Abstract.One of the main present industry challenges is finding the most efficient manufacturing process for a certain part. When parts are made of strong steels like Hardox, their fabrication method is usually difficult. Abrasive waterjet cutting (AWJ) is one of the cutting processes which can be used in this case. This paper presents an experimental research on the machinability of Hardox steel by AWJ. The experiments were conducted using a factorial design model considering two of the main influence parameters like the traverse speed and the distance between the nozzle and the surface of the material. Based on the measurement of the dimensions and the roughness of the parts, the influence of the parameters was revealed and analyzed. The manufacturing time was also compared, as it directly influences the production cost. Further research is considered to develop a mathematical model which can be used for a proper choice of the process parameters depending on the initial requirements.
Abstract. The manufacturing process of special steels like Hardox is usually difficult. Abrasive waterjet cutting (AWJ) is one of the machining processes which can be used in this case, with good results, as proved in previous research of the authors. This paper presents an experimental study on the influence of the AWJ main process parameters to the dimensional accuracy of holes manufactured in Hardox steels. The experiments were conducted using a L8(2 4 ) fractional factorial design matrix considering four parameters: the traverse speed, the part thickness, the hole dimension and the material type. Based on the measurement of the dimensions of the holes, the influence of those parameters was revealed and analyzed. The manufacturing time was also registered, as this parameter directly influences the production cost. Further research aims developing a mathematical model which will be a useful tool in workshop process planning.
ncremental sheet forming (ISF) is one the manufacturing methods for sheet metal parts which has an increased rate of flexibility combined with relatively simple and cheap common technological equipment. This paper presents the results of researches on ISF performed on a CNC lathe, for thin sheet parts made of DC04Am mild steel. The main objective of the paper was to establish the maximum wall angle of the parts and its dependence on the main parameters of the process: thickness and diameter of the part, the tool radius, the feed rate, the spindle speed and the lubricating/cooling conditions. The tests were performed with original equipment designed by the authors and the results were commented and presented in diagrams and images of the parts. The main conclusion is that ISF on a CNC lathe can be successfully used for manufacturing conical shaped parts made of mild steel thin sheet, having a certain maximum angle of the parts wall, for small sized batches. The limit values of the parameters analyzed are a useful technological database for engineers.
Abstract. This paper presents a study of dynamic aspects of the milling cutters used in particular case of low depth channels. A new calculation method was developed, taking into account the high variations of cutting forces during milling small depth channels with peripheral cutting tools. A new formula was established for the minimal value of channel depth that allows cutting process to be performed in conditions of dynamic stability.
The paper presents the way the 3D scanning was used to correct miss-alignment of the tools on a metal sheet bending press. Parts obtained by bending where not conform to requirements, and the reason was unknown. In order to find the error, the shape, size, and alignment of bending board and stamp had to be checked. The particular very long tools imposed as the single appropriate method of measurement: 3D scanning. The point clouds gathered by 3D scanning were processed to get the 3D models of the tools. Analyzing the models of the tools and their relative position led to conclusions that revealed the error and allowed fixing the problem.
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