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Byrne, Gerald
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Byrne, Gerald
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Byrne, Gerald
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Now showing 1 - 5 of 5
- PublicationTool Wear in Milling of Medical Grade Cobalt Chromium Alloy - Requirements for Advanced Process Monitoring and Data Analytics(Machine Tool Technologies Research Foundation, 2016-07-07)
; ; ; ; Computer Aided Design (CAD), Computer Aided Manufacturing (CAM) and Computer Numerical Control (CNC) are platform technologies in high end manufacturing. However, the machining process on the CNC Machine Tool is generally the main source of loss of component accuracy, precision and extraneous effects on surface finish and integrity. Moreover these 'losses', and therefore costs, only increase in cutting processes due to the inherent modes and mechanisms of progressive and catastrophic tool wear. In high end manufacturing sectors, these losses are also exacerbated by the use of 'difficult-to-cut (DTC)' materials while more stringent specifications apply and higher levels of process capability are demanded. The use of Cobalt Chromium (Co-Cr-Mo) alloys in the Medical Device sector is indicative of the many challenges. However, notwithstanding the importance of the application, there are few publications on the fundamental mechanisms in cutting this alloy, other than by the present authors. This paper builds on our research to date by reporting some preliminary results on tool wear progression in CNC milling of the Co-Cr-Mo alloy conforming to ASTM F75. It also assesses the feasibility of real time tool wear monitoring on a Mori Seiki NMV1500 CNC Machining Centre using the MTConnect communication standard. The results obtained through MTConnect are provided by embedded sensors within the machine tool and are correlated with a laboratory piezoelectric dynamometer. The results from both methods, obtained at two cutting speeds, are also related to observed tool wear progression and the cumulative volume of material removed. The results are discussed in terms of the potential and limitations of using of MTConnect and the machine tools embedded sensors, for monitoring of the process and the onset of tool wear.665 - PublicationHigh Performance Cutting in the New Era of Digital Manufacturing - A RoadmapWe are rapidly moving into the new era of digitisation, into an era of the Massive Internet of Things - towards the Gigabit Society and towards 5G Technology. The implications are truly far reaching. Rapid transformation through the implementation of INDUSTRY 4.0 is becoming visible in industries all over the world. Disruption to the more traditional industrial practices and processes is inevitable. High Performance Cutting is no exception. Developments in the Internet of Things (IoT) opens up new and extremely powerful capabilities to help us gain a significantly deeper understanding of the fundamentals of cutting processes and offers entirely new connectivity possibilities at all interfaces, some old and some new, 'between the Chip Root and the Cloud'. This supports us in our attempts since the foundation of CIRP in 1951 to remove technological roadblocks and can lead on a new journey towards new and unprecedented scientific/technological developments as well as new business models for companies involved in the various elements of the supply chain for cutting processes (DIN 8580). 'Performance' will take on a new and unanticipated meaning over what was originally meant when we established this CIRP-HPC Conference back in the early 2000’s. In this paper a critical review of a previous roadmap is undertaken for cutting processes presented in a CIRP Keynote Paper in 2003 by Byrne, Dornfeld and Denkena [1] and new thoughts and ideas are presented on a vision for a 2020 skeleton Roadmap for High Performance Cutting in the new age of Digitisation.
386Scopus© Citations 23 - PublicationDual mode control of the rotational grinding processThe rotational grinding process enables the production of substrates to meet the submicron planarity specifications required for micro-fabrication of semiconductor integrated circuits. Improvements in process capability, with respect to both form and finish, have been generally realised by the development of machine tools and systems based on a principle of precise and predictable “position” control. An alternative principle for optimisation is demonstrated here comprising a dual mode control system where a “finishing mode” is based on local normal force control. Test results show significant relative improvements in levels of surface roughness and a reduction in the normal spatial variation.
427Scopus© Citations 2 - PublicationThe influence of built-up layer formation on cutting performance of GG25 grey cast ironThe success of high speed machining of grey cast iron relates to the protective built-up layer (BUL) that forms on the tool. The present work investigates BUL formation on pcBN tools for dry, high speed machining of GG25 grey cast iron (up to vc = 750 m/min). This work suggests that the BUL distribution on the tool at high cutting speed (vc = 750 m/min) is key to tool protection. Protection in the area of maximum cutting temperature is critical in preventing thermally driven wear modes, such as crater wear, found at low cutting speeds (vc = 250 m/min).
444Scopus© Citations 15 - PublicationBiologicalisation: Biological Transformation in ManufacturingA new emerging frontier in the evolution of the digitalisation and the 4th industrial revolution (Industry4.0) is considered to be that of “Biologicalisation in Manufacturing”. This has been defined by the authorsto be “The use and integration of biological and bio-inspired principles, materials, functions, structures andresources for intelligent and sustainable manufacturing technologies and systems with the aim of achievingtheir full potential.” In this White Paper, detailed consideration is given to the meaning and implications of“Biologicalisation” from the perspective of the design, function and operation of products, manufacturingprocesses, manufacturing systems, supply chains and organisations. The drivers and influencing factorsare also reviewed in detail and in the context of significant developments in materials science andengineering. The paper attempts to test the hypothesis of this topic as a breaking new frontier and toprovide a vision for the development of manufacturing science and technology from the perspective ofincorporating inspiration from biological systems. Seven recommendations are delivered aimed at policymakers, at funding agencies, at the manufacturing research community and at those industries involvedin the development of next generation manufacturing technology and systems. It is concluded that it isvalid to argue that Biologicalisation in Manufacturing truly represents a new and breaking frontier ofdigitalisation and Industry 4.0 and that the market potential is very strong. It is evident that extensiveresearch and development is required in order to maximise on the benefits of a biological transformation.
407Scopus© Citations 131