Cutting force measurement based on tool embedded Ni-chrome thin-film micro-sensors

Cutting force measurement has become a crucial activity for enhancing machining process performance. This paper described the design and fabrication of embedded Ni-chrome thin-film micro-sensors in tool holders to measure the cutting force in machining operations. A Ni-chrome thin-film sensor device is embedded within a substrate structure through a dy- namic brazing process, which consists of a Ti6A14V substrate, a nickel-chromium thin-film sensor and an alumina insulating layer. The Wheatstone bridge which consists of four sensors would produce the output voltage when the thin film caused de- formation by the cutting forces. The relationship between input and output voltages was theoretically analyzed. According- ly, an in-process cutting force measurement system is established. The results show that the thin-film sensor had good lineari- ty and less mutual interference, and it is suitable for all kinds of turning forces under the measurement conditions.

An appraisal of techniques and equipment for cutting force measurement

Current research focussed on the assessment of metal machining process parameters and on the development of adaptive control, shows that machine performance, work-piece and tool material selections, tool life, quality of machined surfaces, the geometry of cutting tool edges, and cutting conditions are closely related to the cutting forces. This information is of great interest to cutting tool manufactures and users alike. Over the years there have been significant developments and improvements in the equipment used to monitor such forces. In 1930 mechanical gauges were replaced by resistance strain gauges, and some 30 years later compact air gauge dynamometers were invented. Since this time intensive research has continued being directed to- wards developing new approaches to cutting force measurement. The Kistler Company, well-known manufacturer of acceleration and piezoelectrical dynamometers, has worked in this field for more than three decades, and developed very sensitive devices. While leading manufacturing research laboratories are often equipped with this technology, classical electrical strain gauges and other dynamometers of individual designs are still commonly used in industry. The present paper presents data obtained using different techniques of force measurement in metal machining processes. In particular, areas of uncertainties, illustrated through results concerning the turning process, are analysed, leading to an appraisal of the current status of these measurements and their significance.

Remedial Technical Measures Following Freezing Injury of Rapeseed

[Objective] The aim was to explore effects of occurrence frequency of freezing injury on rapeseed production and remedial measures. [Method] The re- search utilized three turns of freezing injury during the growth period of winter-sown rapeseed in 2013, analyzed the freezing injury resistibility and the remedial mea- sures of ten varieties（combination）. [Result] The results showed that for different va- rieties （combinations） of rapeseed, compared cutting ones with non-cutting ones, the plant silique, seeds number and seed weight increased in diverse level, ＂however, the plant yield remained the same. Correlation analysis suggested that freezing in- jury had the greatest impact on plant silique. [Conclusion] After cutting processing, yield traits were able to partially recover and showed kind of positive correlation with Plant yield.

Fabrication, Characterization and Machining of Al6061 Reinforced with Red Mud Composite

The Metal Matrix Composites application has increased in many areas of science and technology, because of its additional physical, wear and mechanical properties. In comparison with all MMC’s, aluminum-based MMC’s are finding wide applications due to their better strength to weight ratio, better stiffness, and high thermal conductivity as well as very good wear and corrosion properties. The properties of a composite mainly depend on better distribution of reinforcement in the matrix, which is very difficult to achieve. Basically Redmud is a byproduct of alumina, and it is waste product obtained during Bayer’s process. This waste product must be recycled else it may be dangerous to the environment. Redmud can be used as reinforcement for aluminium composites in order to achieve better properties. The proposed research work includes preparation of Aluminum 6061-Red mud metal matrix composites using liquid metallurgy route following stir casting technique. An alloy Al6061 containing 0.60 percent silicon and Magnesium of 0.82 percent was used as the matrix material. Two different compositions of the Aluminum 6061-Red mud composites are prepared in addition to the base matrix and evaluated for mechanical properties also the force acting on the cutting tool at different spindle speeds during machining of the composite materials were analyzed.

Development of a low-cost measurement system for cutting edge profile detection

The use of a compact disk （CD） pickup head as a displacement measurement system is described. The components contained in a pickup head are explained and how they are combined to obtain the functionality of a pickup head. The application of measuring a knife edge profile is introduced. The results reveal some insuffiencies with the current system. The cutting edge＇s radius of curvature can be estimated.