scholarly journals Parametric optimization of non-traditional machining processes using Taguchi method and super ranking concept

2019 ◽  
Vol 29 (2) ◽  
pp. 249-271 ◽  
Author(s):  
Partha Das ◽  
Shankar Chakraborty
Keyword(s):  
Taguchi Method ◽  
Optimization Technique ◽  
Dimensional Accuracy ◽  
Optimization Techniques ◽  
Machining Process ◽  
Simultaneous Optimization ◽  
Drilling Process ◽  
Regression Equations ◽  
Machining Processes ◽  
Electro Discharge Machining

In order to achieve higher dimensional accuracy along with better surface quality, the conventional machining processes have now-a-days being replaced by non-traditional machining (NTM) processes, because of their ability to generate intricate shape geometries on various advanced engineering materials. In order to exploit their fullest machining potential, it is often recommended to operate those NTM processes at their optimal parametric settings. Several optimization tools and techniques are now available which can be effectively applied to obtain the optimal parametric conditions of those processes. In this paper, Taguchi method and super ranking concept are integrated together to present an efficient optimization technique for simultaneous optimization of three NTM processes, i.e. electro-discharge machining process, wire electro-discharge machining process and electro-chemical discharge drilling process. The derived results are validated with the help of developed regression equations, which show that the proposed approach outperforms the other popular multi-response optimization techniques. Analysis of variance is also performed to identify the most influencing control parameters for the considered NTM processes. The developed response surface plots further help the process engineers in identifying the effects of various NTM process parameters on the calculated sum of squared rank values.

Review of Composite Machining and Related Optimization Techniques

2015 ◽  
Vol 813-814 ◽  
pp. 398-403
Author(s):  
M.M. Thamizharasan ◽  
Y.J. Nithiya Sandhiya ◽  
K.S. Vijay Sekar
Keyword(s):  
Composite Materials ◽  
Taguchi Method ◽  
Weight Ratio ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Processes ◽  
Surface Method ◽  
Simulated Algorithm ◽  
Modeling Techniques ◽  
Experimental Trials

This paper provides an inclusive review of literature, mostly from the past decade, on optimization techniques of composite materials machining, both conventional and non-conventional process. Composite materials are continually replacing conventional materials due to their excellent corrosion resistance, higher strength to weight ratio, but the machining of composites is a challenging process. Experimental trials notwithstanding, researchers have also used various optimization techniques such as Taguchi method, Genetic Algorithm, Simulated Algorithm, Response Surface Method, and Fuzzy Logic with ANOVA etc., to identify the optimal parameters for the machining processes. Also predictive modeling techniques such as Artificial Neural Networks and Finite Element Methods have also been employed as an optimization tools for studying the composite machining process. It was found that Taguchi method is the most preferred technique in the optimization studies.

scholarly journals Temperature monitoring in the subsurface during single lip deep hole drilling

2020 ◽  
Vol 87 (12) ◽  
pp. 757-767
Author(s):  
Robert Wegert ◽  
Vinzenz Guski ◽  
Hans-Christian Möhring ◽  
Siegfried Schmauder
Keyword(s):  
Cutting Parameters ◽  
Drill Hole ◽  
Machining Process ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Machining Processes ◽  
Deep Hole Drilling ◽  
Feed Force ◽  
Cutting Zone

AbstractThe surface quality and the subsurface properties such as hardness, residual stresses and grain size of a drill hole are dependent on the cutting parameters of the single lip deep hole drilling process and therefore on the thermomechanical as-is state in the cutting zone and in the contact zone between the guide pads and the drill hole surface. In this contribution, the main objectives are the in-process measurement of the thermal as-is state in the subsurface of a drilling hole by means of thermocouples as well as the feed force and drilling torque evaluation. FE simulation results to verify the investigations and to predict the thermomechanical conditions in the cutting zone are presented as well. The work is part of an interdisciplinary research project in the framework of the priority program “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG).This contribution provides an overview of the effects of cutting parameters, cooling lubrication and including wear on the thermal conditions in the subsurface and mechanical loads during this machining process. At first, a test set up for the in-process temperature measurement will be presented with the execution as well as the analysis of the resulting temperature, feed force and drilling torque during drilling a 42CrMo4 steel. Furthermore, the results of process simulations and the validation of this applied FE approach with measured quantities are presented.

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.

An extensive review on sustainable developments of dry and near-dry electrical discharge machining processes

2021 ◽  
pp. 1-37
Author(s):  
Sampath Boopathi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Optimization Techniques ◽  
Machining Process ◽  
Working Fluid ◽  
Dielectric Fluid ◽  
Extensive Literature ◽  
Machining Processes ◽  
Research Activities ◽  
Dry Edm

Abstract Electrical discharge machining (EDM) is very essential unconventional electro-thermal machining process to machine the contour profile of hard materials in modern production industries. The liquid dielectric fluid has been replaced by the gas and minimum quantity of liquid mixed with gas (gas-mist) to encourage the green machining processes. The various gases and gas-mist have been used as the working fluid in dry and near-dry EDM respectively. The research-contextual, various dielectric fluids, sustainable and innovative developments, process parameters, machining characteristics, and optimization techniques applied in various dry and near-dry EDM have been illustrated through an extensive literature survey. Future research opportunities in both dry and near-dry EDM have been summarized to promote eco-friendly EDM research activities.

Simulation and Optimization of U-Bending Springback Using Genetic Algorithms

2011 ◽  
Vol 69 ◽  
pp. 17-22
Author(s):  
Lei Chen
Keyword(s):  
Genetic Algorithms ◽  
Optimization Technique ◽  
Dimensional Accuracy ◽  
Element Model ◽  
Optimization Techniques ◽  
Simulation And Optimization ◽  
Sheet Metal Parts ◽  
Blank Holding Force ◽  
Elastoplastic Materials ◽  
Updated Lagrangian

Springback during unloading affects the dimensional accuracy of sheet metal parts. This paper proposes a finite element model to predict springback with contact evolution between the sheet and dies. The underlying formulation is based on updated Lagrangian elastoplastic materials model. The solutions validated with experimental data of NUMISHEET’93 show more accurately. The effects of the variable blank holding force (VBHF) on springback results are investigated based on genetic algorithms (GAs) for the determination of the parameters in blank holding operations. It has been found that the GAs based optimization technique is very effective in solving this kind of problem. The difficulty of choosing correct starting values for the constants in the traditional optimization techniques has been completely overcome and the GAs technique provides a better chance to converge to the global minimum.

scholarly journals Analysis of the Performance of Drilling Operations for Improving Productivity

2021 ◽  
Author(s):  
Majid Tolouei-Rad ◽  
Muhammad Aamir
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Vital Role ◽  
Machining Process ◽  
Drilling Process ◽  
Single Shot ◽  
Drilling Operations

Drilling is a vital machining process for many industries. Automotive and aerospace industries are among those industries which produce millions of holes where productivity, quality, and precision of drilled holes plays a vital role in their success. Therefore, a proper selection of machine tools and equipment, cutting tools and parameters is detrimental in achieving the required dimensional accuracy and surface roughness. This subsequently helps industries achieving success and improving the service life of their products. This chapter provides an introduction to the drilling process in manufacturing industries which helps improve the quality and productivity of drilling operations on metallic materials. It explains the advantages of using multi-spindle heads to improve the productivity and quality of drilled holes. An analysis of the holes produced by a multi-spindle head on aluminum alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single shot drilling. Also the effects of using uncoated carbide and high speed steel tools for producing high-quality holes in the formation of built-up edges and burrs are investigated and discussed.

scholarly journals Tool Wear Rate Prediction by using Optimization Techniques

2019 ◽  
Vol 9 (2) ◽  
pp. 1271-1277
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

scholarly journals Research and Modelling of Surface Roughness, Cutting Forces and I-kaz Coefficients for S42C in Turning using Response Surface Methodology

2019 ◽  
Vol 8 (12S2) ◽  
pp. 608-620
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Statistical Analysis ◽  
Response Surface ◽  
Cutting Parameters ◽  
Machining Process ◽  
Regression Equations ◽  
Turning Process ◽  
Machining Processes ◽  
Surface Method

This paper presents the optimization in machining processes on the cutting parameters for the S45C in turning process using the response surface method (RSM). The experimental work conducted investigates the influence of cutting parameters on statistical analysis of signals and surface quality. The paper also presents a statistical analysis of signal processing. The cutting force was measured during machining using the Kistler 9129AA dynamometer to monitor the force signals and the data was analyzed using the I-kazTM method of statistical analysis. This statistical analysis was used to assess the effect of force signals during the machining process. The RSM models for Ra and Rz, and Ideveloped with ANOVA and multiple regression equations. The models also were compared and validated with the predicted and measured of Ra and Rz values, and I-kaz coefficients. The optimal configuration of cutting parameters was observed at 200 m/min, 0.1 mm/rev and 0.521 mm with desirability of 95.9%. It is observed that the models developed are suggested to be utilized for predicting surface roughness values and I-kaz coefficients for the machining of S45C steel.

Investigation of Heat Pipe Cooling in Drilling Applications: Part 2—Thermal, Structural Static, and Dynamic Analyses

2009 ◽  
Author(s):  
Lin Zhu ◽  
Tien-Chien Jen ◽  
Chen-Long Yin ◽  
Yi-Hsin Yen ◽  
Mei Zhu ◽  
...  
Keyword(s):  
Heat Pipe ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Mechanical Effect ◽  
Machining Process ◽  
Drilling Process ◽  
Dynamic Analyses ◽  
Thermal Wear ◽  
3D Finite Element Method

Drilling is a highly complex machining process coupled with thermo-mechanical effect. Both the rapid plastic deformation of the workpiece and the friction along the drill-chip interface can contribute to localized heating and increasing temperature in the workpiece and tool. The cutting temperature at the tool-chip interface plays an important role in determining the tool thermal wear. This in turn affects the dimensional accuracy of the workpiece and the tool life of drill. A new embedded heat pipe technology has been proven to be able to effectively not only remove the heat generated at the tool-chip interface in drilling, but also minimize pollution and contamination of the environment caused by cutting fluids. Less tool wear can then be achieved, thus prolonging the tool life. 3D Finite Element method using COSMOS/works is employed to study coupled effects of thermal, structural static and dynamic analyses in a drilling process to check the feasibility and effectiveness of the heat pipe drill. Four different cases, solid drill without coolant, solid drill with coolant, heat pipe drill, and heat pipe drill with coolant, are explored, respectively. The results from this study can be used to define geometric parameters for optimal designs.

Optimization on the Performance of a Precision Flank-Locking Locknut Considering the Machining and Operational Parameters

2017 ◽  
Vol 35 (1) ◽  
pp. 41-49 ◽  
Author(s):  
C. M. Chen ◽  
C. Y. Lee
Keyword(s):  
Taguchi Method ◽  
Axial Force ◽  
Machining Process ◽  
Average Error ◽  
Optimized Design ◽  
Control Parameters ◽  
Operational Parameters ◽  
Machining Processes ◽  
Tightening Torque ◽  
Force Ratio

AbstractIn this study, the anti-loosening characteristics of a precision flank-locking locknut fabricated under various machining processes and tested in different dynamic environments were investigated. The control parameters considered include the tightening torque and thread pitch of the set screw, machining process on the end plane of locknut, and vibration amplitude and frequency of dynamic loading in service, etc. Their sensitivities on the axial force ratio and anti-loosening ratio of the locknut were evaluated using Taguchi method. It was found that the pretension of locknut, the tightening torque and the pitch of set screw, and the machining process of the nut's end plane were the significant control parameters for the anti-loosening performance of the locknut. Moreover, the results of experimental measurements were employed in the regression fit on the performance of the locknut. The regression model was able to predict the anti-loosening ratio with 4.42% average error comparing with the measurements. Furthermore, the optimized design of the locknut through the Taguchi method was able to increase the axial force ratio and anti-loosening ratio by 20.4% and 16.8%, respectively, comparing with standard locknut.

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