Novel Laser/Water-Jet Hybrid Manufacturing Process for Cutting Ceramics

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Raathai Molian ◽  
Clayton Neumann ◽  
Pranav Shrotriya ◽  
Pal Molian
Keyword(s):  
Manufacturing Process ◽  
Material Removal ◽  
Synergistic Effects ◽  
Pure Water ◽  
Cutting Speed ◽  
Erosive Wear ◽  
Water Jet ◽  
Hybrid Manufacturing ◽  
Slag Formation ◽  
Diamond Saw

Laser and water-jet manufacturing processes are independently used to cut monolithic and composite ceramics. While these processes offer many advantages over diamond sawing and other abrasive processes, the energy efficiency, precision, cutting speed, and environmental threats remain as barriers to their continued success. This is partly attributed to the material removal mechanisms, which are melting, and subsequent evaporation (laser) and energy-intensive erosive wear (water jet). In this paper, we describe a novel laser and water-jet (LWJ) hybrid manufacturing process that enables the synergistic effects of CO2 laser and pressurized pure water jet, facilitating precise material removal by thermal shock-induced fracture and overcoming the deficiencies listed above. Experiments of the LWJ effects on the cutting of aluminum nitride, an electronic ceramic substrate, are presented. The most exciting results are very narrow kerf dictated by the crack width; the absence of thermally affected zone, slag formation, chemical decomposition; and controlled thermal cracking, implying that the LWJ process is far superior to conventional laser cutting of ceramics. The LWJ process also improved the surface finish while reducing energy losses in the process. The practical realization of the LWJ manufacturing process could be a potential alternative to diamond saw, high-power laser, and high-pressure abrasive water-jet methods for machining hard and brittle ceramics.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

scholarly journals Ice Growth Suppression in the Solution Flows of Antifreeze Protein and Sodium Chloride in a Mini-Channel

Processes ◽  
2021 ◽  
Vol 9 (2) ◽  
pp. 306
Author(s):  
Kazuya Taira ◽  
Tomonori Waku ◽  
Yoshimichi Hagiwara
Keyword(s):  
Sodium Chloride ◽  
Synergistic Effects ◽  
Pure Water ◽  
Interface Velocity ◽  
Antifreeze Protein ◽  
Layer Growth ◽  
Mixed Solution ◽  
Solution Flow ◽  
Ice Growth ◽  
Cold Energy

The control of ice growth inside channels of aqueous solution flows is important in numerous fields, including (a) cold-energy transportation plants and (b) the preservation of supercooled human organs for transplantation. A promising method for this control is to add a substance that influences ice growth in the flows. However, limited results have been reported on the effects of such additives. Using a microscope, we measured the growth of ice from one sidewall toward the opposite sidewall of a mini-channel, where aqueous solutions of sodium chloride and antifreeze protein flowed. Our aim was to considerably suppress ice growth by mixing the two solutes. Inclined interfaces, the overlapping of serrated interfaces, and interfaces with sharp and flat tips were observed in the cases of the protein-solution, salt-solution, and mixed-solution flows, respectively. In addition, it was found that the average interface velocity in the case of the mixed-solution flow was the lowest and decreased by 64% compared with that of pure water. This significant suppression of the ice-layer growth can be attributed to the synergistic effects of the ions and antifreeze protein on the diffusion of protein.

scholarly journals Blade Segment with a 3D Lattice of Diamond Grits Fabricated via an Additive Manufacturing Process

2020 ◽  
Vol 33 (1) ◽  
Author(s):  
Bin Chen ◽  
Peng Chen ◽  
Yongjun Huang ◽  
Xiangxi Xu ◽  
Yibo Liu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Service Life ◽  
Manufacturing Process ◽  
Cutting Speed ◽  
Inspection System ◽  
Layer By Layer ◽  
Filling Rate ◽  
Pressure System ◽  
Manufacturing Equipment ◽  
Diamond Blade

Abstract Diamond tools with orderly arrangements of diamond grits have drawn considerable attention in the machining field owing to their outstanding advantages of high sharpness and long service life. This diamond super tool, as well as the manufacturing equipment, has been unavailable to Chinese enterprises for a long time due to patents. In this paper, a diamond blade segment with a 3D lattice of diamond grits was additively manufactured using a new type of cold pressing equipment (AME100). The equipment, designed with a rotary working platform and 16 molding stations, can be used to additively manufacture segments with diamond grits arranged in an orderly fashion, layer by layer; under this additive manufacturing process, at least 216000 pcs of diamond green segments with five orderly arranged grit layers can be produced per month. The microstructure of the segment was observed via SEM and the diamond blade fabricated using these segments was compared to other commercial cutting tools. The experimental results showed that the 3D lattice of diamond grits was formed in the green segment. The filling rate of diamond grits in the lattice could be guaranteed to be above 95%; this is much higher than the 90% filling rate of the automatic array system (ARIX). When used to cut stone, the cutting amount of the blade with segments made by AME100 is two times that of ordinary tools, with the same diamond concentration. When used to dry cut reinforced concrete, its cutting speed is 10% faster than that of ARIX. Under wet cutting conditions, its service life is twice that of ARIX. By applying the machine vision online inspection system and a special needle jig with a negative pressure system, this study developed a piece of additive manufacturing equipment for efficiently fabricating blade segments with a 3D lattice of diamond grits.

Investigation of the Water Guided Laser Micro-Jet Machining of Aero Engine Components

2017 ◽  
Author(s):  
Zhigang Wang
Keyword(s):  
Energy Density ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Potential Method ◽  
Laser Machining ◽  
Aero Engine ◽  
Engine Components ◽  
The Relationship ◽  
Dual Laser

The water guided laser micro-jet (LMJ) is a new potential method to machine aero engine parts with much less heat affected area and faster cutting speed than dry laser machining. The focus of this paper is to investigate the energy density and material removal for a dual-laser LMJ system. Then, the effects of dominated parameters on the energy density of LMJ are analyzed. Finally, a mathematical model is developed to describe the relationship between dominant laser parameters with the energy density of LMJ and material removal rate followed by machining case studies of aero engine components.

Experimental Assessment of Roughness Changes in the Cutting Surface and Microhardness Changes of the Material S 355 J2 G3 after Being Cut by Non-Conventional Technologies

2011 ◽  
Vol 314-316 ◽  
pp. 1944-1947 ◽  
Author(s):  
Jozef Maščeník ◽  
Stefan Gaspar
Keyword(s):  
Mechanical Properties ◽  
Production Process ◽  
Laser Plasma ◽  
Manufacturing Process ◽  
Production Quality ◽  
Water Jet ◽  
Cutting Edge ◽  
Experimental Assessment ◽  
Cutting Surface ◽  
The Impact

Production of components, necessary for the construction of the machine resp. or device is a demanding manufacturing process. One of the possibilities of increasing efficiency and production quality is the introduction of unconventional technologies to the production process. Knowing the dependence of the impact of non-conventional technologies on the mechanical properties of products and their subsequent verification is an important aspect when designing and manufacturing them. The article deals with the impact of used unconventional technology, that means laser, plasma and water jet on the roughness of a cutting edge and microhardness of material S 355 J2 G3.

Preliminary Study on Cutting Solid Object Using Water at Pressure Exceeding 1000 MPa

2012 ◽  
Vol 488-489 ◽  
pp. 372-376
Author(s):  
Ahmad Humaizi Hilmi ◽  
Norazman Mohamad Nor ◽  
Ariffin Ismail ◽  
Mohamed Yusof Alias ◽  
Zi Jun Zhao ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Pure Water ◽  
Cutting Speed ◽  
Solid Object ◽  
Ultra High Pressure ◽  
Solid Objects ◽  
Stainless Steel 304 ◽  
Optimum Geometry ◽  
Preliminary Study ◽  
Pump Pressure

To date, the highest pump pressure available in market is 648 MPa from FLOW International Corp. Cutting with ultra high pressure reduces abrasive usage, faster cutting speed, increased depth of cuts and increase efficiency. This research explores the possibility of applying pressure exceeding 1000 MPa to push pure water to cut solid objects. 10 grams of PE4 explosives are exploded in a confined chamber with a rectangular opening. Simulations in designing the blast test jig are discussed. Simulations are done using Autodyn software. The simulation aims to get the optimum geometry that can give the highest pressure at nozzle exit. Two materials are chosen to cut; stainless steel 304 and aluminum 1100. Simulations show the optimum blast test jig can cut aluminum and stainless steel at certain thickness.

Cutting Speed of Electric Discharge Machining for SiC Ingot

2012 ◽  
Vol 717-720 ◽  
pp. 861-864 ◽  
Author(s):  
Hideki Yamada ◽  
Satarou Yamaguchi ◽  
Norimasa Yamamoto ◽  
Tomohisa Kato
Keyword(s):  
Silicon Carbide ◽  
Electric Discharge ◽  
Cutting Speed ◽  
Experimental Results ◽  
New Method ◽  
Electric Discharge Machining ◽  
Hard Materials ◽  
Diameter Ingot ◽  
Diamond Saw

A new method based on electric discharge machining (EDM) was developed for cutting a silicon carbide (SiC) ingot. The EDM method is a very useful technique to cut hard materials like SiC. By cutting with the EDM method, kerf loss and roughness of sample are generally smaller than those obtained by cutting with a diamond saw. Moreover, the warpage is smaller than that by the diamond saw cutting, and the cutting speed can be 10 times faster than that of the diamond saw at the present time. We used wires of 50 mm and 100 mm diameters in the experiments, and the experimental results of the cutting speed and the kerf losses are presented. The kerf loss of the 50 mm wire is less than 100 mm, and the cutting speed is about 0.8 mm/min for the thickness of a 6 mm SiC ingot. If we can maintain the cutting speed, the slicing time of a 2 inches diameter ingot would be about seven hours.

Sign in / Sign up

Export Citation Format

Share Document