Optimizing of Integral Impeller NC Program Based on the Material Removal Rate

2014 ◽  
Vol 1030-1032 ◽  
pp. 1305-1308
Author(s):  
Shi Chao Li ◽  
Song Lin Wu ◽  
Yan Kun Liang
Keyword(s):  
Material Removal Rate ◽  
Machine Tools ◽  
Material Removal ◽  
Removal Rate ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Nc Machine ◽  
Nc Machine Tools ◽  
Five Axis

It is a general processing technology that multi-axis NC machine tools is used for machining impeller at present. In order to improve the machining accuracy of the five-axis NC machine tools, the paper analyzes the computing interpolation error of the Multi-axis CNC system in detail. Some of the measures of tools selection have been proposed in purpose of diminishing the accumulative error of the system. The paper also establishes the optimized objective function to optimize the process parameters of the CNC machining based on the material removal rate. All these measures will improve the machining efficiency significantly and increase the stationary of the machining process.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Schruppfräsbearbeitung von Verdichterscheiben/Milling of compressor disk - Identification of a cutting material and coating combination for high process reliability

2017 ◽  
Vol 107 (09) ◽  
pp. 674-680
Author(s):  
E. Prof. Abele ◽  
C. Hasenfratz ◽  
C. Praetzas ◽  
G. M. Schüler ◽  
C. Stark ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Manufacturing Technology ◽  
Machining Process ◽  
Complex Task ◽  
Eine Hohe ◽  
Process Reliability ◽  
Rough Milling ◽  
Compressor Disk

Die Herstellung von Verdichterscheiben stellt hohe Ansprüche an die Fertigungstechnik. Neue, schwer zu zerspanende Materialien und Integralkonstruktionen erzeugen eine hohe Komplexität bei der Ausführung. Das Projekt „SchwerSpan“ stellt sich dieser Herausforderung und entwickelt einen Prozess zur Schruppfräsbearbeitung von Verdichterscheiben. Ziel des Projekts ist eine Reduktion der Werkzeugkosten bei erhöhtem Zeitspanvolumen.   The production of compressor disks places high demands on the manufacturing technology. A very complex task is created by new difficult-to-cut materials and integral components. The project “SchwerSpan” is taking on this task by developing a machining process for rough milling in the production of compressor disks. The aim of the process is to reduce the tool costs by increasing material removal rate.

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

2018 ◽  
Vol 233 (6) ◽  
pp. 1896-1909 ◽  
Author(s):  
VG Ladeesh ◽  
R Manu
Keyword(s):  
Material Removal Rate ◽  
Borosilicate Glass ◽  
Chemical Etching ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Hybrid Technique ◽  
Machined Surface ◽  
Influence Of Process Parameters ◽  
Electrochemical Discharge

The electrically non-conductive materials like glass, ceramics, quartz, etc. are of great interest for many applications in modern industries. Machining them with high quality and at a faster rate is a challenging task. In this study, a novel technique called grinding aided electrochemical discharge drilling (G-ECDD) is demonstrated which uses a hollow diamond core drill as the tool for performing electrochemical discharge machining of borosilicate glass. The new hybrid technique enhances the material removal rate and machining accuracy to several folds by combining the thermal melting action of discharges and grinding action of the abrasive tool. This paper presents the experimental investigation on the material removal rate during G-ECDD of glass while using different electrolytes. An attempt has been made to explore the influence of electrolyte temperature on G-ECDD performance by maintaining the electrolyte at different temperatures. Experiments were conducted using three different electrolytes which include NaOH, KOH, and the mixture of both. The results obtained from this study revealed that an increase in temperature will favor chemical etching as well as electrochemical reaction rate. Also, it was observed that heating the electrolyte leads to an increase in the bubble density and enhances the ion mobility. This causes the formation of gas film at a faster rate and thereby improving the discharge activity. Thus, machining will be done at a faster rate. Better results are obtained while using a mixture of NaOH and KOH. From the microscopic images of the machined surface, it was observed that material removal mechanism in G-ECDD is a combination of grinding action, electrochemical discharges, and chemical etching. Response surface methodology was adopted for studying the influence of process parameters on the performance of G-ECDD. The new technique of grinding aided electrochemical discharge drilling proved its potential to machine borosilicate glass and simultaneously offers good material removal rate, repeatability, and accuracy.

Effect of Frequency to Ultrasonic Vibration-Assisted Wire-EDM

2019 ◽  
Vol 814 ◽  
pp. 127-131
Author(s):  
Patittar Nakwong ◽  
Apiwat Muttamara
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Machining Process ◽  
Wire Electrode ◽  
Ultrasonic Machine ◽  
Lower Amplitude ◽  
Wedm Process

Wire electrical discharge machine (WEDM) is non-conventional machining process. It can be used for hard cutting material. The study has been presented the combining WEDM with an ultrasonic machine (USM) with brass and tungsten were used as a wire electrode and workpiece respectively. The experiment was carried out with an ultrasonic transducer at 40, 80 kHz. The results were observed with the material removal rate (MRR) and surface roughness (Ra). This research introduced the method of USM setup and described the effected of vibration with the wire electrode on the displacement of amplitude. The result shows that the WEDM process with USM at 40 kHz can be more improved with the material removal rate and surface roughness than that of USM at 80 kHz. This can be explained that higher frequency affected to vibration displacement which makes lower amplitude.

Intelligent Modeling and Optimization of Material Removal Rate in Electric Discharge Diamond Grinding

2012 ◽  
Author(s):  
Pankaj Kumar Shrivastava ◽  
Avanish Kumar Dubey
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Iron Carbide ◽  
Hybrid Approach ◽  
Weight Ratio ◽  
Manufacturing Industries ◽  
Machining Process ◽  
Diamond Grinding

Metal matrix composites (MMCs) have wide applications in modern manufacturing industries due to their specific and improved technological characteristics such as high strength to weight ratio, high hardness, high thermal, corrosion and wear resistances. Such characteristics are highly demanded in automobile, aircraft and space research organizations. Shaping of MMCs has been a big challenge for manufacturing industries due to their superior mechanical properties and the peculiar microstructure composed of different phases in MMCs poses machining challenges. Unconventional machining methods have become an alternative to give desired shapes with intricate profiles and stringent design requirements. The aim of present research is to investigate the machining performance of copper-iron-carbide MMC using hybrid machining process, electric discharge diamond grinding (EDDG). A hybrid approach of neural network and genetic algorithm has been used to develop the intelligent model for material removal rate (MRR) and subsequent optimization with the experimental data obtained by scientifically designed experimentation.

scholarly journals An Experimental Study on the Precision Abrasive Machining Process of Hard and Brittle Materials with Ultraviolet-Resin Bond Diamond Abrasive Tools

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 125 ◽  
Author(s):  
Lei Guo ◽  
Xinrong Zhang ◽  
Shibin Chen ◽  
Jizhuang Hui
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Manufacturing Process ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Ultraviolet Curable

Ultraviolet-curable resin was introduced as a bonding agent into the fabrication process of precision abrasive machining tools in this study, aiming to deliver a rapid, flexible, economical, and environment-friendly additive manufacturing process to replace the hot press and sintering process with thermal-curable resin. A laboratory manufacturing process was established to develop an ultraviolet-curable resin bond diamond lapping plate, the machining performance of which on the ceramic workpiece was examined through a series of comparative experiments with slurry-based iron plate lapping. The machined surface roughness and weight loss of the workpieces were periodically recorded to evaluate the surface finish quality and the material removal rate. The promising results in terms of a 12% improvement in surface roughness and 25% reduction in material removal rate were obtained from the ultraviolet-curable resin plate-involved lapping process. A summarized hypothesis was drawn to describe the dynamically-balanced state of the hybrid precision abrasive machining process integrated both the two-body and three-body abrasion mode.

The Study of Closed-Loop Position Control System Based on CNC Processing

2014 ◽  
Vol 941-944 ◽  
pp. 2243-2246
Author(s):  
Xin Zhou
Keyword(s):  
Control System ◽  
Machine Tools ◽  
Closed Loop ◽  
Position Control ◽  
Machining Accuracy ◽  
Closed Loop Control ◽  
Loop Control ◽  
Nc Machine ◽  
Nc Machine Tools ◽  
Position Control System

In view of the existing problems of indirect position closed-loop control, a digitized closed-loop control method is presented and a new kind of position control system with fully digitized closed-loop based on that method is developed. In this way, the fully digitized control of cutter trajectory is implemented with the features of digitized driving, digitized measuring and digitized position control, so that the machining accuracy of the NC machine tools is effectively assured. This system has been used on varieties of NC machine tools and very good results have been obtained in the machining of complex precision parts.

Experimental Research on Ultrasonic Assisted Pulse Electrochemical Compound Finishing for Hard and Brittle Metal

2010 ◽  
Vol 42 ◽  
pp. 170-174
Author(s):  
Cheng Guang Zhang ◽  
Xue Ling Yang ◽  
Bo Zhao
Keyword(s):  
Particle Size ◽  
Surface Quality ◽  
Experimental Research ◽  
Material Removal Rate ◽  
Vibration Amplitude ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Ultrasonic Assisted ◽  
Metal Materials

The experiment of ultrasonic assisted pulse electrochemical compound finishing is carried in this paper. The machining principle of the compound finishing is discussed in this paper. Processing experiments of compound finishing are carried out to study the effects of the main processing para- meters, including the particle size, the ultrasonic vibration amplitude, the minimum gap between the tool head and workpiece and the pulse voltage, on the material removal rate and the surface quality for hard and brittle metal materials. The curves of the corresponding relationships are also obtained. The study indicates that the processing velocity, machining accuracy and surface quality can be improved under the compound finishing, obtaining the processing technology conductions of the compound finishing. Introductions

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