Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.

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Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽

10.3390/machines9040075 ◽

2021 ◽

Vol 9 (4) ◽

pp. 75

Author(s):

Nikolaos E. Karkalos ◽

Panagiotis Karmiris-Obratański ◽

Szymon Kurpiel ◽

Krzysztof Zagórski ◽

Angelos P. Markopoulos

Keyword(s):

Surface Roughness ◽

Surface Quality ◽

Process Parameters ◽

Manufacturing Industry ◽

High Surface ◽

Cutting Tools ◽

Cutting Speed ◽

Depth Of Cut ◽

High Surface Quality ◽

Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

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Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

International Journal of Engineering & Technology ◽

10.14419/ijet.v7i2.8.10316 ◽

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.

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Experimental investigation of the machining characteristics in diamond wire sawing of unidirectional CFRP

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-021-07146-8 ◽

2021 ◽

Author(s):

Lukas Seeholzer ◽

Stefan Süssmaier ◽

Fabian Kneubühler ◽

Konrad Wegener

Keyword(s):

Surface Quality ◽

Influencing Factors ◽

Material Properties ◽

High Surface ◽

Workpiece Surface ◽

High Surface Quality ◽

High Productivity ◽

Surface Temperatures ◽

Process Forces ◽

The Wire

AbstractEspecially for slicing hard and brittle materials, wire sawing with electroplated diamond wires is widely used since it combines a high surface quality with a minimum kerf loss. Furthermore, it allows a high productivity by machining multiple workpieces simultaneously. During the machining operation, the wire/workpiece interaction and thus the material removal conditions with the resulting workpiece quality are determined by the material properties and the process and tool parameters. However, applied to machining of carbon fibre reinforced polymers (CFRP), the process complexity potentially increases due to the anisotropic material properties, the elastic spring back potential of the material, and the distinct mechanical wear due to the highly abrasive carbon fibres. Therefore, this experimental study analyses different combinations of influencing factors with respect to process forces, workpiece surface temperatures at the wire entrance, and the surface quality in wire sawing unidirectional CFRP material. As main influencing factors, the cutting and feed speeds, the density of diamond grains on the wire, the workpiece thickness, and the fibre orientation of the CFRP material are analysed and discussed. For the tested parameter settings, it is found that while the influence of the grain density is negligible, workpiece thickness, cutting and feed speeds affect the process substantially. In addition, higher process forces and workpiece surface temperatures do not necessarily deteriorate the surface quality.

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Variothermal Foam Injection Molding - Dimensional Stability with High Surface Quality

Cellular Polymers ◽

10.1177/026248931703600303 ◽

2017 ◽

Vol 36 (3) ◽

pp. 151-166 ◽

Cited By ~ 3

Author(s):

Christian Hopmann ◽

Nicolai Lammert ◽

Yuxiao Zhang

Keyword(s):

Surface Quality ◽

Surface Defects ◽

Control Strategies ◽

High Surface ◽

Skin Layer ◽

High Surface Quality ◽

Major Disadvantage ◽

Scope Of Application ◽

Specific Material ◽

Foam Injection Molding

Thermoplastic foam injection moulding offers various advantages for both processing and product design. Despite its many benefits, the moderate surface quality still constitutes a major disadvantage of this process. The mould temperature can be controlled dynamically to improve the surface quality. Different dynamic temperature control strategies are employed and analysed regarding their effectiveness and scope of application. Mould temperatures above the specific material transition temperatures allow the surface defects to be cured and enable the production of foamed thermoplastic parts with surface qualities comparable to those of the compact reference samples. The high mould temperatures during the injection phase alter the foam structure and the skin layer thicknesses, which impacts the mechanical properties.

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Influence of Manufacturing Process on the Fatigue Strength of Gears

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1018.269 ◽

2014 ◽

Vol 1018 ◽

pp. 269-276

Author(s):

Andrea Reiß ◽

Ulf Engel

Keyword(s):

Fatigue Strength ◽

Surface Quality ◽

Fatigue Behavior ◽

High Surface ◽

Research Work ◽

Dimensional Accuracy ◽

Cold Forging ◽

Hardness Distribution ◽

Forming Process ◽

High Surface Quality

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between manufacturing parameters on the one side, strength and other properties like hardness distribution and surface quality of the component on the other side. The research work covered in this paper focuses on the correlation of the components properties influenced by its manufacturing history and their fatigue strength. The used component is a gear produced by a lateral cold forging process. For the investigations an experimental setup has been designed. The aim for the design of the setup is to reproduce the real contact condition for the contact of two gears. To obtain different component properties the production process of the gear was varied by producing the parts by a milling operation. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

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The growth of gallium phosphide layers of high surface quality by liquid phase epitaxy A commercial process for green licht emitting diodes

Journal of Crystal Growth ◽

10.1016/0022-0248(74)90433-3 ◽

1974 ◽

Vol 27 ◽

pp. 193-204 ◽

Cited By ~ 1

Author(s):

A Mottram

Keyword(s):

Liquid Phase ◽

Surface Quality ◽

Liquid Phase Epitaxy ◽

Gallium Phosphide ◽

High Surface ◽

High Surface Quality ◽

Commercial Process

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Obtaining high surface quality in electrolyte jet machining TB6 titanium alloy via enhanced product transport

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2019.116381 ◽

2020 ◽

Vol 276 ◽

pp. 116381 ◽

Cited By ~ 4

Author(s):

Yang Liu ◽

Ningsong Qu

Keyword(s):

Titanium Alloy ◽

Surface Quality ◽

High Surface ◽

High Surface Quality ◽

Tb6 Titanium Alloy ◽

Electrolyte Jet

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Research of Grinding Material Tools by Modern Grinding Wheels

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.581.211 ◽

2013 ◽

Vol 581 ◽

pp. 211-216 ◽

Cited By ~ 2

Author(s):

Jiří Čop ◽

Imrich Lukovics

Keyword(s):

Boron Nitride ◽

Surface Quality ◽

High Surface ◽

Cubic Boron Nitride ◽

High Accuracy ◽

Grinding Wheels ◽

Cutting Depth ◽

High Surface Quality ◽

Materials Used

This research paper focuses on grinding of materials used for tools (100Cr6 (CSN 4 14109), X210Cr12 ( CSN 4 19436) and epoxy resin) using grinding wheels from cubic boron nitride and diamond. The disadvantage of grinding of difficult-to-machine materials is higher wear of grinding wheels. The modern grinding wheels are able to achieve high accuracy of dimensions and high surface quality with a smaller wear of grinding wheels then grinding wheels from conventional materials. Correctly selected technological conditions are one of the most important matters to achieve the required surface quality. The main aim of this research is to determine the influence of technological conditions to quality of surface after planar grinding. The research determines the influence of the grain type of grinding wheels, feed rate and cutting depth on the quality of functional surfaces.

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Technique Optimization of Dual Rotation Plates Lapping Method for Ceramic Ball

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.359-360.314 ◽

2007 ◽

Vol 359-360 ◽

pp. 314-318

Author(s):

Xun Lv ◽

Ju Long Yuan ◽

Yong Dai

Keyword(s):

Experimental Design ◽

Taguchi Method ◽

Surface Quality ◽

Process Parameters ◽

Ceramic Ball ◽

Slurry Concentration ◽

Machining Conditions ◽

Technique Optimization ◽

Dual Rotation

Dual rotation plates lapping method can effectively solve the limitations of traditional ceramic ball machining methods. This paper focuses on the application of Taguchi method to optimize the technique parameters to lap ceramic ball. The main objective is to study impact degree of the process parameters (lapping load, lapping speed combination and slurry concentration). The results show that the experimental design based on Taguchi method can determine the optimum machining conditions which improve the surface quality and geometrical precision of ceramic ball.

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