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Results for “CUTTING TOOLS”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Shaped cutting tool

A cutting tool for forming a finished part from a rotating workpiece includes a first cutting edge extending from a first end of the cutting tool, a second cutting edge extending from a second end of the cutting tool, and a shaping edge disposed between the first cutting edge and the second cutting edge. The first cutting edge is operable to remove a trailing end of the rotating workpiece and the second cutting edge is operable to remove a working portion of the rotating workpiece disposed between the trailing end and a leading end. The shaping edge is operable to shape the working portion of the rotating workpiece by advancing the cutting tool into the rotating workpiece until the first cutting edge removes the trailing end of the rotating workpiece and the second cutting edge removes the working portion of the rotating workpiece to form the finished part.

42 ENGINEERING↗
DOE OSTI2020

Internal cooling passages for rotating cutting tools

A cutting tool comprising a tool body comprising a shank and a cutter opposite the shank, the body defining a length from a shank end to an end face opposite the shank end, a central axis extends along the length of the body; at least one tooth having a cutting edge, the cutting edge extending along the tooth from the shank to the end face; a flute formed adjacent the at least one tooth; at least one cooling channel formed in the tooth proximate the at least one cutting edge, the at least one cooling channel having an elongated cross sectional shape with an elliptical portion and a circular portion opposite the elliptical portion, wherein the elliptical portion is located proximate the cutting edge.

Wang, Zhigang↗
DOE OSTI2019

Influence of Alternating Stress on the Life of Metal-Cutting Tools

Abstract—The failure of cutting tools is investigated. A generalized approach to describing failure is proposed, on the basis of the theory of random point processes. Two mechanisms by which the abrasive particles act on the tool’s cutting edge are considered. The corresponding dynamics of damage accumulation is described.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Shaped cutting tool and method of use to efficiently form a finished part

A method of efficiently forming a finished part, the method includes providing a cutting tool having a first cutting edge extending from a first end of the cutting tool, a second cutting edge extending from a second end of the cutting tool, and a shaping edge disposed between the first cutting edge and the second cutting edge. The cutting tool is advanced into a rotating workpiece such that the first cutting edge removes a trailing end of the rotating workpiece, the shaping edge shapes a working portion of the rotating workpiece, and the second cutting edge removes the working portion of the rotating workpiece to form the finished part.

Ripley, Edward B.↗
DOE OSTI2015

Surface dimpling on rotating work piece using rotation cutting tool

A combined method of machining and applying a surface texture to a work piece and a tool assembly that is capable of machining and applying a surface texture to a work piece are disclosed. The disclosed method includes machining portions of an outer or inner surface of a work piece. The method also includes rotating the work piece in front of a rotating cutting tool and engaging the outer surface of the work piece with the rotating cutting tool to cut dimples in the outer surface of the work piece. The disclosed tool assembly includes a rotating cutting tool coupled to an end of a rotational machining device, such as a lathe. The same tool assembly can be used to both machine the work piece and apply a surface texture to the work piece without unloading the work piece from the tool assembly.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Estimation of cutting tool wear using an elastomeric tactile sensor

Machining performance of cutting tools and part quality are affected by the geometric condition of the cutting edge, which is influenced by thermomechanical loads experienced during the process. Tool condition monitoring (TCM) systems provide insight for timely replacement of cutting tools. However, existing TCM systems are expensive and require specialized equipment or sensors, hindering widespread adoption. A novel TCM system is developed herein using an elastomeric tactile sensor. Sensor images of the cutting edge are used to quantify wear using two distinct algorithms. In the first algorithm, the unworn and worn edges are identified based on Canny edge detect. In the second, the unworn edge is identified using edge detection while the region of wear is identified using a relative intensity method. In both cases, the maximum wear width is calculated based on an experimentally determined pixel to-physical distance scale. The TCM system is first used to estimate flank wear on a solid carbide helical end mill before evaluating its robustness by employing it to estimate insert wear of an indexable helical end mill. Measurements are also performed manually using an optical microscope and a high-resolution focus variation microscope for verification. The novel technique estimates flank wear in the solid carbide tool with a high accuracy of 98%. Larger discrepancies are observed for the inserts, however, with overlapping uncertainties. In conclusion, the technique shows promise in adaptability, automation, and closed loop control of machine tools.

Machining↗
DOE OSTI2019

Selection of a Cutting Tool by Means of a Digital Model

A digital model of a cutting tool produced by neural-network modeling is considered. By means of this model, the composition and structure of a wear-resistant coating may be optimized. The machining conditions that ensure maximum wear resistance of the tool may also be identified.

42 ENGINEERING↗
DOE OSTI2017

Wear resistance of cutting tools with a plasma-modified surface layer

An analytical model is obtained for calculating the working life of a cutting tool with a plasmamodified surface layer. It permits calculation of the conditions ensuring increased wear resistance of the tool and hence increased reliability in manufacturing on numerically controlled machine tools.

42 ENGINEERING↗
DOE OSTI2015

High power laser downhole cutting tools and systems

Downhole cutting systems, devices and methods for utilizing 10 kW or more laser energy transmitted deep into the earth with the suppression of associated nonlinear phenomena. Systems and devices for the laser cutting operations within a borehole in the earth. These systems and devices can deliver high power laser energy down a deep borehole, while maintaining the high power to perform cutting operations in such boreholes deep within the earth.

42 ENGINEERING↗
DOE OSTI2018

Evaluation of Caprolon Turning Efficiency with a Ceramic Cutting Tool

A comparative analysis is provided for turning caprolon using replaceable polyhedral plates made from different materials, and in fact made of tungsten-cobalt alloy VK8 and ceramic material, i.e., tungsten-free hard alloy KNT60. It is established by experiment that for machining caprolon workpieces it is expedient to use replaceable cutting tools made from ceramic materials KNT60, which makes it possible to expand the range of tools used and improve turning efficiency as a whole.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Development of Remote Cutting Tools for use at ATR - 20438

As a result of years of operations of the Advanced Test Reactor (ATR) at the Idaho National Lab (INL), the ATR canal has become congested due to the storage of materials including waste consisting of highly irradiated remote handled (RH) metals. In order to support its continuing nuclear mission the ATR requires canal space to support fuel storage and future core internal change out (CIC) components. INL staff determined that the canal must be cleaned out and waste removed to efficiently utilize the valuable canal floor space. It was determined that a methodology for processing, packaging, characterizing, and removing current and future irradiated hardware from the ATR canal is needed. Orano Federal Services (OFS) and its subcontractor Babcock Services Inc. (BSI) were selected to provide remote tooling in order to safely and efficiently size reduce the material currently stored in the ATR canal. INL developed detailed requirements that established the design and performance requirements for the tooling. Orano TN and BSI had recently successfully completed similar tasks in clearing highly activated materials from spent fuel pools and canals at commercial nuclear plants. That experience directly translated into a proven approach that could be used at the ATR thereby saving time and money and lowering risks. Based on BSI's demonstrated proficiency in the design and deployment of remote size reduction specialty tooling at comparable commercial facilities, Orano Federal Services was confident that a solution to INL's requirements could be delivered. The tooling had to be designed to be compatible with the operational requirements of the ATR canal as well as the functionality needed by the facility operators that will use the equipment. Some of the major design requirements and functions of the equipment included remote operations, capability to shear highly irradiated sections of aluminum and steel tubing, pipe, and components ranging in size from 0.6 cm to 16.5 cm diameter into 1.5 m -1.8 m lengths, utilizing buoyancy compensation to assist with underwater operations, and use commercially available existing technology and components as much as practical. The design team evaluated and selected commercially available equipment that could be modified to meet the design and performance specifications. In addition, a waste sizing table (WST) was designed and fabricated to further ensure the size reduction equipment would perform as expected and give the facility operators a stable and usable remote, underwater work platform. After successful development of the tooling, a mock up test and operator training was conducted to ensure the tooling performed as expected and met the requirements of INL. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Commercialization of Ultra-Hard Ceramics for Cutting Tools Final Report CRADA No. TC0279.0

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Greenleaf Corporation (Greenleaf) to develop the technology for forming unique precursor nano-powders process that can be consolidated into ceramic products for industry. LLNL researchers have developed a solgel process for forming nano-ceramic powders. The nano powders are highly tailorable, allowing the explicit design of desired properties that lead to ultra hard materials with fine grain size. The present CRADA would allow the two parties to continue the development of the sol-gel process and the consolidation process in order to develop an industrially sound process for the manufacture of these ultra-hard materials.

36 MATERIALS SCIENCE↗
DOE OSTI2014

High-precision micro/nano-scale machining system

A high precision micro/nanoscale machining system. A multi-axis movement machine provides relative movement along multiple axes between a workpiece and a tool holder. A cutting tool is disposed on a flexible cantilever held by the tool holder, the tool holder being movable to provide at least two of the axes to set the angle and distance of the cutting tool relative to the workpiece. A feedback control system uses measurement of deflection of the cantilever during cutting to maintain a desired cantilever deflection and hence a desired load on the cutting tool.

42 ENGINEERING↗
DOE OSTI2016

LaserSnake2: Remote High Powered Laser Cutting in Confined Hazardous Spaces - 16161

LaserSnake2, a UK collaborative project, seeks to deliver remotely operated cutting techniques into high hazard nuclear environments. This paper describes the developments and results of combining proven robotic manipulators with high-powered laser cutting tools, to allow for selective dismantling within complex nuclear process cells. Decommissioning old and poorly catalogued nuclear plant is a problem faced the world over. Designed with little consideration for decommissioning, or adapted significantly from the original drawings, legacy plant and infrastructure is full of spaces where it is undesirable or impossible to send people. Typically, a process cell or cave will require modification to ensure suitability for human entry or deployment of heavy duty equipment to complete the decontamination processes. The process of widening access routes, or selectively moving sections of highly contaminated material, is ideally suited to remote handling technology. The results of TWI's research into fibre-delivered laser cutting techniques, and integration with a dexterous snake-arm robot, are presented. Coupled with novel laser process head design and diffractive optical elements, the result is an integrated system capable of cutting up to 100 mm thick C-Mn steel plate at significant stand-off distances, encompassing the range of infrastructure found in a typical nuclear plant. Two options have been considered for deployment of the laser cutting tool. The first is focused on a fixed installation using a standard industrial robot. The second is a large, highly flexible snake-arm robot capable of entering cluttered cells through existing penetrations. Designed to operate through a standard 11'' MSM port, the 4.5 m snake-arm robot has the capacity to carry grippers, sensors or the laser cutting tool at the tip. The snake-arm is sealed and housed within a glove box for contamination control, allowing operation within a radioactive environment. Significant technical developments and material research are presented which have led to improved operational life, payload and bend. This paper describes the series of inactive trials which have been conducted to demonstrate the LaserSnake2 system's capabilities. These include: horizontal and vertical deployment, underwater operation, object manipulation and laser cutting. With global nuclear decommissioning costs running in to the $trillions, safe and cost efficient tools such as the LaserSnake2 system are essential as part of the decommissioning toolbox. Remote handling can account for up to 20% of a decommissioning project's costs, however significant time and financial savings can be made by utilising this new technology to reduce operator exposure and reach previously inaccessible areas. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Welding of Haynes 282 to Steels to Enable Modular Rotors for Advanced Ultra Super-Critical Steam Turbines

Steam turbines for an Advanced Ultra Super Critical (AUSC) fossil fired power plant will operate at temperatures well above those of current commercial steam cycles with inlet temperatures more than 760 C , which is beyond the capabilities of alloy steels presently used for steam turbine applications and requires advanced materials. Large components such as steam turbine rotors may be made of nickel based super alloys such as Haynes 282 (H282). However, monolithic forgings of superalloys in the sizes required for large steam turbines rotors can be prohibitively expensive besides many technical challenges. To minimize cost and alleviate the related technical challenges, superalloy use needs to be limited to locations on the steam turbine rotor where strength and temperature requirements cannot be met by conventional steels. This is possible if nickel-based superalloys can be successfully welded to steels and the related technical challenges - machining parts made of dissimilar welded materials, non-destructive examination of such welds for flaw detection; and, material properties of such hybrid components – are sufficiently addressed. In this technology development project, we successfully welded H282 to plates up to ~ 75 mm (~ 3 inches) to a 3.5NiCrMoV steel of similar thickness. Advanced ultrasonic inspection technique called Phased Array Ultrasonic Testing (PAUT) was employed to examine the dissimilar H282-Steel welds, into which flat bottomed side drilled holes (SDH) of various diameters were introduced, to determine the minimum detectable feature sizes; it was shown that with PAUT SDH of dia. down to 0.5 mm could be detected in the base alloys and SDH with dia. down to 2.4 mm could be detected in the weld metal under multiple orientations successfully. An autonomous machining process monitoring system was developed and demonstrated whereby the forces acting on the cutting tool could be actively monitored as the cutting tool transitioned from H282 to Steel across the weld using which the machining parameters can be potentially altered without interruption to extend tool life. This project successfully achieved its objectives of - i. Developing a welding methodology and viable welding geometries, to successfully join H282 to steel 3.5CrMoNiV steel to enable manufacture of modular steam turbine rotors for AUSC applications (conditions of at least 760 °Celsius and 3,100 psia (pounds per square inch absolute pressure) and evaluate the material properties of the welded specimen. ii. Employ the advanced ultrasonic inspection technique to the dissimilar weld metal joint and determine the minimum detectable feature sizes. iii. Develop effective machining techniques to machine such hybrid structures with online tool force monitoring and effect machine state metrics for optimal results.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Lathe leveler

A lathe leveler for centering a cutting tool in relation to a cylindrical work piece includes a first leveling arm having a first contact point disposed adjacent a distal end of the first leveling arm, a second leveling arm having a second contact point disposed adjacent a distal end of the second leveling arm, a leveling gage, and a leveling plate having a cutting tool receiving surface positioned parallel to a horizontal axis of the leveling gage and on a same plane as a midpoint of the first contact point and the second contact point. The leveling arms and leveling plate are dimensioned and configured such that the cutting tool receiving surface is centered in relation to the work piece when the first and second contact points are in contact with one of the inner surface and outer surface of the cylindrical work piece and the leveling gage is centered.

42 ENGINEERING↗
DOE OSTI2022

Cross-Cutting Metrology Tools for In Operando Characterization of Carrier Dynamics in Photovoltaic Devices (Final Technical Report)

Understanding the nature of recombination and its dependence on defects and interfaces is essential for engineering materials and contacts for higher V oc and photovoltaic (PV) efficiency. Time-resolved photoluminescence (TRPL) has conventionally been used to evaluate recombination, but not all materials are strongly emissive or otherwise suitable. Time-resolved terahertz spectroscopy is a pump – probe method that presents valuable complementary information, wherein an optical pump pulse photoexcites carriers within the absorber and the transient photoconductivity is probed with a terahertz pulse. Until now, experimental constraints have prohibited the use of terahertz probes to interrogate full device stacks, and measurements were instead made on exfoliated films or films grown on unconventional substrates. However, interfaces are critical to the behavior of photoexcited carriers in solar cells, and the substrates themselves often influence the film growth and bulk properties. Therefore, it is important to probe the behavior of PV absorbers as close as possible to their normal operating conditions. Here we have developed cross-cutting metrology that enable in operando characterization of carrier dynamics and recombination mechanisms in working PV devices. Through a combination of complementary non-contact TRTS and TRPL experiments and modeling, we have obtained key parameters including photoexcited carrier bulk lifetime and interface and back surface recombination velocities with greater precision and accuracy than can be achieved with conventional TRPL alone. By varying pulsed photoexcitation conditions, the contributions of interface and bulk recombination mechanisms can be determined. We have developed and refined this characterization approach by investigating CdTe PVs, which is a well-established technology but with significant margin for further improvements in efficiency. Results were published in Journal of Applied Physics (DOI: 10.1063/5.0064730) and Proceedings of the IEEE PVSC (DOI: 10.1109/PVSC43889.2021.9518559). After validating the approach, we have applied it to correlate recombination rates to processing conditions and material properties, including composition and defects as well as interfaces and surface treatments. Such feedback can inform processing and design choices to enable higher PV efficiency, not only for CdTe, but also CdSe x Te 1-x , CIGS, perovskites, kesterites, and future technologies. A perspective on predicting solar cell performance from terahertz spectroscopy was published in Advanced Energy Materials (DOI: 10.1002/aenm.202102776). The cross-cutting metrology tools developed here will enable determination of the locus and mechanism of performance-limiting recombination in thin film PV devices. This feedback can guide the engineering of PV devices with higher V oc and efficiency, thereby leading to reductions in levelized cost of electricity to meet the SunShot 2030 target of $0.03/kWh for utility-scale PV. Lower costs will enable rapid expansion of renewable electricity generation that is nearly free of carbon emissions. Reducing carbon emissions of the electricity sector is one of the most important solutions to climate change. The project’s specific focus on CdTe PV can benefit First Solar, the US company that is the global leader in CdTe technology, through both technology and workforce development.

14 SOLAR ENERGY↗