Surface roughness study of polyamide in nano-metric polishing using low-frequency acoustic energy

2021 ◽  
pp. 095440542110573
Author(s):  
Sajjad Beigmoradi ◽  
Mehrdad Vahdati
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrochemical Machining ◽  
Low Frequency ◽  
Acoustic Energy ◽  
Machining Process ◽  
Surface Topology ◽  
Vibration Source ◽  
Before And After ◽  
Process Factors

Polymers have gained the attention of manufacturers due to their significant advantages such as low density, high corrosion resistance, and high humidity resistance. Producing high-precision polymeric components is one the most challenging issues especially in fabricating complex or micro-scale systems. Some of the machining techniques such as electro discharge machining (EDM) and electrochemical machining (ECM) cannot be employed for machining the non-conductive parts. Using abrasive particles is one of the best options for machining these types of materials. In this work, the capability of the acoustic energy for machining polyamide (PA) workpieces is studied. To this end, an experimental setup is installed and design of experiment (DoE) algorithm is employed to survey the effect of process parameters on surface roughness. Three parameters at three levels are considered as the effective factors of the process and the sensitivity of the surface roughness on the process factors is investigated. In the next step, a hybrid finite element/boundary element approach was used to discuss the relation of process parameters to the vibrational characteristics of the container, then the mechanism of the process was investigated employing the discrete element method. Finally, the surface topology of the optimal workpiece before and after the process was presented and compared. It was observed that acoustic energy can be considered as a vibration source of the container’s floor to provide kinetic energy for machining PA parts on the nano-metric scale. Moreover, it was found that the initial roughness of the workpiece and the chosen parameters play a crucial role in the machining process. Experimental results show that in this technique by selecting appropriate process factors the surface roughness can be reduced up to 50%.

scholarly journals Effect on Material Removal Rate and Surface Finish in ECM Process When Machining Stainless Steel-316 with Cu Electrode

2019 ◽  
Vol 8 (4) ◽  
pp. 2933-2941
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Process Parameters ◽  
Surface Finish ◽  
Feed Rate ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Processes

Electrochemical Machining process is one of the popular non-traditional machining processes which is used to machine materials such as super alloys, Ti-alloys, stainless steel etc. Its working principle is based upon Faraday law of electrolysis. The aim of the present work is to optimize the ECM process parameters with the combination of SS 316 (job material) and Copper electrode (tool material). To explore the effect of ECM process parameters such as electrolyte concentration, voltage and current, feed rate on MRR and surface finish (Ra) of the job, total 27 experiments were conducted as per experimental scheme. The results of these experiments revealed that increase in electrolyte concentration decrease the mrr and surface roughness initially increases then decreases. Further, increase in current increases mrr initially and then decreases, surface roughness also increases. It is also noticed that increase in Feed rate mrr decreases and then increases, also surface roughness decreases then increases. Through RSM analysis it is found that the optimum conditions for maximum MRR, and minimum Surface roughness (Ra) is electrolyte concentration 150gm/lit, Voltage 13.5 V & feed 0.8 mm/min. The findings are discussed in the light of previous researches and subsequently conclusions are drawn.

scholarly journals Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

2018 ◽  
Vol 7 (2.8) ◽  
pp. 10
Author(s):  
A VS Ram Prasad ◽  
Koona Ramji ◽  
B Raghu Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Optimization Technique ◽  
Machining Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

Multi-Response Optimization of Electrochemical Machining of Al-Si/B4C Composites Using RSM

2013 ◽  
Vol 3 (3) ◽  
pp. 42-56 ◽  
Author(s):  
Sadineni Rama Rao ◽  
G. Padmanabhan
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Casting Process ◽  
Stir Casting ◽  
Machining Parameters ◽  
Electron Microscopic ◽  
Sem Images

The present work reports the electrochemical machining (ECM) of the aluminium-silicon alloy/boron carbide (Al-Si /B4C) composites, fabricated by stir casting process with different weight % of B4C particles. The influence of four machining parameters including applied voltage, electrode feed rate, electrolyte concentration and percentage of reinforcement on the responses surface roughness (SR) and radial over cut (ROC) were investigated. The process parameters are optimized based on the response surface methodology (RSM) and the optimum values for minimizing surface roughness and radial over cut are voltage 15.25 V, feed rate 1.0 mm/min, electrolyte concentration 13.56g/lit and percentage of reinforcement 7.36 wt%. The quality of the machined surfaces is studied by using scanning electron microscopic (SEM) images. The surface plots are generated to study the effect of process parameters and their interaction on the surface roughness and radial over cut, for the machined Al-Si/B4C composites.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

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