Ultrasonic Polishing of Electric Discharge Machined Surface Using Al2O3 Suspension

2011 ◽  
Vol 291-294 ◽  
pp. 53-56
Author(s):  
Won Sik Lee ◽  
Jung Sik Seo ◽  
Se Hyun Ko ◽  
Jin Man Jang ◽  
Bermha Cha ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Wave ◽  
Electric Discharge ◽  
Complex Shape ◽  
Abrasive Particle ◽  
Particle Suspension ◽  
Machined Surface ◽  
3 Dimensional ◽  
Micro Parts ◽  
The Impact

The aim of this work is to investigate the possibility of improvement of surface roughness in the wire-EDMed sample by usinig ultrasonic wave and abrasive particle suspension. For this study, two-type ultrasonic polishing methods were used. Removal of the white layers on surface of EDMed sample depended largely on the movement of the suspended particles : the white layers are removed by the impact of free moving particles due to ultrasonic wave, so-called micro chipping mechanism. Even though the surface roughness was improved very slowly, 3-dimensional fine polishing was achieved in wire-EDMed micro PIM molds. These results indicated that micro polishing by ultrasonic wave using suspension is applicable to improvement of surface roughness of micro parts with 3-dimensional complex shape.

Mechanism Research on the Swirling Air Flow Compounded with Magnetic-Field Finishing

2008 ◽  
Vol 53-54 ◽  
pp. 51-55 ◽  
Author(s):  
Xiu Hong Li ◽  
Shi Chun Yang
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Air Flow ◽  
Abrasive Particle ◽  
Solid Particles ◽  
Two Phase ◽  
Machining Time ◽  
Machined Surface ◽  
Magnetic Field Coupling ◽  
Swirling Air Flow

A new finishing technology of the swirling air flow compounded with magnetic-field is advanced. Force acting on abrasive is analyzed by the action of airstream and magnetic-field coupling according to gas-solid particles two-phase flow. Finishing mechanism on the swirling air flow compounded with magnetic-field is illustrated, namely, burrs and microcosmic peak on the surface of workpiece are broken, grinded and cut via a great deal of abrasive particle impacting, microchipping and rolling machined surface. Unthreaded hole is experimented on the condition of changing magnetic induction intensity B and machining time t. Changing curve of surface roughness Ra along with time t is shown. Research indicates that machining time of the swirling air flow compounded with magnetic-field is short and machining efficiency is high. The longer machining time is, the smaller surface roughness Ra is and the better machining effect is.

A Study of the Impact of Workpiece Location on Machining Performance of a 2-DoF PKM Based Machine Tool

2013 ◽  
Author(s):  
A. B. Koteswara Rao ◽  
Sanjay Darvekar ◽  
K. Ramji
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Structural Deformation ◽  
Quality Level ◽  
Machining Performance ◽  
Machined Surface ◽  
Milling Operations ◽  
Milling Operation ◽  
Tool Position ◽  
The Impact

This paper presents the impact of workpiece location on the machining performance of a 2-degree of freedom Parallel Kinematic Machine (PKM) tool. The PKM behavior is highly non-uniform and depends on the tool position within the workspace. The structural deformation and vibration due to cutting loads affect the quality of machined surfaces. The aim of the present study is to find the optimal tool position (workpiece location) where the workpiece is machined to a specific quality level. End-milling operations are carried out at various locations within the workspace and the surface roughness of machined surface (Ra) is measured at each location. A regression model is developed to predict the surface roughness. The study shows that the workpiece location has significant impact upon surface roughness of the machined part. Finally, a suitable workspace is defined for end-milling operation.

Research on Surface Topography and Roughness of Micro Parts by High Speed Turn-Milling

2014 ◽  
Vol 800-801 ◽  
pp. 607-612 ◽  
Author(s):  
Cheng Zhe Jin ◽  
Rui Fang
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
High Speed ◽  
Orthogonal Experiment ◽  
High Surface ◽  
Cutting Speed ◽  
Machined Surface ◽  
High Surface Quality ◽  
Micro Parts ◽  
Turn Milling

High speed turn-milling has superiority on the productivity and the quality of work pieces, and is more suitable to machine micro-shaft parts and desirable miniature parts based on the turn-milling technology. In this papers adopting orthogonal experiment method cutting experiments of orthogonal turn-milling Aluminum alloy have been done. The relation between turn-milling regimes (cutter rotate speed, axial feed, feed per tooth etc.) and machined surface roughness has been ascertained. Finally, primary and secondary order of cutting regimes impacting surface roughness has more been confirmed through orthogonal experiments variance analysis, the rotate speed of cutter (cutting speed) influence greatly on surface roughness. Through 2-dimension surface topography diagram and 3-dimension surface topography of processed surface, it can be seen that high speed turn-milling processing technology can process micro miniature component of high surface quality, and features excellent development prospect and application value.

scholarly journals Surface Characterization and Tribological Performance Analysis of Electric Discharge Machined Duplex Stainless Steel

Micromachines ◽  
2020 ◽  
Vol 11 (10) ◽  
pp. 926 ◽  
Author(s):  
Timur Rizovich Ablyaz ◽  
Evgeny Sergeevich Shlykov ◽  
Karim Ravilevich Muratov ◽  
Amit Mahajan ◽  
Gurpreet Singh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Electrode Material ◽  
Material Removal ◽  
Surface Characterization ◽  
Removal Rate ◽  
Machined Surface

The present article focused on the surface characterization of electric discharge machined duplex stainless steel (DSS-2205) alloy with three variants of electrode material (Graphite, Copper-Tungsten and Tungsten electrodes). Experimentation was executed as per Taguchi L18 orthogonal array to inspect the influence of electric discharge machining (EDM) parameters on the material removal rate and surface roughness. The results revealed that the discharge current (contribution: 45.10%), dielectric medium (contribution: 18.24%) majorly affects the material removal rate, whereas electrode material (contribution: 38.72%), pulse-on-time (contribution: 26.11%) were the significant parameters affecting the surface roughness. The machined surface at high spark energy in EDM oil portrayed porosity, oxides formation, and intermetallic compounds. Moreover, a pin-on-disc wear analysis was executed and the machined surface exhibits 70% superior wear resistance compared to the un-machined sample. The surface thus produced also exhibited improved surface wettability responses. The outcomes depict that EDMed DSS alloy can be considered in the different biomedical and industrial applications.

scholarly journals Correlation between mechanical scales and analysis scales of topographic signals under milling process of natural fibre composites

2016 ◽  
Vol 51 (19) ◽  
pp. 2743-2756 ◽  
Author(s):  
Faissal Chegdani ◽  
Sabeur Mezghani ◽  
Mohamed El Mansori
Keyword(s):  
Surface Roughness ◽  
Natural Fibre ◽  
Milling Process ◽  
Contribution Rate ◽  
Machined Surface ◽  
Polypropylene Composites ◽  
Reinforced Plastic ◽  
Machined Surface Roughness ◽  
The Impact ◽  
Machined Surfaces

This article aims to find the relation between the multiscale mechanical structure of natural fibre reinforced plastic composites and the analysis scales in the topographic signals of machined surfaces as induced by profile milling process. Bamboo, sisal and miscanthus fibres reinforced polypropylene composites were considered in this study. The multiscale process signature of natural fibre reinforced plastic machined surfaces based on wavelet decomposition was determined. Then, the impact of wavelet function was inspected by testing different wavelet shapes. Finally, the analysis of variance was carried out to exhibit the contribution rate of fibre stiffness and tool feed on the machined surface roughness at each analysis scale. Results demonstrate that studying the machining of natural fibre reinforced plastic requires the selection of the relevant scales. They show also the insignificance of the wavelet choice. This study proves that the contribution rate of fibre stiffness and tool feed on machined surface roughness is significantly dependent on the analysis scales, which are directly related to the mechanical properties of natural fibres structure inside the composite.

scholarly journals SURFACE ROUGHNESS MODELING DURING ELECTRIC DISCHARGE GRINDING WITH VARIABLE POLARITY OF ELECTRODES

2021 ◽  
pp. 77-84
Author(s):  
Roman Strelchuk
Keyword(s):  
Surface Roughness ◽  
Statistical Model ◽  
High Altitude ◽  
Statistical Modeling ◽  
Electric Discharge ◽  
Machined Surface ◽  
Surface Parameters ◽  
Variable Polarity ◽  
Part Surface

The article presents the probabilistic-statistical modeling of surface roughness in the process of electric discharge grinding with the variable polarity of electrodes. The correlation between electric modes of machining and indicators of the quality of the machined surface was established. A probabilistic-statistical model of part surface roughness formed during grinding is obtained, which establishes the correlation between high-altitude surface parameters and electrical machining modes. The developed model makes it possible to calculate the height parameters of the part roughness depending on the electrical modes of grinding. The height of microroughness is determined by the same machining conditions as the depth of erosion pits. It is possible to obtain low roughness if electrical machining modes are reduced.

Optimization of Material Removal Rate and Surface Roughness for Wire Electric Discharge Machining of AA7075 Composites using Grey Relational Analysis

2018 ◽  
Vol 9 (5) ◽  
Author(s):  
G. Ramanan ◽  
J. Edwin Raja Dhas ◽  
M. Ramachandran
Keyword(s):  
Surface Roughness ◽  
Electric Discharge ◽  
Grey Relational Analysis ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Relational Analysis ◽  
Wire Electric Discharge Machining ◽  
Grey Relational ◽  
Pulse On Time ◽  
The Impact

In automobile industries, usage of unconventional machining is increased due to their precision and accuracy. This research work is planned to upgrade the Wire Electric Discharge Machining (WEDM) process parameters by considering the impact of discharge current, pulse on time, pulse off time and servo speed rate. Tests have been led with these parameters for the measurement of metal removal rate and surface roughness for each of the trial run. This information has been used to fit a quadratic numerical model. Predicted information has been used as a graphical representation for demonstrating the impact of the parameters on chose reactions. Predicted information given by the models has been utilized as a part of an ideal parametric mix to accomplish the unrealistic yield of the procedure. Response surface method with grey relational analysis has been utilized for enhancement. The ideal value has been checked to the predicted value from the confirmation tests.

scholarly journals Smoothing additive manufactured parts using ns-pulsed laser radiation

2021 ◽  
Author(s):  
Florian Kuisat ◽  
Fernando Lasagni ◽  
Andrés Fabián Lasagni
Keyword(s):  
Surface Roughness ◽  
Mechanical Performance ◽  
State Of The Art ◽  
Pulsed Laser ◽  
Industrial Applications ◽  
Laser Source ◽  
Pulsed Laser Radiation ◽  
Current State ◽  
The Impact

AbstractIt is well known that the surface topography of a part can affect its mechanical performance, which is typical in additive manufacturing. In this context, we report about the surface modification of additive manufactured components made of Titanium 64 (Ti64) and Scalmalloy®, using a pulsed laser, with the aim of reducing their surface roughness. In our experiments, a nanosecond-pulsed infrared laser source with variable pulse durations between 8 and 200 ns was applied. The impact of varying a large number of parameters on the surface quality of the smoothed areas was investigated. The results demonstrated a reduction of surface roughness Sa by more than 80% for Titanium 64 and by 65% for Scalmalloy® samples. This allows to extend the applicability of additive manufactured components beyond the current state of the art and break new ground for the application in various industrial applications such as in aerospace.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

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