Analysis and Optimization of Process Parameters of Abrasive Flow Machining Process for Super Finishing of Non-Ferrous Material Nozzle

2014 ◽  
Vol 612 ◽  
pp. 97-104 ◽  
Author(s):  
Vijay B. Patil ◽  
Amol S. Bhanage ◽  
Rajat S. Patil
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
New Technology ◽  
Mesh Size ◽  
Flow Speed ◽  
Machining Process ◽  
Plasma Cutting ◽  
Abrasive Flow Machining ◽  
Number Of Cycles ◽  
Hierarchy Process

This paper deals with the improving lay of finish and the superfinishing of the nozzles which is used in plasma cutting operation. This is basically alternative solution to present finish obtained by turning, drilling and reaming of the profiled bores and orifices. The advance micromachining process were developed, known as Abrasive Flow Machining (AFM) which is capable to altering the orifice (nozzle of plasma cutting machines) so that present process is to be improved without altering the geometry of the component. The effects of different process parameters such as number of cycles, concentration of abrasive, abrasive mesh size and media flow speed, surface finish are studied here. The design of the experiments 16(24) provides two levels for each variable. These levels are taken into consideration for finding out the effect of variation of parameters on the surface roughness of the copper orifice. The objective of paper is to learn how each parameter is considered for Abrasive Flow Machining such as: abrasive concentration in media, number of cycles, abrasive mesh size and media flow speed affects the surface roughness of copper orifice also to find out the mathematical relationship between surface roughness value and process parameters. Analysis of Variance (ANOVA) for the experimental data has been carried out and optimizations of abrasive flow machining process parameters were done. Also Analytic Hierarchy Process (AHP) done here for selecting hierarchy process parameter .Capabilities of the machine ultimately improved with the new technology developed.

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.

Development of the improved Preston equation for abrasive flow machining of aerofoil structures and components

2018 ◽  
Vol 233 (9) ◽  
pp. 1397-1404 ◽  
Author(s):  
Kai Cheng ◽  
Yizhi Shao ◽  
Mitul Jadva ◽  
Rodrigo Bodenhorst
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Machining Process ◽  
Dynamics Simulation ◽  
Abrasive Machining ◽  
Abrasive Particles ◽  
Abrasive Flow Machining ◽  
Flow Features ◽  
The Media ◽  
Experimental Trials

The paper presents an improved Preston equation, which aims to be part of the industrial application to abrasive flow machining. The equation will aid the engineers to optimise the process for desired surface roughness and edge tolerance characteristics on complex geometries in an intuitive and scientific manner. The methodology presented to derive the equation underpins the fundamental cutting mechanics of abrasive machining or polishing assuming all abrasive particles within the media are spherical as manufacturers defined. Further to derivation, full four factorial experimental trials and computational fluid dynamics simulation are implemented to generate the flow features of media on coupon to evaluate and validate the equation for its competency and accuracy on prediction of material removal. The modified Preston equation can significantly contribute to optimise the abrasive flow machining process, and will advantage the integrated machine design to predict better virtual surface roughness and material removal rates.

Study on the improvement of the surface integrity and efficiency of electrical-discharge-machined TC4 titanium alloy via abrasive flow machining

2020 ◽  
pp. 095440542097109
Author(s):  
Ze Yu ◽  
Dunwen Zuo ◽  
Yuli Sun ◽  
Guohua Li ◽  
Xuemei Chen ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Small Hole ◽  
Machining Process ◽  
Machining Efficiency ◽  
Abrasive Flow Machining ◽  
Tc4 Titanium Alloy

To simultaneously optimize the surface quality and machining efficiency of the electrical discharge machining (EDM) processes used to produce titanium alloy quadrilateral group small hole parts, a combined “EDM + AFM” machining technology is proposed in this paper as an efficient and high-quality machining approach. In the proposed method, TC4 titanium alloy is first machined using the EDM process with graphite electrodes and the abrasive flow machining (AFM) process is then used to finish the machined surface. The effects of various electrical parameters on EDM-derived surface quality and improvements in EDM-derived quality under the application of AFM were assessed and, using the final surface roughness as a constraint condition, the effects of various combinations of EDM and “EDM + AFM” on efficiency were studied. The results revealed that the thickness and surface roughness of the superficial recast layer of the TC4 titanium alloy increase with both current and pulse width; in particular, increasing these parameters can increase the surface roughness by two to three grades. Following AFM, the alloy has a more uniform hardness distribution and the surface stress state changes from tensile to compressive stress, indicating that the combined “EDM + AFM” machining scheme can significantly enhance the surface quality of EDM-produced titanium alloy quadrilateral small group holes. The combined scheme achieves a balancing point beyond which increasing the roughness or the number of machining holes enhances either the machining efficiency or the machining surface quality. In the case of typical titanium alloy quadrilateral group small hole parts, the combined machining process can improve the finishing efficiency and total machining efficiency by 71.2% and 25.36%, respectively.

Analysis of the surface roughness obtained by the abrasive flow machining process using an abrasive paste with oiticica oil

2020 ◽  
Vol 106 (11-12) ◽  
pp. 5061-5070 ◽  
Author(s):  
Marcelo Rodrigo Munhoz ◽  
Larissa Galante Dias ◽  
Ricardo Breganon ◽  
Fernando Sabino Fonteque Ribeiro ◽  
Janaina Fracaro de Souza Gonçalves ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Machining Process ◽  
Abrasive Flow Machining

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

Optimization of Process Parameters on Ti-6Al-4V Using Central Composite Design Method

2011 ◽  
Vol 189-193 ◽  
pp. 1393-1400 ◽  
Author(s):  
M.M. Rahman
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Peak Current ◽  
Long Pulse ◽  
Pulse On Time

Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of process parameters on output response of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. Mathematical models for material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) are developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest EWR. Long pulse off time provides minimum EWR and the impact of pulse interval on EWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters. It found that the peak current, servo voltage and pulse on time are significant in material removal rate and surface roughness. Peak current has the greater impact on surface roughness and material removal rate.

scholarly journals Experimenting and Predicting Flatness and Surface Roughness during Face Milling Operation of CF8M Grade A-351

10.29007/dcj5 ◽  
2018 ◽  
Author(s):  
Purvi Chauhan ◽  
Sagar Patel ◽  
Karan Patel
Keyword(s):  
Surface Roughness ◽  
Regression Model ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Check Valve ◽  
Face Milling ◽  
Machining Process ◽  
Milling Operation ◽  
Surface Flatness ◽  
Two Parameters

Surface flatness and roughness has a pivotal role in the functioning of any kind of check valve. These two parameters are mainly obtained by face milling[16] during the manufacturing process of valves. The values of these affect during leakage rejection and redesign of check valves. To achieve the desired values of surface flatness and roughness here analysis is carried out. A regression model is generated to predict the values of surface roughness and flatness. ANOVA is also developed to see the effect of machining process parameters on the surface roughness and flatness.

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