Influence of Dielectric Jet Flushing during Electro Discharge Diamond Surface Grinding Process

2013 ◽  
Vol 652-654 ◽  
pp. 2187-2190
Author(s):  
Gopal Agarwal ◽  
Manoj Modi
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Hybrid Machining Process

The influence of dielectric jet flushing during Electro Discharge Diamond Surface Grinding (EDDSG) on Ti-6A-4V has been reported in this paper. The metal bonded diamond grinding wheel is used as electrode in Electro Discharge Diamond Surface Grinding process. In this process mechanical grinding is coupled with electrical spark of electrical discharge machine to take up the advantages associated with hybrid machining process. The important input parameters in this investigation were “duty factor”, “wheel speed (rpm)”, “magnitude of current (ampere)” and its “duration (Ton, micro-second)”. The effects of these parameters on outcomes i.e. material removal rate (MRR) and surface roughness (Ra) are measured. The noticeable enhancements in material removal rate and surface finish have been seen during EDDSG of Ti-6Al-4V with effective jet flushing. The performance of EDDSG with jet flushing and without jet flushing has been compared.

Design, Development & Experimental Investigation of Electro-Discharge Diamond Surface Grinding of Ti-6Al-4V

2011 ◽  
Vol 418-420 ◽  
pp. 1478-1481 ◽  
Author(s):  
Manoj Modi ◽  
Gopal Agarwal
Keyword(s):  
Removal Rate ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Hybrid Machining ◽  
Hard Materials ◽  
Hybrid Machining Process ◽  
Pulse On Time

Abstract: Ti-6Al-4V are used extensively in aerospace, medical, marine and surgical implants etc. but it is hard to machine. Machining of advanced difficult-to-machine very hard materials (Ti-6Al-4V, composites and ceramics) is a big challenge. By conventional machining processes, their machining is not only costly but results in poor surface finish and shorter tool life. To meet these challenges, new hybrid machining process (HMP) has been developed. This article is focused on hybrid machining process comprising of conventional surface grinding along with electro-discharge machining between the periphery of metal bonded diamond grinding wheel and flat rectangular shape workpiece. This process has the advantage of shaping advance engineering materials and difficult-to- machine very hard materials. The experimental investigations of various input parameters like wheel RPM, duty factor, current and pulse on-time on material removal rate of Ti-6Al-4V in EDDSG process have been reported here on newly self designed & fabricated set up. Keywords: Electro-Discharge Diamond Surface Grinding (EDDSG), Hybrid Machining Process (HMP), Ti-6Al-4V.

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.

scholarly journals Improve the Material Removal Rate of Electrochemical Grinding on Monel 400 Using RSM

2019 ◽  
Vol 8 (2) ◽  
pp. 3219-3222
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Mechanical Grinding ◽  
Monel 400 ◽  
Electrochemical Grinding

Electrochemical grinding is combination of electrochemical machining and mechanical grinding process.in this process 90%-98% percentage of material are removed by electrochemical machining, only 3%-5% of materials can only remove by mechanical grinding process. Faradays law of electrolysis (or) reverse electroplating act as a basic principle for this ECG process. This ECG has various advantages than other machining process for high strength materials .low induvial stress, large depth of cut .here Monel 400 alloy take base material ,its Ni-Cu alloy so it’s have very high level corrosion resistance, so it’s used in marine engineering ,heat exchanger. Here silicon carbide abrasive insulated brass grinding wheel used instead of copper bonded diamond wheel. Voltage, electrolyte concentration, electrolyte flowrate take are the parameters of this process. Three factors and two levels of RSM methodology takes for optimization. The Analysis of variance (ANOVA) has been delivers the variation between the parameters performed to develop mathematical model. The parameters high voltage and concentration of electrolyte to produce maximum material removal rate.

Effect of Dressing Parameters on Material Removal Rate when Surface Grinding SKD11 Tool Steel

2021 ◽  
Vol 1020 ◽  
pp. 60-67
Author(s):  
Thi Hong Tran ◽  
Thanh Danh Bui ◽  
Nguyen Anh Tuan ◽  
Vu Trung Tuyen ◽  
Luu Anh Tung ◽  
...  
Keyword(s):  
Tool Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
Optimization Problem ◽  
Removal Rate ◽  
Optimal Solution ◽  
Surface Grinding ◽  
Machining Process ◽  
The Real ◽  
The Difference

Nowadays, surface grinding is one of the most common of metal finishing methods. The efficiency of this process is affected by the so-called process parameters such as dressing feed rate (S), rough dressing depth (ar), rough dressing times (nr), fine dressing depth (af), fine dressing times (nf), and non-feeding dressing (nnon). etc. In this paper, the optimization of dressing parameters in surface grinding SKD11 tool steel is studied. The aim of the study is to find the most appropriate value set of dressing parameters to maximize the material removal rate (MRR). In order to solve the problem, the Taguchi method is used. Based on an orthogonal array L16(44x22), sixteen experiments have been conducted. By analyzing the experimental results, an optimal solution of such optimization problem has been solved, presenting the most appropriate dressing parameters as follows: ar = 0.015 mm, nr = 2 times, af = 0.005 mm, nf = 0 times, nnon = 0 times, S = 1.6 m/min. The discovered technology mode has been applied to the real machining process and the outcome shows out a much better result in comparison with default setting modes, that the difference between the model values and the real values of the roughness average is controlled within 3.87% of the ranges.

A Study on Grinding Tungsten Carbide with Ultrasonic Assisted

2013 ◽  
Vol 797 ◽  
pp. 374-381
Author(s):  
Pei Lum Tso ◽  
Chao Chun Tseng
Keyword(s):  
Tungsten Carbide ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Temperature ◽  
Limited Range ◽  
Machining Process ◽  
Grinding Wheel ◽  
Hard Alloys ◽  
Ultrasonic Assisted

In order to cope with high demanded industry requirements. The super-hard alloys such as Tungsten Carbide have been widely used in aerospace and defense industries. So far, the grinding operation is still the most popular machining process being used to cut these materials in shape. But, owing to the nature of these materials mechanical properties, always made it very difficult to grind as well as to cut. Nevertheless, the allowable grinding parameters are resisted to very limited range and always require use very expensive super abrasive grinding wheel. Recently, study by many researchers show that the ultrasonic assist grinding had the advantage of higher material removal rate, less cutting force and lower cutting temperature. In the mean time, the tool life had been improved greatly. In this study, the conventional GC grinding wheel was used in the experiments to study the material removal rate; grinding force; surface roughness as well as specific grinding energy with and without the ultrasonic assist. The results show that these difficult-to-cut materials can be ground easier with proper ultrasonic assist and low-priced grinding wheel.

scholarly journals Machine Ability Characteristics of PWEDM Process

2019 ◽  
Vol 9 (1) ◽  
pp. 3580-3583
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Machining Process ◽  
Work Piece ◽  
Tool Wear Rate

The traditional machining consists of a specific contact between the tool and work piece. As a result of this contact the tool may wear out after a few operations. In addition to that, the MRR (Material Removal Rate), Surface Finish, etc. is also lowered. As a result of these drawbacks, traditional or conventional machining processes cannot be used to machine ceramic based alloys and thus we opt for unconventional machining process. The Electrical Discharge Machine contains of two spaces one is Electrode and other is Work piece. In this concept the among the tool wear rate is moderate and the surface roughness is to be poor. The tool cost is so high. Hence continuously tool modification is not possible. So in the work main objective of the problem is reduced the tool wear rate and increase the MRR. (Material removal rate). So in the case we are consider in the surface roughness. The surface roughness is to be high is the taken in industrial application. So we have focus with surface roughness. These are the considering with in our problems. In our aim is reducing the toll wear and improve the Material Remove rate. In order to addition of graphite in Electrolyte. When added the electrolyte in Graphite the Toll wear rate decrease and increase a material Removal Rate. Finally we have disc the DOE process

Investigation on Material Removal Rate in Rotation Grinding for Large-Scale Silicon Wafer

2004 ◽  
Vol 471-472 ◽  
pp. 362-368 ◽  
Author(s):  
Y.B. Tian ◽  
Ren Ke Kang ◽  
Dong Ming Guo ◽  
Zhu Ji Jin ◽  
Jian Xiu Su
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Rotational Speed ◽  
Material Removal ◽  
Removal Rate ◽  
Geometric Dimension ◽  
Grit Size ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Cup Wheel

In this paper, the formula of material removal rate (MRR) in wafer rotation grinding process is deduced based on kinematics. The main effect on MRR of the grit size and the process parameters, including the rotational speed of the cup grinding wheel, the down feed rate of the grinding wheel spindle and the rotational speed of the chuck table, is both theoretically and experimentally investigated. The influence on MRR of the cup wheel grinding status, the geometric dimension of the cup-grinding wheel, the rigidity of the grinding machine and the coolant is also analyzed. The investigating results show that, the increase of the grit size and the down feed rate of the cup grinding wheel results in great increase of the MRR; the MRR increases as the rotational speed of the cup wheel increases whereas the MRR reduces and the ground surface becomes bad due to size effect if the rotational speed of the cup wheel is overlarge; in normal grinding, the MRR decreases as the rotational speed of the chuck table increases. The results provide a theoretical basis to improve grinding efficiency, reduce grinding cost and select the proper parameters of grinding process.

scholarly journals COMBINATION OF TAGUCHI METHOD, MOORA AND COPRAS TECHNIQUES IN MULTI-OBJECTIVE OPTIMIZATION OF SURFACE GRINDING PROCESS

2020 ◽  
pp. 1-9
Author(s):  
Do Duc Trung
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Optimization Problem ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Surface Grinding ◽  
Grinding Process ◽  
Multi Objective Optimization ◽  
Multi Objective

This study presentes a combination method of several optimization techniques and Taguchi method to solve the multi-objective optimization problem for surface grinding process of SKD11 steel. The optimization techniques that were used in this study were Multi-Objective Optimization on basis of Ratio Analysis (MOORA) and Complex Proportional Assessment (COPRAS). In surface grinding process, two parameters that were chosen as the evaluation creterias were surface roughness (Ra) and material removal rate (MRR). The orthogonal Taguchi L16 matrix was chosen to design the experimental matrix with two input parameters namely workpiece velocity and depth of cut.  The two optimization techniques that mentioned above were applied to solve the multi-objective optimization problem in the grinding process. Using two above techniques, the optimized results of the cutting parameters were the same. The optimal workpiece velocity and cutting depth were 20 m/min and 0.02 mm. Corresponding to these optimal values of the workpiece velocity and cutting depth, the surface roughness and material removal rate were 1.16 µm and 86.67 mm3/s. These proposed techniques and method can be used to improve the quality and effectiveness of grinding processes by reducing the surface roughness and increasing the material removal rate.

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