scholarly journals Some Experimental Investigations in the Performance of Electochemical Machining Process.(Dept.M)

2021 ◽  
Vol 10 (1) ◽  
pp. 83-91
Author(s):  
M. Abdel-Moneim ◽  
S. Ibrahim
Keyword(s):  
Machining Process ◽  
Experimental Investigations

Design, Development & Experimental Investigation of Electro-Discharge Diamond Surface Grinding of Ti-6Al-4V

2011 ◽  
Vol 418-420 ◽  
pp. 1478-1481 ◽  
Author(s):  
Manoj Modi ◽  
Gopal Agarwal
Keyword(s):  
Removal Rate ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Hybrid Machining ◽  
Hard Materials ◽  
Hybrid Machining Process ◽  
Pulse On Time

Abstract: Ti-6Al-4V are used extensively in aerospace, medical, marine and surgical implants etc. but it is hard to machine. Machining of advanced difficult-to-machine very hard materials (Ti-6Al-4V, composites and ceramics) is a big challenge. By conventional machining processes, their machining is not only costly but results in poor surface finish and shorter tool life. To meet these challenges, new hybrid machining process (HMP) has been developed. This article is focused on hybrid machining process comprising of conventional surface grinding along with electro-discharge machining between the periphery of metal bonded diamond grinding wheel and flat rectangular shape workpiece. This process has the advantage of shaping advance engineering materials and difficult-to- machine very hard materials. The experimental investigations of various input parameters like wheel RPM, duty factor, current and pulse on-time on material removal rate of Ti-6Al-4V in EDDSG process have been reported here on newly self designed & fabricated set up. Keywords: Electro-Discharge Diamond Surface Grinding (EDDSG), Hybrid Machining Process (HMP), Ti-6Al-4V.

Analysis of Cutting Technologies for Lightweight Frame Components

2006 ◽  
Vol 10 ◽  
pp. 121-132 ◽  
Author(s):  
Klaus Weinert ◽  
Sven Grünert ◽  
Michael Kersting
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Thermal Stresses ◽  
Machining Process ◽  
Frame Structure ◽  
Experimental Investigations ◽  
Promising Alternative ◽  
Thin Walled ◽  
Process Strategy ◽  
Conventional Drilling

Most technical components applied in industrial practice are subjected to metal cutting operations during their production process. However, this leads to undesirable thermal and mechanical loads affecting the machined workpiece, which can result in an impairment of its serviceability. Due to their small wall thickness lightweight hollow profiles are highly susceptible to the inevitable machining loads and thermal stresses during drilling processes. For the virtual optimization of the machining process and in order to ensure a suitable process strategy, a finite element simulation of cutting operations for thin-walled light metal profiles is conducted. Due to the flexibility within creating drill holes of different diameters without tool changes circular milling represents a promising alternative to the application of conventional drilling tools for variable process strategies to handle batch sizes down to one piece efficiently. Hence, this article gives an insight into the investigations regarding the modeling concepts of the mechanical and thermal loads induced into the thin-walled lightweight frame structure during the circular milling process. Furthermore, process reliability aspects as well as the correlation of the calculated and the measured results will be discussed on the basis of experimental investigations. Finally, this article compares Finite Element Analysis aspects of circular milling processes with conventional drilling processes.

scholarly journals Experimental Investigations into Abrasive Waterjet Machining of Carbon Fiber Reinforced Plastic

2015 ◽  
Vol 2015 ◽  
pp. 1-9 ◽  
Author(s):  
Prasad D. Unde ◽  
M. D. Gayakwad ◽  
N. G. Patil ◽  
R. S. Pawade ◽  
D. G. Thakur ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Fiber Orientation ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Experimental Investigations ◽  
Abrasive Waterjet Machining ◽  
Kerf Taper ◽  
Waterjet Machining

Abrasive waterjet machining (AWJM) is an emerging machining process in which the material removal takes place due to abrasion. A stream of abrasive particles mixed with filtered water is subjected to the work surface with high velocity. The present study is focused on the experimental research and evaluation of the abrasive waterjet machining process in order to evaluate the technological factors affecting the machining quality of CFRP laminate using response surface methodology. The standoff distance, feed rate, and jet pressure were found to affect kerf taper, delamination, material removal rate, and surface roughness. The material related parameter, orientation of fiber, has been also found to affect the machining performance. The kerf taper was found to be 0.029 for 45° fiber orientation whereas it was 0.036 and 0.038 for 60° and 90°, respectively. The material removal rate is 18.95 mm3/sec for 45° fiber orientation compared to 18.26 mm3/sec for 60° and 17.4 mm3/sec for 90° fiber orientation. The Ra value for 45° fiber orientation is 4.911 µm and for 60° and 90° fiber orientation it is 4.927 µm and 4.974 µm, respectively. Delamination factor is found to be more for 45° fiber orientation, that is, 2.238, but for 60° and 90° it is 2.029 and 2.196, respectively.

The Modulation of Chatter Vibrations

1969 ◽  
Vol 91 (3) ◽  
pp. 673-677 ◽  
Author(s):  
R. A. Thompson
Keyword(s):  
Mathematical Model ◽  
Vibrational Frequency ◽  
Machining Process ◽  
Experimental Investigations ◽  
Characteristic Frequencies ◽  
Chatter Vibrations ◽  
Machining Chatter

The results of several experimental investigations concerning the nature of machining chatter are discussed. They indicate that chatter vibrations are generally amplitude modulated and that the chatter frequency may or may not vary from the free vibrational frequency of the chattering component. Of the several results considered each is explained in terms of an extension of the empirically derived lag equation for the machining process of Doi and Kato whereby the characteristic frequencies of the lag equation are determined. The fact that the frequency related phenomena of several independent tests are confirmed by the lag equation, which was not derived from frequency considerations, seems to justify it as a valid mathematical model for the machining process.

scholarly journals Extension of the Process Window in Laser Chemical Machining by Temperature-Dependent Reduction of the Electrolyte Viscosity

2021 ◽  
Author(s):  
Marcel Simons ◽  
Tim Radel ◽  
Frank Vollertsen
Keyword(s):  
Sulfuric Acid ◽  
Chemical Process ◽  
Machining Process ◽  
Shielding Effect ◽  
Process Window ◽  
Experimental Investigations ◽  
Temperature Dependent ◽  
Local Overheating ◽  
Boiling Process ◽  
Titanium Grade

AbstractThe laser chemical process is a material-removing machining process in the micro range. The process is based on a laser-assisted etching process between an electrolyte and a metallic workpiece. Local overheating causes a laser-induced electrolyte boiling process, which limits the laser chemical process window. In order to reduce the laser-induced electrolyte boiling process and thus expand the process window, the laser chemical process is carried out at different electrolyte start temperatures and thus different electrolyte viscosities and surface tensions. The experimental investigations were carried out on Titanium Grade 1 with the electrolytes phosphoric acid and sulfuric acid at different electrolyte temperatures and laser powers to determine the limits of the process window by evaluating the properties of the removal cavities. As a result, the process window is extended at lower electrolyte viscosities. Thereby, the electrolyte viscosities have no influence on the geometric shape of the removal. The extension of the process window is attributed to the fact that a reduction in electrolyte viscosity results in a less pronounced formation of the boiling process, the bubble diameters decrease, and the shielding effect of the bubbles is reduced.

A Systematic Approach to the Adaptive Control of the Electro-Discharge Machining Process

1978 ◽  
Vol 100 (3) ◽  
pp. 303-309 ◽  
Author(s):  
M. M. Tseng
Keyword(s):  
Adaptive Control ◽  
Process Planning ◽  
Systematic Approach ◽  
Machining Process ◽  
Experimental Investigations ◽  
Machining Performance ◽  
Electric Pulses ◽  
Electro Discharge Machining ◽  
On Line ◽  
Line Process

Electro-discharge machining removes metal with very short lived electric pulses between electrode and workpiece which are immersed in dielectric liquid. With limited feedback available to the operator, the process is very difficult to approach and maintain efficient machining performance. A systematic approach is taken here by applying incomplete process information for off-line process planning and by minicomputer technology for on line adaptive control. Off-line process planning determines the optimal current level and pulse duration for the roughing and finishing. By sensing down feed and pulse efficiency, on line adaptive control adjusts servo voltage and off time. Experimental investigations with two repetitions show that the system can complete the job with a shorter machining time by detecting and responding more efficiently to disturbances in the process than manual control.

scholarly journals Experimental investigations and multi criteria optimization during machining of A356/WC MMCs using EDM

2022 ◽  
Vol 11 (2) ◽  
pp. 147-158
Author(s):  
Akash Singh ◽  
Karan Kumar ◽  
K. Gnana Sundari ◽  
Rishitosh Ranjan ◽  
B. Surekha
Keyword(s):  
Smart Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Casting Process ◽  
Stir Casting ◽  
Functionally Graded ◽  
Machining Process ◽  
Experimental Investigations ◽  
Process Factors ◽  
Pulse On Time

In the current paper, the authors are intended to manufacture the aluminum based metal matrix composite (MMC) employing the stir casting process. Further, the fabricated composite sample is investigated for machining characteristics during the die sink electrical discharge machining process (EDM). EDM is most commonly employed to satisfy the special needs of industry such as developing deep holes and complex contours from high strength materials such as composites, alloys, smart materials, and functionally graded materials. In the current study A356 and 4%, tungsten carbide (WC) powder are considered as matrix and strengthening materials respectively to fabricate the MMCs. During the machining activity, the input factors like discharge current (Ip), Voltage (Vg), Pulse On-Time (Ton), and flushing pressure (P) are optimized for achieving optimum surface roughness (SR), Tool Wear Rate (TWR) and Material Removal Rate (MRR). To estimate the ideal set of process factors grey regression analysis (GRA) is used. From the results, it was observed that the GRA is found to perform better than the RSM.

Machinability Studies on Aluminium Matrix Hybrid Composites

2014 ◽  
Vol 894 ◽  
pp. 27-31 ◽  
Author(s):  
T.N. Shridhar ◽  
L. Krishnamurthy ◽  
B.K. Sridhara
Keyword(s):  
Hybrid Composites ◽  
Matrix Material ◽  
Weight Ratio ◽  
High Strength ◽  
Cutting Parameters ◽  
Machining Process ◽  
Experimental Investigations ◽  
Matrix Composites ◽  
The Matrix ◽  
New Generation

Aluminium metal matrix composites due to their excellent properties like high strength to weight ratio and high wear resistant are becoming new generation of materials useful for various engineering applications. A continuing problem with these composites is that they are difficult to machine. Machining of these composites depends on the relative content of the reinforcement and the matrix material as well as on its response to the machining process. Experimental investigations have been carried out on the machinability aspects of Aluminium hybrid composites reinforced with Graphite and Silicon Carbide particulates. Experiments have been carried out by Design of Experiments approach. Mathematical models which correlate the interactive and higher order influences of cutting parameters on the resultant force have been developed.

Enhancing process capabilities of electric discharge machining for nonconductive ceramics

2020 ◽  
Vol 234 (12) ◽  
pp. 2402-2416
Author(s):  
Sanjeev Verma ◽  
PS Satsangi ◽  
KD Chattopadhyay
Keyword(s):  
Analysis Of Variance ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
High Resistivity ◽  
Experimental Investigations ◽  
Electrode Wear ◽  
Grey Relational

The application of nonconductive ceramic materials is growing in engineering and manufacturing field due to their properties such as high hardness, low thermal conductivity, and resistance to oxidation. But fabricating structures from such materials are difficult and most of the traditional machining techniques are not appropriate. The electrical discharge machining has become a popular machining process for machining nonconducting oxide and nonoxide ceramics such as alumina, silicon nitrides, SiAlON, and zirconium. In the present study, a technique to machine the nonconductive SiAlON ceramic, having resistivity of the order of 100000 Ω-cm is developed. An assistive electrode technique along with graphite powder mixed specially made dielectric mixture of hydrocarbon fluids was used for the electrical discharge machining process. The experiments were conducted according to the Taguchi design and analysis of variance using signal-to-noise ratios showcasing significant parameters and their optimal values for material removal, electrode wear, and size overcut achieved after electrical discharge machining. For multiparameter optimization, the grey relational analysis was carried out for response parameters with suitable weights. Analysis of variance on the grey relational grade showed discharge current, duty factor, and additive percentage as most significant parameters. As the central aim of this research is material removal, the significant parameters found for material removal rate were further used for response surface methodology and their optimum values as central design values for experimentation. A second-order response model was formulated to estimate the machining performance. To validate the study, confirmation experiments were carried out and predicted results have been found to be in good agreement with experimental findings. Based on the experimental investigations, it can be said that a novel and efficient technique has been developed to machine the high resistivity ceramics. The scanning electron microscopic images confirmed that material is removed mostly by spalling and no significant cracks are visible.

Sign in / Sign up

Export Citation Format

Share Document