Modeling and Optimization of Ultrasonic Machining Process Using a Novel Evolutionary Algorithm

2019 ◽  
pp. 153-174
Author(s):  
Mantra Prasad Satpathy ◽  
Bharat Chandra Routara
Keyword(s):  
Evolutionary Algorithm ◽  
Removal Rate ◽  
Ceramic Matrix Composites ◽  
Imperialist Competitive Algorithm ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Ultrasonic Machining ◽  
Hard And Brittle Materials ◽  
Experimental Values ◽  
Single Response

Ultrasonic machining (USM) is one of the non-conventional techniques for machining of hard and brittle materials like glass, ceramics, and ceramic matrix composites. The objective of the study includes the investigation of material removal rate (MRR), hole oversize (HOS), and circularity of holes (COH) during USM of soda lime glass and finding out the optimal parametric condition by an evolutionary algorithm. Taguchi philosophy was employed to carry out experiments using the process parameters such as power rating, abrasive slurry concentration, and static load. A novel optimization algorithm called imperialist competitive algorithm (ICA) was used to obtain maximum MRR and minimum HOS and COH. This algorithm is inspired by the imperialistic competition and has several advantages over other evolutionary algorithms like its simplicity, less computational time, and accuracy in predicting the results. The Technique for order of preference by similarity to ideal solution (TOPSIS) is utilized to convert these multiple performance characteristics to a single response. Moreover, the prediction outcomes of this TOPSIS integrated ICA methodology demonstrates excellent conformity with the experimental values and can be applied to solve complex problems.

Grey Relation Approach in Abrasive Jet Machining Process

2019 ◽  
Author(s):  
Lijo Paul ◽  
J. Babu
Keyword(s):  
Removal Rate ◽  
Brittle Materials ◽  
Soda Lime ◽  
Machining Process ◽  
Soda Lime Glass ◽  
Abrasive Particles ◽  
Abrasive Jet Machining ◽  
Conducting Materials ◽  
Hard And Brittle Materials ◽  
Relation Approach

Abstract Micro machining of conducting and non-conducting materials with high accuracy has great demand in industries especially in machining of ceramic, brittle materials. Abrasive Jet Machining (AJM) has shown tremendous application especially in machining of hard and brittle materials. In the present paper drilling of soda lime glass has been carried out to determine the machinability under different controlling parameters. A set of L9 series experiments were carried out by varying process parameters such as Stand Off Distance (SOD), Silicon carbide abrasive particles mesh sizes and jet pressure. Material Removal Rate (MRR) and Radial Over Cut (ROC), were taken as the output responses and are optimised with multi objective optimisation.

Characterisation of Micro Channels in Electrochemical Discharge Machining Process

2014 ◽  
Vol 490-491 ◽  
pp. 238-242 ◽  
Author(s):  
Lijo Paul ◽  
Somashekhar S. Hiremath
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Soda Lime ◽  
Machining Process ◽  
Soda Lime Glass ◽  
Micro Channels ◽  
Hybrid Machining Process ◽  
Response Surface Modelling ◽  
Experimental Values ◽  
Machining Operations

Micromachining techniques has increased the demand for precise and accurate instruments which are used in many industries. Glass materials offer higher challenges in micro machining as they are tough, non-conducting and difficult to machine with conventional machining operations. Electro Chemical Discharge Machining (ECDM) is a new non-conventional hybrid machining process which combines the features of Electrical Discharge Machining (EDM) and Electro Chemical Machining (ECM) to machine both conducting and nonconducting materials. In the present paper effect of various process parameters like voltage, concentration of electrolyte, duty factor and temperature on ECDM process are studied to obtain desired micro channels in soda lime glass. Design of Experiment (DOE) is used to plan and conduct the experiments. The Response Surface Modelling (RSM) is used for characterising non linear output responses in terms of material removal rate and surface finish. Modeled results are validated with experimental values.

A Comparative Study on Ultrasonic Machining of Red Granite

2011 ◽  
Vol 175 ◽  
pp. 150-156 ◽  
Author(s):  
Shu You Zheng ◽  
Xi Peng Xu
Keyword(s):  
Machine Tool ◽  
Removal Rate ◽  
Hole Drilling ◽  
Natural Material ◽  
Ultrasonic Machining ◽  
Ultrasonic Machine ◽  
Higher Power ◽  
Hard And Brittle Materials ◽  
Stone Material ◽  
The Given

Ultrasonic machining has been proven to be a promising machining method on hard and brittle materials. However, due to the absence of high power ultrasonic machine tools, reported studies on ultrasonic machining were mainly concerned of relatively small hole drilling of the given materials. In the present work, with the development of the higher power Rotary Ultrasonic Machine Tool, two kinds of ultrasonic face machining with free abrasives, namely, Non-rotating Ultrasonic Machining with Free Abrasives (NRUSM) and Rotary Ultrasonic Machining with Free Abrasives (RUSM) are designed and comparatively conducted for the red granite, which is a typical hard-to-machine natural material. The effects of static force, spindle speed and amplitude of ultrasonic vibration on the performance of the machining are evaluated in terms of the material removal rate and surface quality. Experimental results indicate that ultrasonic machining is effective for face milling of the stone material with the designed machine tool. Furthermore, machining performances in RUSM are superior to those in NRUSM.

A 3D Spark Model to Evaluate MRR in ECDM

2019 ◽  
Vol 18 (03) ◽  
pp. 435-446 ◽  
Author(s):  
Dilpreet Singh ◽  
Mudimallana Goud
Keyword(s):  
Removal Rate ◽  
Convection Heat Transfer ◽  
Soda Lime ◽  
Spark Discharge ◽  
Machining Process ◽  
Soda Lime Glass ◽  
Chemical Action ◽  
Electrochemical Discharge Machining ◽  
Element Simulation ◽  
Advanced Machining

Electrochemical discharge machining (ECDM) is an advanced machining process which uses both chemical action and spark discharge method for removal of materials. Till date, most of the applications of ECDM are in machining nonconductive materials, although some authors have also tried machining conductive materials. This paper attempts to develop a finite element simulation model based on heat generation in the spark region to evaluate material removal rate (MRR) in case of quartz and soda lime glass. The calculation of MRR is based on melting and evaporation of the material due to high temperature generated due to spark discharge. Convection heat transfer is also considered in the analysis. The results obtained from the simulation are compared with available experimental results and previous simulation results. Although this process is not used in the industry till now, it has a lot of scope for research and development.

An Investigation on Electrochemical Discharge Micro-Drilling of Glass

2013 ◽  
Author(s):  
Mohammad Reza Razfar ◽  
Jun Ni ◽  
Ali Behroozfar ◽  
Shuhuai Lan
Keyword(s):  
Mathematical Models ◽  
Response Surface ◽  
Applied Voltage ◽  
Electrolyte Concentration ◽  
Design Method ◽  
Removal Rate ◽  
Soda Lime ◽  
Immersion Depth ◽  
Soda Lime Glass ◽  
Electrochemical Discharge

Electrochemical Discharge Machining (ECDM) as an innovative spark-based micromachining method has been successfully applied for fabricating micro-holes in non-conductive brittle materials such as glass. However, the effects of influencing parameters for attaining accurate structures and dimensions remain to be explored. This paper attempts to analyze the effects of process parameters including applied voltage, tool immersion depth and electrolyte concentration on process outputs such as radial overcut (ROC), material removal rate (MRR), heat affected zone (HAZ) thickness and roundness error (RE) of the holes. In this regard, a set of experiments based on response surface experiment design method were conducted on soda lime glass. The relevant experimental data were used to establish mathematical models for process outputs using the response surface methodology (RSM). The obtained results show that applied voltage significantly increases the ROC, MRR, HAZ and RE. Also, electrolyte concentration has the same effects on mentioned outputs except the ROC. In addition, greater tool immersion depth decreases the MRR and HAZ thickness. The adequacy of the developed mathematical models was also evaluated by an analysis of variance (ANOVA) test. The relevant results show the capability of the proposed approach to investigate the ECDM process of glass.

Hydrophobic Templates with Rough Patterns Fabricated by Laser Micromachining for Liquid Droplets Generation

2011 ◽  
Vol 264-265 ◽  
pp. 1234-1239
Author(s):  
Shih Feng Tseng ◽  
Kuo Cheng Huang ◽  
Don Yau Chiang ◽  
Ming Fei Chen ◽  
Sheng Yi Hsiao ◽  
...  
Keyword(s):  
Sessile Drop ◽  
Removal Rate ◽  
Liquid Droplet ◽  
Glass Plate ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Laser Exposure ◽  
Single Shot ◽  
Liquid Droplets ◽  
Atomic Force

This paper presents an approach to utilize high precision pulsed Nd:YAG laser to fabricate a rough array-pattern on a soda-lime glass plate by a laser-induced backside writing (LIBW) process, and a laser-induced plasma assisted ablation (LIPAA) technique. The current study investigates the effect of process parameters such as single-shot laser exposure time and number of passes on the material removal rate. After depositing 695 nm thick Teflon thin film on the glass plate, the surface of the laser micro-machined template becomes hydrophobic. The surface roughness, annular groove profile and surface micrograph were measured by an atomic force microscope, a profilometer, and a scanning electron microscope, respectively. A uniform liquid droplet by the sessile drop method is generated on the hydrophobic template. Droplet characteristics, such as contacted angle, size, and shape, are measured with a surface tension analyzer and microscope. This work also discusses the relationship between the formed droplets and the process recipe of the micro-machined template. The proposed approach can apply to future for uniform lens array formation.

Tool Wear and Form Accuracy in Ultrasonic-Assisted Milling of Soda-Lime Glass

2018 ◽  
Vol 786 ◽  
pp. 206-214
Author(s):  
Yasmine El-Taybany ◽  
Mohab Hossam ◽  
Hassan El-Hofy
Keyword(s):  
Tool Wear ◽  
Brittle Materials ◽  
Soda Lime ◽  
Machining Process ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Form Accuracy ◽  
Ultrasonic Assisted ◽  
Hard And Brittle Materials ◽  
Vibration Assistance

Machining of hard and brittle materials is inherently involved with tool wear, which influences the dimensional and form accuracy of the machined product. Ultrasonic-assisted machining process is suitable for hard-to-cut materials such as ceramics, glass, and metal matrix composites, etc. In the current study, the mechanism of tool wear is investigated during ultrasonic-assisted milling of soda-lime glass as one of hard and brittle materials. Ultrasonic-Assisted Milling (UAM) combines the material removal mechanism of grinding and the milling kinematics with ultrasonic assistance. The effect of different process parameters, i.e. feed rate, depth of cut, cutting fluid, and ultrasonic vibration assistance on the tool wear behavior are investigated. Form accuracy of the machined slots is also investigated. The results showed that UAM produces less tool wear than conventional milling (CM). However, CM gives less error in the slot dimensions than UAM.

Highly efficient biocide silver-doped soda lime glass for application in water quality optical sensors

2020 ◽  
Vol 111 (10) ◽  
pp. 857-862
Author(s):  
Branimir Bajac ◽  
Jovana Stanojev ◽  
Slobodan Birgermajer ◽  
Milena Radojevic ◽  
Jovan Matovic
Keyword(s):  
Water Quality ◽  
Optical Sensors ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Highly Efficient

scholarly journals Microfabrication and Surface Functionalization of Soda Lime Glass through Direct Laser Interference Patterning

Nanomaterials ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 129
Author(s):  
Marcos Soldera ◽  
Sabri Alamri ◽  
Paul Alexander Sürmann ◽  
Tim Kunze ◽  
Andrés Fabián Lasagni
Keyword(s):  
Laser Radiation ◽  
Surface Functionalization ◽  
Incident Light ◽  
Chemical Properties ◽  
Visible Spectrum ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Textured Surfaces ◽  
Aspect Ratios ◽  
Direct Laser

All-purpose glasses are common in many established and emerging industries, such as microelectronics, photovoltaics, optical components, and biomedical devices due to their outstanding combination of mechanical, optical, thermal, and chemical properties. Surface functionalization through nano/micropatterning can further enhance glasses’ surface properties, expanding their applicability into new fields. Although laser structuring methods have been successfully employed on many absorbing materials, the processability of transparent materials with visible laser radiation has not been intensively studied, especially for producing structures smaller than 10 µm. Here, interference-based optical setups are used to directly pattern soda lime substrates through non-lineal absorption with ps-pulsed laser radiation in the visible spectrum. Line- and dot-like patterns are fabricated with spatial periods between 2.3 and 9.0 µm and aspect ratios up to 0.29. Furthermore, laser-induced periodic surface structures (LIPSS) with a feature size of approximately 300 nm are visible within these microstructures. The textured surfaces show significantly modified properties. Namely, the treated surfaces have an increased hydrophilic behavior, even reaching a super-hydrophilic state for some cases. In addition, the micropatterns act as relief diffraction gratings, which split incident light into diffraction modes. The process parameters were optimized to produce high-quality textures with super-hydrophilic properties and diffraction efficiencies above 30%.

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