Machining

Summary

Machining is a process in which a material (often metal) is cut to a desired final shape and size by a controlled material-removal process. The methods that have this common theme are collectively called subtractive manufacturing, which utilizes machine tools, in contrast to additive manufacturing (3D printing), which uses controlled addition of material. Machining is a part of the manufacture of many metal products, but it can also be used on other materials such as wood, plastic, ceramic, and composite material. A person who specializes in machining is called a machinist. A room, building, or company where machining is done is called a machine shop. Much of modern-day machining is carried out by computer numerical control (CNC), in which computers are used to control the movement and operation of mills, lathes, and other cutting machines. This increases efficiency, as the CNC machine runs unmanned, reducing labor costs for machine shops. The precise meaning of the term machining has evolved over the past one and a half centuries as technology has advanced. In the 18th century, the word machinist meant a person who built or repaired machines. This person's work was primarily done by hand, using processes such as the carving of wood and the writing-forging and hand- of metal. At the time, millwrights and builders of new kinds of engines (meaning, more or less, machines of any kind), such as James Watt or John Wilkinson, would fit the definition. The noun machine tool and the verb to machine (machined, machining) did not yet exist. Around the middle of the 20th century, the latter words were coined as the concepts they described evolved into widespread existence. Therefore, during the Machine Age, machining referred to (what we today might call) the "traditional" machining processes, such as turning, boring, drilling, milling, broaching, sawing, shaping, planing, abrasive cutting, reaming, and tapping. In these "traditional" or "conventional" machining processes, machine tools, such as lathes, milling machines, drill presses, or others, are used with a sharp cutting tool to remove material to achieve a desired geometry.

Official source

https://en.wikipedia.org/wiki/Machining

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Electron Cloud and Synchrotron Radiation characterization of technical surfaces with the Large Hadron Collider Vacuum Pilot Sector

Elena Buratin

This PhD thesis presents the experimental study on electron cloud (EC) and synchrotron radiation (SR) phenomena affecting the LHC storage ring performance. These phenomena are one of the major issues of the LHC storage ring, generating beam instabilities, pressure rise and heat loads on the beam pipes. This experimental study is carried out with an innovative system installed in a room temperature and field free section of the Large Hadron Collider (LHC), the Vacuum Pilot Sector (VPS). ln this system, several surfaces are simultaneously tested, in particular standard copper, amorphous carbon coating, NEG. Thanks to a wide spectrum of detectors, the EC and SR signals were studied as a function of beam parameters and beam pipe properties. The EC behaviour increases linearly with the number of bunches and bunch population above the multipacting threshold. This phenomenon increases linearly also with the bunch length for the Long Straight Sections of LHC (LSS). As expected, the bunch spacing has a crucial importance on the formation of EC dynamic: the 50 ns filling scheme avoids the multipacting effect at 450 GeV. At 6.5 TeV the photoelectron contribution is visible, with no multipacting. This scheme is not sufficient for the LHC collision studies and cannot be used as standard filling scheme. Instead, the 25 ns bunch spacing scheme suffers of EC; in this case this phenomenon can be drastically reduced only by bombarding the surface with electrons during dedicated scrubbing runs, or thanks to the installation of beam pipe surface with a low SEY, such as the amorphous-carbon coating. The measurements performed with pick-ups show the evolution of the EC dynamics for the first time in the LHC. The energy spectrum detectors and the gas analysers were also installed for the first time in the LHC history: the electron cloud spectrum and the gas composition could be measured during the machine operation. The electron energy spectrum evidences a peak at around 100 eV, corresponding to the accelerated electrons responsible for multipacting. The gas analysers measured the main gasses present in the LHC ultra-high vacuum system, such as methane, carbon dioxide and monoxide, water, hydrogen and traces of 2-Propynenitrile 3-fluoro (C3FN), probably linked to the effect of radiation into the kapton cables. It has been possible to estimate the Electron Stimulated Desorption (ESD) parameter of a copper surface as a function of the accumulated electron dose. The heat loads due to impedance, EC and SR were measured and, finally, the operation of HL-LHC machine has been estimated in terms of electron current, pressure and power deposition thanks to the results of this study. Doubling of the bunch population will increase the electron current and the pressure of one order of magnitude, while the deposited power due to EC will be smaller than 1 W/mchamber for a beam pipe SEY lower than 1.8.

EPFL2020

Substantial progress and development in additive manufacturing (AM) technologies have been realised during the last decade but have hardly been implemented on AM systems due to old numerical solutions still used by the AM digital thread, for instance STL (1987) and G-code (ISO 6963, 1982). In this field, more traditional processes like machining have challenged this issue by adopting the Standard for the Exchange of Product model data compliant Numerical Control (STEP-NC) standard that enables advanced and intelligent manufacturing by taking advantage of the full computing performance of numerical controllers in manufacturing machines. This standard integrates the whole digital chain (CAD-CAM-CAPP-CNC-CMM) in a unique file with information on design and manufacturing and enables manufacturing of high-value products directly without numerical data conversion or post-processing. This study presents a new STEP-NC data model for AM technologies developed with the ISO TC184/SC1/WG7 committee. A STEP-NC platform initially developed for machining processes has been adapted to implement and validate the AM data model. It enables AM directly from a STEP-NC file, as well as hybrid manufacturing (AM and machining), and allows integration of several optimisation and simulation modules that extend the possibility of advanced and intelligent AM, for instance in-process manufacturing optimisation.

TAYLOR & FRANCIS LTD2018

The LHeC and the CLIC Drive Beam share not only the high-current beams that make them prone to show instabilities, but also unconventional lattice topologies and operational schemes in which the time sequence of the bunches varies along the machine. In order to asses the feasibility of these projects, realistic simulations taking into account the most worrisome effects and their interplays, are crucial. These include linear and non-linear optics with time dependent elements, incoherent and coherent synchrotron radiation, short and long-range wakefields, beam-beam effect and ion cloud. In order to investigate multi-bunch effects in recirculating machines, a new version of the tracking code PLACET has been developed from scratch. PLACET2, already integrates most of the effects mentioned before and can easily receive additional physics. Its innovative design allows to describe complex lattices and track one or more bunches accordingly to the machine operation, reproducing the bunch train splitting and recombination to and from multiple beamlines. After some initial testing, PLACET2 has been applied to the LHeC Energy Recovery Linac design in order to complete the first end-to-end tracking simulation. The transport of the beam to the dump has been verified in presence of incoherent synchrotron radiation, wakefields and beam-beam effect. Unexpected high radiation losses have been found in specific sections of the lattice, solutions have been proposed to improve both the machine performance and the beam quality. These include a new design of the spreading sections and return arcs based on combined function magnets. The detector bypass, that was originally missing, have now been designed and integrated in the lattice. Tracking simulations have also been performed for PERLE, which have been developed to validate on a smaller scale the technology and the operation of the LHeC. Its performances have been assessed and the design has been consolidated and improved. The work at CTF3 focused on the Combiner Ring. Its length plays a crucial role in the phase structure of the combined beam and must be carefully tuned. The control of the ring length by means of optics scaling, has been measured on the machine and reproduced with the PLACET2 model. Moreover the code has been used to verify a multi-bunch instability that appeared during the commissioning of the ring.

EPFL2016