Thesis supervisor: Márton Takács
Location of studies (in Hungarian): Manufacturing Science and Engineering Abbreviation of location of studies: GTT
Description of the research topic:
a.) Antecedents:
Modern manufacturing technology requires a continuous development to ensure economic and sustainable machining of parts of devices. There is an increasing request for part miniaturization, too. Conventional material removal processes, such as milling and electro discharge machining can be applied also for micro manufacturing, but the characteristics and mechanism of material removal will be influenced by the size effect. Wide spread application of NC and CNC machines enables collecting information and data about the ongoing machining process by on-line measurements. This expands the experimental base of the technology planning, and decreases its costs, therefore the task of experimental research can be moved from the laboratories to the production plants. Data analysis and creating predictive models for tool life, tool wear, and properties of machined quality are essential requirements for implementation of micro chip removal processes into the new revolution of production, which is called as Industry 4.0.
b.) Aim of research:
Deep understanding of specialties of micro material removal processes (such as micro milling and micro EDM milling) considering size effect. Finding optimal machining parameters. Obtaining performance indexes for micro milling and micro EDM milling processes. In-process tool condition monitoring system will be developed using a statistical regression technique and an artificial neural network. Preparing surface roughness, tool life, and tool wear predictive models based on huge amount of data collected at different micro machining processes.
c.) Tasks, main items, necessary time:
Literature survey regarding micro machining and micro EDM process (1st semester)
Literature survey regarding size effect and micro material removal. Comparison of micro milling and micro EDM milling processes. Evaluation of theoretical models (2nd semester).
Summary of literature survey in written form. Specification and set-up of measurement system for recording machining data. Specification of workpiece materials and machining parameters. Design of experiments (3rd semester).
Carrying out micro milling and micro EDM milling experiments. Collection of machining data. Investigation of tool degradation (4th semester).
Signal analysis. Investigation of dynamic effects at micro material removal processes. Obtaining optimal machining parameters. Evaluation of machinability of high performance material by micro milling and micro EDM milling processes (5th and 6th semester).
Creating predictive models for properties of machined parts and tool wear (5th, 6th and 7th semester).
Publication of the results (between 3rd and 8th semester).
Preparing of scientific thesis (7th and 8th semester).
d.) Required equipment:
5-axis micro milling center, micro EDM machine, force and vibration sensors, digital and confocal microscopes, surface roughness measuring units, evaluation software, FEM software are required, which are available at the department, or at partner departments.
e.) Expected scientific results:
Optimal machining parameters at micro milling and micro EDM milling of high performance materials. Introducing machinability index. Predictive model for tool life, tool wear, and surface roughness at micro milling and micro EDM milling processes.
f.) References:
J C, Jáuregui ; J R, Reséndiz ; S, Thenozhi ; T, Szalay ; Á, Jacsó ; M, Takács: Frequency and Time-Frequency Analysis of Cutting Force and Vibration Signals for Tool Condition Monitoring, IEEE ACCESS 6 pp. 6400-6410., 11 p. (2018)
Balázs, B Z ; Takács, M, Finite element modelling of thin chip removal process, IOP CONFERENCE SERIES: MATERIALS SCIENCE AND ENGINEERING 426 Paper: 012002 (2018)
M, Takács ; B Z, Balázs ; J C, Jáuregui: Dynamical Aspects of Micro Milling Process, In: Tomaz, Pepelnja; Zlatan, Car; Jan, Kudlacek (szerk.) International Conference on Innovative Technologies : IN-TECH 2017, Faculty of Engineering University of Rijeka, (2017) pp. 181-184., 4 p.
Takács M, Verő B: Material Structural Aspects of Micro-Scale Chip Removal, MATERIALS SCIENCE FORUM 414-415, 2003, pp. 337-342.
M Takács, B Verő, I Mészáros: Micromilling of Metallic Materials, JOURNAL OF MATERIALS PROCESSING TECHNOLOGY 138, 2003, pp. 152-155.
Required language skills: english Number of students who can be accepted: 1
Deadline for application: 2019-10-12
2024. IV. 17. ODT ülés Az ODT következő ülésére 2024. június 14-én, pénteken 10.00 órakor kerül sor a Semmelweis Egyetem Szenátusi termében (Bp. Üllői út 26. I. emelet).
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