ADAPTIVE LEARNING CONTROL OF CUTTING PARAMETERS FOR SCULPTURED SURFACE CUTTING BASED ON GENETIC ALGORITHMS AND NEURAL NETWORK

An adaptive learning control scheme intended to the on-lineoptimization of sculptured. The scheme uses a back-propagation neuralnetwork to learn the relationships between process inputs and processstates. The cutting parameters of the process model are optimizedthrough a genetic algorithms(GA). The capacity of the proposed schemefor determining optimum process inputs under a variety of processconditions and optimization strategies is evaluated on the basis ofmilling of a sculptured surface using a ball-end mill. Theexperimental results show that the neural network could model thecutting process efficiently, and the cutting conditions such asspindle speed could be regulated for achieving high efficiency andhigh quality. Therefore the proposed approach can be well applied tothe manufacturing of dies and molds.

Rock excavation using surface miners: An overview of some design and operational aspects

Surface miner, a continuous mining machine, is being manufactured in India and abroad owing to enhanced demand of production in various mining industries like coal, limestone, gypsum, bauxite etc. Different types of surface miners are manufactured today based on cutting drum placement and design specifications. Selective mining without drilling and blasting, high production and small size products are some of the prominent attractive features obtained with these moving marvels. This machine can be used with good efficiency in soft to medium hard rock (100-120 MPa). This paper synthesizes the different applications, equipment models, features offered, operating methods, cutting performance assessment models as well as typical production performance of surface miner in coal and limestone mines of India. Engine hour metre reading, diesel and pick consumptions are linearly influenced by production. The emphasis for future research is also brought out.

Development of a drill energy utilization index for aiding selection of drill machines in surface mines

Drill machines used in surface mines, particularly in coal, is characterized by a very poor utilization （around 40%） and low availability （around 60%）. The main purpose of this study is to develop a drill selec- tion methodology and simultaneously a performance evaluation technique based on drill cuttings produced and drilling rate achieved. In all 28 blast drilled through were investigated. The drilling was accomplished by 5 different drill machines of Ingersoll-Rand and Revathi working in coal mines of Sonepur Bazari （SECL） and Block-II （BCCL）. The drills are Rotary and Rotary Percussive type using tri- cone rock roller bits. Drill cuttings were collected and sieve analysis was done in the laboratory. Using Rosin Ramler Diagram, coarseness index （CI）, mean chip size （d）, specific-st trace area （SSA） and charac- teristic particle size distribution curves for all the holes drilled were plotted. The predictor equation for drill penetration rate established through multiple regressions was found to have a very good correlation with an index of determination of 0.85. A comparative analysis of particle size distribution curves was used to evaluate the drill efficiency. The suggested approach utilises the area under the curve, after the point of trend reversal and brittleness ratio of the respective bench to arrive at drill energy utilization index （DEUI）, for mapping of drill machine to bench, The developed DEU1 can aid in selecting or mapping a right machine to right bench for achieving higher penetration rate and utilizations.

Adaptive compensation of sculptured surface machining errors by open architecture manufacturing system

Presents the adaptive compensation of sculptured surface machining errors by using the open architecture intelligent manufacturing system to ensure real time high precision machining of sculptured surface, and the tool deflection model constructed for prediction of machining errors to be compensated and analysis of the effect of tool deflection on machining errors, and concludes from experimental results that the open architecture intelligent manufacturing system can effectively improve the machining precision and reduce the machining errors by 30%.

RULED SURFACE MACHINING BY 4-AXES SIMULTANEOUS CONTROL WIRE-EDM

On the tasis of study in the mathematical model of 3-dimensional ruled surface (RS),this paper introduces a new concept of distance paramcter (DP) and also puts forward that themethod of modeling a RS depends on not only two boundary curves but also DP. According toabove theory, the formulas to calculate corresponding point coordinates to any kind of top and bot-tom profile of a workpiece and formulas to calcuate the maximum inclination angle of ruling linehave been obtained. Then a different top and bottom RS mathining method including profile withline-are combination as well as parametric curves has been achieved by 4-axes simultancous con-trol programming proposed.

Optimal machining conditions for turning Ti-6Al-4V using response surface methodology

Machining titanium is one of ever-increasing magnitude problems due to its characteristics such as low thermal conductivity, modulus of elasticity and work hardening. The efficient titanium alloy machining involves a proper selection of process parameters to minimize the tangential force （Fz） and surface roughness （Ra）. In the present work, the performance of PVD/TiA1N coated carbide inserts was investigated using response surface methodology （RSM） for turning Ti-6A1-4V. The effects of process parameters such as speed （v）, feed （/＇）, depth of cut （d） and back rake angle （Ty） on Fz and Ra were investi- gated. The experimental plan used for four factors and three levels was designed based on face centered, central composite design （CCD）. The experimental results indi- cated that Fz increased with the increase in d, f and decreased with the increase in v and yy, whereas Ra decreased with the increase in v and 7y, and increased with d and v. The goodness of fit of the regression equations and model fits （R2） for Fz and Ra were found to be 0.968 and 0.970, which demonstrated that it was an effective model. A confirmation test was also conducted in order to verify the correctness of the model.

Cutting Performance of WC-Co Alloys Modified by Nano-Additives

In this paper,the microstructure of WC-Co alloys with and without nano-additives was characterized by scanning electron microscopy（SEM） and transmission electron microscopy（TEM）.The hardness and fracture toughness was tested by using a Vickers hardness tester and a universal testing machine.The cutting test was carried out at different feed velocities（250 r/min and 320 r/min）,and the contact pairs are cutting tools and 45# steel bars.Results showed that the hardness and fracture toughness of WC-Co cemented carbides with nano-additives are higher than that of WC-Co cemented carbides without nano-additives,and they are increased 10.21% and 19.69%,respectively.The flank worn width and crater width of cutting tools decrease greatly with the addition of nano-additives.For the nano-modified specimen with WC grain size of 7 μm,both the flank worn width and crater width are the minimum after the cutting process.And there are little built-up layers and some pile-up regions on the flank face leading to high cutting performance for the nano-modified cemented carbides.There are some melted regions on the flank face of cutting tools without nano-additives,and the WC grains on the cross section of alloys without nano-additives show severe fragmentation.The wear type of WC-Co is flank wear,and the wear mechanism is abrasive,adhesion and oxidation wear.

Longitudinal leaky surface acoustic wave on Y-rotated cut quartz substrates

The properties of Quasi-longitudinal leaky surface acoustic wave(QLLSAW) on Y-rotated cut quartz substrates were presented. The phase velocity of QLLSAW on the quartz substrate along some orientations can be up from 6200 m/s to 7100 m/s, circa 100% above that of regular SAW. Both theoretical and experimental results show that QLLSAW propagating along some promising orientations for SAW devices are of small power flow angle and low tem-perature coefficient, for example, along the Euler angle (0°155.25°? 42°?, the measurements of phase velocity and temperature coefficient of delay of QLLSAW are 6201 m/s and 12.9 ppm/℃. The experimental results show that QLLSAW had little absorption by liquid loading on the substrate surface, which proved that the direction of particle motion is the same as wave vector and parallel to the surface of the substrates, i.e., the wave is of the properties of longitudinal wave.