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HONORARY KEYNOTE SPEAKER:
Prof.Dr. Yusuf ALTINTAŞ
Mechanical Engineering Department, University of British Columbia (UBC)


UNIVERSITY – INDUSTRY RESEARCH PARTNERSHIP MODELS IN MANUFACTURING ENGINEERING


Abstract:
This paper presents a survey of university – industry research models practiced in North America, Europe and Asia. While universities value scholarly research that leads to archival journal publications with high impact, industry considers only the development of innovative and practical methods which reduce the cost of producing the parts. The author believes that the university researcher cannot try to replicate the practices of engineers in industry. Instead the researcher must try to develop new, science-based methods which lead to archival journal articles, while transferring knowledge to industry by training highly- qualified specialists and packaging the scientific know-how in industry-friendly formats.

Key Words: University, Industry, Partnership, Research

KEYNOTE SPEAKERS:

Prof. Dr. K.-D. Bouzakis
Mechanical Engineering Department, Aristoteles University of Thessaloniki



CUTTING PERFORMANCE PREDICTION OF COATED TOOLS BASED ON INNOVATIVE PROCEDURES TO DETECT PROPERTIES OF THE COMPOUND FILM-INTERFACE-SUBSTRATE

Authors:
K.-D. Bouzakis, R. Paraskevopoulou, E. Bouzakis, G. Skordaris, P. Charalampous, S. Kombogiannis, G. Katirtzoglou, S. Makrimallakis

Abstract:
The cutting performance of coated tools can be significantly improved by tailoring the compound film-interface-substrate properties to the application specific requirements. The present paper describes novel analytical-experimental methods for predicting properties, facilitating the quick assessment of the cutting performance of coated tools. Characteristic application's examples of such methodologies are introduced.

In up and down milling of various steels by coated cemented carbide inserts, the effect of the complicated chip geometry and contact conditions between tool and workpiece is crucial for the wear evolution. To approach such contact conditions, repetitive impact tests were conducted at adjustable force signal characteristics on coated cemented carbide inserts. The applied loads correspond to the developed ones in milling when the cutting edge penetrates the workpiece material. Considering these results, the effective tool life is described up to a certain flank wear width dependent on the cutting speed and the cutting edge entry impact duration. An application example will be presented in the case of NC milling a turbine blade of high hardness steel (?56 HRC).

Furthermore, a method for assessing the fatigue strength of nano-composite diamond (NCD) coating interfaces via inclined impact tests is also introduced. Dependent on the applied load, after a certain number of impacts, damages in the film interface region may develop resulting in coating detachment. In this way, residual stresses of the NCD-film are released leading to its lifting (bulge formation). The geometry of the developed film's elevations was sufficiently described by appropriate FEM calculations. Based on the attained impact test results, Woehler-like diagrams were developed for monitoring the fatigue endurance of NCD coating interfaces at various impact conditions. In this way, cutting conditions can be approximately adapted for enhancing the NCD-coated tools performance.

Key Words: PVD coatings, NCD films, fatigue, strain rate, milling

Dr. Stuart Barnes
WMG, University of Warwick, UK



ADVANCES IN CRYOGENIC AND ULTRASONIC ASSISTED MACHINING


Abstract:
The modern machine tool is virtually unrecognisable in terms of its physical appearance and technical capabilities compared to those which were in use only a few years ago. Developments such as high speed spindles, live tooling and multi-axis machining have been combined with advances in cutting tool design, materials and coatings plus enhancements in cutting fluid performance in order to achieve unprecedented improvements in productivity. However, the continual development of increasingly difficult-to-machine materials, combined with the ever present desire for further increases in productivity, continue to drive the evolution of machine tools and machining processes. This paper will consider two techniques which although they have been known about for some time, have recently matured to the point that they are demonstrating commercial potential for further improvements in conventional machining processes; cryogenic cooling and ultrasonic assisted machining.

Cryogenic cooling of the cutting tool or the cutting zone has the potential to remove the heat generated during machining more efficiently that conventional cutting fluid and various researchers have investigated a range of techniques over the years. However, this presentation will describe research at WMG using a commercially available system and consider the advantages / viability of the process.

Ultrasonic assisted machining is also a technique which has been known to have a positive effect on certain aspects of machining for some time with several laboratory scale set-ups being developed by researchers. However, the system which is being used at WMG is integral within a commercially available, fully functional, 5-axis machine tool provided by DMG Mori Seiki. The application of this commercially available implementation of the technology will be reviewed along with some of the research work performed using this facility.

Dr Stuart Barnes
3 December 2013

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