogel Scaffold 18
1. Introduction 18
2. Apparatus 19
3. Modeling Approach 20
4. Experimental Model Validation 21
5. Future Control Strategy 21
6. Conclusions 21
References 22
1-2 An innovative approach for the fabrication of highly conductive nanocomposites with different carbon 23
1. Introduction 23
2. Experimental work 23
2.1 Materials and sample preparation 23
2.2 Measurements 24
3. Results and Discussion 24
3.1 Effects of CCB and MWCNTs on rheological properties of PA6 24
3.2 Electrical conductivity of PA6 induced by CCB and MWCNT 25
3.3 Enhanced electrical conductivity due to the formation of a conductive network from MWCNTs and CCB 26
4. Conclusions 27
Acknowledgements 27
References 27
1-3 Analysis of local field enhancement including tip interaction for the application to nano-manipulation using FDTD calculations 28
1. Introduction 28
2. Model of The Calculations 28
3. Calculations and Analyses 29
4. Conclusions 31
Acknowledgments 31
References 31
PART 2 - Forming 32
2-1 Numerical Simulation of the Four Roll Bending Process 33
1. Introduction 33
2. New Roll Bending System 33
3. Simulation of MDRB system 34
3.1 Simulation results 34
4. Experimental validation of simulation 35
5. Conclusions 36
References 36
2-2 Investigation on the Process Parameters and Process Window of Three-Roll-Push-Bending 37
1. Introduction 37
2. Three-Roll-Push-Bending Technology 37
3. Process Design by Experiments 38
4. Aims of Investigation 38
5. Experimental design and set-up 38
6. Results and Interpretation 39
7. Summary and Outlook 40
References 40
2-3 Casting of Aluminum Alloy Strip by Improved Single-Roll Caster 41
1. Introduction 41
2. Experimental apparatus 41
2.1 Single roll caster 41
2.2 Scriber 42
3 Experimental conditions 42
4 Result and discussion 42
4.1 Effect of the load on the scribed surface 42
Cold rolling 43
Microstructure 43
Mechanical property 44
Conclusions 44
References 44
2-4 Casting of Al-Si-SiCp composite alloy strip by a vertical type twin roll caster 45
1. Introduction 45
2. The Conventional Twin-Roll Caster 45
3. The Vertical Type Twin-Roll Caster 46
4. Experimental conditions and specifications 46
5. Results and Discussions 47
6. Conclusions 48
7. Suggestion for a New process 48
References 48
2-5 Casting of aluminium alloy clad strip using a vertical type tandem twin roll caster 49
1. Introduction 49
2. Vertical type tandem twin roll caster 49
3. Process of the connecting on a vertical type tandem twin roll caster 50
4. Experimental conditions 50
5. Results and discussion 51
5.1 Surface of the clad strip cast 51
5.2 Effect of connecting conditions of the clad strip by roll speed 51
5.3 Effect of connecting conditions of the clad strip by melt temperature of overlay strips 51
5.4 Line analysis of the interface 51
5.5 Cold rolling of three layers clad strip 52
5.6 Bending test 52
6. Conclusions 52
References 52
2-6 Micro-forming of aluminum alloy by cold rolling 53
1. Introduction 53
2. Experimental condition 53
3. Result and discussion 55
4. Result and discussion 56
References 56
2-7 Rapid shape measurement of micro deep drawing parts by means of digital holographic contouring 57
1 Introduction 57
1.1 Principle of Contouring by means of Multiple Illumination Directions 57
1.2 System Setup 58
2. Experimental Results 59
3. Conclusion 60
Acknowledgement 60
References 60
2-8 Fracture Limits of Metal Foils in Micro Forming 61
1. Introduction 61
2. Experiments 61
3. Results 62
3.1 Strain Distribution over Specimen 62
3.2 Fracture Distribution over Specimen 62
4. Discussion 63
4.1 Yield Strength Distribution over Specimen 63
4.2 Grain Size Distribution over a Specimen 63
5. Conclusion 64
Acknowledgements 64
References 64
2-9 A theoretical model for the velocity field of the extrusion of shaped sections taking into account the variation of the axial component 65
1. Introduction 65
2. Theory 65
3. Results and Discussions 67
References 69
2-10 A theoretical model for the material flow for the forward extrusion of complicated and non-symmetric sections 70
1. Introduction 70
2. Deforming Region 70
3. Velocity Field 71
4. Upper bound solution 72
5. Results and Discussions 72
References 73
2-11 An Optimization Algorithm for Improving Combined Multi-Stage Deep-Drawing and Ironing Processes of Axisymmetric Components. Analysis and Experimentation 74
1. Introduction 74
2. Initial solution 75
3. Optimization process 75
4. Algorithm resolution process 76
5. Experimental results 76
6. Analysis of results 76
7. Conclusions 77
References 77
2-12 Nanofinishing Process for 3D Freeform Surfaces Using Ball End MR Finishing Tool 78
1. Introduction 78
2. Design of New Magnetorheological Finishing Setup 79
3. Electromagnetic Modeling for MR Finishing Tool 80
4. Results and Discussion 80
4.1 Effect of Ferromagnetic Work Material on the variation of Magnetic flux density at the Tool Tip 81
4.2 Effect of Non Ferromagnetic Work Material on variation of Magnetic flux density at the Tool Tip 81
5. Conclusion 81
References 81
2-13 Pressure Distribution in Cold Rolling of Turbo-engine Thin Compressor Blades 82
1. Introduction 82
2. Evaluation of pressure in the rolling process 82
3. Experimental test 83
4. Simulation of the process 84
5. Analysis of simulation and experimental test results 84
6. Conclusion 85
7. References 85
2-14 Determination of the duty cycle in thermoset pultrusion 86
1 Introduction 86
2 Analysis 86
3 Simulation Results 87
4 Experimental Measurements 88
5 Conclusions 89
6 References 89
2-15 Development of New Press-Forming Process for a Screw-Threaded Fuel Filler Pipe 90
1. Introduction 90
2. Formed Product 90
2.1 Manufacturing Method 90
2.2 Estimating the Thickness of the Formed Specimen 91
3. Three-Dimensional Finite-Element Simulation 91
3.1 Strain of Analyzed Pipe 91
3.2 Thickness of analyzed pipe 92
4. Discussion 92
5. Conclusion 93
References 93
2-16 Roller Hemming: A New Simulation Model for the Automotive Industry 94
1. Introduction 94
2. Process 94
3. Finite Element Model 95
4. Experimental Procedure 95
5. Results and discussion 96
6. Conclusions 97
References 97
2-17 Control of the uniformity of direct electrical heating for Rotational Moulding 98
1 Introduction 98
2 The CHARM Process 98
3 Analysis 99
3.1 Boundary Conditions 99
3.2 Thermal Loads 99
4 Results and Discussion 100
5 Experimental Verification 101
6 Conclusions 101
7 References 101
PART 3 - Grinding 102
3-1 High Efficiency Deep Grinding, an Application with conventional wheels 103
1. Background 103
2. Thermal Modelling 103
3. Single Pole Thermocouple Technique for Temperature measurement in HEDG 104
4. Grinding Control Strategy 105
5. Grinding Wheel performance in HEDG 105
6. Conclusion 106
Acknowledgement 106
References 106
3-2 Detection of High and Low Temperature in the Grinding Zone using Laser Irradiation Technique 107
1. Introduction 107
2. Laser Irradiation Tests 107
3. Grinding experiments 109
4. Pattern recognition: Artificial neural network (ANN) approach 109
5. Conclusion 110
References 110
3-3 Investigation of Influences of Wheel Speed on Root Geometrical Dimension of Gas Turbine Blade 111
1. Introduction 111
1.1 Gas turbine blades 112
2. Description of Material 112
3. Experimental Modeling 112
3.1 The measurement of output parameters 112
3.2 The input parameters and experiment conditions 113
3.3 The experimental design 113
4. Analysis of the Experimental Results 113
5. Discussion 113
6. Conclusion 114
References 114
3-4 Ultra-fine Finishing of Metallic surfaces with Ice Bonded Abrasive Polishing Process 115
1. Introduction 115
2. Development of Experimental Setup 116
3. Preparation and Characterization of Ice Bonded Abrasive Polishing Tool 116
3.1 Preparation of Ice Bonded Abrasive Polishing Tool 116
3.2 Tool Characterization 117
4. Methodology 117
4.1 Workpiece preparation 117
4.2 Selection of process parameters 117
5. Results and Discussion 118
6. Conclusion 118
Acknowledgement 118
References 118
3-5 Plane surface grinding with application of Minimum Quantity Lubrication (MQL) 119
1. Introduction 119
2. Experiment 120
3. Results 120
3.1. Specific tangential force 120
3.2. Force Ratio - Tangential/Normal 121
3.3. Surface Roughness 121
3.4. Temperature 121
4. Conclusions 122
5. Acknowledgment 122
6. References 122
3-6 Study of the Behavior of Air Flow around a Grinding Wheel under the Application of Pneumatic Barrier 123
1. Introduction 123
2. Objective 124
3. Experimental Details 124
4. Results and Discussion 124
5. Conclusion 126
References 126
PART 4 - Manufacturing Systems and Management 127
4-1 A cutting plane algorithm for solving single machine scheduling problems with uncertain sequence-dependent setup times 128
1. Introduction 128
2. Problem Definition 128
3. Deterministic Mathematical Model 129
4. Robust-Counterpart Mathematical Model 129
5. Cutting Plane Algorithm 130
6. Computational Experiments 130
7. Conclusion 131
References 131
4-2 A Knowledge-Based Engineering System for Assembly Sequence Planning 132
1. Introduction 132
2. Working scheme and processes 133
3. Illustrative manually-assembled examples for developing a KBE system 134
4. Operational procedures of the KBE system 135
5. Conclusions 135
Acknowledgements 135
References 135
4-3 Product Family Modeling and Optimization Driven by Customer Requirements 136
1. Introduction 136
2. Product Family Expression 136
3. FS-SKM modeling and Optimizing 137
3.1 FS-SKM Integrated Modeling 137
3.2 FS-SKM Dynamic Optimization 137
4. A Case Study 138
5. Conclusion and Future Work 139
References 139
4-4 Transparency in Production by Monitoring the Condition of Molds, Dies and Machines 140
1. Introduction 140
2. Avoiding Downtime is Crucial 140
3. Knowledge Feedback in Production 141
4. Structured Procedure to Find the Influencing Factors for Availability 141
5. Exemplary Discussion of Condition Monitoring Signals 142
6. Summary 143
Acknowledgements 143
References 143
4-5 Simulation Modelling of Product-Service Systems: the Missing Link 144
1. Introduction 144
2. Modelling in PSS and its purpose 145
3. Simulation in PSS 145
4. Factor analysis 146
5. Discussion and conclusions 146
References 147
4-6 RFID Deployment at an Airport: A Simulation Study 148
1. Introduction 148
2. Literature Review 148
3. Airport Baggage Handling Systems 149
4. Simulation Model 150
5. Simulation Results 150
6. Conclusions 151
References 151
PART 5 - Design and Structures 152
5-1 Failure knowledge based decision-making in product quality 153
1. Introduction 153
2. Failure knowledge 153
2.1 Expressions of failure cases 153
2.2 Failure knowledge network 154
3. Decision-making based on failure knowledge network 155
4. Experimentation and case study 155
5. Conclusion 156
Acknowledgments 156
References 156
5-2 Predicting the End-Of-Life of Defence Electronic Systems at the Conceptual Design Stage 157
1. Introduction 157
2. Methodology of the New Approach 157
2.1 Cost categories 157
2.2 Cost elements 158
3. Product-Assembly Level Cost Elements 158
3.1 Disassembly depth factor 158
3.2 Component level cost elements 159
4. EoL Process Options 159
5. Cost Equations 159
5.1 Refurbish 159
5.2 Remanufacture 159
5.3 Recycle 160
5.4 Collective waste processing (landfill) 160
6. Conclusion 160
References 160
5-3 Design of Multi-Span Microfixturing Cell for Parallel Assembly of Microparts Using Electrothermally Actuated Microclamps 161
1. Introduction 161
2. Electrothermal Microclamps 161
2.1 Principal of Microassembly 162
2.2 Piezoelectric Actuation System 162
3. Design Strategies and Advantages 162
3.1 Fabrication Considerations and Analysis 163
4. Analysis Results 163
5. Conclusion 164
References 164
5-4 An Evaluation Method Based on Multiple Quality Characteristics for CNC Machining Center using Fuzzy Matter Element 165
1. Introduction 165
2. Quality evaluation model based on FME 165
3. Calculating synthesized weight by using information entropy and AHP 166
3.1 Determining weight by information entropy 166
3.2 Confirming weight by AHP 166
3.3 Synthesizing the weights 167
4. Quality evaluation for CNC machining centers 167
5. Conclusions 168
Acknowledgment 168
References 168
5-5 Design of a Meso-scale 3-axis Milling with Nanometer Accuracy 169
1. Introduction 169
2. Meso-scale 3-axis Milling machine tool design and analysis 169
2.1 The Meso-scale 3-axis milling machine tool 169
2.2 Z-axis design and analysis 170
2.3 XY coplanar positioning stage design and analysis 171
3. Conclusion 172
References 172
Acknowledgement 172
5-6 A Novel Concept to Design Machine Tool Structures using Multifunctional Materials 173
1. Introduction 173
2. MT multifunctional structures 173
3. Multifunctional structures and their mechanical proprieties 174
4. Thermal performance of multifunctional structures: experimental trials 175
5. Conclusions 176
References 176
5-7 Design Synthesis of a three legged SPS Parallel Manipulator 177
1. Introduction 177
2. Modelling issues 178
2.1 Position Analysis 178
2.2 Jacobian Analysis 179
3. Self-lockable spherical joints 179
4. Conclusion 181
Acknowledgements 181
References 181
5-8 Piezo-Metal-Composites as Smart Structures 182
1. Design and manufacturing of Piezo-Metal-Compounds 182
2. Forming operations with different MFC positions 182
3. Test of functionality 183
4. Numerical investigation 184
5. Summary 185
Acknowledgement 185
References 185
5-9 A Methodology for Engineering Design Change Management Using Modelling and Problem Solving Techniques 186
1. Introduction 186
2. The process of design change management 187
3. Analytical method for design change management – an illustrative example 187
4. Conclusions and Further Work 189
References 189
5-10 Modeling and Analysis of the strength of Adhesively Bond CFRP-Aluminium T-joints 190
1. Introduction 190
2. Modling of adherends and adhesive layer 191
3. Boundary conditions 192
4. Case Studies 192
5. Conclusions 193
Acknowledgements 193
References 193
PART 6 - Metal Cutting 194
6-1 Modelling of Machine Tapping with Straight Flute Taps 195
1. Introduction 195
2. Geometry and Specification of Taps 195
3. A Predictive Force and Torque Model 197
4. Results 198
5. Concluding remarks 198
References 198
6-2 High Speed MQL Drilling of Titanium Alloy using Synthetic Ester and Palm Oil 199
1. Introduction 199
2. Experimental Setup 199
2.1 Drilling tests to determine tool life 199
2.2 Drilling tests to measure thrust force, torque and workpiece 200
3. Results and Discussion 200
3.1 Tool Life and Failure Mode 200
3.2 Thrust Force and Torque 201
3.3 Workpiece Temperature 202
4. Conclusions 202
References 202
6-3 Estimation of minimum chip thickness for multi-phase steel using acoustic emission signals 203
1. Introduction 203
2. Micro milling experiments 204
2.1 AE signal acquisition 204
3. Results and Discussions 204
3.1 Uncut chip thickness below tool edge radius 204
3.2 Uncut chip thickness above tool edge radius 205
4. Conclusions 206
References 206
6-4 Extension of a Simple Predictive Model for Orthogonal Cutting to Include Flow below the Cutting Edge 207
1. Introduction 207
2. Upper Bound Solution 207
3. Optimization 208
4. Force Prediction 209
4.1 Optimized Slip-Line Fields 209
4.2 Comparison with Data from Recent Experiments 210
5. Conclusions 210
Acknowledgements 210
References 210
6-5 Drilling Carbon Fiber Reinforced Plastics with Diamond Coated Carbide Cutting Tools 211
1. Introduction 211
2. Experimentation 212
3. Results 213
4. Conclusions 214
Acknowledgement 214
References 214
6-6 Research on 3D Groove for Cutting Heat Distribution of Coated Carbide Milling Inserts 215
1. Introduction 215
2. Experiments 215
2.1 Milling inserts and workpiece 215
2.2 Experimental equipments 216
2.3 Experimental method 216
3. Results and analyses 216
3.1 Calculation of total cutting heat 216
3.2 Calculation of cutting heat conducted to chips 216
3.3 Calculation of cutting heat conducted to the workpiece 217
3.4 Calculation of cutting heat distribution 217
3.5 Workpiece temperature measured with thermocouples 217
4. Conclusion 218
References 218
6-7 In-Process Monitoring and Prediction of Surface Roughness on CNC Turning by using Response Surface Analysis 219
1. Introduction 219
2. In-process monitoring of cutting forces and cutting temperatures 219
3. Models of surface roughness, cutting force ratio and cutting temperature 220
4. Experimental cutting conditions and procedures 220
5. Experimental resuls and discussion 220
5.1 Response Surface Analysis 220
5.2 Verification of the models 221
6. Conclusions 222
Acknowledgement 222
References 222
6-8 Influence of Edge Beveling on Burr Formation in Face Milling of an Aluminium Alloy 223
1. Introduction 223
2. Experimental Investigation 224
3. Results and discussion 224
4. Conclusion 227
References 227
6-9 Experimental Investigations on Drilling of Woven CFRP Epoxy Laminates: The Effect of Pilot-hole or Drill Chisel Edge on Delamination 228
1. Research Motivation and Objectives 228
2. Experimental Details 229
3. Results and Discussions 229
4. Conclusions 231
References 231
6-10 Modeling of hard turning: effect of tool geometry on cutting force 232
1. Introduction 232
2. Geometry modeling 232
3. Computer Simulation 233
3.1 Modeling of Workpiece 233
3.2 Contact Friction Model & Heat Transformation
4. Results and Discussion 234
5. Conclusions 235
Acknowledgement 235
References 235
6-11 Selection of optimal process parameters for gear hobbing under cold air minimum quantity lubrication cutting environment 236
1. Introduction 236
2. Experimental procedure 236
3. Experimental results and discussion 237
4. Conclusions 239
Acknowledgment 239
References 239
6-12 The Formation of Adiabatic Shear Bands as a result of Cryogenic CNC Machining of Elastomers 240
1. Introduction 240
2. Adiabatic shear band formation 240
3. State of the art in cryogenic manufacturing 241
3.1 Cryogenic processing 241
3.2 Cryogenic hard metal machining 241
3.3 Cryogenic CNC machining of elastomers 241
4. Methodology 242
5. Experimental Results 242
6. Conclusions 243
References 243
6-13 Analysis of process parameters in the micromachining of Ti-6Al-4V alloy 244
1. Introduction 244
1.1 Titanium alloys in micromachining applications 244
2. Experimental details 245
2.1 Determination of minimum chip thickness 245
3. Results and Discussions 246
3.1 Analysis of variance 246
4. Conclusions 247
Acknowledgements 247
References 247
6-14 Tool Orientation Effects on the Geometry of 5-axis Ball-end Milling 248
1. Introduction 248
2. Terminology in 5-axis ball-end milling 248
3. Engagement regions and uncut chip thickness under the effects of lead and tilt angles 249
4. Conclusion 251
References 251
6-15 On deposition and characterisation of MoSx-Ti multilayer coating and performance evaluation in dry turning of aluminium alloy and steel 252
1. Introduction 252
2. Experimental Details 252
3. Results and Discussion 253
3.1 Characterisation of the coating 253
3.2 Performance evaluation in machining 254
4. Conclusion 255
5. References 255
6-16 Novel Developments in Cutting and Grinding of Preheated Billets 256
1 Introducion 256
2 Some features of hot machining 256
3 The ways of control the cutting temperature 257
4 New schemes and methods of machining with variable cutting edge 257
5 Conclusion 259
References 259
6-17 Investigation of the Cutting Forces and Tool Wear in Laser Assisted Milling of Ti6Al4V Alloy 260
1. Introduction 260
2. Materials and Experiemental Procedures 260
3. Results and discussion 261
3.1 Reduction in cutting forces during laser assisted milling 261
3.2 Effect of laser beam on tool failure 262
4. Conclusions 263
Acknowledgments 263
References 263
6-18 Numerical Techniques for CAM Strategies for Machining of Mould and Die 264
1. Introduction 264
2. Numerical techniques in NC tool-path planning 264
2.1 Configuration space determination 265
2.2 Trochoidal tool-path in parametric space 265
2.3 Space frame conversion 265
2.4 Process parameters verification 266
3. Implementation and verification 266
4. NC path planning for moulds 267
5. Conclusion 267
Acknowledge 267
References 267
PART 7 - Welding 269
7-1 Net Shape Laser Butt Welding of Mild Steel Sheets 270
1 Introduction 270
2 Experimental Design and Procedures 271
2.1 Design of Experiments and Methodology 271
2.2 Laser welding preparation and methodology 271
2.3 Sample preparation 271
2.4 Response surface methodology 271
3 Results and Discussion 272
3.1 Weld Profiles 272
3.2 Weld Bead Offset from the Top Surface 272
3.3 Relationship between welding speed and top height 272
3.4 Weld Bead Bottom Offset 273
4 Conclusion 273
Acknowledgement 273
References 273
7-2 Humping Modeling in Deep Penetration Laser Welding 274
1. Introduction 274
2. Modeling 274
3. Results and discussions 275
4. Conclusion 277
References 277
7-3 Keyholing or Conduction – Prediction of Laser Penetration Depth 278
1. Introduction 278
2. Experimental Set-up 278
3. Results and discussions 278
4. Conclusions 281
5. References 281
7-4 Dual Focus Nd:YAG Laser Welding of Titanium Alloys 282
1. Introduction 282
2. Methodology 282
2.1 Materials and Material Preparation 282
2.2 Equipment and Experimental Procedure 282
2.3 Process Variables 283
2.4 Porosity Assessment 283
3. Results and Discussions 283
3.1 Welding Performance 283
3.2 Statistical Analysis 283
3.3 Transverse Foci Orientation Porosity 284
3.4 In-line Foci Orientation Porosity 284
3.5 High Speed Observations 285
4. Conclusions 285
Acknowledgements 285
References 285
7-5 Product design for welding 286
1. Introduction 286
2. Model for design for welding 286
3. Design procedure 287
4. Application examples 288
5. Conclusions 289
Acknowledgements 289
References 289
7-6 Studies on the Effect of Process Parameters on the Shear Performance of Joints of Aluminium Alloy Produced by Adhesive Joining, Spot Welding and Weld-Bonding 290
1. Introduction 290
2. Weld bonding 290
3. Experimental Procedure 291
3.1 Adhesive Joining 291
3.2 Resistance Spot Welding 291
3.3 Weld Bonding 291
3.4 Shear Test 292
4. Results and Discussion 292
4.1 Effect of Curing Time on Strength of theAdhesive Joint 292
4.2 Role of Surface Roughness on Adhesive Joining ofAluminum 292
4.3 Shear Strength of Resistance Spot Weld 293
4.4 Shear Strength of Weld-Bonding 293
5. Conclusions 295
References 295
7-7 Influence of Electron Beam Local Annealing on the Residual Stresses for the joints with Electron Beam Welding of near a titanium alloy 296
1. Introduction 296
2. Experimental procedures 296
3. Results and discussion 297
3.1 Residual stresses along the vertical and centre lines of the welds (Y) 297
3.2 Residual stresses along the welds (X) on the front welds 298
4. Conclusions 298
References 299
7-8 Similar and Dissimilar Welding of Ductile Cast Iron 300
1. Introduction 300
2. Experimental Work 300
3. Results and Discussion 301
4. Conclusions 305
References 305
PART 8 - Metrology 306
8-1 Recognition of Contact States in Robotized Assembly Using Qualitative Wavelet Based Features and Support Vector Machines 307
1. Introduction 307
2. Contact State Recognition Machine 307
2.1 Quasi-static Model of Forces 308
2.2 Feature Extraction and Selection 308
2.3 Classification 309
3. Experimental verification 310
4. Conclusion 310
References 310
8-2 Linear Axes Performance Check on a Five-Axis Machine Tool by Probing an Uncalibrated Artefact 311
1. Introduction 311
2. Artefact design 312
3. Distance based analysis 312
4. Experimental results 312
5. Conclusion 314
Acknowledgement 314
References 314
8-3 A Holistic Approach to Quantifying and Controlling the Accuracy, Performance and Availability of Machine Tools 315
1. Introduction 315
1.1 Machine tool complexity 315
1.2 Machine tool characteristics 316
1.3 Total productive maintenance (TPM) and Six Sigma 316
2. The MPEOM™ Framework 317
2.1 Pre-assessment review 317
2.2 Machine condition evaluation 317
2.3 Post-assessment review 317
2.4 Machine condition optimisation 317
2.5 Post optimisation review 318
2.6 Go, No-Go system 318
3. Conclusion 318
References 318
8-4 Development of a Small 3-axis Angular Sensor for Real-time Abbé Error Compensation on Numerically Controlled Machine Tools 319
1. Introduction 319
2. Abbé Error in Machine Tools 319
3. Development of Angular Sensors 320
3.1 The DVD Autocollimator 320
3.2 DVD Optoelectronic Level 321
4. On-Machine Experiments 321
4.1 Testing on Machine Tool 321
4.2 Testing on a Stage with a Linear Scale 322
5. Conclusions 322
References 322
8-5 Micro-scale co-ordinate metrology at the National Physical Laboratory 324
1. Introduction 324
2. Current micro-CMM research at NPL 324
3. Micro-probe research at NPL 325
4. Future work 327
Acknowledgements 327
References 327
8-6 Coating Thickness Measurement 328
1 Introduction 328
2 Sensor Development 328
3 Sensor Optimisation 329
4 Neural Network Model Inversion 330
5 Results 330
6 Conclusion 331
References 331
8-7 Digital Alignment of a reconstructed Hologram for Measurement of Deterioration of Tools 332
1. Introduction 332
2. Reconstruction algorithm 333
3. Active modification of the reconstructed wave front 334
3.1 Lateral adjustment of the wave front 334
3.2 Rotation of the wave front 335
4. Conclusion 335
Acknowledgements 335
References 335
8-8 Implementation of decision rules for CMM sampling in a KBE system 336
1. Introduction 336
2. Decision rules for an optimal CMM sampling 336
2.1 Inspection of non-form tolerances 337
2.2 Inspection of geometrical tolerances (form errors) 338
3. Implementation in a KBE system 339
4. Conclusions 339
Acknowledgements 339
References 339
8-9 Machine Vision System for Inline Inspection in Carbide Insert Production 340
1. Introduction 340
2. Machine vision system 340
2.1 Hardware system 340
2.2 Image processing 341
3. Experimental results 343
3.1 Test results 343
3.2 Measurement uncertainty 343
3.3 Performance evaluation 343
4. Summary 343
References 343
8-10 Assembly Tolerance Analysis including Flatness: Using Virtual Mating Plane 344
1. Introduction 344
2. The Virtual Mating Plane 344
2.1 The Micro-motion Plane 345
2.2 The Reference Coordinate System (RCS) 345
2.3 Parameters of The VMP 345
3. Assembly Tolerance Analysis Based On VMP 346
3.1 The Global Coordinate System 346
3.2 The Rotation Matrix 346
3.2 Mapping of The Flatness to The Dimension Chain 346
4. Case Study 347
5. Conclusion 347
References 347
8-11 Inspection of defects in CFRP-Foam Layered structure composite plates of aerospace materials using lock-in thermography 348
1. Introduction 348
2. FEM models 349
3. Experimental procedure 351
3.1 Specimen 351
3.2 Experimental set up 351
4. Results and discussion 351
4.1 Simulation results 351
4.2 Experimental results 352
5. Conclusion 354
Acknowledgement 354
References 354
8-12 Image Processing Methods For Online Measurement In Radial-Axial Ring Rolling 355
1. Introduction 355
1.1 Radial-Axial Ring Rolling 355
1.2 Process Errors And Errors Of The Rings Shape 355
1.3 Process Control 356
1.4 The task at hand 356
2. Method Of Resolution 356
2.1 Image Processing Systems – A Possible Solution 356
2.2 The Research Project “Image Processing In Radial-Axial Ring Rolling” 357
3. State of the Development 357
4. Summary And Outlook 358
References 358
8-13 Cognitive Production Metrology: A new concept for flexibly attending the inspection requirements of small series production 359
1. Introduction 359
2. Self-optimisation and the concept of Cognitive Production Metrology 360
3. Vision of the CPM project 360
4. An example scenario 361
5. Conclusions and Perspectives 362
Acknowledgments 362
References 362
8-14 The Metrology Enhanced Tooling for Aerospace (META) Framework 363
1. Introduction 363
2. Metrology Enhanced Tooling for Aerospace 364
3. The META Framework Architecture 364
3.1 Functions of the measurement network 364
4. Future Considerations 366
5. References 366
PART 9 - Rapid Prototyping 367
9-1 Application of 3D Printing for the Rapid Tooling of Thermoforming Moulds 368
1. Introduction 368
2. Thermoforming of plastic sheets 368
3. Introduction to rapid tooling 369
4. The 3D printing process 369
5. Example for rapid tooling with 3D printers 370
6. Results of the test 371
7. Economic considerations 371
8. Summary 371
Acknowledgments 371
References 371
9-2 Printing Characteristics and Performance of Polymer Thick Film Inks for Direct Write Applications 372
1. Introduction 372
2. Experimental Method 373
3. Results and Discussion 373
3.1 Viscosities of the Inks 373
3.2 Printing Performance of the Inks on Different Substrates 373
3.3 Printing Performance at Various Cure Temperatures 374
4. Conclusions 375
References 375
9-3 Effect of work piece volume on statistically controlled rapid casting solution of aluminum alloys using three dimensional printing 376
1. Introduction 376
2. Methodology 376
3. Results and Discussion 378
3.1 Calculation for Z (standard normal deviate) above and below at 1mm shell thickness, or 60mm 378
4. Conclusions 379
References 379
9-4 Using Additive Manufacturing Effectively: A CAD Tool to Support Decision Making 380
1. Introduction 380
2. Design Issues 380
3. Materials Selection 381
3.1 Selection methods 382
4. Additive manufacturing materials selection 382
5. Conclusion 383
Acknowledgments 383
References 383
9-5 Dynamic strength and fracture toughness analysis of beam melted parts 384
1. Dynamic strength analysis of beam melted parts 384
2. Manufacturing and finishing of rotating bend test specimen 384
3. Rotating bending test 385
4. Evaluation and interpretation of the results 385
5. Fracture toughness analysis of beam melted parts 386
6. Manufacturing and finishing of compact tension (CT) test specimen 386
7. Fracture toughness test 386
8. Evaluation and interpretation of the results 386
References 387
9-6 An additive method for photopatterning of metals on flexible substrates 388
1. Introduction 388
2. Experimental Setup 388
2.1 Substrate preparation 388
2.2 Direct laser writing exposure 389
2.3 Photomask exposure 389
2.4 Post-Exposure Treatment 389
2.5 Electroless Plating 389
2.6 Characterisation 389
3. Laser Direct-Writing Results 389
3.1 Morphology 389
3.2 Effects of Write Speed 390
3.3 3-Dimensional Direct-Writing 390
3.4 Photomask Exposure and Plating Results 391
4. Conclusion 391
Acknowledgement 391
References 391
PART 10 - Green Engineering 392
10-1 An investigation of the EREE-based low carbon manufacturing on CNC machine 393
1. Introduction 393
2. EREE-based LCM: Conception 394
3. Generic modelling of EREE-based LCM for CNC machines 394
3.1 Objectives 395
3.2 Constraints 395
4. Case study and applications 396
5. Conclusions 397
References 397
10-2 Reduced Energy Consumption by Adapted Process Chains 398
1. Introduction 398
2. Alternative Process Chains 398
2.1 Grind Hardening 398
2.2 Cold Surface Hardening 399
3. Prediction of Energy Consumption 400
4. Summary and Outlook 401
Acknowledgements 401
References 401
10-3 Model-Based Predictive Consumption of Compressed Air for Electro-Pneumatic Systems 402
1. Introduction 402
2. Modelling approach 402
2.1 Simulation model 403
3. Experimental setup 404
4. Results 404
5. Conclusions & future work
Acknowledgements 405
References 405
10-4 Schottky Solar Cells Based on Graphene and Silicon 406
1. Introduction 406
2. Experimental 406
2.1 Materials preparation 406
2.2 Solar cell assembly 407
3. Results and disscussion 407
3.1 Structural characterizations of graphene 407
3.2 Solar cell characterization 407
4. Conclusions 408
References 408
10-5 Variation of Engine Performance and Emissions Using Ethanol Blends 409
1 Introduction 409
2 Experimental Apparatus 410
3 Engine Performance Results and Discussion 410
3.1 Effect of engine speed on brake torque 410
3.2 Effect of engine speed on (BSFC) 411
3.3 Effect of engine speed on brake thermal efficiency 411
4 Exhaust Emission Results and Discussion 411
4.1 Effect of throttle setting on the hydrocarbon 411
4.2 Effect of throttle setting on the carbon monoxide 411
5 Conclusions 412
6 References 412
PART 11 - ECM an EDM 413
11-1 EDM performance is affected by the white layer 414
1. Introduction 414
2. Experimental methodology 414
3. Experimental results 415
3.1 Effect of white layer on material removal rate 415
3.2 Effect of white layer on electrode wear rate 416
4. Conclusion 417
References 418
11-2 Development of a hybrid method for electrically dressing metal-bonded diamond grinding wheels 419
1. Introduction 419
2. Design Considerations 419
3. Development Stages 420
3.1 Hardware Implementation 420
3.2 Software Implementation 420
4. Reference Results 420
5. Electrical Dressing Results 421
References 422
11-3 Robust Parameter Design and Multi-Objective Optimization of Electro-Discharge Diamond Face Grinding of HSS 423
1. Introduction 423
2. Experimental procedure and machining parameters 424
3. Response surface modelling 425
4. Results and discussion 425
4.1 Multi-objective optimisation results using Taguchi approach 425
4.2 Multi-objective optimisation results using hybrid approach 426
5. Conclusions 427
References 427
11-4 Analysis of Non-limiting Current Resistance and Isopulse Power Supply for WEDM 428
1. Introduction 428
2. Pulse Power Supply of HS-WEDM 428
3. Switching Methodology 429
4. Design Principles of Isopulse Machining 430
5. Machining Experiment Results and Discussion 430
6. Conclusion 431
Acknowledgment 431
References 431
11-5 Some Aspects of Surface Integrity Study of Electro Discharge Machined Inconel 718 432
1. Introduction 432
2. Experimental Procedure 433
3. Results and Discussion 434
3.1 Recast Layer Formation 434
3.2 Surface Crack 434
3.3 Chemical Composition of the Recast Layer 435
3.4 Surface Roughness 436
4. Conclusions 436
Acknowledgment 437
References 437
PART 12 - Laser Technology – Cladding and Deposition 438
12-1 Advances in Direct Metal Deposition 439
1. Introduction 439
2. System control 440
2.1 Geometry control 440
2.2 Temperature and cooling rate control 440
2.3 Composition Sensor 441
2.4 Microstructure Sensor [3] 441
3. Conclusion 442
Acknowledgements 442
References 442
12-2 Effect of processing parameters in manufacturing of 3D parts through laser direct metal deposition 443
1. Introduction 443
2. Experimental procedure 443
3. Results and discussion 444
3.1 Dimensional aspects 444
3.2 Microstructure 445
3.3 Online control of the process 445
4. Conclusiones 446
Acknowledgements 446
References 446
12-3 A numerical investigation of powder heating in coaxial laser metal deposition 447
1. Introduction 447
2. Numerical modelling 447
2.1 Modelling of powder flow 447
2.2 Modelling of powder heating 448
3. Experimental verification 448
4. Results and discussion 448
5. Conclusions 450
References 450
12-4 Laser cladding of NiCr-WC metal matrix composites: dependence on the matrix composition 451
1. Introduction 451
2. Spheroidal fused Tungsten Carbides 451
3. Experiments 452
4. Results and Discussion 452
5. Conclusions 454
Acknowledgements 454
References 454
PART 13 - Laser Technology – Bio and Micro System Processes 455
13-1 Wettability analysis of CO2 laser surface patterned nylon 6,6 samples soaked in simulated body fluid (SBF) 456
1. Introduction 456
2. Experimental Techniques 456
2.1 CO2 laser patterning procedure, topography, wettability and surface chemistry 456
2.2 In vitro simulated body fluid (SBF) experimentation 456
3. Results and Discussion 457
3.1 Effects of CO2 laser patterning on topography 457
3.2 Effects of CO2 laser patterning on wettability characteristics 457
3.3 Effects of CO2 laser patterning on simulated body fluid (SBF) response 458
4. Conclusions 459
Acknowledgements 459
References 459
13-2 Fast parallel diffractive multi-beam laser surface micro-structuring 460
1. Introduction 460
2. Experiments 460
3. Results and Discussion 461
4. Conclusions 463
Acknowledgments 463
References 463
13-3 Effect of different processing parameters of Ti: Sapphire femtosecond laser on human dental dentine 464
1. Introduction 464
2. Experimental 464
3. Results and Discussion 465
4. Conclusion 466
References 467
13-4 Forming microchannels on a glass substrate by CO2 laser 468
1. Introduction 468
2. Experimental 468
3. Results and discussion 468
3.1 Glass strip peeling off induced by laser irradiation 468
3.2 Optimal energy deposition rate to induce microchannel formation on glass substrate 469
3.3 Characterisation of the microchannel 470
4. Conclusion 471
References 471
13-5 Influence of pressure on aluminium plasma expansion produced by a nanosecond laser pulse: a numerical study 472
1. Introduction 472
2. Modelling 473
3. Results 473
3.1 Plume Size and Shape 473
3.2 Temperature profiles 474
4. Conclusion 475
References 475
PART 14 - Laser Technology – Powder Bed Processes 476
14-1 Consolidation behaviour and microstructure characteristics of pure aluminium and alloy powders following Selective Laser Melting processing 477
1. Introduction 477
2. Method 478
3. Results 478
4. Discussion 479
5. Conclusion 480
Acknowledgements 480
References 480
14-2 Influence of distortion on part accuracy of Indirect Metal Selective Laser Sintering 481
1. Introduction 481
2. Experimental Details 481
2.1. Part manufacture 481
2.2. Part Assessment 482
3. Results 483
4. Discussion and conclusions 484
References 484
14-3 Surface Roughness Studies in Selective Laser Sintering of Glass filled Polyamide 485
1. Introduction 485
2. Planning of Experiments 486
3. Analysis of the Experimental Data 487
3.1 Surface Roughness Modeling for Upward Facing Surfaces 487
3.2 Surface Roughness Modeling for Downward Facing Surfaces 487
4. Effect of Process Parameters on Surface Roughness 487
4.1 Upward facing Surface 487
4.2 Downward facing Surface 488
5. Conclusions 488
References 489
PART 15 - Laser Technology – Forming 490
15-1 Finite Element Modelling of the Laser Forming of AISI 1010 Steel 491
1 Introduction 491
2 Experimental 491
3 Results 492
3.1 Thermal effects 492
3.2 Variation in absorption 493
3.3 Geometrical effects 494
3.4 Edge effects 495
4 Conclusions 495
5 References 495
15-2 The effect of laser beam geometries on laser forming of sheet metal 496
1. Introduction 496
2. Numerical Modelling 496
2.1 Finite Element equations 496
2.2 Specimen material, size 497
2.3 Beam geometries 497
3. Results and discussion 497
3.1 Thermal analysis 497
3.2 Structural analysis 498
4. Summary and conclusions 499
References 499
15-3 Towards Controlled 3D Laser Forming 500
1. Introduction 500
2. Experimental 501
3. Results and Discussion 502
4. Conclusions 503
5. References 503
PART 16 - Laser Technology – Surface Modification 504
16-1 Fracture Toughness Modifications By Means of CO2 Laser Beam Surface Processing of a Silicon Nitride Engineering Ceramic 505
1. Introduction 505
2. Experimental Techniques and Analysis 505
2.1 CO2 laser treatment 505
2.2 Vickers indentation method 505
2.3 Calculation of K1c 506
3. Results and Discussion 506
3.1 As-received surface: Hardness, crack lengths and the K1C 506
3.2. CO2 laser treated surface: Hardness, crack lengths and the K1C 507
4. Conclusions 508
References 508
16-2 Surface oxygen diffusion hardening of TA2 pure titanium by pulsed Nd: YAG laser under different gas atmosphere 509
1. Introduction 509
2. Experimental work 509
3. Results and Discussion 510
4. Conclusions 512
Acknowledgements 512
References 512
16-3 Investigation on the Key Techniques of Confined Medium and Coating Layer for Laser Shock Processing on Aeroengine Blade 513
1. Introduction 513
2. Principle of LSP 513
3. Results and discussions 514
3.1 The eliminating of folds and bubbles on Al foil surface 514
3.2 Modes of pasting Al foil 514
3.3 Mode of inclined spouting 515
3.4 Flowing water used on the rear blade for abating the bulging foil 515
3.5 The abating of pockmark 516
4. Conclusion 516
References 516
16-4 Improvement of Corrosion Performance of HVOF MMC Coatings by Laser Surface Treatment 517
1. Introduction 517
2. Experimental Procedure 517
3. Results and discussion 518
3.1 Coating characteristics 518
3.2 Electrochemical impedance spectroscopy 518
4. Conclusions 520
References 520
16-5 Numerical and Experimental Studies on the Laser Melting of Steel Plate Surfaces 521
1. Introduction 521
2. Simulation Model 521
2.1 Material Modelling 522
2.2 Finite Element Model 522
3.Experimental Set Up 522
4. Results and Discussion 523
4.1 Temperature Field Distribution on Steel Platform 523
4.2 Surface Profilometry (Model Validation) 523
4.3 Stress Field Results 523
4.4 Stress-Depth Profile 524
5. Conclusions 524
References 524
16-6 Analysis of temperature distribution during fibre laser surface treatment of a zirconia engineering ceramic 525
1. Introduction 525
2. Experimental Techniques and Analysis 525
2.1 Fibre laser treatment 525
2.2 Temperature measurements 526
2.3 Finite element analysis (FEA) 526
2.4 Thermogravimetry-differential scanning calorimetry (TG-DSC) analysis 526
3. Results and Discussion 527
3.1 Finite element analysis (FEA) model validation 527
3.2 Temperature mapping 527
3.3 Phase changes 527
4. Conclusions 528
References 528
PART 17 - Laser Technology – Micro and Nano Processes 529
17-1 WC Nano powder cold planting via laser shock peening onto aluminium/magnesium alloy surfaces 530
1. Introduction 530
2. Experimental Procedures 530
3. Results and Discussion 531
3.1 Confirmationon nano particles planting 531
3.2 Hardness and wear resistance analyses 532
4. Conclusion 533
Acknowledgement 533
References 533
17-2 Femtosecond laser induced two-photon polymerization of dielectric-loaded surface plasmon-polariton nanowaveguides 534
1. Introduction 534
2. Experiment 534
3. Results and discussion 535
4. Conclusion 537
References 537
17-3 Real-time control of polarization in ultra-short pulse laser micro-processing 538
1. Introduction 538
2. Experiment 538
2.1 Experimental setup 538
2.2 Test strategy 539
3. Results and discussion 539
3.1 Scanner-synchronized polarization switching 539
3.2 Laser-synchronized polarization switching 540
3.3 Un-synchronized polarization switching 541
4. Conclusions 541
Acknowledgements 541
References 541
PART 18 - Laser Technology – Industrial Applications 542
18-1 Laser Inertial Fusion-based Energy (LIFE) - Developing Manufacturing Technology for low cost and high volume fusion fuel is critical to our future energy needs. 543
1. Introduction 543
2. LIFE Fuel Capsule Specification 544
3. Fuel Capsule Fabrication 544
3.1 Metal Working 545
3.2 Description of Micro Injection Molding 545
3.3 Micro-encapsulation 546
3.4 Diamond Plasma-Assisted Chemical Vapor Deposition 548
4. Fuel Capsule Assembly 549
4.1 Description 549
4.2 Material Considerations 549
4.3 Research needs 550
5. Emerging Fabrication Technologies 550
5.1 Projection Microstereolithography 550
5.2 Electrophoretic Deposition 551
5.3 Hollow Jet Instability Method 552
6. Conclusion 552
Acknowledgements 552
18-2 Initial Strategies for 3D RAP Processing of Optical Surfaces Based on a Temperature Adaptation Approach 553
1. Introduction 553
2. Experiments, results and discussion 554
2.1 Process characterisation 554
2.2 Neutral removal and temperature control 555
2.3 Roughness assessment 556
3. Conclusions 556
Acknowledgements 556
References 556
18-3 Wireless & Powerless Laser Welding Monitoring System
1. Introduction 557
2. Communication module 558
3. Self-powered generator design 558
4. Experiments 559
4.1 Communication module 559
4.2 Energy harvesting module 559
5. Conclusions 560
References 560
18-4 System Design for Laser Assisted Milling of Complex Parts 561
1. Introduction 561
2. Thermal modeling for laser assisted milling 561
3. Establishment of experimental system 563
4. Conclusion 564
References 564
18-5 Direct Laser Writing System of Mask for Integrated Photonics Devices 565
1 Introduction 565
2 Experimental setup 565
3 Results and discussion 566
4 Conclusion 567
Acknowledgments 567
5 References 567
PART 19 - Laser Technology – Welding 569
19-1 Direct Laser Welding for Al- Li Alloy Plate without the Cleaning of Surface Film 570
1. Introduction 570
2. Experimental equipment and material 570
2.1 Experimental equipment 570
3. Results and disscussion 571
3.1 Influence of surface film on porosity 571
3.2 Porosity in bead on plate special dual-beam laser welding 572
3.3 Porosity in butt joint special dual-beam laser welding 572
4. Conclusion 573
References 573
19-2 Characteristics of keyhole and molten pool during laser welding of TC4 Ti-alloy 574
1. Introduction 574
2. Experimental Setup and Material 574
3. Results and Discussion 575
3.1 The characteristics of the keyhole during YAG laser welding of TC4 575
3.2 The characteristics of the molten pool duringYAG laser welding of TC4 575
3.3 The influence of welding parameters on the characteristics of the molten pool 576
Conclusions 577
References 577
19-3 Typical Joint Defects in Laser Welding of Aluminium-Lithium Alloy 578
1. Introduction 578
2. Material and Equipment 578
3. Result and Discussion 578
3.1 The Characteristics of Laser Welded Joints 578
3.2 The External Defects of Joints 579
3.3 The Internal Defects of Joints 580
4. Conclusion 581
References 581