The machinability of rapidly solidified aluminium alloy for optical mould inserts
- Authors: Otieno, Timothy
- Date: 2018
- Subjects: Aluminum alloys , Automobiles -- Materials Materials -- Mechanical properties
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/23097 , vital:30415
- Description: Ultra-high precision machining is a material removing process under the nanotechnology regime whereby the highest dimensional accuracies are attained. Critical components for optical devices and optical measuring systems are mainly produced through ultra-high precision machining. Their mass production is usually implemented by utilising optical moulds. Aluminium alloys have proven to be advantageous and very commonly used in the photonics industry for moulds. This ever-increasing use and demand within optics have led to the development of newly modified grades of aluminium alloys produced by rapid solidification in the foundry process. The newer grades are characterised by finer microstructures and improved mechanical and physical properties. The main inconvenience in their usage currently lies in their very limited machining database. This research investigates the machinability of rapidly solidified aluminium, RSA 905, under varying cutting conditions in single point diamond turning. The machining parameters varied were cutting speed, feed rate and depth of cut. The resulting surface roughness of the workpiece and wear of the diamond tool were measured at various intervals. Acoustic emissions and cutting force were also monitored during machining. The results were statistically analysed and accurate predictive models were developed. Generally, very low tool wear, within 3 to 5 μm, and very low surface roughness, within 3 to 8 nm, was obtained. Acoustic emissions recorded were in the range of 0.06 to 0.13 V and cutting forces were in the range of 0.08 to 0.94 N. The trends of the monitored acoustic emissions and cutting force showed to have a linked representation of the tool wear and surface roughness results. Contour maps were generated to identify zones where the cutting parameters produced the best results. In addition, a range of machining parameters were presented for optimum quality where surface roughness and tool wear can be minimised. As the machining is of a nanometric scale, a molecular dynamics approach was applied to investigate the underlying mechanisms at atom level. The nanomachining simulations were found to have a correlation to the actual machining results and microstructural nature of the alloy. This research proves that rapidly solidified aluminium is a superior alternative to traditional aluminium alloys and provides a good reference with room for flexibility that machinists can apply when using rapidly solidified aluminium alloys. Efficiency could be improved by reducing the required machining interruption through effective monitoring and performance could be improved by maintaining quality and extending tool life through parameter selection.
- Full Text:
- Date Issued: 2018
- Authors: Otieno, Timothy
- Date: 2018
- Subjects: Aluminum alloys , Automobiles -- Materials Materials -- Mechanical properties
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/23097 , vital:30415
- Description: Ultra-high precision machining is a material removing process under the nanotechnology regime whereby the highest dimensional accuracies are attained. Critical components for optical devices and optical measuring systems are mainly produced through ultra-high precision machining. Their mass production is usually implemented by utilising optical moulds. Aluminium alloys have proven to be advantageous and very commonly used in the photonics industry for moulds. This ever-increasing use and demand within optics have led to the development of newly modified grades of aluminium alloys produced by rapid solidification in the foundry process. The newer grades are characterised by finer microstructures and improved mechanical and physical properties. The main inconvenience in their usage currently lies in their very limited machining database. This research investigates the machinability of rapidly solidified aluminium, RSA 905, under varying cutting conditions in single point diamond turning. The machining parameters varied were cutting speed, feed rate and depth of cut. The resulting surface roughness of the workpiece and wear of the diamond tool were measured at various intervals. Acoustic emissions and cutting force were also monitored during machining. The results were statistically analysed and accurate predictive models were developed. Generally, very low tool wear, within 3 to 5 μm, and very low surface roughness, within 3 to 8 nm, was obtained. Acoustic emissions recorded were in the range of 0.06 to 0.13 V and cutting forces were in the range of 0.08 to 0.94 N. The trends of the monitored acoustic emissions and cutting force showed to have a linked representation of the tool wear and surface roughness results. Contour maps were generated to identify zones where the cutting parameters produced the best results. In addition, a range of machining parameters were presented for optimum quality where surface roughness and tool wear can be minimised. As the machining is of a nanometric scale, a molecular dynamics approach was applied to investigate the underlying mechanisms at atom level. The nanomachining simulations were found to have a correlation to the actual machining results and microstructural nature of the alloy. This research proves that rapidly solidified aluminium is a superior alternative to traditional aluminium alloys and provides a good reference with room for flexibility that machinists can apply when using rapidly solidified aluminium alloys. Efficiency could be improved by reducing the required machining interruption through effective monitoring and performance could be improved by maintaining quality and extending tool life through parameter selection.
- Full Text:
- Date Issued: 2018
Shape memory Alloy Actuator for cross-feed in turning operation
- Authors: Otieno, Timothy
- Date: 2012
- Subjects: Shape memory alloys -- Mechanical properties , Shape memory alloys , Intermetallic compounds , Materials -- Mechanical properties
- Language: English
- Type: Thesis , Masters , MA
- Identifier: vital:9650 , http://hdl.handle.net/10948/d1012590 , Shape memory alloys -- Mechanical properties , Shape memory alloys , Intermetallic compounds , Materials -- Mechanical properties
- Description: A shape memory alloy (SMA) is an intermetallic compound able to recover, in a continuous and reversible way, a predetermined shape during a thermal cycle while generating mechanical work. In this thesis, its use in developing an actuator for a machining process is investigated. The actuator is to drive the tool cross feed into an aluminium workpiece in a finishing lathe operation. The actuator structure was designed with an output shaft to transfer the movement and force of the SMA wire outside the device. The actuator was fabricated and the experimental setup was assembled which also included a power supply control circuit, displacement sensor, temperature sensor and current sensor for feedback, and data collection and monitoring within software. PID control was implemented within the software that regulated the power supplied to the SMA, thereby providing the position control. This study covers the mechatronics system design and development of the actuator, the experiments carried out to determine performance and the results. Open loop tests were conducted to determine the maximum stroke, the effect of cooling and response to radial forces. These tests revealed the expected non-linearity of the SMA. The actuator achieved the rated maximum stroke of 3-4 percent. The forced cooling test showed a general improvement of approximately 65 percent with fans. The radial force tests showed the value of the maximum stroke remained unaffected by force. The results from the closed loop tests responses with a tuned PID controller produced a stable system for various displacement setpoints. The actuator had a feed rate of 0.25 mm/s and an accuracy of 0.0153mm, which was within the acceptable accuracy for turning operations. The system was deemed accurate for a conventional lathe machine cross feed.
- Full Text:
- Date Issued: 2012
- Authors: Otieno, Timothy
- Date: 2012
- Subjects: Shape memory alloys -- Mechanical properties , Shape memory alloys , Intermetallic compounds , Materials -- Mechanical properties
- Language: English
- Type: Thesis , Masters , MA
- Identifier: vital:9650 , http://hdl.handle.net/10948/d1012590 , Shape memory alloys -- Mechanical properties , Shape memory alloys , Intermetallic compounds , Materials -- Mechanical properties
- Description: A shape memory alloy (SMA) is an intermetallic compound able to recover, in a continuous and reversible way, a predetermined shape during a thermal cycle while generating mechanical work. In this thesis, its use in developing an actuator for a machining process is investigated. The actuator is to drive the tool cross feed into an aluminium workpiece in a finishing lathe operation. The actuator structure was designed with an output shaft to transfer the movement and force of the SMA wire outside the device. The actuator was fabricated and the experimental setup was assembled which also included a power supply control circuit, displacement sensor, temperature sensor and current sensor for feedback, and data collection and monitoring within software. PID control was implemented within the software that regulated the power supplied to the SMA, thereby providing the position control. This study covers the mechatronics system design and development of the actuator, the experiments carried out to determine performance and the results. Open loop tests were conducted to determine the maximum stroke, the effect of cooling and response to radial forces. These tests revealed the expected non-linearity of the SMA. The actuator achieved the rated maximum stroke of 3-4 percent. The forced cooling test showed a general improvement of approximately 65 percent with fans. The radial force tests showed the value of the maximum stroke remained unaffected by force. The results from the closed loop tests responses with a tuned PID controller produced a stable system for various displacement setpoints. The actuator had a feed rate of 0.25 mm/s and an accuracy of 0.0153mm, which was within the acceptable accuracy for turning operations. The system was deemed accurate for a conventional lathe machine cross feed.
- Full Text:
- Date Issued: 2012
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