This paper addresses the application of Design for Six Sigma (DFSS) methodology to the design of a marine riser joint hydraulic line test fixture. The original test fixture was evaluated using Value Steam Mapping (VSM) and appropriate Lean design tools such as 3D Modeling and Finite Element Analysis (FEA). A new test fixture was developed which resulted in improving the process cycle efficiency for the test from 25&#x25; to 50&#x25; percent, leading to a 50&#x25; reduction in test cost. Handling of the new test fixture is greatly improved as compared to the original fixture.

Charles G. Kibbe

Jim Lee

Kanjicai Dong

Designing a Test Fixture with DFSS Methodology

Manufacturing operations that assemble parts often receive components in expensive highly engineered shipping containers. As these containers circulate among suppliers, assembly operations, and logistic providers, they require inspections and repairs. This paper presents mathematical models that predict the number of available containers as functions of damage, repair times, and scheduled daily production. The models allow making complex decisions with a few basic parameters. Results not only show a minimal investment in the number of containers and safety stock but also quantify the dependence on damage rates and repair times for ordering additional containers.

David A. Field

Dennis E. Blumenfeld

Supply Chain Inventories of Engineered Shipping Containers

Consumable materials for welding processes such as filler alloy, electrode, and shielding gas have major implications in welding technology. Selecting the appropriate set of consumable materials for welding aluminum alloys from various available alternates gives rise to a significant decision making problem. This study proposes a strategic justification tool based on integrated analytical hierarchy process, technique for order preference by similarity to ideal solution (AHP-TOPSIS), to screen and select the best possible combination of filler alloy, electrode, and shielding gas for TIG welding. Based on qualitative analysis of available alternates, ER5356 filler alloys and 0.8&#x25; zirconiated electrode are selected as suitable consumable in combination with pure argon as shielding gas. The proposed result is experimentally validated using mechanical property testing.

P. K. Baghel

D. S. Nagesh

Multiattribute Assessment of Consumables for TIG Welding of Aluminum Alloys

This paper presents a study of tool wear and geometry response when machinability tests were applied under milling operations on the Super Austenitic Stainless Steel alloy AL-6XN. Eight milling trials were executed under two cutting speeds, two feed rates, and two depths of cuts. Cutting edge profile measurements were performed to reveal response of cutting edge geometry to the cutting parameters and wear. A scanning electron microscope (SEM) was used to inspect the cutting edges. Results showed the presence of various types of wear such as adhesion wear and abrasion wear on the tool rake and flank faces. Adhesion wear represents the formation of the built-up edge, crater wear, and chipping, whereas abrasion wear represents flank wear. The commonly formed wear was crater wear. Therefore, the optimum tool life among the executed cutting trails was identified according to minimum length and depth of the crater wear. The profile measurements showed the formation of new geometries for the worn cutting edges due to adhesion and abrasion wear and the cutting parameters. The formation of the built-up edge was observed on the rake face of the cutting tool. The microstructure of the built-up edge was investigated using SEM. The built-up edge was found to have the austenite shear lamellar structure which is identical to the formed shear lamellae of the produced chip.

Mohanad Alabdullah

Ashwin Polishetty

Guy Littlefair

Impacts of Wear and Geometry Response of the Cutting Tool on Machinability of Super Austenitic Stainless Steel

Additive manufacturing is one of the key technologies of the 21st century. Additive manufacturing processes are often combined with subtractive manufacturing processes to create hybrid manufacturing because it is useful for manufacturing complex parts, for example, 3D printed sensor systems. Currently, several CNC machines are required for hybrid manufacturing: one machine is required for additive manufacturing and one is required for subtractive manufacturing. Disadvantages of conventional hybrid manufacturing methods are presented. Hybrid manufacturing with one CNC machine offers many advantages. It enables manufacturing of parts with higher accuracy, less production time, and lower costs. Using the example of fused layer modeling (FLM), we present a general approach for the integration of additive manufacturing processes into a numerical control for machine tools. The resulting CNC architecture is presented and its functionality is demonstrated. Its application is beyond the scope of this paper.

Marcel M&#xfc;ller

Elmar Wings

An Architecture for Hybrid Manufacturing Combining 3D Printing and CNC Machining

The demand for higher productivity requires machine tools to work on the adequate critical speed to have faster and more accurate ball screw system. Ball screw affects severely over the higher rotation speed of the shaft in computer numeric control (CNC) machining centers. This paper deals with an approach to calculate the initial critical speed of the shaft. Critical speed requires significant attention due to its major use in the manufacturing sectors. The impacts of weight on the critical speed of shaft assembly have been analyzed from theoretical as well as analytical investigations. Additionally, we evaluated the impact of weight on the deflection of the shafts along with failure analysis of shafts with respect to critical speed. Further, we computed the results for critical speed based factor to enhance the accuracy of CNC machining centers. Finally, the analytical estimations have been carried out to prove the validity of our proposal.

Kuldeep Verma

R. M. Belokar

Pervasive Investigations of Critical Speed over Weight and Deflection Factors of Shaft Assembly in CNC Ball Screw System

The bobbin friction stir welding (BFSW) process has benefits for welding aluminium alloy 6082-T6 in the boat-building industry. However this alloy is difficult to weld in the thin state. There are a large number of process variables and covert situational factors that affect weld quality. This paper investigates how tool holder and machine-type affect BFSW weld quality of 4&#x2009;mm Al6082-T6. The variables were tool features (three types), machine-controller type (two types), and tool holder (fixed versus floating). Fourier analysis was performed on motor spindle current to determine the frequency response of the machine. An interaction was found between the computer numerical control (CNC), the degrees of freedom of the tool holder, and the substrate (workpiece). The conventional idea that the welding tool has a semisteady interaction with the substrate is not supported. Instead the interaction is highly dynamic, and this materially affects the weld quality. Specific vibrational interactions are associated with poor welding. The CNC machine-type also emerges as a neglected variable that needs to be given attention in the selection of process parameters. Although compliance in the tool holder might seem useful, it is shown to have negative consequences as it introduces tool positioning problems.

Mohammad K. Sued

Dirk J. Pons

Dynamic Interaction between Machine, Tool, and Substrate in Bobbin Friction Stir Welding

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The <svg xmlns:xlink="http://www.w3.org/1999/xlink" xmlns="http://www.w3.org/2000/svg" style="vertical-align:-3.29112pt" id="M1" height="11.6791pt" version="1.1" viewBox="-0.0498162 -8.38798 12.0663 11.6791" width="12.0663pt"><g transform="matrix(.013,0,0,-0.013,0,0)"><path id="g121-74" d="M495 163C480 117 462 85 444 65C421 39 387 34 332 34C290 34 256 36 236 47C218 57 213 77 213 131V526C213 612 222 616 301 622V650H40V622C122 616 128 611 128 526V126C128 41 120 34 36 28V0H489C498 31 519 126 525 157L495 163Z"/></g><g transform="matrix(.0091,0,0,-0.0091,6.994,3.132)"><path id="g50-58" d="M247 635C116 635 39 518 39 421C39 315 113 237 221 237C239 237 258 241 281 253L349 289C315 140 204 42 60 19L66 -15C90 -15 153 -5 207 16C344 70 447 199 447 385C447 521 373 635 247 635ZM231 598C329 598 356 478 356 390C356 371 355 347 352 325C330 309 297 297 262 297C179 297 127 369 127 456C127 515 156 598 231 598Z"/></g></svg> Taguchi orthogonal arrays, signal-to-noise (<svg xmlns:xlink="http://www.w3.org/1999/xlink" xmlns="http://www.w3.org/2000/svg" style="vertical-align:-2.15067pt" id="M2" height="11.439pt" version="1.1" viewBox="-0.0498162 -9.28833 22.5826 11.439" width="22.5826pt"><g transform="matrix(.013,0,0,-0.013,0,0)"><path id="g113-84" d="M449 634C442 637 425 643 405 650C376 660 341 666 307 666C181 666 98 590 98 485C98 400 170 343 215 310L246 288C307 243 343 204 343 147C343 67 291 18 219 18C104 18 61 124 51 202L23 199C28 124 27 71 27 47C47 22 122 -16 204 -16C324 -16 428 60 428 174C428 256 379 309 307 360L276 382C223 419 179 455 179 516C179 576 221 632 293 632C379 632 410 564 418 487L448 490C446 536 446 592 449 634Z"/></g><g transform="matrix(.013,0,0,-0.013,6.136,0)"><path id="g113-48" d="M368 703H309L44 -163H104L368 703Z"/></g><g transform="matrix(.013,0,0,-0.013,11.497,0)"><path id="g113-79" d="M822 650H589L583 622C660 617 677 607 674 561C672 534 664 481 647 390L600 137H596L273 650H126L120 622C176 620 194 615 207 594C221 571 225 557 214 504L161 257C141 166 129 112 121 85C108 42 83 30 29 28L23 0H260L266 28C193 33 173 42 176 89C178 122 186 172 202 255L256 527H259L583 -8H612L690 390C708 481 720 535 728 558C744 603 756 619 816 622L822 650Z"/></g></svg>) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

M. Nurhaniza

M. K. A. M. Ariffin

F. Mustapha

B. T. H. T. Baharudin

Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

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International Journal of Manufacturing Engineering - Table of contents 2016

International Journal of Manufacturing Engineering | Hindawi

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International Journal of Manufacturing Engineering

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International Journal of Manufacturing Engineering