Examination of Machining Parameters on the Surface Roughness of Stavax ESR Material Using Electro Discharge Machining

2016 ◽  
Vol 1133 ◽  
pp. 339-343
Author(s):  
Mebrahitom Asmelash ◽  
Muhamad Azhari
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Optical Microscope ◽  
Machining Parameters ◽  
Mould Insert ◽  
Machined Surface ◽  
Peak Current ◽  
Electro Discharge Machining ◽  
Spark Gap

An experimental study was conducted to investigate the effect of EDM die sinking machining parameters on surface roughness of Stavax material for mould insert. The spark gap, peak current and servo voltage were manipulated to find the best combination of EDM machining parameters. The surface roughness of the machined surface of each specimen was measured using Perthometer and the image of texture was observed by using optical microscope. It was observed that the surface roughness was highly affected by the spark gap and peak current whereas the servo voltage had little effect.

Research on Wire-Electro Discharge Machining of SiC Particle Reinforced Cu Matrix Composite

2011 ◽  
Vol 347-353 ◽  
pp. 1088-1092
Author(s):  
Jian Gang Li ◽  
Jin Wang
Keyword(s):  
Surface Roughness ◽  
Matrix Composite ◽  
Pulse Width ◽  
Cutting Speed ◽  
Pulse Interval ◽  
Machined Surface ◽  
Peak Current ◽  
Electro Discharge Machining ◽  
Composite Microstructure ◽  
Sic Particle

The law of peak current, pulse width and working voltage parameter etc which influencing on wire-electro discharge machining (WEDM) cutting speed and surface roughness of the SiC particle reinforced Cu matrix composite in the WEDM machining were studied; the machined surface of Cu matrix composite was analyzed by means of scanning electron microscope (SEM); SiC Particle reinforced Cu matrix composite microstructure was analyzed by means of metallographic microscope. The results show that the first factors are peak current and pulse width, the second is working voltage. While pulse interval has reached a certain degree, pulse interval has slightly influence on surface roughness. If peak current is higher and pulse width is narrower, the wire electric discharging machining is ideal for matrix composite.

Optimization of process parameters of wire electro discharge machining for Ti49.4Ni50.6 shape memory alloys using the Taguchi technique

2019 ◽  
Vol 10 (4) ◽  
pp. 548-568 ◽  
Author(s):  
Adik Takale ◽  
Nagesh Chougule
Keyword(s):  
Shape Memory ◽  
Process Parameters ◽  
Dynamic Compression ◽  
Machining Parameters ◽  
Machined Surface ◽  
Content Type ◽  
Electro Discharge Machining ◽  
Spark Gap ◽  
Pulse On Time ◽  
Pulse Off Time

Purpose Ti49.4Ni50.6 (at. %) shape memory alloy (SMA) is a unique class of smart materials because of unbeatable property which given a wide variety of their applications across a broad range of fields including an orthopedic implant. It plays a very important role in the constructions of novel orthopedic implants application (like dynamic compression plate) because of lower Young’s modulus compared to other biomedical implant materials, high mechanical strength, excellent corrosion resistance and unique property like shape memory effect. Conventional machining of Ti-Ni yields poor surface finish and low dimensional accuracy of the machined components. Hence, wire electro-discharge machining (WDEM) of Ti-Ni has been performed. The purpose of this paper is to investigate the effect of variation of five process parameters, namely, a pulse-on time, pulse-off time, spark gap set voltage (SV), wire feed and wire tension on the material removal rate, surface roughness (SR), kerf width (KW) and dimensional deviation (DD), in the WDEM of Ti49.5Ni50.6 SMA. Design/methodology/approach The effect of machining parameters on Ti49.4Ni50.6 has been fully explored using WEDM with zinc coated brass wire as an electrode. In this work, L18 orthogonal array based on Taguchi method has been used to conduct a series of experiments and statically evaluate the experimental data by the use of the method of analysis of variance. Scanning electron microscope images of the machined surface, at the highest and lowest pulse-on time, have been taken to evaluate the quality of surface in terms of their SR values. Findings For the highest pulse-on time, it is observed that blow holes, cracks, melted droplets and craters have been formed on the machined surface with an SR of 2.744 µm, while for the lowest pulse-on time, these are not formed with an SR of 0.862 µm. It is seen that the pulse-on time is the most significant process parameter for MRR, SR and KW, while the DD is significantly affected by spark gap SV. The optimal values of the process parameters have been obtained by the method of analysis of mean and the confirmatory experiments have been carried out to validate results of optimization. Energy dispersive spectroscopy analysis of the machined surface of Ti49.4Ni50.6 has shown a certain amount of deposition of material on the machined surface. Originality/value This is an original paper.

Effect of Tightening Speed on the Torque-Tension and Wear Pattern in Bolted Connections

2006 ◽  
Author(s):  
Sayed A. Nassar ◽  
Ramanathan M. Ranganathan ◽  
Saravanan Ganeshmurthy ◽  
Gary C. Barber
Keyword(s):  
Experimental Data ◽  
Experimental Study ◽  
Surface Roughness ◽  
Initial Level ◽  
Zinc Coating ◽  
Optical Microscope ◽  
Wear Pattern ◽  
Highly Sensitive ◽  
Contact Surfaces ◽  
Scanning Electron

This experimental study investigates the effect of tightening speed and coating on both the torque – tension relationship and wear pattern in threaded fastener applications. The fastener torque – tension relationship is highly sensitive to normal variations in the coefficients of friction between threads and between the turning head and the surface of the joint. Hence, the initial level of the joint clamp load and the overall integrity and reliability of a bolted assembly is significantly influenced by the friction coefficients. The effect of repeated tightening and loosening is also investigated using M12, Class 8.8, fasteners with and without zinc coating. The torque – tension relationship is examined in terms of the non-dimensional nut factor K. The wear pattern is examined by monitoring the changes in surface roughness using a WYKO optical profiler and by using a LECO optical microscope. A Hitachi S-3200N Scanning Electron Microscope (SEM) is used to examine the contact surfaces, under the fastener head, after each tightening/loosening cycle. Experimental data on the effect of variables and the tightening speed, fastener coating and repeated tightening on the nut factor are presented and analyzed for M8 and M12, class 8.8, fasteners.

Effect of Machining Parameters and MQL Liquids on Surface Integrity of High Speed Drilling Ti-6Al-4V

2010 ◽  
Vol 447-448 ◽  
pp. 816-820 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Surface Roughness ◽  
Palm Oil ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Subsurface Deformation ◽  
High Speed Drilling ◽  
Coated Carbide

Surface integrity is particularly important for the aerospace industry components in order to permit longer service life and maximized its reliability. This present work compares the performance of palm oil and synthetic ester on surface roughness, surface defect, microhardness and subsurface deformation when high speed drilling of Ti-6Al-4V under MQL condition. The drilling tests were conducted with AlTiN coated carbide tool. The surface roughness decreased with increasing in cutting speed and thicker subsurface deformation was formed underneath the machined surface. Grooves, cavities, pit holes, microcracks and material smearing were the dominant surface damages thus deteriorated the machined surface. For both lubricants, the machined surface experienced from thermal softening and work hardening effect thus gave a variation in microhardness values. The results indicated the substantial benefit of MQL by palm oil on surface integrity.

Multi Objective Optimization of Cutting Parameters in Machining Cellulose Based Hybrid Composites

2015 ◽  
Vol 761 ◽  
pp. 287-292
Author(s):  
Raja Izamshah ◽  
Zainudin Zuraidah ◽  
Mohd Shahir Kasim ◽  
M. Hadzley ◽  
M. Amran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hybrid Composites ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
Machining Performance ◽  
Machined Surface ◽  
Multi Objective ◽  
Optimization Of Cutting Parameters

Cellulose based hybrid composites are gaining popularity in the growing green communities. With extensive studies and increasing applications for future advancement, the need for an accurate and reliable guidance in machining this type of composites has increased enormously. Smooth and defect free machined surface are always the ultimate objectives. The present work deals with the study of machining parameters (i.e. spindle speed, feed rate and depth of cut) and their effects on machining performance (i.e. surface roughness and delamination) to establish an optimized setup of machining parameters in achieving multi objective machining performance. Cellulose based hybrid composites consist of jute (a bast fiber) and glass fiber embedded in polyester resins. Response Surface Methodology (RSM) using Box-Behnken Design (BBD) was chosen as the design of experiment approach for this study. Based on that experimental approach, 17 experimental runs were conducted. Mathematical model for each response was developed based on the experimental data. Adequacy of the models were analyzed statistically using Analysis of Variance (ANOVA) in determining the significant input variables and possible interactions. The multi objective optimization was performed through numerical optimization, and the predicted results were validated. The agreement between the experimental and selected solution was found to be strong, between 95% to 96%, thus validating the solution as the optimal machining condition. The findings suggest that feed rate was the main factor affecting surface roughness and delamination .

Machining Finish of Titanium Alloy Prepared by Additive Manufacturing

2017 ◽  
Vol 872 ◽  
pp. 43-48 ◽  
Author(s):  
Xin Huang ◽  
Qian Bai ◽  
Yong Tao Li ◽  
Bi Zhang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Additive Manufacturing ◽  
Surface Finish ◽  
Functional Performance ◽  
Critical Role ◽  
Lower Surface ◽  
Machining Parameters ◽  
Machined Surface ◽  
Slot Milling

Surface finish plays a critical role in functional performance of machined components. This study investigates machining finish of Ti-6Al-4V alloy prepared by Additive Manufacturing (AM) with a series of slot-milling experiments. The study compares the machined AMed part with that made of the conventional wrought Ti-6Al-4V. The microstructure of AMed parts is acicular α and Widmanstatten α lath structures compared to lamellar α structure of that in the wrought parts. Due to the unique microstructure from AM process, the AMed parts present higher strength and lower ductility. Therefore, a lower surface roughness is obtained in the milling of AMed parts compared to its counterpart of wrought parts. In addition, the machined surface of AMed parts possesses a topography of discontinued ridges. It is believed that the topography is due to low ductility of AMed part. The results show that the machined AMed part presents better surface finish. The study provides a guidance to optimization of machining parameters for AMed Ti-6Al-4V alloys.

Effect of SiC Particles on the Machining of Aluminum/SiC Composite

2009 ◽  
Vol 626-627 ◽  
pp. 219-224 ◽  
Author(s):  
Gao Feng Zhang ◽  
Yuan Qiang Tan ◽  
Bi Zhang ◽  
Zhao Hui Deng
Keyword(s):  
Surface Roughness ◽  
Aluminum Matrix ◽  
Volume Ratio ◽  
Damage Mechanism ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Aluminum Metal ◽  
Sic Particles ◽  
Average Grain Size

The objective of this study is to experimentally investigate the effect of reinforced SiC particles on the machining of Aluminum/SiC composite (15% volume ratio of SiC particles with average grain size 15m). Aluminum/SiC composite and aluminum metal were milled by a tungsten carbide endmill in this study. Based on the surface observation and surface roughness inspection, it is found that the machining parameters of Aluminum/SiC composite have optimum values, and that the surface roughness of aluminum/SiC composite is smaller than that of aluminum metal. when feedrate and depth of cut are smaller than limited values, satisfactory surface finish can be attainable, however, as the depth of cut and feedrate increases, the microcracks are first initiated at the interface of SiC particles and aluminum matrix, and then periodically macrocracks are formed on the machined surface, The damage mechanism during the machining of aluminum/SiC are discussed in this paper.

Influence of Machining Parameters on Surface Roughness in WEDM Titanium Alloy

2013 ◽  
Vol 701 ◽  
pp. 349-353 ◽  
Author(s):  
J.B. Saedon ◽  
Paul J.R. Ding J.R. ◽  
M.S.M. Shawal ◽  
H. Husain ◽  
M.S. Meon
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Feed Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Thermo Electric ◽  
Peak Current ◽  
Wire Tension

Wire electrical discharge machining (WEDM) is a material removal process of electrically conductive materials by the thermo-electric source of energy .This kind of machining extensively used in machining of materials with highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using wire electro-discharge machining with brass wire diameter 0.25mm.The objective of this work is to study the influence of three machining parameters namely peak current (IP), feed rate (FC) and wire tension (WT) to material removal rate and surface roughness followed by suggesting the best operating parameters towards good surface finish. A full factorial experimental design was used with variation of peak current, feed rate and wire tension, with results evaluated using analysis of variance (ANOVA) techniques. Parameter levels were chosen based on best practice and results from preliminary testing. Main effects plots and percentage contribution ratios (PCR) are included for the main factors and their interactions. Peak current was shown to have the greatest effect on surface roughness (33% PCR).

Wire Electro Discharge Machining of Al/SiC Metal Matrix Composite

2011 ◽  
Vol 121-126 ◽  
pp. 564-567
Author(s):  
Bao Ji Ma ◽  
Yu Quan Zhu ◽  
Xiao Li Jin
Keyword(s):  
Surface Roughness ◽  
Current Pulse ◽  
Pulse Duration ◽  
Cutting Speed ◽  
Machining Performance ◽  
Peak Current ◽  
Positive Effects ◽  
Electro Discharge Machining ◽  
Input Variables ◽  
Pulse On Time

The machining characteristics of SiC/Al composite using wire electro discharge machining (WEDM) were investigated in this study. Material cutting speed and surface roughness value were adopted to evaluate the machinability. Peak current, pulse on time, pulse duration and working voltage were selected as the input variables to investigate the machining performance. Effects of input variables on the cutting speed and surface roughness were experimentally tested. Peak current, pulse on time and working voltage were confirmed to have positive effects on cutting speed and surface roughness value. Whereas the cutting speed and surface roughness value decrease with the increase of pulse duration.

scholarly journals Machinability Investigation in Dry Turning of Ti–6al–4v With a Novel Tib2-based Cermet Tool Using Response Surface Methodology

2020 ◽  
Author(s):  
Yikun Yuan ◽  
Wenbin Ji ◽  
Shijie Dai ◽  
Huibo Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Dry Turning ◽  
Diffusion Wear ◽  
Cutting Length ◽  
Machined Surface Roughness

Abstract To ensure accuracy and improve the processing efficiency of Ti–6Al–4V alloys, dry turning experiment of Ti–6Al–4V was carried out using a novel TiB2-based cermet tool. The tool was reinforced by nanoscale VC additive and exhibited excellent hardness and fracture toughness.Response Surface Methodology (RSM) was used in the experiment to verify andevaluatethe cutting performance ofTiB2-based cermet tool.The cutting forces and machined surface roughness (Ra) were selected as the optimization objective. An analysis of variance (ANOVA) was used to find out the effective machining parameters on response factorsand demonstrate correctness of the models. It was found that theeffective factor on surface roughness was feed rate, while cutting depth significantly affected cutting forces.And the confirmation experiments showedthat the predicted values were in good agreement with experimental values. Based on the optimized cutting parameters, the tool life was measured and tool wear mechanismwasinvestigated. When the vc, apandfwere 100 mm/min, 0.16 mm, 0.1 mm/rev respectively for Ra optimization, the cutting length and tool lifecould reach to 3233 m and 29.4 min, respectively, due to the excellentwear resistance and stability of TiB2-based cermet tool at high cutting temperature. In this case, the main wear mechanism was adhesive wear and diffusion wear.

Sign in / Sign up

Export Citation Format

Share Document