Investigation into rotary mode ultrasonic drilling of bioceramic: an experimental study with PSO-TLBO based evolutionary optimization

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ravi Pratap Singh ◽  
Narendra Kumar ◽  
Ashutosh Kumar Gupta ◽  
Madhusudan Painuly
Keyword(s):  
Mathematical Model ◽  
Feed Rate ◽  
Fitness Function ◽  
Real Life ◽  
Spindle Speed ◽  
Ultrasonic Power ◽  
Material Loss ◽  
Additional Advantage ◽  
Content Type ◽  
Ultrasonic Drilling

Purpose The purpose of this paper is to investigate experimentally the effect of several input process factors, namely, feed rate, spindle speed, ultrasonic power and coolant pressure, on hole quality measures (penetration rate [PR] and chipping diameter [CD]) in rotary mode ultrasonic drilling of macor bioceramic material. Design/methodology/approach The main experiments were planned using the response surface methodology (RSM). Scanning electron microscopy was also used to examine and study the microstructure of machined samples. This study revealed the existence of dominant brittle fracture and little plastic flow that resulted in a material loss from the base work surface. Experiment findings have shown the dependability and adequacy of the proposed mathematical model. Findings The percentage of brittle mode deformation rises as the penetration depth of abrasives increases (at increasing levels of feed rate). This was due to the fact that at greater depths of indentation, material loss begins in the form of bigger chunks and develops inter-granular fractures. These stated causes have provided an additional advantage to increasing the CD over the machined rod of bioceramic. The desirability method was also used to optimize multi-response measured responses (PR and CD). The mathematical model created using the RSM method will be very useful in industrial revelation. Furthermore, the investigated answers’ particle swarm optimization (PSO) and teacher-learner-based optimization (TLBO) make the parametric analysis more relevant and productive for real-life industrial practices. Originality/value Macor bioceramic has been widely recognized as one of the most highly demanded innovative dental ceramics, receiving expanded industry approval because of its outstanding and superior characteristics. However, effective and efficient processing remains a problem. Among the available contemporary machining methods introduced for processing typical and advanced materials, rotary mode ultrasonic machining has been identified as one of the best suitable candidates for precise processing of macor bioceramics, as this process produces thermal damage-free profiles, as well as high accuracy and an increased material removal rate. The optimized combined setting obtained using PSO is feed rate = 0.16 mm/s, spindle speed = 4,500 rpm, ultrasonic power = 60% and coolant pressure = 280 kPa with the value of fitness function is 0.0508. The optimized combined setting obtained using TLBO is feed rate = 0.06 mm/s, spindle speed = 2,500 rpm, ultrasonic power = 60% and coolant pressure = 280 kPa with the value of fitness function is 0.1703.

Corrosion of a chrome-moly pipe transporting sulfuric acid in a demineralization section: a failure analysis

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Andres Marquez ◽  
Chris Maharaj
Keyword(s):  
Sulfuric Acid ◽  
Material Selection ◽  
Real Life ◽  
Main Idea ◽  
Petrochemical Plant ◽  
Material Loss ◽  
Corrosion Failure ◽  
Content Type ◽  
Characterization Methods ◽  
X Ray

Purpose The purpose of this study was to carry out an analysis of the corrosion failure on a chrome-moly pipeline transporting highly concentrated sulfuric acid in a demineralization section at a petrochemical plant, along with the feasibility of using inhibitors to minimize the corrosive effects of sulfuric acid. Design/methodology/approach X-ray fluorescence spectroscopy, high-resolution optical microscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy and accelerated corrosion experiments (ACE) were performed. Findings Erosion-corrosion failure was confirmed by the significant reduction in thickness of the internal surface of the material exposed to sulfuric acid, as well as the formation of an oxide scale/layer. ACE accurately predicted high material loss from exposure to sulfuric acid. Moreover, adding ascorbic acid as a corrosion inhibitor (even at low concentrations) was found to reduce the oxidation by more than 50% in the presence of sulfuric acid. Originality/value The main idea/purpose of this work relies on the analysis of recurrent real-life corrosion-attributed failures that are common in industry but are not properly addressed for a variety of reasons, poor management and lack of corrosion preventive strategies being the main ones. This study once again highlights readily available solutions/implementations that are capable of not only addressing technically the issue investigated but also, and as important, economically. By using microscopic imaging, reliable well-tested and widely used characterization methods, all combined with basic experiments and tests, the nature of the repetitive failure investigated was clearly demonstrated as well as readily available alternatives to minimize it in the short term. Nevertheless, implementing material selection techniques appropriately as effective corrosion prevention/control and cost-saving strategies must be enforced in any process.

Experimental Study on the Surface Roughness in Mesoscopic-Scale Grinding of Nickel-Based Superalloy

2016 ◽  
Vol 1136 ◽  
pp. 9-14
Author(s):  
Yun Guang Zhou ◽  
Ya Dong Gong ◽  
Yang Sun ◽  
Zhong Xiao Zhu ◽  
Qi Gao
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Feed Rate ◽  
Theoretical Basis ◽  
Spindle Speed ◽  
Range Analysis ◽  
Mesoscopic Scale ◽  
Nickel Based Superalloy ◽  
Grinding Parameters ◽  
Grinding Tool

This paper uses micro-grinding tool with 500# grains and 0.9 mm diameter to grind nickel-based superalloy Inconel600 through three factors(grinding depth, feed rate, spindle speed ) at three levels orthogonal grinding experiment in mesoscopic scale. Then according to the range analysis of surface roughness, the primary and secondary influencial factors are found; the micro grinding parameters are optimized ,the results show: the influence of the feed rate(vf)is the biggest, followed by the spindle speed(n), the grinding depth(ap) is minimal, when n=50kr/min, vf=100μm/s, ap=6μm, the grinding surface roughness is minimum: Ra=579nm; finally , the regression mathematical model of micro grinding surface roughness is established, the relative error of the calculated value and experimental measurements is low, showing that this regression mathematical model is accurate and effective. This study provides a theoretical basis for the micro grinding parameters and surface quality control of nickel-based superally.

Mobile logistics hubs prepositioning for emergency preparedness and response in Nepal

2020 ◽  
Vol 10 (4) ◽  
pp. 555-572
Author(s):  
Rajali Maharjan ◽  
Yashaswi Shrestha ◽  
Biplob Rakhal ◽  
Saurav Suman ◽  
Jurgen Hulst ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Focus Group ◽  
Focus Group Discussion ◽  
Expert Knowledge ◽  
Group Discussion ◽  
Real Life ◽  
Content Type ◽  
Wide Range ◽  
The Government ◽  
Multiple Experts

PurposeThe purpose of this study is to develop a methodology which amalgamates quantitative and qualitative approaches to determine the best placement of mobile logistics hubs (MLH) to be established in different parts of Nepal as a part of real-life project, “Augmentation of National and Local-Level Emergency Logistics Preparedness in Nepal” (2017–2020), implemented by the World Food Programme in cooperation with the Government of Nepal.Design/methodology/approachThe study develops a methodology using a combination of a modified version of the maximal covering location problem (MCLP) and focus group discussion. The MCLP model is used to determine the optimal number and spatial location of MLHs, and focus group discussion is used to identify the five first-priority strategic MLH locations using expert knowledge.FindingsThe authors identify the five first-priority locations for establishing MLHs using an amalgamation of quantitative approach (mathematical model) and qualitative approach (focus group discussion). By amalgamating mathematical model with expert knowledge, findings acceptable to a wide range of stakeholders are obtained. The focus group discussion helps to pinpoint the location of MLHs to city-level granularity which is otherwise impossible with data available on hand.Research limitations/implicationsAlthough multiple experts’ judgements were obtained via focus group discussion, subjectivity and possible bias is inevitable. Overall, the quantitative results of the study are purely based on the data available during the study period; therefore, having updated data could possibly improve the quality of the results.Originality/valueThis study is the first of its kind that uses an amalgamation of mathematical model and expert knowledge to determine the strategic locations of MLHs and has been successful to an extent that the selected locations have been vetted by the government of Nepal for establishing MLHs and are undergoing implementation in real life. This study also considers multiple disaster scenarios and employs the concepts of human development, disaster risk and transportation accessibility to reflect Nepal's socioeconomic, geo-climatic and topographical features.

Thrust Force Studies in Drilling of Medium Density Fiberboard Panels

2012 ◽  
Vol 622-623 ◽  
pp. 1285-1289 ◽  
Author(s):  
T.N. Valarmathi ◽  
K. Palanikumar ◽  
S. Sekar
Keyword(s):  
Mathematical Model ◽  
Feed Rate ◽  
Cutting Forces ◽  
Thrust Force ◽  
Medium Density Fiberboard ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Medium Density ◽  
Taguchi Design Of Experiments ◽  
The Mathematical Model

Medium density fiberboard (MDF) is an engineered wood generally used in wooden industries. Drilling is the most frequently used machining operation in the assembly of furniture working. During drilling cutting forces are developed. These cutting forces are affecting the surface qualities and also causes delamination damage. The cutting conditions and the process parameters play an important role in controlling the cutting forces. The objective of this work is to study the influence of cutting parameters such as spindle speed, feed rate and point angle to reduce the cutting forces developed during drilling. Drilling tests are conducted using Taguchi design of experiments. The mathematical model is developed using response surface methodology (RSM) to evaluate the influence of spindle speed, feed rate and point angle on thrust force. It is seen that high spindle speed with low feed rate combination gives better results in drilling of MDF panels.

Multi-response optimization while machining of stainless steel 316L using intelligent approach of grey theory and grey-TLBO

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Rakesh Chandmal Sharma ◽  
Vishal Dabra ◽  
Gurpreet Singh ◽  
Rajender Kumar ◽  
Ravi Pratap Singh ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Feed Rate ◽  
Spindle Speed ◽  
Empirical Modeling ◽  
Depth Of Cut ◽  
Grey Theory ◽  
Content Type ◽  
Response Characteristics ◽  
Single Response ◽  
Intelligent Approach

Purpose Stainless steel is widely used in different manufacturing sectors. The purpose of this study is to optimize the process parameters of machining while processing SS316L alloy. The optimization of machining characteristics in the case of SS316L alloy greatly improves the quality and productivity economically. Design/methodology/approach The machining variables in current research are depth of cut, spindle speed and feed rate. The optimization of response characteristics was carried out using the intelligent approach of grey, regression and teaching learning-based optimization (TLBO) and Taguchi-Grey approach. Planning of experiments was made using Taguchi’s based L27 orthogonal array. With the implementation of grey, the response characteristics were normalized and converted into a single response. The regression analysis was used for empirical modeling of the single response induced from the grey application. TLBO is further used to investigate the combinations of machining variables and compared with grey theory. Findings The grey-TLBO based multi-criteria decision-making approach suggests that the optimized setting for material removal rate, mean roughness depth (Rz) and cutting force (Fz) is spindle speed (N): 720 rpm; feed rate (F): 0.3 mm/rev; depth of cut (DoC): 1.7 mm. The grey theory suggests an optimized setting as N: 720 rpm; F: 0.2 mm/rev and DoC: 1.7 mm. Originality/value The parametric optimization during the turning of SS316L using grey-TLBO based intelligent approach is not performed till now. Thus, this intelligent approach will give a path to the researchers working in this direction. However, the grey theory performs better as compared to the grey-TLBO approach.

scholarly journals Surface Roughness Optimization in Drilling Process Using Response Surface Method (RSM)

2014 ◽  
Vol 66 (3) ◽  
Author(s):  
Mohd Amran ◽  
Siti Salmah ◽  
Mohd Sanusi ◽  
Mohd Yuhazri ◽  
Noraiham Mohamad ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Feed Rate ◽  
Spindle Speed ◽  
Drilling Process ◽  
Surface Method ◽  
Drilling Parameters ◽  
Drill Diameter

This paper presents the effect of drilling parameters on surface roughness and surface appearance by applying response surface method (RSM). The mathematical model for correlating the interactions of drilling parameters such as spindle speed, feed rate and drill diameter on surface roughness was developed. RSM methodology was used as it is a technique that most practical and effective way to develop a mathematical model. In addition, this method also can reduce trial and error in experiment. Since the number of factors are three; spindle speed, feed rate and drill diameter, by applying RSM the total numbers of experiment involved are 20 experimental observations. From the experimental result, it is found that the minimum surface roughness on the hole was 1.06 mm from combination of 2000 rpm spindle speed, 78 mm/min feed rate and 2.5 mm drill diameter. While the maximum surface roughness 2.59 mm was the combination of 250 rpm spindle speed, 153 mm/min feed rate and 3.5 mm drill diameter. A mathematical equation was developed with percentage of error are 0% to 29%. Thus, from the result we understand that to find the smooth surface in drilling process, it needs higher spindle speed with lower feed rate and smaller diameter.

Experimental Investigation and Optimization in Rotary Ultrasonic Drilling of C/C Composites

2016 ◽  
Vol 874 ◽  
pp. 313-319
Author(s):  
Song Mei Yuan ◽  
Qi Wu
Keyword(s):  
Feed Rate ◽  
Elevated Temperatures ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
High Fracture Toughness ◽  
Drilling Force ◽  
High Fracture ◽  
Machining Quality ◽  
Ultrasonic Drilling ◽  
Rotary Ultrasonic Drilling

C/C composites are widely used in aviation and aerospace due to their low density, superior specific strength, special elastic modulus at elevated temperatures, small thermal expansion coefficient and high fracture toughness. However, there are numerous problems such as delamination, chipping, poor machining quality and tool wear in drilling of C/C composites due to inhomogeneous, anisotropic, wear resistance and varying thermal properties of the composites. In this paper, related experiments on rotary ultrasonic drilling of C/C composites using diamond core drill were conducted to compare the drilling force and machining quality of ultrasonic drilling with conventional drilling, analyze the rotary ultrasonic drilling mechanism and research the influence of spindle speed, feed rate and ultrasonic amplitude on the drilling force. Experimental results showed that rotary ultrasonic drilling can significantly improve the removal of the chips thus preventing the core drill blockage, effectively reduce the drilling force and improve processing quality. In addition, the drilling force decreased with increasing of spindle speed and ultrasonic amplitude, while it increased with increasing of feed rate. Finally, the cutting parameters were optimized by consideration of the drilling force and efficiency.

Multi-response optimization for machining GFRP composites using GRA and DFA

2018 ◽  
Vol 14 (3) ◽  
pp. 482-496 ◽  
Author(s):  
Naresh Neeli ◽  
M.P. Jenarthanan ◽  
G. Dileep Kumar
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Fibre Orientation ◽  
Orientation Angle ◽  
Helix Angle ◽  
Spindle Speed ◽  
Gfrp Composites ◽  
Content Type ◽  
Fibre Orientation Angle

Purpose The purpose of this paper is to optimise the process parameters, namely, fibre orientation angle, helix angle, spindle speed, and feed rate in milling of glass fibre-reinforced plastic (GFRP) composites using grey relational analysis (GRA) and desirability function analysis (DFA). Design/methodology/approach In this work, experiments were carried out as per the Taguchi experimental design and an L27 orthogonal array was used to study the influence of various combinations of process parameters on surface roughness and delamination factor. As a dynamic approach, the multiple response optimisation was carried out using GRA and DFA for simultaneous evaluation. These two methods are best suited for multiple criteria evaluation and are also not much complicated. Findings The process parameters were found optimum at a fibre orientation angle of 15°, helix angle of 25°, spindle speed of 6,000 rpm, and a feed rate of 0.04 mm/rev. Analysis of variance was employed to classify the significant parameters affecting the responses. The results indicate that the fibre orientation angle is the most significant parameter preceded by helix angle, feed rate, and spindle speed for GFRP composites. Originality/value An attempt to optimise surface roughness and delamination factor together by combined approach of GRA and DFA has not been previously done.

scholarly journals Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools

2017 ◽  
Vol 7 (1) ◽  
pp. 461-469 ◽  
Author(s):  
Imhade Princess Okokpujie ◽  
Omolayo M. Ikumapayi ◽  
Ugochukwu C. Okonkwo ◽  
Enesi Y. Salawu ◽  
Sunday A. Afolalu ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Radial Depth ◽  
Machining Parameter ◽  
Axial Depth

AbstractIn recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N), feed rate (f), axial depth of cut (a) and radial depth of cut (r). The experiment was designed using central composite design (CCD) in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM). The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.

Inventory models for joint pricing and greening effort decisions with discounts

2018 ◽  
Vol 13 (1) ◽  
pp. 2-26 ◽  
Author(s):  
Syed Asif Raza ◽  
Mohd. Nishat Faisal
Keyword(s):  
Mathematical Model ◽  
Decision Support ◽  
Inventory Management ◽  
Real Life ◽  
Quantity Discounts ◽  
Decision Support Tools ◽  
Content Type ◽  
Support Tools ◽  
Demand Rate ◽  
Joint Pricing

Purpose This paper aims to develop efficient decision support tools for a firm’s environment protection by using greening effort while yet improving profitability by utilizing pricing and inventory decisions with discount consideration. Design/methodology/approach This study proposed a mathematical model for price- and greening effort-dependent demand rate with discount considerations. Later, the mathematical model is extended to the situation in which the demand rate is also dependent on the stock level, in addition to the price and greening effort. Efficient solution methodologies are developed for finding the optimal solution to the proposed models. Findings Simple yet elegant models are proposed to mimic real-life applications. Structural properties of the models are explored to outline efficient algorithms with quantity discounts. Research limitations/implications The paper considers monopoly and assumes deterministic demand. Only a more commonly observed all-units discount scheme is studied. Practical implications The models provide decision support tools for firms in pursuit of joint profit maximization and environment consciousness goals. Social implications The study develops environment-friendly approaches for inventory management and improving the profitability alike. Originality/value This study is among the first to consider environmental protection with an investment in greening effort along with inventory management and pricing decision. The study also explored the effect of all-unit quantity discounts.

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