Design and evaluation of a feed handle for a bench drilling machine

Work ◽  
2020 ◽  
Vol 67 (2) ◽  
pp. 441-448
Author(s):  
Masood Ashraf ◽  
M. Muzammil ◽  
Abid A. Khan
Keyword(s):  
Task Performance ◽  
Performance Measures ◽  
Metal Removal ◽  
Removal Rate ◽  
Drilling Machine ◽  
Drilling Speed ◽  
Anova Analysis ◽  
Task Duration ◽  
Worker Performance ◽  
Industrial Use

BACKGROUND: Despite extensive industrial use, no major modifications to the bench drilling machine, with respect to ease of operation, have been undertaken. OBJECTIVE: The objectives of the study were to design a new feed handle (NFH) to perform the drilling task on a bench drilling machine and evaluate the existing (EFH) and new feed handles on the basis of performance measures like drilling productivity in terms of metal removal rate (MRR) and worker performance in terms of perceived discomfort score (PDS). METHODS: Participants performed the drilling task on a steel block for three different working durations at two drilling speeds. RESULTS: ANOVA analysis carried out for the MRR data showed that drilling speed had a statistically significant effect on the task performance of the operator for both handles. However, the task duration was found to be statistically significant only for the EFH. The ANOVA results obtained on the PDS data showed that the task duration and drilling speed had a statistically significant effect on the task performance of the operator for both systems. CONCLUSIONS: The MRR obtained was higher when the drilling task was carried out using NFH. An appreciable decrease in PDS was also observed using the proposed system.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Quantification of tool chatter and metal removal rate using wavelet denoising and statistical approach

2018 ◽  
Vol 49 (2) ◽  
pp. 62-81 ◽  
Author(s):  
Shailendra Kumar ◽  
Bhagat Singh
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Removal ◽  
Removal Rate ◽  
Statistical Significance ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Metal Removal Rate ◽  
Chatter Index ◽  
Tool Chatter

Tool chatter is an unavoidable phenomenon encountered in machining processes. Acquired raw chatter signals are contaminated with various types of ambient noises. Signal processing is an efficient technique to explore chatter as it eliminates unwanted background noise present in the raw signal. In this study, experimentally recorded raw chatter signals have been denoised using wavelet transform in order to eliminate the unwanted noise inclusions. Moreover, effect of machining parameters such as depth of cut ( d), feed rate ( f) and spindle speed ( N) on chatter severity and metal removal rate has been ascertained experimentally. Furthermore, in order to quantify the chatter severity, a new parameter called chatter index has been evaluated considering aforesaid denoised signals. A set of 15 experimental runs have been performed using Box–Behnken design of experiment. These experimental observations have been used to develop mathematical models for chatter index and metal removal rate considering response surface methodology. In order to check the statistical significance of control parameters, analysis of variance has been performed. Furthermore, more experiments are conducted and these results are compared with the theoretical ones in order to validate the developed response surface methodology model.

Multiresponse Optimization of Al Alloy-SiC Composite Machining Parameters for Minimum Tool Wear and Maximum Metal Removal Rate

2013 ◽  
Vol 135 (2) ◽  
Author(s):  
Rajesh Kumar Bhushan
Keyword(s):  
Tool Wear ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Machining Parameters ◽  
Metal Removal Rate ◽  
Nose Radius ◽  
Multiresponse Optimization

Optimization in turning means determination of the optimal set of the machining parameters to satisfy the objectives within the operational constraints. These objectives may be the minimum tool wear, the maximum metal removal rate (MRR), or any weighted combination of both. The main machining parameters which are considered as variables of the optimization are the cutting speed, feed rate, depth of cut, and nose radius. The optimum set of these four input parameters is determined for a particular job-tool combination of 7075Al alloy-15 wt. % SiC (20–40 μm) composite and tungsten carbide tool during a single-pass turning which minimizes the tool wear and maximizes the metal removal rate. The regression models, developed for the minimum tool wear and the maximum MRR were used for finding the multiresponse optimization solutions. To obtain a trade-off between the tool wear and MRR the, a method for simultaneous optimization of the multiple responses based on an overall desirability function was used. The research deals with the optimization of multiple surface roughness parameters along with MRR in search of an optimal parametric combination (favorable process environment) capable of producing desired surface quality of the turned product in a relatively lesser time (enhancement in productivity). The multi-objective optimization resulted in a cutting speed of 210 m/min, a feed of 0.16 mm/rev, a depth of cut of 0.42 mm, and a nose radius of 0.40 mm. These machining conditions are expected to respond with the minimum tool wear and maximum the MRR, which correspond to a satisfactory overall desirability.

Swirling Fluidized Bed Polishing: A New Non-Conventional Method of Surface Modification

2015 ◽  
Vol 813-814 ◽  
pp. 634-640
Author(s):  
N.K. Francis ◽  
K.G. Viswanadhan ◽  
M.M. Paulose
Keyword(s):  
Surface Modification ◽  
Fluidized Bed ◽  
Metal Removal ◽  
Complex Geometry ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Surface Finishing ◽  
Polished Surface ◽  
Work Piece ◽  
Machining Accuracy

Swirling Fluidized Bed Polishing (SFBP) is a non–traditional alternative abrasive flow surface finishing form of Fluidized Bed Machining (FBM) in which the former has special features to overcome certain significant limitations of the latter, namely the variation of the surface roughness vertically along the component surface and the screening effect owing to the complex contours in the work piece geometry. Owing to its ability to perform machining and generate polished surface from a roughness value of Ra 1.2μ to 0.2 μ within 8 hours of processing, this new method offers greater scope in the surface modification of rough machined surfaces with complex geometry such as component with ducts and grooves. This research focus on investigating the effect of abrasive particle concentration on metal removal rate per unit area of the specimen surface. 3D surface morphology analysis investigates the quality of the polished surface and the study of circumferential uniformity and machining accuracy analysis on a complex-contoured component further investigate its scope and relevance in industrial applications.

scholarly journals Multi response Particle Swarm Optimization of Wire Electro Discharge Machining parameters of Nitinol alloys

2020 ◽  
Author(s):  
Mohammed Yunus ◽  
Mohammad S. Alsoufi
Keyword(s):  
Particle Swarm Optimization ◽  
Metal Removal ◽  
Removal Rate ◽  
Particle Swarm ◽  
Optimization Method ◽  
Machining Parameters ◽  
Swarm Optimization ◽  
Electro Discharge Machining ◽  
Process Factors ◽  
Wedm Process

Abstract The conventional process of Machining of Nitinol alloy leads to extensive wear on the tool and deprived surface quality. Wire electro discharge machining (WEDM) is widely accepted for machining this alloy involving various input factors, namely, P, (pulse-on-duration), Q, (pulse-off-duration), C, (maximum-current), and V, (voltage). The factor’s effect on MRR (metal removal rate) and SR (surface roughness) responses and multi-response optimization of the WEDM process by employing PSO (particle swarm optimization) method are studied. The relationship model between factors and response characteristics were generated by ANOVA and optimized by response surface methodology has shown more significant factors (A and C). Though the effect of WEDM process factors on SR and MRR are contradictory when studied individually. MRPSO method was employed to get the best optimum condition for minimizing SR and maximizing MRR. MRPSO results improved the responses for vast combination of optimal setting of factors to meet the product requirements.

Steel Wire Grinding Testing Based on New Type Abrasive Belt Grinding Machine

2012 ◽  
Vol 602-604 ◽  
pp. 2273-2278
Author(s):  
Ping Zhang ◽  
Jia Chun Li
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Steel Wire ◽  
Research Work ◽  
Wire Drawing ◽  
Belt Grinding ◽  
Abrasive Belt ◽  
New Type ◽  
Working Principle ◽  
Grinding Machine

As a new process, the abrasive belt grinding plays an increasingly important role in the field of machining. It meets a variety of processing requirements. The concept of abrasive belt grinding and its working principle were introduced, and a new type of abrasive belt grinding equipment for removing the rust on steel wire surface was designed. Some key experiments for testing grinding force，the metal removal rate，belt wear rate、grinding ratio，grinding depth and wire speed were studied. The research work provides rational parameters for the pretreatment of rust removal in metal wire drawing processing.

Optimization of MRR and Surface Roughness of AlMg3 (AA5754) Alloy in CNC Lathe Machine by Using Taguchi Method

2018 ◽  
Vol 877 ◽  
pp. 110-117 ◽  
Author(s):  
Poornesh Kumar Chaturvedi ◽  
Harendra Kumar Narang ◽  
Atul Kumar Sahu
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Metal Removal ◽  
Removal Rate ◽  
Surface Condition ◽  
Point Of View ◽  
Depth Of Cut ◽  
Metal Removal Rate ◽  
Cnc Lathe ◽  
Lathe Machine

Quality of the product is the major concern in manufacturing industries from customers as well as producers point of view. There are number of factors in the product such as surface condition, height, weight, length, width etc., which may be consider for the measurement of the quality. Surface roughness and Metal Removal Rate (MRR) are the two main outcomes on which numerous researchers have applied different approaches for several years to get optimum results. In this study, Taguchi Method is applied for getting optimum parameters settings for Surface roughness and Metal Removal Rate (MRR) in case of turning AlMg3 (AA5754) in CNC Lathe machine, which is an aluminum alloy having diameter 20 mm and length 100 mm. The three parameters i.e. spindle speed, feed rate and depth of cut with 3 levels are taken as the process variables and the working ranges of these parameters for conducting experiments are selected based on Taguchi’s L9 Orthogonal Array (OA) design. To analyze the significant process parameters; main effect plots for data means and for S/N ratio are generated using Minitab statistical software.

scholarly journals Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

2021 ◽  
Author(s):  
Dragan Rodic ◽  
Marin Gostimirovic ◽  
Milenko Sekulic ◽  
Borislav Savkovic ◽  
Branko Strbac
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Positive Effects ◽  
Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

EDM Process Parameters Optimization for Al-TiO2 Nano Composite

2015 ◽  
Vol 2 (2) ◽  
pp. 17-30 ◽  
Author(s):  
Arvind Kumar Dixit ◽  
Richa Awasthi
Keyword(s):  
Discharge Current ◽  
Titanium Aluminide ◽  
Metal Removal ◽  
Removal Rate ◽  
Stir Casting ◽  
Parameters Optimization ◽  
Parameter Design ◽  
Nano Composite ◽  
Pulse On Time ◽  
Edm Process

Titanium aluminide reinforced aluminium based metal matrix nano composite was prepared by stir casting route. Experiments were conducted with Cu electrode using L9 orthogonal array based on the Taguchi method. Discharge current (Lv), Pulse on time (Ton) and Flushing pressure (FP) are selected to calculate Metal removal rate (MRR), Tool wear rate (TWR) and Surface roughness (SR) based on Taguchi's parameter design. Moreover, the signal-to-noise ratios associated with the observed values in the experiments were determined using MINITAB software for MRR, TWR and SR. PCR – TOPSIS method is used to optimize Taguchi's multi response. Optimum parameter setting is found at Discharge current (Lv) 10 A, Pulse on time (Ton) 150 µs and Flushing pressure (FP) 1 kg/cm2.

Effect of the Al2O3 powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

2020 ◽  
Vol 234 (12) ◽  
pp. 1538-1548 ◽  
Author(s):  
Hossam M Yehia ◽  
Mohamed Hakim ◽  
Ahmed El-Assal
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Lower Surface ◽  
Maximum Effect ◽  
Metal Removal Rate ◽  
Powder Addition ◽  
Different Depths ◽  
Electrochemical Grinding ◽  
Better Than

The integrated electrochemical grinding machining has received wide acceptance in the aircraft turbine industry for the machining of blades, vanes, and honeycomb seal rings. Also, medical devices, instruments and forceps, shells, precision nozzles, instrument coupling, and air rotor motors that produced from stainless steel and new materials have all successfully been accomplished with electrochemical grinding. To improve the metal removal rate and to reduce the surface roughness ( Ra) of the electrochemical grinding at high voltages, an integration between the alumina abrasive jet and the electrochemical grinding machining has been performed. The effect of the Al2O3 abrasive content on the metal removal rate and the Ra of the K110 alloy steel using Everite electrochemical grinding 618 at different voltages, different feed rates, different electrolyte NaCl concentrations, and different depths of the cut were successfully investigated. The results revealed that the abrasive electrochemical grinding was better than the electrochemical grinding results. The maximum effect of the Al2O3 on the metal removal rate was achieved at 5 wt.%. The current density in the machining gap was affected by the addition of the Al2O3, where it was decreased at percentages over 5-wt.% Al2O3. The abrasive electrochemical grinding resulted in lower surface roughness than the electrochemical grinding process.

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