scholarly journals Media-assisted machining processes

Mechanik ◽  
2018 ◽  
Vol 91 (12) ◽  
pp. 1050-1056
Author(s):  
Wit Grzesik
Keyword(s):  
High Pressure ◽  
Material Removal ◽  
Tribological Behavior ◽  
Removal Rate ◽  
Subsurface Layer ◽  
Optimization Procedure ◽  
Special Group ◽  
Machining Processes ◽  
Gaseous Media ◽  
Cutting Zone

A special group of hybrid assisted processes termed media-assisted processes which various liquid and gaseous media supplied to the cutting zone is highlighted. Special attention is paid on such cooling techniques as high-pressure machining (HPC), high-pressure jet assisted machining (HPJAM), minimum quantity cooling/lubrication (MQC/MQL) and a group of cryogenically cooled machining including such cryogenic media as CO2 snow and liquid nitrogen (LN2). Some important effects resulting from the various cooling strategies are outlined and compared. In particular, quantitative effects concerning chip breaking, thermal and tribological behavior of the cutting process as well as burr reduction, surface quality and subsurface layer are presented. The optimization procedure concerning both energy consumption and machining costs in terms of material removal rate (MRR) is presented.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

Interaction Between Wire and Ingot in Wiresaw Slicing

1999 ◽  
Author(s):  
Fuqian Yang ◽  
J. C. M. Li ◽  
Imin Kao
Keyword(s):  
Finite Element ◽  
Contact Zone ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Bending Stiffness ◽  
Mechanical Interaction ◽  
Wire Tension ◽  
Cutting Zone ◽  
The Wire

Abstract The deformation of the wire in the wiresaw slicing process was studied by considering directly the mechanical interaction between the wire and the ingot. The wire tension on the upstream is larger than on the downstream due to the friction force between the wire and the ingot. The tension difference across the cutting zone increases with friction and the span of the contact zone. The pressure in the contact zone increases from the entrance to the exit if the wire bending stiffness is ignored. The finite element results show that the wire bending stiffness plays an important role in the wire deformation. Higher wire bending stiffness (larger wire size) generates higher force acting onto the ingot for the same amount of wire deformation, which will leads to higher material removal rate and kerf loss. While larger wire span will reduce the force acting onto the ingot for a given ingot displacement in the direction perpendicular to the wire.

scholarly journals Thermal Modeling of Tool Temperature Distribution during High Pressure Coolant Assisted Turning of Inconel 718

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 408 ◽  
Author(s):  
Doriana D'Addona ◽  
Sunil Raykar
Keyword(s):  
High Pressure ◽  
Temperature Distribution ◽  
Inconel 718 ◽  
Tool Temperature ◽  
Machining Processes ◽  
Nickel Chromium ◽  
Work Material ◽  
Cutting Zone ◽  
Overall Performance ◽  
High Pressure Coolant

This paper presents a finite-element modeling (FEM) of tool temperature distribution during high pressure coolant assisted turning of Inconel 718, which belongs to the heat resistance superalloys of the Nickel-Chromium family. Machining trials were conducted under four machining conditions: dry, conventional wet machining, high pressure coolant at 50 bar, and high pressure coolant at 80 bar. Temperature during machining plays a very important role in the overall performance of machining processes. Since in the current investigation a high pressure coolant jet was supplied in the cutting zone between tool and work material, it was a very difficult task to measure the tool temperature correctly. Thus, FEM was used as a modeling tool to predict tool temperature. The results of the modeling showed that the temperature was considerably influenced by coolant pressure: the high pressure jet was able to penetrate into the interface between tool and work material, thus providing both an efficient cooling and effective lubricating action.

Reduction of Vibrations due to Unbalance with Anti-Vibration Clearance Angle in High Speed Milling

2016 ◽  
Vol 836-837 ◽  
pp. 161-167
Author(s):  
Anna Thouvenin ◽  
Xin Li ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Machining Process ◽  
High Speed Machining ◽  
Machining Processes ◽  
High Speed Milling ◽  
Clearance Angle ◽  
Fast Solution ◽  
Considerable Problem

High speed milling is one of the most commonly used machining processes in many fields of the industry. It is regarded as a simple and fast solution to achieve a high material removal rate, which allows an important production of parts. Unbalance is a problem in any machining process but becomes a considerable problem when reaching high speed machining. The vibrations due to an unbalanced tool or tool holder can result in a poor surface quality and a damaged tool. The damping of the vibrations can be achieved with a specially designed tool showing an anti-vibration clearance angle. This paper shows the influence of the anti-vibration clearance angle by a computational model and a set of experiments to see if it can reduce or suppress the vibrations due to unbalance in high speed milling.

Effect of Lubricant in Output Parameters of Milling

2010 ◽  
Vol 44-47 ◽  
pp. 335-339
Author(s):  
Ramezan Ali Mahdavinejad
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Surface Finishing ◽  
Machining Parameters ◽  
Machining Processes ◽  
High Speed Milling ◽  
Cooling Lubricant ◽  
Machined Surfaces

The usage of lubrication in machining processes especially in high speed milling is very important. In this research, some steel samples are machined with and without cooling lubricant conditions. In these cases, the material removal rate and surface finishing of machined surfaces are analyzed. The comparison between two conditions shows that the usage of lubricant as coolant material, improves the output machining parameters significantly.

Goodness Indicator and Technological Optimization of Honing

2013 ◽  
Vol 581 ◽  
pp. 261-265 ◽  
Author(s):  
Ottó Szabó
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Complex Surface ◽  
Technology Planning ◽  
Technological Parameters ◽  
Machining Processes ◽  
Important Field ◽  
Abrasive Cutting

Optimisation of technological processes is an important field of research of machining processes. Honing process, its aim and results are affected more factors. Effectiveness is expressed by the following parameters: accuracy, surface roughness, complex surface quality (integrity),material removal rate, costs and productivity of the process. Developed method helps the technology planning and with the introduced new goodness indicator, investigates and corrects it. Optimization and minimization of costs can be ensured at given technological circumstances and technological parameters. With adjustment of the pressure (p) and the cutting speed (vc) economy of the process can be increased in the factory. Developed method can be applied for machining by other abrasive cutting tools. The paper summarizes new results of this theoretical and experimental research.

Manufacturing of Mini-Channel by Electrical Chemical Machining Processes

2016 ◽  
Vol 842 ◽  
pp. 111-114
Author(s):  
Muslim Mahardika ◽  
Agung Mulianto ◽  
Andi Sudiarso
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Manufacturing Industry ◽  
Complex Shape ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Hard Material ◽  
Machining Processes ◽  
Conventional Machining

The manufacturing industry is now growing rapidly in the area of non-conventional machining, especially Electrical Chemical Machining (ECM). The ECM can be used for machining of very hard material and very complex shape. This research is performed in order to manufacture mini-channel, which has a complex shape. The ECM machine cutting conditions are as follow; voltage: 7 Volt, feed rate: 1 .0 mm/minute, electrolyte: Natrium Cloride (NaCl), electrolyte concentration: 15 %, electrolyte speed: 3.32 m/s. The result shows that the mini-channel can be manufactured with the average of Material Removal Rate 0.035 g/min with the overcut average is 0.481 mm, and the surface roughness is 5.19 micro meter.

scholarly journals Design and Optimization of EDM using Metal Matrix Composite by Genetic algorithm and Jaya Algorithm

2020 ◽  
Vol 9 (4) ◽  
pp. 3216-3221
Keyword(s):  
Genetic Algorithm ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Model ◽  
Jaya Algorithm ◽  
Machining Processes ◽  
Design And Optimization

Aluminum Boron carbide (Al-B4C) is a form of metal matrix composite (MMC) belongs to advanced category of material which is gaining popularity now-a-days because of its excellent mechanical and physical properties. Unconventional machining processes (UMPs) are now day’s best options to machine such kinds of modern materials. Electro discharge machining (EDM) process now days the best UMP whichever utilizes thermic energy power of spark for material removal. In present research the EDM has been carried out in Al-B4C MMC by varying different EDM parameters to evaluate material removal rate (MRR) and tool wear rate (TWR). The response surface model (RSM) has been developed for both the MRR and TWR. The developed RSM has been utilized during optimization. Optimizations of responses the MRR and or TWR have been done by using genetic algorithm and jaya algorithm. Finally both the algorithms have been compared with respect to current manufacturing paradigm.

scholarly journals A Role of cryogenic in Wire cut EDM process

2020 ◽  
Vol 184 ◽  
pp. 01067
Author(s):  
Kosaraju Satynarayana ◽  
Kumkuma Rajkiran ◽  
Pujari Anil kumar ◽  
D Chakradhar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Performance Characteristics ◽  
Machining Processes ◽  
Current Voltage ◽  
Tension Wire ◽  
Wedm Process

Novel techniques are being focused on the enrichment of the performance characteristics under different machining processes. Cryogenic is one of such novel practices that tunes the surface integrity with vast variations with the traditional machining processes. Dimensional accuracy, surface roughness, material removal rate with less reduction in scrap of material is one of the prior targets of production process. Wire cut Electro Discharge Machining (WEDM) is one method that satisfy with upgrading performance characteristics. In order to step-up these performance characteristics in attaining superior quality, cryogenics practices have collaborated with the WEDM process. Present paper deals with the reviews of the researchers that have been performed over cryogenic treated WEDM process. Effect of performance characteristics like pulse on, pulse off, current, voltage, wire tension, wire feed is discussed with relation to material removal rate, tool wear rate and surface roughness evolved. Key concept of paper is to include the research ideology with best feasible techniques that can prevail in production practice in order of contribute to the forthcoming researches in industrial and production departments.

scholarly journals Fuzzy control of the dual-stage feeding system consisting of a piezoelectric actuator and a linear motor for electrical discharge machining

2019 ◽  
Vol 234 (5) ◽  
pp. 945-955
Author(s):  
Muyad K Bani Melhem ◽  
Milan Simic ◽  
Chow Yin Lai ◽  
Yong Feng ◽  
Songlin Ding
Keyword(s):  
Fuzzy Control ◽  
Piezoelectric Actuator ◽  
Electrical Discharge ◽  
Material Removal ◽  
Control Algorithm ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Linear Motor ◽  
Motor Speed ◽  
Machining Processes

Gap width is an important factor that affects material removal rate, surface finish, and machining stability in electrical discharge machining processes. This research is to develop a novel control method for a new hybrid positioning system which consists of a linear motor and a piezoelectric actuator for high-efficiency electrical discharge machining processes. In the new system, the linear motor provides the macro feeding while the piezoelectric actuator feeds the workpiece in micro scale at high frequency. To reduce the delay caused by separate movements of the linear motor and piezoelectric actuator, a new control algorithm was developed to synchronize the movements of the motor and piezoelectric actuator. A fuzzy control system was used to control the feeding process. Piezoelectric actuator position and its speed were selected as the fuzzy inputs, while the fuzzy output was the linear motor speed. Cutting experiments were conducted, and results show that the fuzzy system is more powerful than the conventional algorithm and the new algorithm with constant motor speed. An increase in material removal rate of 1.6 times was achieved using the proposed fuzzy control algorithm.

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