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3. An investigation of the relationship between temperature, forces and tool wear in turning and drilling

Author

Boud, Fathi M.

Subjects
621.8, Mechanical Engineering
Abstract

Developing a means of predicting tool life has been and continues to be a focus of much research effort. A common experience in attempting to replicate such efforts is an inability to achieve the levels of agreement between theory and practice of the original researcher or to extrapolate the work to different materials or cutting conditions to those originally used. This thesis sets out to examine why most equations or models when replicated do not give good agreements. One reason which was found is that researchers in wear prediction, their predictions are limited because they generally fail to properly identify the nature of wear mechanisms operative in their study. Also they fail to identify or recognise factors having a significant influence on wear such as bar diameter. Also in this research the similarities and differences between the two processes of single point turning and drilling are examined through a series of tests. A literature survey was undertaken in wear and wear prediction. As a result it was found that there was a paucity in information and research in the work of drilling as compared to the turning operation. This was extended to the lack of standards that exist for the drilling operation. One reason for this scarcity in information on drilling is due to the complexity of the drilling and the tool geometry of the drill. In the comparative drilling and turning tests performed in this work, the same tool material; HSS, and similar work material was used in order to eliminate the differences which may occur due to this factor. Results of the tests were evaluated and compared for the two operations and SEM photographs were taken for the chips produced. Specific test results were obtained for the cutting temperatures and forces of the tool. It was found that cutting temperature is influenced by various factors like tool geometry and cutting speed, and the temperature itself influenced the tool wear and wear mechanisms that act on the tool. It was found and proven that bar diameter influences the temperature, a factor not considered previously.

Published
1998
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4. On the Lubricity and Comparative Life Cycle of Biobased Synthetic and Mineral Oil Emulsions in Machining Titanium Ti-6Al-4V at Low Cutting Speed

Author

Wood, Paul, primary, Boud, Fathi, additional, Carter, Wayne, additional, Varasteh, Hirbod, additional, Gunputh, Urvashi, additional, Pawlik, Marzena, additional, Clementson, Jenny, additional, Lu, Yiling, additional, Hossain, Syed, additional, Broderick, Matthew, additional, Raguraman, Munusamy, additional, Smith, Andy, additional, Mantle, Andy, additional, and McGourlay, Jamie, additional

Published
2022
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5. (Special Issue Responsive Manufacturing) - Application of multi-sensor signals for monitoring tool/workpiece condition in broaching

Author

Boud, Fathi, Gindy, N N Z, School of Mechanical, Materials and Manufacturing Engineering, University of Nottingham, UK (UON), and School of Mech, Materials & Man Eng'g

Subjects
Physical Sciences
Abstract

International audience; Process monitoring can be used for improving machining reliability and failure prediction. As manufacturing anomalies are a potential cause of gas turbine disc failure in aero-engines, Engine life and performance can be improved by developments of manufacturing anomaly detection. The paper identifies appropriate techniques for monitoring tool condition and surface anomalies in broaching, and presents results of the output signals obtained from multiple sensors such as acoustic emission, cutting forces, vibration, hydraulic pressure and table displacement. The results show that the signals obtained proved to be efficient in detecting surface deviations and anomalies. Tool wear was identified by the cutting force, pressure and table displacement signals. While the acoustic emission signals did not prove to be sensitive in detecting tool wear, they were efficient in detecting surface anomalies such as smearing, scoring and overheating.

Published
2008

6. A new approach in standardising a European curriculum in production engineering

Author

Boud, Fathi, Bayard, Ove, Chatti, Sami, Axinte, Dragos, Nicolescu, Mihai, Agirre, Jaione, Boud, Fathi, Bayard, Ove, Chatti, Sami, Axinte, Dragos, Nicolescu, Mihai, and Agirre, Jaione

Abstract

The need for a flexible and versatile workforce that is constantly learning and upgrading its skills has led to a continual demand for courses in which employees are re-trained and updated on a lifelong basis. Students and workers now have to be prepared for a labour market in which they can be expected to change jobs many times, and they need to acquire appropriate skills that are transferable and portable across sectors, countries and cultures. This paper presents a new approach to unifying a European curriculum for production engineering. The paper discusses the background, developments, module structure, testing and ongoing work that is carried out in the European Production Engineering Certification project – a two year pilot project granted by the European Union Programme Leonardo da Vinci., QC 20120220, EPRODEC

Published
2009
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