Genetic evolutionary approach for surface roughness prediction of laser sintered Ti–6Al–4V in EDM

2020 ◽  
Vol 0 (0) ◽  
Author(s):  
Mehmet Mahir Sofu ◽  
Fatih Taylan ◽  
Tolgahan Ermergen
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Mathematical Relationship ◽  
Electro Discharge Machining ◽  
Ti Alloys ◽  
Notable Effect ◽  
Major Disadvantage ◽  
Roughness Prediction

AbstractAdditive Manufacturing (AM) methods, in the field of production, are increasing rapidly. In particular, the use of Ti alloys has an important role in AM methods. The major disadvantage of AM methods is low surface quality of the manufactured parts. Therefore, parts produced using AM methods need subsequent surface treatment. Electro Discharge Machining (EDM) is one of the nontraditional machining methods, which can be used to improve the surface quality with appropriate parameters. In this study, EDM was investigated to improve the surface quality of sintered Ti–6Al–4V alloy by using 160 different finish parameters. It was observed that Current (I) has a notable effect on surface roughness showing that best surface quality is achieved with low current values, which is under Ra = 2 µm. To estimate the final result of EDM, roughness values obtained from the experiments were modeled by using the Genetic Expression Programming (GEP), and a mathematical relationship between the obtained roughness values and EDM parameters was proposed. As a result of 830,900 iterations, GEP model created can estimate the final surface roughness of the parts with 84% accuracy.

scholarly journals Improving surface quality in selective laser melting based tool making

2021 ◽  
Author(s):  
Filippo Simoni ◽  
Andrea Huxol ◽  
Franz-Josef Villmer
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Remelting ◽  
Laser Melting ◽  
Great Cost ◽  
Starting Point ◽  
Processing Techniques

AbstractIn the last years, Additive Manufacturing, thanks to its capability of continuous improvements in performance and cost-efficiency, was able to partly replace and redefine well-established manufacturing processes. This research is based on the idea to achieve great cost and operational benefits especially in the field of tool making for injection molding by combining traditional and additive manufacturing in one process chain. Special attention is given to the surface quality in terms of surface roughness and its optimization directly in the Selective Laser Melting process. This article presents the possibility for a remelting process of the SLM parts as a way to optimize the surfaces of the produced parts. The influence of laser remelting on the surface roughness of the parts is analyzed while varying machine parameters like laser power and scan settings. Laser remelting with optimized parameter settings considerably improves the surface quality of SLM parts and is a great starting point for further post-processing techniques, which require a low initial value of surface roughness.

Observation in the Surface Roughness of Silicon Wafer during Semi-Fixed Abrasive Machining with Large Grains

2009 ◽  
Vol 69-70 ◽  
pp. 253-257
Author(s):  
Ping Zhao ◽  
Jia Jie Chen ◽  
Fan Yang ◽  
K.F. Tang ◽  
Ju Long Yuan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Silicon Wafer ◽  
Processing Parameters ◽  
Wafer Surface ◽  
Abrasive Machining ◽  
Fixed Abrasive ◽  
Is Failure ◽  
Better Than

Semi-fixed abrasive is a novel abrasive. It has a ‘trap’ effect on the hard large grains that can prevent defect effectively on the surface of the workpiece which is caused by large grains. In this paper, some relevant experiments towards silicon wafers are carried out under the different processing parameters on the semi-fixed abrasive plates, and 180# SiC is used as large grains. The processed workpieces’ surface roughness Rv are measured. The experimental results show that the surface quality of wafer will be worse because of higher load and faster rotating velocity. And it can make a conclusion that the higher proportion of bond of the plate, the weaker of the ‘trap’ effect it has. Furthermore the wet environment is better than dry for the wafer surface in machining. The practice shows that the ‘trap’ effect is failure when the workpiece is machined by abrasive plate which is 4.5wt% proportion of bond in dry lapping.

The mechanism of process parameters influencing the AlSi10Mg side surface quality fabricated via laser powder bed fusion

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Shimin Dai ◽  
Hailong Liao ◽  
Haihong Zhu ◽  
Xiaoyan Zeng
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Laser Power ◽  
Side Surface ◽  
Laser Powder Bed Fusion ◽  
Scanning Velocity ◽  
Content Type ◽  
Powder Bed

Purpose For the laser powder bed fusion (L-PBF) technology, the side surface quality is essentially important for industrial applicated parts, such as the inner flow parts. Contour is generally adopted at the parts’ outline to enhance the side surface quality. However, the side surface roughness (Ra) is still larger than 10 microns even with contour in previous studies. The purpose of this paper is to study the influence of contour process parameters, laser power and scanning velocity on the side surface quality of the AlSi10Mg sample. Design/methodology/approach Using L-PBF technology to manufacture AlSi10Mg samples under different contour process parameters, use a laser confocal microscope to capture the surface information of the samples, and obtain the surface roughness Ra and the maximum surface height Rz of each sample after analysis and processing. Findings The results show that the side surface roughness decreases with the increase of the laser power at the fixed scanning velocity of 1,000 mm/s, the side surface roughness Ra stays within the error range as the contour velocity increases. It is found that the Ra increases with the scanning velocity increasing and the greater the laser power with the greater Ra increases when the laser power of contour process parameters is 300 W, 350 W and 400 W. The Rz maintain growth with the contour scanning velocity increasing at constant laser power. The continuous uniform contour covers the pores in the molten pool of the sample edge and thus increase the density of the sample. Two mechanisms named “Active adhesion” and “Passive adhesion” cause sticky powder. Originality/value Formation of a uniform and even contour track is key to obtain the good side surface quality. The side surface quality is determined by the uniformity and stability of the contour track when the layer thickness is fixed. These research results can provide helpful guidance to improve the surface quality of L-PBF manufactured parts.

Investigation of the Effects of Technological Parameters on Surface Roughness in Extrusion Bars of Aluminum Alloy

2019 ◽  
Vol 889 ◽  
pp. 155-160
Author(s):  
Trong Mai Nguyen ◽  
Đuc Quy Tran ◽  
Van Nghe Pham ◽  
Van Canh Nguyen
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Surface Quality ◽  
Research Work ◽  
Extrusion Process ◽  
Optimal Parameters ◽  
Technological Parameters

In this research work, the result of the effects of technological parameters on surface roughness in extrusion bars of aluminum alloy were pesented. The results of this study may be used for choosing optimal parameters of extrusion process so that surface quality of extruded bar was improved.

scholarly journals Impact of Structural Defects on the Surface Quality of Hardwood Species Sliced Veneers

2020 ◽  
Vol 10 (18) ◽  
pp. 6265
Author(s):  
Vasiliki Kamperidou ◽  
Efstratios Aidinidis ◽  
Ioannis Barboutis
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Wood Species ◽  
Research Work ◽  
Structural Defects ◽  
Material Surface ◽  
Typical Structure ◽  
Hardwood Species ◽  
The Impact

The surface roughness constitutes one of the most critical properties of wood and wood veneers for their extended utilization, affecting the bonding ability of the veneers with one another in the manufacturing of wood composites, the finishing, coating and preservation processes, and the appearance and texture of the material surface. In this research work, logs of five significant European hardwood species (oak, chestnut, ash, poplar, cherry) of Balkan origin were sliced into decorative veneers. Their surface roughness was examined by applying a stylus tracing method, on typical wood structure areas of each wood species, as well as around the areas of wood defects (knots, decay, annual rings irregularities, etc.), to compare them and assess the impact of the defects on the surface quality of veneers. The chestnut veneers presented the smoothest surfaces, while ash veneers, despite the higher density, recorded the highest roughness. In most of the cases, the roughness was found to be significantly lower around the defects, compared to the typical structure surfaces, probably due to lower porosity, higher density and the presence of tensile wood. The results reveal that the presence of defects does not affect the roughness of the veneers and increases neither the processing requirements of the veneer sheets before finishing, nor the respective production cost of veneers and the veneer-based wood panels. The high utilization prospects of the examined wood species in veneer production, even those bearing various defects, is highlighted.

scholarly journals Surface Roughness Investigation of Poly-Jet 3D Printing

Mathematics ◽  
2020 ◽  
Vol 8 (10) ◽  
pp. 1758
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Nikolaos Vaxevanidis ◽  
John Kechagias
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Surface Quality ◽  
Back Propagation ◽  
Physical Models ◽  
Layer By Layer ◽  
Linear Regression Models ◽  
Feed Forward Back Propagation ◽  
The Impact

An experimental investigation of the surface quality of the Poly-Jet 3D printing (PJ-3DP) process is presented. PJ-3DP is an additive manufacturing process, which uses jetted photopolymer droplets, which are immediately cured with ultraviolet lamps, to build physical models, layer-by-layer. This method is fast and accurate due to the mechanism it uses for the deposition of layers as well as the 16 microns of layer thickness used. Τo characterize the surface quality of PJ-3DP printed parts, an experiment was designed and the results were analyzed to identify the impact of the deposition angle and blade mechanism motion onto the surface roughness. First, linear regression models were extracted for the prediction of surface quality parameters, such as the average surface roughness (Ra) and the total height of the profile (Rt) in the X and Y directions. Then, a Feed Forward Back Propagation Neural Network (FFBP-NN) was proposed for increasing the prediction performance of the surface roughness parameters Ra and Rt. These two models were compared with the reported ones in the literature; it was revealed that both performed better, leading to more accurate surface roughness predictions, whilst the NN model resulted in the best predictions, in particular for the Ra parameter.

Mechanical Testing of Additive Manufactured Metal Parts

2015 ◽  
Vol 651-653 ◽  
pp. 713-718 ◽  
Author(s):  
Marion Merklein ◽  
Raoul Plettke ◽  
Daniel Junker ◽  
Adam Schaub ◽  
Bhrigu Ahuja
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Stainless Steel ◽  
Additive Manufacturing ◽  
Laser Beam ◽  
Round Robin Test ◽  
Metal Parts ◽  
Laser Beam Melting ◽  
Made In

The quality of additive manufactured parts however depends pretty much on the workers experience to control porosity, layer linkage and surface roughness. To analyze the robustness of the Laser Beam Melting (LBM) process a Round Robin test was made in which specimens from four institutes from different countries were tested and compared. For the tests each institute built a set of specimens out of stainless steel 1.4540. The aim of this work is to analyze the influence of the process parameters on the mechanical properties. The results show that there is a high potential for additive manufacturing but also a lot of further research is necessary to optimize this technology.

scholarly journals Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

2020 ◽  
Vol 10 (5) ◽  
pp. 1667 ◽  
Author(s):  
Basem M. A. Abdo ◽  
Abdualziz El-Tamimi ◽  
Emad Abouel Nasr
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Surface Quality ◽  
Tool Path ◽  
Removal Rate ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Roughness Surface ◽  
Tool Wear Mechanisms

Pocket milling has been regarded as one of the most widely used operations in machining. The surface quality of the machined pockets is an essential aspect of any engineering and medical applications. In the current study, rotary ultrasonic machining (RUM) was applied for milling micro-pockets on alumina (Al2O3) ceramic. The objective of this research was to analyze the effect of the tool overlapping parameters on the surface roughness, surface morphology and the profiles of the machined pockets. Subsequently, the effect of different tool path strategies was analyzed on the surface quality and the material removal rate (MRR) of the machined pockets. A scanning electron microscope is used for analyzing the tool wear mechanisms. The experimental results provide evidence that the surface roughness, surface morphology and the MRR have been significantly affected by the considered tool overlapping and the tool path strategies. Furthermore, among the selected tool overlapping parameters (5–25%) and the tool path strategies, the best surface roughness (Ra = 0.155 μm and Rt = 1.432 µm) of the machined pockets can be found at 20% of the tool overlapping with a mix of uni-directional and zigzag tool path strategy.

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

Comparison between different methods for experimental analysis of surface integrity in die-sinking electro-discharge machining processes

2019 ◽  
Vol 234 (3) ◽  
pp. 479-488 ◽  
Author(s):  
Carlos Mascaraque-Ramírez ◽  
Patricio Franco
Keyword(s):  
Surface Roughness ◽  
Penetration Depth ◽  
Surface Quality ◽  
Experimental Analysis ◽  
Current Intensity ◽  
Geometrical Parameters ◽  
Main Process ◽  
Machining Processes ◽  
Crater Diameter ◽  
Electro Discharge Machining

Advanced manufacturing techniques such as die-sinking electro-discharge machining have been introduced in different industries such as the naval, automotive and product manufacturing. The surface finish of the parts subjected to these processes is influenced by diverse factors related to geometrical parameters, electric circuit, lubrication system and materials. For that reason, this work is focused on the analysis of the surface morphology of machined part that can be achieved by electro-discharge machining, as a function of some of the main process parameters such as the current intensity and penetration depth. In this work, three different methods for experimental analysis of surface quality, based on the measuring of surface roughness, material profile ratio and crater diameter, were applied and compared. The experimental phase included tests with copper tools on AISI 316 stainless steel workpieces. The surface roughness and accumulated material profile were recorded using measurements made with a profilometer, and for the purpose of measuring the diameter of the craters, scanning electron microscopy technology was used. According to the results, crater diameter can be adopted as a better indicator to characterize the surface quality in electro-discharge machining, because it exhibits a clearer tendency as a function of current intensity and penetration depth.

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