Development of analytical and CAE models for a slotting process using thin-blades

  • Author / Creator
    Kordestany, Yazdan
  • Steam assisted gravity drainage (SAGD) is one of the most popular methods used for heavy oil extraction in Canada. Of the existing sand control methods that can be used for SAGD, slotted liners can be considered among the superior ones in terms of their performance and cost of manufacturing. RGL reservoir management Inc. (RGL) is a company operating worldwide supplying sand control and flow control devices for oil extraction process. To manufacture slotted liners, RGL uses a custom made multi spindle slotting machine that has the capacity to cut 80 columns of slots at once. The manufacturing process employed by RGL has not been investigated for efficiency and opportunities to increase its production rate. In this study, RGL’s manufacturing process is taken as the case to analyze the mechanism involved in the cutting process affecting the process efficiency. The analysis results are then used to identify the major contributors to undesired conditions such as short tool life. The analysis techniques used in this research include force analysis through existing analytical and numerical models and implementing the results to conduct an in-depth analysis of the cutting dynamics. The input parameters considered are blade geometry, cutting speed, and feed rate to investigate their effects on tool life. The resulting effects on tool life are studied through the analysis of forces that are involved in the cutting process. The study of dynamics of the cutting process was also extended to determine the effect of vibration by determining the stability lobe diagram of the process. Results coupled from these two primary parts of the investigation were used to identify optimal processing conditions. The outputs from force analysis were used to compare different rake angle, relief angle, and blade material. Increasing rake angle resulted in decrease in the required force. As the rake angle increases, the relief angle should be decreased to preserve the material angle of the tooth A stability lobe diagram which is used to identify ranges for stable operation was determined by making used of the results from force distribution. The approaches employed to specify conditions for the stability lobe diagram showed that the method can be applied to analyze different combinations of tool and workpiece materials. The most common circular saw blade material was selected and its natural frequency was determined from analytical models and the literature. Existing machining constraints were also considered in determining the optimal shape. After comparing different geometries that results from optimization, a blade that has lower values for outer dimeter (2.93 in), relief angle (28o), tooth height (0.073in), and number of teeth (50); and higher values for bore diameter (1.57 in), rake angle (5o), gullet radius (0.027 in), and tooth pitch (0.184 in) than the current blade used by RGL was identified as the optimal blade.

  • Subjects / Keywords
  • Graduation date
    2017-06:Spring 2017
  • Type of Item
  • Degree
    Master of Science
  • DOI
  • License
    This thesis is made available by the University of Alberta Libraries with permission of the copyright owner solely for non-commercial purposes. This thesis, or any portion thereof, may not otherwise be copied or reproduced without the written consent of the copyright owner, except to the extent permitted by Canadian copyright law.
  • Language
  • Institution
    University of Alberta
  • Degree level
  • Department
    • Department of Mechanical Engineering
  • Supervisor / co-supervisor and their department(s)
    • Ma, Yongsheng (Mechanical Engineering)
  • Examining committee members and their departments
    • Rafiq, Ahmad (Mechanical Engineering)
    • Mousavi, Pedram (Mechanical Engineering)