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International Journal of Abrasive Technology (3 papers in press)
Development of wireless cutting vibration monitoring device fixed to tool holder by Kazuya Kato, Koji Utsumi, Kenji Nishikawa, Ami Nomura Abstract: The aim of this study is to develop a wireless cutting vibration monitoring device fixed to a tool holder for the purpose of improving the productivity of a machining centre. A feature of the developed device is that it can be used at a low cost without modifying the machine tool. Experiments were conducted in endmilling using the developed device. Simultaneous measurement was performed with a cutting dynamometer, and the results indicated that the cutting vibration for each cutting edge can be measured by the developed device. Compared with the wired accelerometer attached to the spindle head, the developed device could measure approximately 10 times higher acceleration. When the cutting speed was constant, the acceleration amplitude was measured via frequency analysis of the cutting vibration, which was proportional to the cutting force, and the developed device could monitor the cutting force. The developed device could also monitor changes in vibration owing to an increase in cutting distance in groove cutting. Keywords: IoT; cutting vibration; accelerometer; tool holder; endmill.
AI-based Modeling and Optimization of Rotating Magnetic Force assisted Powder Mixed EDM by Ram Sajeevan, Avanish Kumar Dubey, Ajit Kumar Singh, Pankaj Kumar Shrivastava Abstract: Though widely used to process newly developed materials, electrical discharge machining (EDM) possesses poor machining efficiency. Modifications/hybridization of EDM can improve its performance with respect to different quality parameters. Mixing powder in dielectric and applying magnetic field near machining zone are few of EDM modifications. The present paper investigates the performance of EDM with above mentioned modifications applied simultaneously. The innovative set-up was designed and fabricated to perform rotary magnetic field assisted powder mixed EDM (MFPMEDM). The experiments were conducted on Aluminium Titanium Di-boride metal matrix composite to evaluate MRR by varying different process parameters including powder concentration under the influence of magnetic field. The performance of both EDM and MFPMEDM has been compared and latter has been found much better in terms of process efficiency. Further, hybrid evolutionary optimization algorithm has been used for modelling and optimization of MRR. Keywords: ANN; GA; Magnetic field assisted EDM; Material removal rate; Powder mixed EDM.
Mechanical characteristics of abrasive composite materials characterized by the Impulse Excitation Technique by Katia Cristiane Gandolpho Candioto, Matheus Mendonça Chitan Abstract: Abrasive composites are widely used in industrial machining, for example as grinding tools. Grinding wheel hardness expresses the retention capacity that the binder has over the abrasive grains and is important to optimize grinding processes and can associate the stages of grinding and cut off. The hardness of the abrasive tools can be characterized by the determination of Young´s modulus using the impulse excitation technique (IET). In this work, Young´s modulus is determined with the IET, which is a non-destructive method with good objectivity, low equipment expenditure, and short measuring time. The results were compared to destructive bending tests. Resin bond composite abrasives with different grit/resin ratio structures were prepared and evaluated on microstructure and density. It was observed that increasing the grit/resin ratio also increases Young´s modulus, except for higher porosity samples, where the hardness decreases because of the larger binder volume within the sample. Keywords: Abrasives; Composite materials; Impulse Excitation Technique; Non-destructive testing; Young´s modulus; Damping