Contents: Variety and Quality. Variability loss and tolerance. Determining tolerances. Tolerance design and experimental design. Offline and online quality control. Parameter design and tolerance design: case study. Experimental design for smaller is better characteristics. Experimental design for larger is better characteristics. Bypassing the S/N ratio: spring experiment. Experimental design for dynamic characteristics.

Introduction to quality engineering. designing quality into products a

Title Mapping Existing Research Output Focused on Higher Education Teaching and Learning in Ireland 1990-2015 Authors(s) O'Sullivan, Sara; Gibney, Amanda; Guerin, Suzanne; Staunton, Michael; Kalaitzake, Manolis Publication date 2015-06 Publisher National Forum Link to online version http://www.teachingandlearning.ie/wp-content/uploads/2015/07/Project-5-Mapping-Existing-Research-Output.pdf Item record/more information http://hdl.handle.net/10197/6860

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Mapping Existing Research Output Focused on Higher Education Teaching and Learning in Ireland 1990-2015

The present work concerns an experimental study of hard turning with CBN tool of AISI 52100 bearing steel, hardened at 64 HRC. The main objectives are firstly focused on delimiting the hard turning domain and investigating tool wear and forces behaviour evolution versus variations of workpiece hardness and cutting speed. Secondly, the relationship between cutting parameters (cutting speed, feed rate and depth of cut) and machining output variables (surface roughness, cutting forces) through the response surface methodology (RSM) are analysed and modeled. The combined effects of the cutting parameters on machining output variables are investigated while employing the analysis of variance (ANOVA). The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of machining parameters with respect to objectives (surface roughness and cutting force values). Results show how much surface roughness is mainly influenced by feed rate and cutting speed. Also, it is underlined that the thrust force is the highest of cutting force components, and it is highly sensitive to workpiece hardness, negative rake angle and tool wear evolution. Finally, the depth of cut exhibits maximum influence on cutting forces as compared to the feed rate and cutting speed.

Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool

Hard turning is gaining grounds for machining hardened steels as it has several benefits over grinding. There are several issues, which should be understood and dealt with, to achieve successful performance of the process. Researchers have worked upon several aspects related to hard turning. The present work is an effort to review some of these works and to understand the key issues related to process performance. The review shows that the type of tool material, cutting edge geometry and cutting parameters affect the process efficiencies in terms of tool forces, surface integrities integrity, and white layer. Adequate machine rigidity is a must essential to minimize the process inaccuracies. Also moreover, for finish hard turning, where the depth of cut is less than the nose radius of the tool, the forces deviate from the conventional trends as the radial force component is the maximum and axial force component becomes minimum. The present work finally lists down certain areas that can be taken up for further research in hard turning.

State of the art in hard turning

Hard machining of hardened bearing steel using cubic boron nitride tool

The use of polycrystalline cubic boron nitride (PCBN) cutting tools in hard turning applications is continuously growing with the number of commercially available grades increasing, allowing new application areas to be explored. In order to take full advantage of the benefits offered by PCBN it is necessary to understand the behaviour of the material in application. Tool behaviour is influenced by many factors which include the composition of the PCBN material, the steel workpiece, the nature of the cutting operation, the cutting conditions and the tool geometry.

The focus of this paper is the continuous turning of hardened steels. A significant amount of research has been carried out in this area and a literature review of the relevant work is presented. This identifies the primary wear modes and discusses the many theories proposed to explain the mechanisms contributing to PCBN tool wear and failure. The final section of the paper considers the critical factors that influence the behaviour of PCBN tools in continuous hard turning and how this knowledge can be applied to optimise tool performance.

PCBN tool wear modes and mechanisms in finish hard turning

This paper presents the response of the technology teacher education programmes at the University of Limerick to the assessment challenge created by the shift in philosophy of the Irish national curriculum from a craft-based focus to design-driven education. This study observes two first year modules of the undergraduate programmes that focused on the development of subject knowledge and practical craft skills. Broadening the educational experience and perspective of students to include design based aptitudes demanded a clear aligning of educational approaches with learning outcomes. As design is a complex iterative learning process it requires a dynamic assessment tool to facilitate and capture the process. Considering the critical role of assessment in the learning process, the study explored the relevance of individual student-defined assessment criteria and the validity of holistic professional judgement in assessing capability within a design activity. The kernel of the paper centres on the capacity of assessment criteria to change in response to how students align their work with evidence of capability. The approach also supported peer assessment, where student-generated performance ranks provided an insight into not only how effectively they evidenced capability but also to what extent their peers valued it. The study investigated the performance of 137 undergraduate teachers during an activity focusing on the development of design, processing and craft skills. The study validates the use of adaptive comparative judgement as a model of assessment by identifying a moderate to strong relationship with performance scores obtained by two different methods of assessment. The findings also present evidence of capability beyond the traditional measures. Level of engagement, diversity, and problem solving were also identified as significant results of the approach taken. The strength of this paper centres on the capacity of student-defined criterion assessment to evidence learning, and concludes by presenting a valid and reliable holistic assessment supported by comparative judgements.

Pat Phelan

Papers

PCBN tool wear modes and mechanisms in finish hard turning

The validity and value of peer assessment using adaptive comparative judgement in design driven practical education

Numerical analysis of axisymmetric wire drawing by means of a coupled damage model

Quick check error verification of coordinate measuring machines

Design improvement using process capability data