Effect of Lubricant Volume and Working Gap on the Surface Roughness and Material Removal Rate in Magnetic Abrasive Finishing

2010 ◽  
Vol 297-301 ◽  
pp. 390-395
Author(s):  
Mehrdad Vahdati ◽  
E. Sadeghinia ◽  
Ali Shokuhfar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Work Piece ◽  
Magnetic Abrasive Finishing ◽  
Complex Curves ◽  
Abrasive Finishing ◽  
Technology Industries ◽  
High Technology Industries

Technological requirements urges high technology industries using materials with advanced properties. Although it is compulsory using these materials due to their advantages, some of them should be tolerated because of their weak machining and mechanical properties. Attempts for qualitative machining of complex curves on many work pieces may result in the advent of new finishing techniques. One of the most newly introduced techniques is Magnetic Abrasive Finishing, MAF. In this paper a study on the effects of tool and work piece gap, and lubricant volume, on the roughness and material removal rate have been studied. The results show that setting the working gap to 3 mm and the lubricant volume to 0.7 ml, yields a change in surface roughness (Ra), and the material removal (MR) will gain its best result.

scholarly journals Improving the process performance of magnetic abrasive finishing of SS304 material using multi-objective artificial bee colony algorithm

2020 ◽  
Vol 41 (1) ◽  
pp. 34-49
Author(s):  
Sandip B. Gunjal ◽  
Padmakar J. Pawar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Artificial Bee Colony Algorithm ◽  
Artificial Bee Colony ◽  
Removal Rate ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Bee Colony ◽  
Abrasive Finishing

Magnetic abrasive finishing is a super finishing process in which the magnetic field is applied in the finishing area and the material is removed from the workpiece by magnetic abrasive particles in the form of microchips. The performance of this process is decided by its two important quality characteristics, material removal rate and surface roughness. Significant process variables affecting these two characteristics are rotational speed of tool, working gap, weight of abrasive, and feed rate. However, material removal rate and surface roughness being conflicting in nature, a compromise has to be made between these two objective to improve the overall performance of the process. Hence, a multi-objective optimization using an artificial bee colony algorithm coupled with response surface methodology for mathematical modeling is attempted in this work. The set of Pareto-optimal solutions obtained by multi-objective optimization offers a ready reference to process planners to decide appropriate process parameters for a particular scenario.

ANALYSIS OF THE MATERIAL REMOVAL RATE IN MAGNETIC ABRASIVE FINISHING OF THIN FILM COATED PYREX GLASS

2017 ◽  
Vol 24 (Supp01) ◽  
pp. 1850004
Author(s):  
HEE HWAN LEE ◽  
SEOUNG HWAN LEE
Keyword(s):  
Process Monitoring ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Measurement Data ◽  
Surface Measurement ◽  
Time Interval ◽  
Magnetic Abrasive Finishing ◽  
Afm Indentation ◽  
Abrasive Finishing

The material removal rate (MRR) during precision finishing/polishing is a key factor, which dictates the process performance. Moreover, the MRR or wear rate is closely related to the material/part reliability. For nanoscale patterning and/or planarization on nano-order thickness coatings, the prediction and in-process monitoring of the MRR is necessary, because the process is not characterizable due to size effects and material property/process condition variations as a result of the coating/substrate interactions. The purpose of this research was to develop a practical methodology for the prediction and in-process monitoring of MRR during nanoscale finishing of coated surfaces. Using a specially designed magnetic abrasive finishing (MAF) and acoustic emission (AE) monitoring setup, experiments were carried out on indium-zinc-oxide (IZO) coated Pyrex glasses. After a given polishing time interval, AFM indentation was conducted for each workpiece sample to measure the adhesion force variations of the coating layers (IZO), which are directly related to the MRR changes. The force variation and AE monitoring data were compared to the MRR calculated form the surface measurement (Nanoview) results. The experimental results demonstrate strong correlations between AFM indentation and MRR measurement data. In addition, the monitored AE signals show sensitivity of the material structure variations of the coating layer, as the polishing progresses.

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

Experimental Studies on Optimization of WEDMed Tungsten-Carbide Metal Matrix Composite

2014 ◽  
Vol 984-985 ◽  
pp. 377-383
Author(s):  
Veluswamy Muthuraman ◽  
Raju Ramakrishnan ◽  
G. Siddarth ◽  
V. Nikilesh ◽  
V. Rangaraja
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Experimental Studies ◽  
Critical Parameters ◽  
Work Piece ◽  
Off Time

Wire Electrical discharge Machining plays an important role in the field of electrically conductive material machining. The process has grown exponentially in the past decade due to advantages like high accuracy, precision, ability to achieve complex, intricate shapes on components, unruffled by material hardness, less noise, leaves little residual stress on work piece and the advantage of unmanned machining. A stochastic process in nature, it is difficult to determine parameters that improve cutting rate and surface roughness, the main stay of the metal machining industries. Tungsten carbide is widely used in tool and die making industry mainly due to its extreme hardness; wear resistance, toughness and high temperature stability. Finding optimized parameters for machining performance improvement and optimization would help the manufacturing community. Design of experiments with an orthogonal array of L 27, on four critical parameters On-Time, Off-Time, Wire Speed and Peak current with three levels had been carried out. The experimental results were optimized using Taguchi analysis. Analysis of variance was done. Confirmation tests validated that the results for material removal rate and surface roughness, 5.021mm3/min and3.26μm with improvement. The most influential parameters were off-time, wire-speed and on-time for material removal rate and wire-speed current and on-time for surface roughness. The optimum levels were reported.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

High-Throughput Picosecond Laser Machining of Aerospace Nickel Superalloy

2021 ◽  
pp. 095440542110288
Author(s):  
Sundar Marimuthu ◽  
Bethan Smith
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Thermal Damage ◽  
Removal Rate ◽  
Picosecond Laser ◽  
Nickel Superalloy ◽  
Laser Machining ◽  
Process Conditions ◽  
Machining Performance

This manuscript discusses the experimental results on 300 W picosecond laser machining of aerospace-grade nickel superalloy. The effect of the laser’s energetic and beam scanning parameters on the machining performance has been studied in detail. The machining performance has been investigated in terms of surface roughness, sub-surface thermal damage, and material removal rate. At optimal process conditions, a picosecond laser with an average power output of 300 W can be used to achieve a material removal rate (MRR) of ∼140 mm3/min, with thermal damage less than 20 µm. Shorter laser pulse widths increase the material removal rate and reduce the resultant surface roughness. High scanning speeds improve the picosecond laser machining performance. Edge wall taper of ∼10° was observed over all the picosecond laser machined slots. The investigation demonstrates that high-power picosecond lasers can be used for the macro-machining of industrial components at an acceptable speed and quality.

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