Cutting force monitoring using strain guage

Force monitoring

An electric circuit, that is fit for estimating the exceptionally little changes in resistance comparing to strain. This circuitry is utilized to quantify the strain with fortified opposition strain gauges. Typically, four strain gauge components are electrically associated with structure a Wheatstone bridge circuitry. 

A Wheatstone bridge is a separated bridge circuit utilized for the estimation of static or dynamic electrical opposition. The yield voltage of the Wheatstone bridge circuit is as milli volts (mv) yield per volt input. The Wheatstone circuit is likewise appropriate for temperature compensation. The numerical representation of the Wheatstone bridge, if R1, R2, R3, and R4 are equivalent, and a voltage, Vin , is applied between focuses A and C, at that point the yield between focuses B and D will show no expected distinction. Notwithstanding if R4 is changed to some esteem which doesn't rise to R1, R2, and R3, the bridge will become unequal and a voltage will exist at the yield terminals. In an alleged G-bridge setup, the variable strain sensor has opposition Rg, while different arms are fixed worth resistors. The sensor, in any case, can involve one, two, or four arms of the Wheatstone bridge, contingent upon the application. The all out strain, or yield voltage of the circuit (Vout) is equal to the contrast between the voltage drop across R1 and R4, or Rg.

 

Strain Gauge location

Example 1

The reason for this model is to ascertain the load force P, as appeared in Figure 2, with the assistance of two strain gages introduced on a rectangular pillar. Remembering that this pillar could be either the cutting tool holder, or it tends to be the cutting tool shank, and the edge or tip of the cutting tool is the main point of activity of the loal P. The two strain gages are locked in on the outside of the cantilever pillar as appeared in the figure. These strains mounted on a superficial level are in pressure when the load P is applied toward the finish of bar. These strain gages must be associated with a Wheatstone bridge in the manner R and R2, or R1 and R3, as appeared in Figure 1, to finish the bridge circuit other two resistors must be added, remembering that these resistors have same ostensible estimation of resistance as that of strain gages. The reason for doing so is to keep the bridge be as equilibrium as could be expected under the circumstances (Vο= 0) when the gages are unreformed.

 

Example 2

The purpose of dynamometer in dynamometer based system was to measure the cutting force. So dynamometer was installed in tool shank so that it can measure the cutting force involve in the turning process. The best feature of this process is that the dynamometer can be installed very easily on the tool shank. Other than this its customization is very easy as the data transmission happen through wireless setup. In order to avoid thermal effect of cutting operation and to increase the sensitivity of the apparatus, the installation of strain gauge is done away from the tip of the cutting tool cutting tip. This helps protect the dynamometer from damages when the tool failure occur. In order to achieve an amplified strain in results most strain gauges are placed at the hole of the tool shank or at the place of high stress concentration. This is done to avoid compromising the stiffness of the tool shank.

 

In above mention circuit of dynamometer based setup, the volte value provided by the Wheatstone Bridge is first amplified about 200 times more the original one and then it is transferred to frequency from voltage by an IC. Then these signals are delivered to an IR Emitter diode that is placed at the back side of shank of tool. After this stage the signal which are in frequency form are then again converted into voltage once again and that voltage is proportional to the strain value of the tool. The offset value of the voltage which is due to the unbalancing of the bridge is considered as the final output value.

Example 3

At the point when load P and Q are applied toward the end rectangular cross sectional zone of the instrument holder, minutes Mp and Mq and powers. Which bring with strain in strain gauges which are mounted on the rectangular cross sectional territory of the cutting tool holder. The circular drill is made at the focal point of cross sectional region, this is where strain gauges are introduced. There are two reason for doing this. First increment the affectability of the dynamometer, second design is to keep the solidness of hardware holder for all intents and purposes unaltered. 

Thinking about the accompanying conditions for this model: 

a) Strain gages with an ostensible resistance estimation of R, 

b) Strain gages of segments 1 and 2 (base and excellent condition) a full bridge with yield voltage V01, 

Considering that the instrument holder is made of a decent thermally conductive material, for example, aluminum, remembering the reality given above it is sensible suspicion that the temperature of all the strain gages is nearly the equivalent. Therefore, variety in temperature influences the affectability of all the strain gages similarly, dropping its impact on the last estimation. Extra strain gages must be introduced to quantify the pivotal power R,

Explain single point cutting tool geometry, angles and materials properties

Tool Geometry
Cutting Tool Geometry

1. Shank:

It is the body of the tool. It includes the part of tool which is inserted in tool post to hold the tool in machine. In simple words, it joins the handle and operational end.

2. Flank:

The surface of the tool adjacent to and facing work piece is called flank. A tool have two types of flanks i.e. major and minor flank. Major flank is also called side flank whereas minor flank is also called end flank. Minor flank is the end face of the tool which is facing the work piece while major flank is the adjacent surface to the minor flank.

3. Base:

The opposite side of shank with respect to the top side of tool is known as base.

4. Face:

Rake surface is also called tool face. This allows the chips of work piece to flow over the tool. 

5. Cutting edge:

The edge of tool that removes material by coming into contact with work piece is known as cutting edge. A tool have two cutting edges. 

i. Side cutting edge: Top edge of side flank is knows as side cutting edge.

ii. End cutting edge: Top edge of end flank is known as end cutting edge.

6. Nose or cutting point:

The point on the tool that separates end cutting edge from side cutting edge is known as nose.

7. Nose radius:

The point where end and side cutting edge meet is given a rounded. The radius given to the intersection point is called nose radius. Nose radius determines the surface quality of the work piece. It also has an effect on tool’s life.

8. Heel:

Intersection of flank and base is called tool heel.

Angles of Single Point Cutting Tool

There are several types of angle in a cutting tool. Each angle have its own importance and function.

1. End Cutting Edge Angle:

It is the angle formed between end face of the tool and plane normal to the side of shank.

2. Side Cutting Edge Angle:

The angle formed between major flank and the longitudinal axis of the tool is known as side cutting edge angle.

3. Back Rake Angle:

The angle made by the face of the tool and plane parallel to the base of tool is known as back rake angle. If the angle is measured in the direction of shank then it is called back rake angle and if it is measured in a direction perpendicular to the shank then it is called side rake angle.

4. End Relief Angle:

It is the angle between side flank and the plane perpendicular to the tool base is known as end relief angle. It prevents the tool from rubbing against the job.

5. Lip Angle/ Wedge Angle:

Angle between the face of tool and end flank is known as lip or wedge angle.

6. Side Rake Angle:

The angle between the face of the tool and plane normal to shank is known as side rake angle. 

7. Side Relief Angle:

The angle between portion of side flank immediately below the side cutting edge and line perpendicular to base of tool measured at right angle to side is known as side relief angle. It prevents interference when tool enters the material.

Single Point Cutting Tool Material Properties

Tool can be made of different materials depending upon the material which is being machined. Three important properties of tool material are given below.

• Hardness: Hardness is the property of the material with which it resists to indentation. The strength exhibited by the tool is directly related to the hardness of material with which the tool is made. Hot hardness is the ability of a material to maintain its hardness at high temperature.

• Toughness: Toughness tells us the about the energy which a material absorbs prior to its fracture. It is usually characterized by a combination of strength and ductility in the material. A material with high value of toughness exhibits good resistance against shock load, fracturing and chipping. For a tool, toughness and hardness vary opposite to each other.

• Wear resistance: A material with high hardness show good wear resistance. Moreover, a tool with good surface finish exhibits good wear resistance due to lower coefficient of friction. The property of wear resistance seems simple but most of the people can’t comprehend it properly. Wear resistance decides the life of tool before its replacement.

How to monitor Cutting Forces and Torques in lathe single point cutting tool

 Monitoring of Cutting Forces/Torques

The tool breakage costs both time and the material. It is estimated that around 20% of downtime is caused due to the tool failure. By employing conservative machining conditions, tool wear and breakage can be avoided at the cost of machining efficiency. Part machining experts select heavy-cut over high-speed machining. This demands intermittent tool changes which increases the cost of tooling. Reliable and accurate Tool Condition Monitoring abbreviated as TCM can decrease machining time up to 10-15%. Scheduling TCM in advance can also reduce downtime which has made it possible to carry out an active study on in-situ breakage detection and tool wear.

Cutting Force Monitoring by External Sensors 

Force Sensors 

Sensors which are installed to observe cutting force on machining tools are collectively known as external sensors. Internal sensors which are also known as current sensors are mounted on tools of NC machines for spindle and servo motors. Cutting force is measured using dynamometers which are commercially available. These dynamometers determine cutting force by means of quartz crystal piezoelectric transducers. Spindle and table dynameters are available commercially and they can be utilized for micro machining due to their sufficient resolution. They are employed using a small rotating or a non-rotating tool whose dimensions are in some dozens of microns. Despite of the fact that commercial dynamometers are accurate and reliable but they are not frequently used in machining because they are very expensive

Torque Sensors 

Commercially available piezoelectric dynamometers are used to determine cutting torque on the spindle. Use of magnetostrictive sensor to determine torque in the spindle was studied. Spindle motors generate heat which is a critical issue associated with the sensors installed in spindles.  In a study suggested temperature compensation can be employed to monitor torque in a reliable manner. In many machines, it is difficult to install force or torque sensor inside the spindle due to limited space. Tool holders are an alternate option to install sensor as they are available commercially. A study used strain gauges in the tool holder for determining radial forces, axial forces and torque. Small sensor-mounted rings or plates mounted at different parts of the machine which are influenced by the cutting force for the commercial use.

Cutting Force Calculation by Spindle Displacement 

Monitoring torque or force by using sensor directly on the spindle of a machine requires an extremely intricate arrangement to obtain required resolution during the entire power range of machine tool. Moreover, it is also mandatory that the measurement signal is transmitted without coming into contact with rotating spindle. It is easier to measure spindle displacement without coming into contact than the measurement of torque or force. The study of calculation of cutting force using spindle displacement has also been carried out. Kim et al. made a capacitance based sensor of a cylindrical shape which can be mounted nearby front spindle bearing to calculate the distance variation between the spinning spindle shaft and sensor head under cutting load. The use of capacitance based sensor for the calculation cutting force. It was shown that a bandwidth of up to 1000 Hz was attained when spindle dynamics was compensated for. In the similar manner the measurement of spindle displacement in turning process incorporating three capacitances based sensor. In a motorized spindle that is supported by active magnetic bearings, the gap is determined from command voltage to magnetic bearings in a manner similar to capacitance based sensor which can be utilized for the calculation of cutting force. A high-speed spindle with integrated sensors installed to monitor different spindle conditions that includes run out, vibration and temperature is being extensively used in commercial high-speed machines. Four contamination-resistant and low-priced eddy-current type displacement sensors were used (S1-S4). However, calculation of cutting force using spindle displacement has two major problems i.e. spindle stiffness and thermal influence. Rotating spindle can get deformed or displaced due to the heat generated by motor which should be differentiated from the displacement triggered by cutting force. In commercially established machining centers, coolant is circulated using cooling jackets to control the spindle temperature. Control period has significant influence on thermal deformation in on-off type temperature control. Several thermocouples are used for the calculation of thermal displacement in our study. Numerous studies have done thermal-mechanical spindle modeling.

Cutting Force Monitoring by Internal Sensors 

Commercial NC machine tools which use servo motors for spindle rotation or feed drive use current sensor for motion control. The most economical way to calculate cutting force or torque is through the armature current of the motor. When motor disturbance is induced by the torque, servo controller modifies the armature current to curb its effect. In this method, there is no need to use any extra sensors. In study for detection of tool breakage using cutting force calculated by the current of servo motor. An analogous attempt was carried out by observing armature current of the spindle motor. In several commercialized CNCs, a screen displays the spindle load which is considered the simplest way to calculate cutting torque. Some CNCs show the disturbance calculated from servo motors in digital form. Commercially available products to observe servo motor or spindle current also offer fault detection. Drive system’s dynamic characteristics affect armature current. Particularly, to compensate for the dynamics of moving mass in a feed drive is imperative in segregating the effect of cutting force. Feed drive can utilize a disturbance observer to achieve this purpose. To detect and analyze unusual machining process i.e. tool breakage, algorithms have caught the focus of academia for years. Complexity Analysis, Wavelet analysis, artificial neural network, statistics analysis and a frequency domain analysis were used in detecting fault.

Basics of Powder Metallurgy

Powder Metallurgy-Present and Future Scope: Production of components by taking initial methods in the form of powder is called as Powder Metallurgy. In this article, we will learn about the Present and Future Scope of Powder Metallurgy with its advantages and disadvantages in a detailed way.

CONTENTS of Powder Metallurgy:

• Introduction to Powder Metallurgy(PM)
• What makes the Powder Metallurgy exist?
• Powder Metallurgy Processes

1. Production of Powders
2. Mixing/Blending
3. Compaction
4. Sintering

• Advantages & Dis-Advantages
• Markets for Powder Metallurgy components
• Present and Future Scope
• Applications of Powder Metallurgy

A form of Powder Metallurgy existed in Egypt as early as 3000 B.C Used in 19thcentuary to produce Platinum and Tungsten wires. Utilized in Germany for producing Tungsten carbide cutting tools after 1stWorld war.

Definition:

Production of components by using initial methods in the form of powders is known as powder metallurgy. Failure of General alloy formation makes the powder metallurgy to exist.

POWDER METALLURGY Processes:

1.Production of Powders:

• Molten liquid is pressurized(P) and allowed to travel through a nozzle of diameter (Dn).
• The molten liquid will break into spherical droplets and are cooled in quench medium.
• They will be solidified and powder of particle size(Dp) is produced.

3.Compaction:

• Wet condition of powder mixture will be kept in the mould and is subjected to compression load under pressure.
• After compaction, the wet condition of powder mixture is called compact.
• The compact possesses low strength compared to the final strength of component called Green Strength.

4. Sintering

• The compact is heated to 80% of M.P. temperature.
• Due to this chemical bonds will form among atoms and thereby, strength increases.
• Sintering is performed in inert atm.(N2/Ar) or in the presence of vacuum to avoid oxidation.
• After sintering, the compact will achieve tremendous strength called as final strength.

Advantages of Powder Metallurgy:

• Alloys can be created from high MP metals including MO, W, Tantalum.
• Used for metals that are too hard to machine.
• In Super hard cutting tool bits, the tips will be coated with Fe3C, WC, SIC coatings by PMP.
• In the production of Ceramics (sustain a temp. of 3000’c), PMP will be used.
• Powder metallurgy components possess high compressive strength.

Dis-Advantages of Powder Metallurgy:

• Powder metallurgy components are expensive compared to General alloy formation method.
• Difficult to produce large & complex shapes with uniform density.
• Tensile strength is low.
• Al, Mg, Sb, Bi, As Ti powders, should not be used because they will undergo explosion at the time of compaction.

Markets for Powder Metallurgy components

• Around 80% of automotive applications are from powder metallurgy.
• 75% of components are used for transmissions.

Future scope of Powder Metallurgy Process

• Lightweight technology and engine downsizing in Automotive fields.
• Hitachi chemicals:
• Engaged in the development of wear-resistant parts, structural parts, magnetic parts (soft magnetic materials) for the development of high-performance parts as next-generation products.

Applications of powder metallurgy

• They are used for making cutting tools and dies.
• Used in making of machinery parts
• Powder metallurgical components are widely used in making bearings and bushes due to its self-lubricating property.

MOHAMMED SHAFI

Mohammed Shafi is a Mechanical Engineering Blogger by Passion and Assistant Professor by Profession. He want to Share his knowledge to the Young People by Presenting the GATE Sessions and all the concepts of Mechanical Engg. in a detailed way so that they can get best jobs in the future. For more info, Visit www.mechanicalstudents.com

Brinell Hardness Test

Hardness is one of the material properties that allows the material to resist plastic deformation. The plastic deformation may be because of penetration or in some other way. The resistance can also be from bending, scratching, abrasion or cutting etc.

Brinell Hardness Test Lab Report

Hardness is the mechanical property of the material which helps him in resisting the plastic deformation of the material. 

Plastics deformation can be form the starching, compression or due to indentation of any object in the work piece. 

Brinell hardness test is performed to find the hardness typically called the Brinell hardness. 

Procedure

• Brinell hardness test in perform in such a way that first of all a work piece made of desire material is obtain and is fixed on the plate form of the brinell hardness testing machine. 

• Then a small ball usually of 10 mm diameter, made of tungsten carbide is used to apply the load of about 3000 kg on the work piece. Load is applied for certain duration and then removed. 

• Due to such high load the ball penetrate into the outer surface of the work piece and upon removal make cavity at that position. 

• Diameter of the cavity is measured from at least two positions and these positions should be at right angle of each other. 

• The diameter measured is then compared with the standard table provided with Brinell hardness machine form where the diameter reading is converted into the Brinell hardness number of the material.

• Cavity diameter measured from the Brinell hardness machine is converted into the Brinell hardness number by the help of following formula

HB=  2F/(π×D×(D-√(D-d) ) )

Here 

F is the load applied

D is diameter of the ball used for indentation

d is the diameter of the impression produce by the ball on the work piece

HB is the Brinell hardness number of the material

Indentation measurement is the biggest error source in the Brinell hardness test because the measuring method is manual due to which the human error can cause problem. 

Due to the inexperience operator taking the reading the results of the experiment will different under the perfect condition but the non-perfect condition will bring more changes in the result. 

Over the years there two technologies developed to overcome the errors of the Brinell hardness test one is the automatic optimal Brinell scope and other is the Brinell units. 

First one make use of computer and images analysis to measure the Brinell hardness and second one make use of the ASTM E103 standard units to measure the Brinell hardness. 

The surface condition of the work piece can really affect the result of the experiment so that’s why the surface of the work piece is prepared by grinding. 

Brinell hardness number which is obtain from the Brinell hardness test is used to determine the hardness of any material or in other works the ability of the material to stop any object from penetrating into it. 

It can be said in the other words like that, Brinell hardness number of any material show its ability to maintain its shape or the ability of the material to resist the change in its shape. 

Brinell hardness number is used to select the material for the application where the outer shape of the object or product is very important like in aerospace application. 

Brinell hardness number can also be used for the selection of the material for the application where the object need to be hard enough to resist the penetration of any object in it like military tanks and built proof vehicles. 

Construction Material for Bushfire Prone Areas

According to Wastiels, L. (2009) building structural design and building material are the two most important factors those need to be considered during the designing phase of the building.  Out of these two factors, building material will be discussed in this report. Selecting a building material is one of the most difficult tasks now a day because now it is not just selecting a strongest material for any building, now it is about fulfilling a certain criteria. 

Self-Healing Concrete

According to the Povindar K (1993) concrete is one of the best construction materials available now due to it’s to take large compressive loads. In the case when the applied load is more than the compressive strength of the concrete, load applied can produce cracks in the concrete column of in any other structure. Due to this crack the other properties of the concrete structure like permeability, durability and strength also start to decrease. To stop this decrease in properties the crack present in the concrete structure has to fix which cost a lot. According to the Kim Van Tittelboom (2008) crack in the concrete structure can be dangerous for the steel placed inside it for the higher strength. Moisture through the crack will enter the concrete structure due to which the steel start to rust, this further decrease the strength of the structure. 

3D Printing (3DP) and Selective Laser Melting (SLM), a comprehensive comparison

1. Working Process

3D printing is an additive manufacturing process that creates physical objects from digital design. In 3DP layer of powder is deposited automatically in the tray. Then print head applies resin to power layer and it dries almost immediately. When the layer dried another layer will be added to finish the model. The working principle of SLM differs from 3DP and it works on the principle of melting. Powder heated and melted and forms pool of liquid where its phase changes from liquid to solid by reforming and hardening. The final part wont porous, thereby it can be used for wide range of applications.

3D Printing (3DP) and Selective Laser Sintering (SLS), a comprehensive comparison

1. Working Process

3D printing creates physical objects from digital design. The material used is power which is located in a build chamber. A printing head deposits liquid binder on to powder, thus it bonded together and forms layer. The build platform is lowered down an amount equal to the layer created. This process repeated to complete the 3D part. SLS principle completely differs from 3DP and works based on sintering principle. The powder material is heated and bonded together by fusion and forms layer. Heat source for sintering process is generated by laser. A Cad model imported to SLS system and completed layer by layer.

SLS vs SLM: 6 Points Comparison between Selective Laser Melting and Selective Laser Sintering

1. Working Process of SLS vs SLM

Starting SLS vs SLM on the working principle. SLM (selective laser melting ) works on the principle of melting. The working is same as SLS (selective laser sintering) where as the power is melted instead of sintering. 

Melting actually creates a pool where the materials can consolidate before reforming and hardening to create new solid structure. 

The final part won’t be porous, thereby making it suitable for a greater range of applications. In SLM, powdered material is melted, whereas in SLS the powder is heated below its melting point (sintering). 

When laser heats the powder material to below melting point, it forms solid by fusion. The working principle is almost same in both printing method.

2. Process Variations of SLM vs SLS

Discussing the process variation for SLM vs SLS. Some Selective Laser Melting SLM industries are works with some other material like magnesium for light weight construction. 

Varieties of materials are tried in SLM process; however very little work has done on gold and its alloys. God and alloys are used to manufacture dental crowns. 

The gold power is cohesive and non- flowing in nature. Selective Laser Sintering SLS selective laser sintering has some limitations when compared to SLM. 

However SLS also has variety of methods like DMSL (Direct Metal Laser Sintering), which use powerful laser to micro-weld the raw material. Yb-fibre or CO2 will be used up to 100W and DMLS used up to 200W.

3. Processing materials of SLS vs SLM

For a greater selective laser sintering vs selective laser melting let us comparing the materials they can process. The normal materials used in selective laser melting  SLM are stainless steel, aluminum or titanium alloys. 

SLM materials are selected depending on the properties like strength, ductility and biocompatibility based on the application. 

Titanium based materials are used in biomedical application due to their good mechanical properties, high bio compatibility and corrosion resistance. SLM works with metals, where as SLS generally works with plastics, glass, ceramics. 

Selective Laser Sintering SLS don’t restrict metals; the same can be used in DMLS. Aluminum filled and glass filled nylon material is used in SLS. 

Nylon is the ideal material, because of its light weight, high durability and heat resistant etc.

4. Design aspects SLM vs SLS

In SLM vs SLS, unlike SLS, SLM is very difficult to control, because of large energy input of laser beam. SLM parts can further processed as many welding part. 

SLM also requires support structures however i can be act as heat transfer medium which can reduce thermal stress and prevents wrapping. 

Selective Laser Sintering SLS is easy to control and better than FDM. Thinner layers also can be achievable by using DMLS. 

The un-sintered powder will act as a support and there is no need to provide additional supports. The layer thickness depends on type of material used and post processing can be done by traditional process.

5. Quality aspects of selective laser sintering vs selective laser melting

Considering the 1uality aspects of the processes for selective laser sintering vs selective laser melting. Selective Laser Melting SLM is a proven technology to produce near net-shape parts up to 99.9% relative density. 

It has good mechanical properties. Tolerance and surface finishes are limited. However it can be improved through post processing. 

The tolerances are ±0.05-0.2mm, however this will vary machine to machine. SLS parts may require stress relieving and annealing to reduce internal residual stress. SLS chamber is maintained with N2 atmosphere which will prevent explosion of powder. 

Additional curing may also required when using ceramic parts. The machine needs thorough cleaning to avoid powder contamination. The achievable tolerance is ±0.05-0.25 mm; may vary material to material.

6. Economical aspects for SLS vs SLM

Discussing the economical aspects for SLS vs SLM. Selective Laser Melting SLM machines are very economical, minimal materials used; time saving and offers reduced cost/cycle time. 

100% usage of lasers cannot be achieved in selective laser melting SLM. It is very compact machines and minimum layer thickness also achievable. 

The process of final approval takes longer time for development and qualification of this technology. Selective laser sintering SLS has high energy requirement. 

It is an automated process but needs skilled man power. The initial investment is huge; however the direct labor costs are low. 

The leftover powder can be re-used and the material utilization also higher. The powder material cost vary in the market depends on its properties.

Fused Deposition Modelling (FDM) and Selective Laser Sintering (SLS), a comprehensive comparison

1. Working Process

Fused Deposition Modelling FDM is an additive manufacturing technology, works on the principle of sintering. The plastic polymer is feeded to a heated nozzle, which will lay down it in layers to produce a product. The number of layers on a product is the deciding factor of manufacturing time. The principle of SLS completely differs from FDM. It works on the principle of sintering. In FDM filament is heated in the nozzle, whereas in SLS, the powder is heated by controlled laser pulse. The laser heats the powder and it forms solids by fusion. SLS don’t require support material since the power itself can act as support.

Fused Deposition Modeling - 3D Printing

Fused deposition modeling is an additive layer manufacturing process also known as layer by layer manufacturing process because in this process a 3 dimensional object is made by adding very thin 2 dimensional layers. Process starts with generating the computer aided design (CAD model) of the component which needed to be manufactured. Then second step is to convert the computer aided design file in to STL (standard triangulation language) file, this file format is internationally accepted by all additive layer manufacturing machines. Third step is to slice the 3 dimensional STL file into 2 D cross sections, this is done by the additive layer manufacturing machine. In fourth step the physical development of the desire component is done. After complete manufacturing of the component the post processing is required which is fifth step where finishing process like cleaning and curing is done and final the component is read to be used. 

Manufacturing from Solid, CNC Milling

Manufacturing of part using CNC milling machine starts with making a completed 2D and 3D drawings of the part which is need to make the CNC code. CNC code for part contains the path of tool which depends on part geometry, feed rate and cutter rotation speed. Types of milling cutter used in part manufacturing depend on the initial condition of raw material provided; part mounting method and construction of cutter.

Resin Transfer Molding Processes

For the composite material like carbon fiber composite, resin transfer molding process can be used quite effectively for the production of composite product. Resign transfer molding process consist of following steps

1.      Placing the carbon fiber preform in mold

2.      Closed mold is heated under low pressure

3.      Resin is transfer into mold under pressure

4.      Mold is left for curing

5.      Finished product is ejected from the mold

Ceramic Material Powder Processing

Productivity Improvement through Computer Integrated Manufacturing CIM

Steps of Sand Casting Process

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