Expert System Approach for Optimization of Design and Manufacturing Process for Rotary Ultrasonic Machining
محورهای موضوعی : Mechanical Engineering
Morteza Sadegh Amalnik
1
(Department of Mechanical Engineering,
University of Qom, Qom, I.R.Iran)
کلید واژه: Expert System, Penetration rate, Rotary ultrasonic, Machining time & cost,
چکیده مقاله :
An expert system for evaluating rotary ultrasonic machining, in concurrent engineering environment and based on object oriented techniques, is developed. The design specification is obtained through a feature based approach. Different classes of design features are interactively acquired. The attributes of different hard and brittle materials like glass, composite, stone and ceramic as work piece materials are stored in database. The system is also linked with tool material and machine databases. For each design feature, information is needed in manufacturing, such as machining cycle time, and cost, penetration rate, and efficiency are estimated by the expert system. Software system such as expert system based on object oriented technique is used to develop the expert system. The system links with a feature based CAD system in order to extract design data. The expert system provides useful information such as machining cycle time and cost, penetration rate, efficiency of machining of the selected design feature for product designers and advises of manufacturing engineers to select optimum machining parameters. In order to test the validity of the system, results of expert system is compared with the results of experimental rotary ultrasonic machining.
[1] Kremer, D., Saleh, S. M., Ghabrial, S. R., Moisan, A., and Paris, F., “The State of the Art of Ultrasonic Machining”, Annals of the CIRP Vol. 30, No. 1, 1981.
[2] Seah, AK. H. W., Wong Y. S., and Lee, L. C., “Design of Tool Holders for Ultrasonic Machining Using FEM”, J. of Materials Proc. Tech., Vol. 37,1993, pp. 801-816.
[3] McGeough, J. A., “Advanced methods of manufacturing”, Chapman & Hall, 1988, Chap 8.
[4] Churi, N. J., P., Pei, Z. J., and Treadwell, C., “Rotary Ultrasonic Machining of Titanium Alloy: Effects of Machining Variables, Material Science and Technology”: An International Journal, vol. 10, 2006, pp. 301-321.
[5] Jiao, Y., Hu, P., Pei, Z. J., and Treadwell, C., “Rotary Ultrasonic Machining of Ceramics: Design of Experiments, International Journal of Manufacturing Technology and Management”, Vol. 7, 2005, pp. 192-206.
[6] Zhang, Q. H., Wu, C. L., and Sun, J. L., “The Mechanism of Material Removal in Ultrasonic Drilling of Engineering Ceramics”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2000, pp. 805-810.
[7] Tyrrell, W. R., “Rotary Ultrasonic Machining”, SME Technical Paper MR70- 516, 1970.
[8] Khanna, N., Pei, Z. J., and Ferreira, P. M., “An Experimental Investigation of Rotary Ultrasonic Grinding of Ceramics Disk”, Technical Papers of the North American Manufacturing Research Institution of SME, 1995, pp. 67–72.
[9] Li, Z. C., Jiao, Y., Deines, T. W., Pei, Z. J., and Treadwell, C., “Rotary Ultrasonic Machining of Ceramic Matrix Composites: Feasibility Study and Designed Experiments”, International Journal of Machine Tools and Manufacture, Vol. 45, 2005, pp. 1402-1411.
[10] Tyrrell, W. R., “New Method for Machining Hard and Brittle Material”, SAMPE Quarterly, Vol. 1, 1970, pp. 55-59.
[11] Kuo, K. L., “A Study of Glass Milling using Rotary Ultrasonic Machining, Key Engineering Materials”, Vol. 364-366, 2008, pp. 624-628.
[12] Li, Z. C., Jiao, Y., and Deines, T. W “Experimental Study on Rotary Ultrasonic Machining (RUM) of Polycrystalline Diamond Compacts (PDC), CD-ROM”, Proceedings of the 13th Annual Industrial Engineering Research Conference, Houston, TX, 2004, pp 15-19.
[13] Churi, N. J., P., Pei, Z. J., Shorter, D. C. and Treadwell, C., “Rotary Ultrasonic Machining of Silicon Carbide: Designed Experiments”, International Journal of Manufacturing Technology and Management, Vol. 12, 2007, pp. 284-298.
[14] Pei, Z. J., Ferreira, P. M., Kapoor, S. G., and Haselkorn, M., “Rotary Ultrasonic Machining for Face Milling of Ceramicsˮ, International Journal of Machine Tools and Manufacture, Vol. 35, 2009, pp. 1033–1046.
[15] Pei, Z. J., Ferreira, P. M., and Haselkorn, M., “Plastic Flow in Rotary Ultrasonic Machining of Ceramics”, Journal of Material Processing Technology, Vol. 48, 1995, pp. 771-777.
[16] Pei, Z. J., Ferreira, P. M., “Modeling of Ductile-Mode Material Removal in Rotary Ultrasonic Machiningˮ, International Journal of Machine Tools and Manufacture, Vol. 38, 1998, pp. 1399-1418.
[17] Cong, W., Pei, Z. J., Churi, N. J., and Wang, Q., “Rotary Ultrasonic Machining of Stainless Steel: Design of Experimentsˮ, Transactions of North American Manufacturing Research Conference, Vol. 37, 2009, pp. 261–268.
[18] Pei, Z. J., Khanna, N., and Ferreira, P. M., “Rotary Ultrasonic Machining of Structural Ceramics: A Review”, Ceramic Engineering and Science Proceedings, Vol. 16, 1995, pp. 259-278.
[19] Petrukha, P. G., “Ultrasonic Diamond Drilling of Deep Holes in Brittle Materials”, Russian Engineering Journal, Vol. 50, 1970, pp. 70-74.
[20] Qin, N., Pei, Z. J., Treadwell, C., and Guo, D. M., “Physics-based Predictive Cutting Force Model in Ultrasonic-Vibration-Assisted Grinding for Titanium Drillingˮ, Journal of Manufacturing Science and Engineering, Vol. 131, 2009, pp. 1-9.
[21] www.bullen-ultrasonics.com/UltraMachine.html (09/11/09).
[22] www.scribd.com/doc/14370435/Advanced-Machining-ProcessHassan-E-Hofi (09/11/09).
[23] Pei, Z. J., Ferreira, P. M., “An Experimental Investigation of Rotary Ultrasonic Face Millingˮ, International Journal of Machine Tools and Manufacture, Vol. 39, 1999, pp. 1327-1344.
[24] Khanna, N., Pei, Z. J., Ferreira, P. M., “An Experimental Investigation of Rotary Ultrasonic Grinding of Ceramics Disk”, Technical Papers of the North American Manufacturing Research Institution of SME, 1995, pp. 67–72.
[25] Uhlmann, E., Spur, G., Holl, S. E., “Machining of Complex Contours by Ultrasonic Assisted Grinding”, SME Technical Paper MR99-284, Society of Manufacturing Engineers, Dearborn, MI, 1999.
[26] Zeng, W. M., Xu, X., and Pei, Z. J., “Rotary Ultrasonic Machining of Advanced Ceramicsˮ, Materials Science Forum”, Vol. 532-533, 2006, pp. 361-364.
[27] Zhang, Q. H., Zhang, J. H., Sun, D. M., and Wang, G. D., “Study on the Diamond Tool Drilling of Engineering Ceramics” Journal of Materials Processing Technology, Vol. 122, 2002, pp. 232-236.
[28] Chao, C. L., Chou, W. C., Chao, C. W., and Chen, C. C., “Material Removal Mechanisms Involved in Rotary Ultrasonic Machining of Brittle Materials”, Key Engineering Materials, Vol. 139, 2007, pp. 391-396.
[29] Kuo, K. L., “Experimental Investigation of Brittle Material Milling Using Rotary Ultrasonic Machining”, Proceedings of the 35th International MATADOR Conference, Springer London, Vol. 10, 2007, pp.195-198.
[30] Marinescu, I., “Handbook of Advanced Ceramics Machining”, CRC Press, 2006.
[31] Venkatachalam, S., “Predictive Modeling for Ductile Machining of Brittle Materials”, PhD Dissertation, Georgia Institute of Technology, 2007.
[32] Ming Zhou, X. J., B. K. A. Ngoi, J., and Gan G. K., “Brittle-ductile Transition in the Diamond Cutting of Glasses with the Aid of Ultrasonic Vibrationˮ, Journal of Materials Processing Technology, Vol. 121, 2002, pp. 243-251.
[33] Zhao, B., Zhang, X. H., Liu, C. S., Jiao, F., Zhu, and X. S., “Study of Ultrasonic Vibration Grinding Character of Nano ZrO2 Ceramics”, Key Engineering Materials, Vol. 291-292, 2005, pp.45-50.
[34] Churi, N. J., Pei, Z. J., and Treadwell, C., “Rotary Ultrasonic Machining of Titanium Alloy (Ti-6Al-4V): Effects of Tool Variables”, International Journal of Precision Technology, Vol. 1, 2007, pp. 85-96.
[35] Churi, N. J., Pei, Z. J., Shorter, D. C., and Treadwell, C., “Rotary ultrasonic machining of dental ceramics‖, International Journal of Machining and Machinability of Materials”, Vol. 6, 2009, pp. 270-284.
[36] Wang, Q., Pei, Z. J., Gao, H., Churi, N. J., Renke, R., “Rotary Ultrasonic Machining of Potassium Dihydrogen Phosphate (KDP) Crystal: An Experimental Investigationˮ, International Journal of Mechatronics and Manufacturing Systems, Vol. 2, 2009, pp. 414-426.
[37] Markov, A. I., Ustinov, I. D., “A Study of the Ultrasonic Diamond: Drilling of Non-metallic Materials,” Industrial Diamond Review, 1972, pp. 97-99.
[38] Kubota, M., Tamura, Y., Shimamura, N., “Ultrasonic Machining with a Diamond Impregnated Toolˮ, Bulletin of Japan Society of Precision Engineering, Vol. 11, 1977, pp. 127-132.
[39] Hu, P., Zhang, J., and Jiao, Y., “Experimental Investigation on Coolant Effects in Rotary Ultrasonic Machiningˮ, Proceedings of the NSF Workshop on Research Needs in Thermal Aspects of Material Removal Processes, Still water, OK, 2003, pp. 340-345.
[40] Zeng W. M., Li, Z. C., Pei, Z. J., and Treadwell, C., “Experimental Observation of Tool Wear in Rotary Ultrasonic Machining of Advanced Ceramics”, International Journal of Machine Tools & Manufacture, Vol. 45, No.12-13, 2005, pp. 1468-1473.
[41] Gonzalo, O., Etxeberria, J., Abasolo, M., and Vicario, I., “Acoustic Emission Tool Wear Monitoring: from Conventional Milling to Rotary Ultrasonic Machining”, 4th E-GLEA Meeting. 2005.
[42] Jiao, Y., Liu, W. J., Pei, Z. J., Xin, X. J., Treadwell, C., “Study on Edge Chipping in Rotary Ultrasonic Machining of Ceramics: An Integration of Designed Experiments and Finite Element Method Analysisˮ, Journal of Manufacturing Science and Engineering, Vol. 127, 2005, pp. 752-758.
[43] Li, Z. C., Cai, L. W., Pei, Z. J., and Treadwell, C., “Edge-chipping Reduction in Rotary Ultrasonic Machining of Ceramics: Finite Element Analysis and Experimental Verification”, International Journal of Machine Tools and Manufacture, Vol. 46, 2006, pp. 1469-1477.
[44] Legge, P., “Machining without Abrasive Slurry”, Ultrasonics, 1996, pp. 157-162.
[45] Prabhakar, D., “Machining of Advanced Ceramic Materials using Rotary Ultrasonic Machining Process”, M. S. Thesis, University of Illinois at UrbanaChampaign, Champaign, IL. 1992.
[46] Suzuki, K., Mishiro, S., Shishido, Y., Iwai, M., Mei, W., and Uematsu, T., “A Micro Ultrasonic Grinding Device with Very High Frequency and its Applicationˮ, Key Engineering Materials, Vol. 39, 2007, pp. 45-50.
[47] Yadava, V., Deoghare, A., “Design of Horn for Rotary Ultrasonic Machining using the Finite Element Methodˮ, International Journal of Advanced Manufacturing Technology, Vol. 39, 2007, pp. 9-20.
[48] Ishikawa, K., Suwabe, H., Nishide, T. and Uneda, M., “A Study on Combined Vibration Drilling by Ultrasonic and Low-frequency Vibrations for Hard and Brittle Materials”, Precision Engineering, Vol. 22, 1998, pp. 196-205.
[49] Li, Z. C., Jiao, Y., Deines, T. W., Pei, Z. J., and Treadwell, C., “Development of an Innovative Coolant System for Rotary Ultrasonic Machining,” International Journal of Manufacturing Technology and Management, Vol. 7, 2005, pp. 318-328.
[50] Prabhakar, D., Pei, Z. J., Ferreira, P. M., and Haselkorn, M., “A Theoretical Model for Predicting Material Removal Rates in Rotary Ultrasonic Machining of Ceramics”, Transactions of the North American Manufacturing Research Institution of SME, Vol. 21, 1993, pp. 167–172.
