Proceedings of the Fifteenth International Machine Tool Design and Research Conference
Proceedings of the Fifteenth International Machine Tool Design and Research Conference
Edited by
S. A. TOBIAS
Chance Professor and Head ofDepartment
Department of Mechanical Engineering
University of Birmingham
and
F. KOENIGSBERGER
Professor of Machine Tool Engineering
University of Manchester Institute ofScience and Technology
CONTENTS
OPENING SESSION
Opening address. J. W. ATWELL
GROUP TECHNOLOGY AND CELLULAR MANUFACTURE
Group technology developments and modes of application. W. EVERSHEIM and M.
Page
1
MIESE 7
Total company appraisal for group technology. K. RATHMILL, P. BRUNN and R.
LEONARD 19
Batch size selection for group technology. K. RATHMILL, P. BRUNN and R. LEONARD 29
The interaction ofNC and GT. F. W. CRAYEN 37
Some organizational aspects of cellular manufacture based on computer simulation. D.
ATHERSMITH and J. R. CROOKALL 45
CNC AND DNC
BCLCNC-a computer numerical control system. N. AKGERMAN 57
Closed loop positioning control for a DNC-milling machine. A. M. LOSS and J. FRISCH 63
Adaptive control constraint and automatic cut distribution system for turning operations.
E. GIESEKE 71
The improvement in accuracy of high precision machine tools by means of adaptive
control. I. WASIUKIEWICZ 79
The machining-centre concept; an analysis of a tool-changing manufacturing system. J. R.
CROOKALL and A. T. M. JAMIL 89
The NEL/MTIRA technological forecast for the computer control of machine tools. B.
DAVIES, J. W. BRUCE and A. E. De BARR 97
CAD AND CAM
Combination of CAD and CAM in machine tool manufacture. P. ST6CKMANN and G.
W6LLNER 107
The application of CAD techniques to machine tool component design, production and
manufacture. A. JEBB, C. B. BESANT and R. C. EDNEY 115
Automatic design of machine tool components. T. G. FOSTER 121
A new generalized concept of computer aided production. J. FERENCZY and J.
LEHOTZKY 129
Computer-aided design of axisymmetric hot forging dies. S. K. BISWAS and W. A. KNIGHT 135
Graph theory applied to computer aided plant layout. A. S. CARRIE 145
MACHINE TOOL ELEMENTS
An analysis of a new type of high precision multiwedge clearanceless bearing for grinding
wheel spindles. G. K. ARORA and T. S. R. MURTHY 155
Characteristics of electro-hydraulic feed drives under dynamic load conditions. D.
AVRAMOVIC and P. FORT 165
Computer-aided design of standardized hydrostatic journal bearings. J. M. SANSINENEA
and R. M. BUENO 175
METAL CUTTING
Coolants and cutting tool temperatures. E. F. SMART and E. M. TRENT 187
Tool wear or tool design (a case study). R. A. ETHERIDGE and A. J. A. SCOTT 197
Ultra-high-speed machining: notes on metal cutting at speeds up to 7300 ft/s. G. ARNDT 203
On line measurement of bending and torque in milling. R. BEDINI and P. C. PINOTTI 209
Power hacksawing. P. J. THOMPSON and M. SARWAR 217
Optimization of drill geometry for orthopaedic surgery. G. H. FARNWORTH and J. A.
BURTON 227
MACHINE TOOL DYNAMICS
The dynamic characteristics of epoxy resin bonded machine tool structures. M. I.
CHOWDHURY, M. M. SADEK and S. A. TOBIAS 237vi CONTENTS
Page
On-line identification of machine tool receptances from cutting experiments. N. H.
HANNA and A. W. KWIATKOWSKI 245
Influence of lathe tool wear on the vibrations sustained in cutting. P. MARTIN, B.
MUTEL and J.-P. DRAPIER 251
Investigation of parametric instability in milling simulated by screw chasing operation. G.
DROUBI and M. M. SADEK 259
Elastic wave transmission and reflection in long uniform bars due to the end impact of a
rigid mass. W. JOHNSON 267
Self-excited vibration of circular saws cutting aluminium. D. S. DUGDALE 279
NOISE AND ITS REDUCTION
Noise generation from an impact forming machine structure. A. E. M. OSMAN, W. A.
KNIGHT and M. M. SADEK 289
Noise reduction in a HERF cropping machine. G. DROUBI, M. M. SADEK and S. A.
TOBIAS 295
The effect of blade wear on noise levels of power hacksaws. G. J. McNULTY 305
GRINDING AND SURFACE TOPOGRAPHY
Optimization of a grinding process and criteria for wheel life. G. TRMAL and H.
KALISZER 311
The collection of data for the assessment of a grinding wheel dressing treatment. E. J.
PATTINSON and J. LYON 317
Chattering phenomena as the criterion of redress life of grinding wheel: a study on the
establishment of optimum operational condition in precision grinding of hardened
steel. H. MAKINO 325
Finishing and running-in of plain bearings, with an economic appraisal. G. TRMAL, H.
KALISZER and G. W. ROWE 333
In-process indication of surface roughness using a fibre-optics transducer. D. SPURGEON
and R. A. C. SLATER 339
Performance analysis of the stylus technique of surface roughness assessment: a random
field approach. J. B. AGULLO and J. PAGES-FITA 349
EDM AND ECM
Conditioning a diamond-grit cup-wheel for electrochemical grinding. M. M. SFANTSIKOPOULOS and C. F. NOBLE 365
Electro-discharge machined surfaces. J. R. CROOKALL and B. C. KHOR 373
Some effects of debris concentration on erosion and electrode wear in electro-discharge
machining. J. R. CROOKALL and P. W. LEE 385
Investigation of the modulation of interface waves in explosive welding. S. R. REID and
D. J. LANGDALE 391
Implosive welding of composite metal-foil cylinders. H. EL-SOBKY and T. Z.
BLAZYNSKI 399
The cold drawing of implosively welded bi-metallic tubes. S. TOWNLEY and T. Z.
BLAZYNSKI 407
HOT FORMING
Transverse deformation in section rolling and forging. G. W. ROWE, I. M. DESAI and
H. S. SHIN 417
A study on plastic working of alloys in their mashy state. S. FUKUOKA and M. KIUCHI 423
Stress strain curves from the ring test. A. N. BRAMLEY and N. A. ABDUL 431
An elemental upper-bound technique for general use in forging analysis. R. P.
McDERMOTT and A. N. BRAMLEY 437
Application of a modular approach to estimate load and energy in closed die forging.
S. K. BISWAS and B. W. ROOKS 445
The elevated temperature extrusion of fluted sections in high-speed steels. C. E. N.
STURGESS and T. A. DEAN 455
DIE LIFE IN HOT FORMING
Cracking and fracture of hot-work die steels. A. THOMAS
Die life estimation in forging. S. STCj)REN, J. EBBESEN, J. SLUTAS and I. &ETRE
467
473CONTENTS
Wear in drop forging dies. T. M. SILVA and T. A. DEAN
The effect of die temperature on metal flow and die wear during high-speed hot forging.
B.W.ROOKS
ROLLING
Ball rolling: a literature survey and some experimental results. N. R. CHITKARA, W.
Page
479
487
JOHNSON and J. R. S. UTTLEY 497
Cold rolling of ring gears. J. B. HAWKYARD, F. R. NAVARATNE and W. JOHNSON 507
An experimental investigation into the S-mill rolling process. D. K. ROBERTSON and
D. H. SANSOME 515
DRAWING, TUBE AND SHEET FORMING
A preliminary investigation of the die-less drawing of titanium and some steels. J. M.
ALEXANDER and T. W. TURNER 525
A fundamental study on dieless drawing. H. SEKIGUCHI, K. KOBATAKE and K.
OSAKADA 539
Theoretical study of the drawing of bi-metal rod and tube. H. T. CHIA and D. H.
SANSOME 545
An oscillatory deep-drawing analogue. M. J. R. YOUNG and D. H. SANSOME 551
Rigid-plastic analysis of bore expanding and flange drawing with anisotropic sheet metals
by the matrix method. S. H. LEE and S. KOBAYASHI 561
Tube inversion: a process for obtaining gross expansions in the diameter of thin-wall
tubes. S. T. S. Al-HASSANI 571
COLD FORMING, BLANKING AND CROPPING
The strength of the material in cold formed parts. J. DATSKO 579
The development of a cold forming process on an automatic high-speed forming machine.
T. SCAIFE, B. PARSONS and B. N. COLE 585
Forward cold extrusion of aluminium-estimation of the maximum extrusion force. L. E.
FARMER and B. Z. PIROG 597
Rigid-plastic analysis of cold heading by the matrix method. S. N. SHAH and S.
KOBAYASHI 603
Production of crankshafts by clamp shearing. T. NAKAGAWA and K. SHIOMORI 611
Analysis of stresses in bar cropping. V. G. WONG and M. K. DAS 617
COMPACTION AND SINTER FORGING
The dynamic compaction of aluminium and iron powder. D. RAYBOULD
The hot extrusion of metal powder preforms. M. NEGM and R. DAVIES
Plasticity of sintered iron-powder compacts. S. D. El WAKIL
The effect of presintering conditions on the cold forgeability of powder preforms. M. A.
RIFAI
The production of extruded material from metal powders. T. SHEPPARD
Comparison between uniaxial and isostatic densified stainless-steel powder preforms
forged in a closed die. H. ALTMANN
Powder compaction at very high pressures. P. N. TOMLINSON, R. L. HEWITT and R. D.
VENTER
GENERAL ASPECTS OF FORMING
Strong composites based on all-metal systems. D. V. WILSON, W. T. ROBERTS, J. J.
MOORE, R. F. STOKES and J. FARMER
Characteristic features in the hole flanging and piercing of thin and thick circular plates
using conical and ogival punches. W. JOHNSON, N. R. CHITKARA and P. A. BEX
The influence of hydrostatic pressure on the plastic deformation of metallic materials. W.
LORREK and 0. PAWELSKI
The toughness ofM2 high-speed steel. G. BERRY and M. J. KADHIM Al-TORNACHI
Analysis oflarge, natural strain increments using the Mohr’s circle. J. WOLAK
Smooth hole wall piercing in the manufacture of precision mechanisms. R. JOHNSTON
and K. SWIFT
Author index
Subject index
AUTHOR INDEX
Foster, T. G., 12I
Fukuoka, S., 423
Gieseke, E., 7I
Hanna, N. H., 245
Hawkyard, J. B., 507
Hewitt, R. L., 677
Jamil, A. T. M., 89
Jebb, A., 115
Johnson, W., 267,497, 507, 695
Johnston, R., 729
Kaliszer, H., 311,333
Khor, B. C., 373
Kiuchi, M., 423
Knight, W. A., 135, 289
Kobatake, K., 539
Kobayashi, S., 561,603
Kwiatkowski, A. W., 245
Langdale, D. J., 391
Lee, P. W., 385
Lee, S. H., 56I
Lehotzy, J., 129
Leonard,R., 19,30
Lorrek, W., 703
Lyon, J., 3I7
McDermott, R. P., 437
McNulty, G. J., 305
Makino, H., 325
Martin, P., 251
Miese, M., 7
Moore, J. J., 685
Murthy, T. S. R., 155
Nakagawa, T., 611
Navaratne, F. R., 507
Negm, M., 637
Noble, C. F., 365
Osakada, K., 539
Osman, A. E. M., 289
Pages-Fita, J., 349
Parsons, B., 585
Pattinson, E. J., 317
Pawelski, 0., 703
Pinotti, P. C., 209
Pirog, B. Z., 597
Rathrnill, K., 19,30
Raybould, D., 627
Reid, S. R., 391
735736
Rifai, M.A., 651
Roberts, W. T., 685
Robertson, D. K., 515
Rooks, B. W., 445,487
Rowe, G. W., 333, 417
Sadek, M. M., 237,259,289,295
&etre, 1., 473
Sansinenea, J. M., 175
Sansome, D. H., 515, 545,551
Sarwar, M., 217
Scaife, T., 585
Scott, A. J. A., 195
Sekiguchi, H., 539
Sfantsikopoulos, M. M., 365
Shah, S. N., 603
Sheppard, T., 659
Shin, H. S., 417
Shiomori, K., 611
Silva, T. M., 479
Slater, R. A. C., 339
Slutis, J ., 473
Smart, E. F., 187
Spurgeon, D., 339
Stockmann, P., 107
Stokes, R. F., 685
St~ren, S., 473
Sturgess, C. E. N., 455
Swift, K., 729
Thomas, A., 467
Thompson, P. J., 217
Tobias, S. A., 237,295
Tomlinson, P. N., 677
Townley, S., 407
Trent, E. M., 187
Trmal, G., 311, 333
Turner, T. W., 525
Uttley, J. R. S., 497
Venter, R. D., 677
Wasiukiewicz, 1., 79
Wilson, D. V., 685
Wolak, J., 721
Wollner, G., 107
Wong, V. G., 617
Young, M. J. R., 551SUBJECT INDEX
CAD and CAM Session, 105
automatic design, 121
axisymmetric hot forging dies, 135
combination of CAD and CAM, 107
generalized concept of production, 129
machine tools
component design, 115
manufacture, 107, 115
production, 115
plant layout, 145
CNC and DNC Session, 55
adaptive control
improvement of accuracy, 79
turning operations, 71
closed loop positioning control, 63
computer NC system, 57
machining centre, 89
technological forecast for, 97
Cold Forming, Blanking, Cropping Session, 577
analysis of stresses, 617
clamp shearing, 612
cold extrusion, 597
cold formed parts
high speed forming machine, 585
strength of the material, 579
cold heading, 603
crankshafts, 612
cropping, 61 7
extrusion force, 597
Compaction and Sinter Forging Session, 625
compaction
aluminium and iron powder, 627
very high pressures, 677
metal powders, 659
plasticity, 645
powder pre-forms
cold forgeability, 651
hot extrusion, 637
stainless steel, 669
production of extruded material, 659
sintered iron-powder, 675
Die Ufe in Hot Forming Session, 465
cracking and fracture, 467
die life estimation, 473
die wear
drop forging dies, 479
high speed forging, 487
effect of die temperature, 487
hot-work die steels, 467
metal flow, 487
Drawing, Tube and Sheet Forming Session, 523
anisotropic sheet metals, 561
bore expanding and flange drawing, 561
die-less drawing
fundamental study, 539
titanium and some steels, 525
drawing
bi-metal rod and tube, 545
oscillatory deep drawing, 551
tube inversion, 571
ECM, EDM and Explosive Welding Session, 363
bi-metallic tubes, cold drawing, 407
composite metal-foil cylinders, 399
diamond-grit cup-wheel, for ECM, 365
electrode wear and erosion, EDM, 385
machined surfaces, EDM, 373
modulation of interface waves, 391
General Aspects of Forming Session, 683
all-metal systems, 685
circular plates, 695
hole flanging and piercing, 695
hydrostatic pressure, 703
M2 high speed steel, 713
natural strain increments, 721
plastic deformation, 703
smooth hole wall piercing, precision mechanisms,
729
strong composite, 685
toughness, 713
Grinding and Surface Topography Session, 309
criteria for wheel life, 311
criteria of redress life, chattering phenomena, 325
dressing treatment, 317
fibre-optics transducer, 341
optimization, 311
plain bearings, running-in, 333
stylus technique, 349
surface roughness, 341
Group Technology Session, 5
batch size selection, 29
developments and modes of application, 7
interaction ofNC and GT, 37
organizational aspect, computer simulation, 45
total company appraisal, 19
Hot Forrning Session, 415
alloys in mashy state, 423
closed die forging, 445
extrusion of fluted sections, 455
forging analysis, 437738 SUBJECT INDEX
high speed steel, 455
load and energy estimation, 445
plastic working, 423
ring test, 431
section rolling and forging, 417
stress-strain curves, 431
transverse deformation, 417
upper-bound technique, 437
Machine Tool Dynamics Session, 235
circular saws, 289
dynamic characteristics, 237
elastic wave transmission and reflection, 267
epoxy resin bonded structures, 237
instability in milling, 259
machine tool receptances, on line identification,
245
-self excited vibrations, 289
tool wear and vibrations, 251
Machine Tool Elements Session, 153
electro-hydraulic feed drives, 165
grinding wheel spindles, 155
hydrostatic journal bearings, 175
Metal Cutting Session, 185
bending and torque in milling, 209
coolants and cutting temperature, 187
drill geometry, 227
orthopaedic surgery, 227
power hacksawing, 217
tool wear and tool design, 195
ultra-high-speed machining, 203
Noise and its Reduction Session, 287
HERF cropping machine, 295
impact forming machine structure, 289
power hacksaws, 305
Rolling Session, 495
ball rolling, 497
cold rolling, 507
ring gears, 507
S-rnill rolling, 515
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