Development of an intelligent decision model for non-traditional machining processes

In order to fulfil the ever increasing requirements of various hard and difficult-to-machine materials in automobile, turbine, nuclear, aviation, tool and die making industries, the conventional material removal processes are now being continuously substituted by an array of non-traditional machining (NTM) processes. The efficient and improved capabilities of these NTM processes have made them indispensible for the present day manufacturing industries. While deploying a particular NTM process for a specific machining application, the concerned process engineer must be aware of its capability which is influenced by a large number of controllable parameters. In this paper, an intelligent decision model is designed and developed in VBASIC to guide the concerned process engineer to have an idea about the values of various NTM process responses for a given parametric combination. It would also advise about the tentative settings of different NTM process parameters for achieving a set of target response values. The operational procedure of this developed system is demonstrated with the help of three real time examples.

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Improvement of Machining Processes: A Case Study

Academic Perspective Procedia ◽

10.33793/acperpro.02.03.67 ◽

2019 ◽

Vol 2 (3) ◽

pp. 634-641

Author(s):

Hakan Gökçe ◽

Ramazan Yeşilay ◽

Necati Uçak ◽

Ali Teke ◽

Adem Çiçek

Keyword(s):

Material Removal ◽

Current Practice ◽

Complex Geometry ◽

Vital Role ◽

Machining Process ◽

Machining Processes ◽

Machining Time ◽

Machining Strategy ◽

Removal Processes

In material removal processes, determination of optimal machining strategy is a key factor to increase productivity. This situation is gaining more importance when machining components with complex geometry. The current practice in the determination of machining strategy mostly depends on the experience of the machine operator. However, poorly designed machining processes lead to time-consuming and costly solutions. Therefore, the improvement of machining processes plays a vital role in terms of machining costs. In this study, the machining process of a boom-body connector (GGG40) of a backhoe loader was improved. Improvements of toolpaths and cutting conditions of 22 different material removal processes were checked through a CAM software. According to the simulation results, the process plan was rearranged. Besides, some enhancements in casting model were conducted to decrease in the number of machining operations. When compared to current practice, a reduction of 55% in machining time was achieved.

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Current Trends in Non-Conventional Material Removal Processes

CIRP Annals ◽

10.1016/s0007-8506(07)60195-4 ◽

1986 ◽

Vol 35 (2) ◽

pp. 467-480 ◽

Cited By ~ 107

Author(s):

R. Snoeys ◽

F. Staelens ◽

W. Dekeyser

Keyword(s):

Material Removal ◽

Current Trends ◽

Conventional Material ◽

Removal Processes

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Surface Modification of SKD 61 by Electrical Discharge Coating (EDM/EDC) with Multilayer Cylindrical Electrode and Jatropha Curcas as Dielectric Fluid

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.319.96 ◽

2013 ◽

Vol 319 ◽

pp. 96-101 ◽

Cited By ~ 4

Author(s):

Dedi Priadi ◽

Triyono Pawiro ◽

Eddy S. Siradj ◽

Winarto

Keyword(s):

Jatropha Curcas ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

White Layer ◽

Dielectric Strength ◽

Dielectric Fluid ◽

Conventional Material ◽

Removal Processes ◽

Edm Process

Electrical Discharge Machining (EDM) is the most extensive non-conventional material removal processes used. In recent years, EDM researchers have been explore several sparking efficiency improvement methods including some unique experimental concepts that begin from the EDM traditional sparking phenomenon. This paper reports the use of layered cylindrical electrodes combined with jatropha curcas as dielectric fluid which is not widely used in the EDM process. The results are compared with the EDM process using kerosene dielectric fluid and single electrode (conventional). Dielectric fluid jatropha curcas is expected to substitute the commonly used dielectric fluid. Dielectric strength was tested by the impulse method. Furthermore, the EDM process is measured using surface roughness and microhardness of white layer values at various cutting conditions on the material SKD 61 as an indicator. The highest value of white layer hardness using jatropha curcas dielectric fluid is provided by three layers of electrodes, whereas the lowest is resulted of two layers of electrodes. Meanwhile, the use of kerosene dielectric fluid, the highest hardness value is achieved by two layers of electrodes, and the lowest is produced by three layers of electrodes. This study shows that jatropha curcas dielectric fluid is potential to be used in the EDM process since it produces a smoother surface and higher white layer hardness value.

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Unit process energy consumption models for material removal processes

CIRP Annals ◽

10.1016/j.cirp.2011.03.018 ◽

2011 ◽

Vol 60 (1) ◽

pp. 37-40 ◽

Cited By ~ 348

Author(s):

S. Kara ◽

W. Li

Keyword(s):

Energy Consumption ◽

Material Removal ◽

Unit Process ◽

Removal Processes ◽

Process Energy

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

Volume 4: Processes ◽

10.1115/msec2018-6573 ◽

2018 ◽

Cited By ~ 1

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.

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