Design of Surface Finish Using Synchronous Process of Grinding and Electrochemical Finishing

2007 ◽  
Vol 359-360 ◽  
pp. 259-263
Author(s):  
Pai Shan Pa
Keyword(s):  
Surface Roughness ◽  
Flow Rate ◽  
Surface Finish ◽  
Feed Rate ◽  
Rotational Speed ◽  
Machining Process ◽  
Grinding Wheel ◽  
High Rotational Speed ◽  
Plate Electrode ◽  
Electrochemical Finishing

In order to elevate the efficiency of the surface finish to reach the fast improvement of the surface roughness of the workpiece, so as to reduce the residual stress on the surface efficiently. The present study discusses the surface after traditional machining, of which the plane surface used a design of finish tool includes an electrode and a nonconductive grinding wheel to execute the synchronous process of grinding and electrochemical finishing. The electrode form and the machining process are obviously different from electrochemical grinding (ECG). In the experiment, the design electrode is used with continuous and pulsed direct current. The controlled factors include die material, and chemical composition and concentration of the electrolyte. The experimental parameters are flow rate of electrolytes, position of plate electrode, electrode thickness, electrode rotational speed, electrical current rating, feed rate of workpiece, and pulsed period. The experimental results show that the supply of current rating is near concern with the position and thickness of the plate electrode. The use of large electrolytic flow rate and thick electrode is advantageous to the finish effect. High rotational speed of finish tool produces better polishing. The finishing effect is better with longer off-time because discharge of polishing dregs becomes easier. Higher current rating with quicker workpiece feed rate effectively reaches the fast improvement of the surface roughness of the workpiece is recommend in current study.

Design of Freeform Surface Finish Using Synchronous Processes of Electrochemical Finishing and Burnishing

2008 ◽  
Vol 375-376 ◽  
pp. 308-312 ◽  
Author(s):  
Pai Shan Pa
Keyword(s):  
Flow Rate ◽  
Feed Rate ◽  
Rotational Speed ◽  
Low Cost ◽  
Electrical Current ◽  
Freeform Surface ◽  
Design System ◽  
High Rotational Speed ◽  
Electrochemical Finishing ◽  
Effective Design

A most effective design system and an advantage of low cost equipment using synchronous processes of electrochemical finishing and burnishing for a freeform surface following turning machining is investigated. The proposed design process uses a feeding finish-tool instead of the mate electrode as in conventional ECM. Hence higher electrical current is not required when the effective design electrode is used to reduce the response area. Through simple equipment attachment, electrochemical finishing can follow the traditional turning on the same machine. The controlled factors include the chemical composition and concentration of the electrolyte, die material, and rotational speed of workpiece. The design finish-tool is primarily discussed among the factors affecting the synchronous processes of electrochemical finishing and burnishing. The experimental parameters are initial gap width, flow rate of electrolyte, current rating, feed rate of finish tool, pulsed period, and the evaluation of different process features. The use of large electrolytic flow rate is advantageous to the finish effect. High rotational speed of the finish tool produces better finish. The finish effect is better with longer off-time because discharge of finish dregs becomes easier. Higher current rating with quicker feed rate of finish tool effectively reaches the fast improvement of the surface roughness of the workpiece is recommend in current study. The effective design finish-tool with an electrode of a globe-form and a burnishing tool of a pin-form have an optimal value for higher current density and provides larger discharge space, which produces a smoother surface. The synchronous processes of electrochemical finishing and burnishing just needs only a short time to make the workpiece smooth and bright and saves the need for the precise process of traditional machining is recommended for the finish process of the freeform surface.

scholarly journals The Effect of Abrasive Waterjet Machining Parameters on the Condition of Al-Si Alloy

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3122 ◽  
Author(s):  
Monika Kulisz ◽  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Flow Rate ◽  
Surface Finish ◽  
Feed Rate ◽  
Abrasive Waterjet ◽  
Strengthening Effect ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Sample Height

This paper analyses the effect of the abrasive waterjet cutting parameters’ modification on the condition of the workpiece surface layer. The post-machined surface of casting aluminium alloys, AlSi10Mg and AlSi21CuNi, was characterised in terms of surface roughness and irregularities, chamfering, and microhardness in order to reveal the effect that variable jet feed rate, abrasive flow rate, and sample height (thickness of the cut material) have on the quality of surface finish. From the analysis of the results, it emerges that the surface roughness remains largely unaffected by changes in the sample height h or the abrasive flow rate ma, whereas it is highly susceptible to the increase in the jet feed rate vf. It has been shown that, in principle, the machining does not produce the strengthening effect, that is, an increase in microhardness. Owing to the irregularities that are typically found on the workpieces cut with higher jet feed rates vf, additional surface finish operations may prove necessary. In addition, chamfering was found to occur throughout the entire range of speeds vf. The statistical significance of individual variables on the 2D surface roughness parameters, Ra/Rz/RSm, was determined using factorial analysis of variance (ANOVA). The results were verified by means of artificial neural network (ANN) modelling (radial basis function and multi-layered perceptron), which was employed to predict the surface roughness parameters under consideration. The obtained correlation coefficients show that ANNs exhibit satisfying predictive capacity, and are thus a suitable tool for the prediction of surface roughness parameters in abrasive waterjet (AWJ) technology.

Design of Surface Finish Using Compound Processes of Grinding and Electrochemical Finishing Following Turning

2008 ◽  
Vol 373-374 ◽  
pp. 782-785 ◽  
Author(s):  
Pai Shan Pa
Keyword(s):  
Direct Current ◽  
Feed Rate ◽  
Rotational Speed ◽  
Low Cost ◽  
Electrical Current ◽  
High Rotational Speed ◽  
Factors Affecting ◽  
Grinding Tool ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing

A new finish method uses an effective electrode connecting with a nonconductive grinding tool to execute the design of compound processes of electrochemical finishing and grinding following turning is investigated. The submitted processes can be used for various turning operations. Through simple equipment attachment, electrochemical finishing and grinding can follow to execute the finishing process on the same machine. Among the factors affecting electrochemical finishing the performance of grinding combined with electrochemical finishing is primarily discussed. In the experiment, the electrode is used with continuous and pulsed direct current. The grinding tool moves following the electrode and grinds the workpiece surface. The experimental parameters are electrical current rating, feed rate of electrode and grinding tool, rotational speed of workpiecel, pulsed period, and geometry of finish-tool. The results show that pulsed direct current with longer off-time can slightly improve the finish effect for its dregs discharge mobility. Using an adequate rotational speed of workpiece with high rotational speed is advantageous to the finish effect. A thinner plate-form electrode with a smaller end radius is associated with larger discharge space and produces higher current density and provides faster feed rate and a better finish effect. The grinding can effectively increase the finish effect. An effective and a low-cost finish process through the design electrode and using the grinding assistance in the electrochemical finishing after turning process make the surface of workpiece smooth and bright.

Empirical study on ultrasonic assisted turn-milling

2021 ◽  
pp. 095440892110087
Author(s):  
Saeid Amini ◽  
Mohammad Baraheni ◽  
Mohammad Khaki
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotational Speed ◽  
Milling Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Turn Milling

Turn-milling process has been paid attention in order to be used in multi-task machining processes. Moreover, looking for new machining techniques aimed at reducing cutting force is of important. Reducing cutting force in machining processes has the benefits of extending tool life and improving surface quality. One of the new concepts for reducing the cutting force is applying ultrasonic vibration. In this paper, effects of ultrasonic vibration under different machining parameters in turn-milling process of Al-7075 alloy will be investigated. In this order, a special mechanism was designed to apply ultrasonic vibration during machining process. Ultrasonic vibration exertion on the tool reduced cutting force and surface roughness up to 75% and 35%, respectively. Also tool rotational speed increment induced cutting force and surface roughness increment. In addition, tool feed rate and workpiece rotational speed increment caused cutting force and surface roughness increment. Although, feed rate was more influential.

Research on Uniform Surface Roughness in Grinding of Revolving Curved Surface

2009 ◽  
Vol 416 ◽  
pp. 113-117 ◽  
Author(s):  
Ling Ye Kong ◽  
Qiu Sheng Yan ◽  
Jun Hui Song ◽  
Ya Nan Song
Keyword(s):  
Surface Roughness ◽  
Rotational Speed ◽  
Feeding Rate ◽  
Experimental Results ◽  
Curved Surface ◽  
Grinding Wheel ◽  
High Rotational Speed ◽  
Grinding Method ◽  
The Relationship ◽  
Constant Feeding

When grinding the revolving curved surface with Arc Envelope Grinding Method, the different curvatures in the convex and concave surfaces make a great difference in the surface roughness. In order to solve this problem, the relationship among envelope height, feeding rate, rotational speed and curvature of workpiece was analyzed based on equal-envelope-height grinding method. The results presented that, low feeding rate of grinding wheel and high rotational speed of workpiece were helpful to obtain smaller envelope height. And the smaller the radius of workpiece curvature, the more different the surface roughness. Besides, it was an effective method to solve this problem by changing feeding rate. The feeding rate should be changed directly proportionally to radius of workpiece curvature. Then, the experimental results indicate that, the fluctuation ratio of surface roughness with variable feeding rate is reduced to 4.896% from 26.17% with constant feeding rate. It proves the validity of hypothesis.

scholarly journals Effect on Material Removal Rate and Surface Finish in ECM Process When Machining Stainless Steel-316 with Cu Electrode

2019 ◽  
Vol 8 (4) ◽  
pp. 2933-2941
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Process Parameters ◽  
Surface Finish ◽  
Feed Rate ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Processes

Electrochemical Machining process is one of the popular non-traditional machining processes which is used to machine materials such as super alloys, Ti-alloys, stainless steel etc. Its working principle is based upon Faraday law of electrolysis. The aim of the present work is to optimize the ECM process parameters with the combination of SS 316 (job material) and Copper electrode (tool material). To explore the effect of ECM process parameters such as electrolyte concentration, voltage and current, feed rate on MRR and surface finish (Ra) of the job, total 27 experiments were conducted as per experimental scheme. The results of these experiments revealed that increase in electrolyte concentration decrease the mrr and surface roughness initially increases then decreases. Further, increase in current increases mrr initially and then decreases, surface roughness also increases. It is also noticed that increase in Feed rate mrr decreases and then increases, also surface roughness decreases then increases. Through RSM analysis it is found that the optimum conditions for maximum MRR, and minimum Surface roughness (Ra) is electrolyte concentration 150gm/lit, Voltage 13.5 V & feed 0.8 mm/min. The findings are discussed in the light of previous researches and subsequently conclusions are drawn.

scholarly journals Effects of drilling parameters on TI-6Al-4V alloy using different coolants

2020 ◽  
Vol 12 (1) ◽  
Author(s):  
Roopsandeep Bammidi ◽  
P.Srinivasa Rao ◽  
K.Siva Prasad
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Pure Water ◽  
Critical Role ◽  
Machining Process ◽  
Scientific Article ◽  
Machining Parameters ◽  
Drilling Parameters ◽  
Cutting Zone

The formulation or application of coolants plays a critical role in machining to bring out the best finished products. In this scientific article, the study focused on the effects of coolants and machining parameters of Ti-6Al-4V are investigated with consideration of their performances by using drilling operation. The design of ex- periments (DOE) was considered and the performance of machining was measured with respect to cutting temperatures and surface responses. The final results put forward that the excellent surface finish and minimal cutting temperatures are ob- tained by application of power metcut s plus when compared with pure water. The factors that impact the surface roughness of Ti-6Al-4V are coolant and feed rate. The coolant also helps in the machining process by reducing temperature at the cutting zone.

A Simultaneous Smooth Processes Using Burnishing and Elecrofinishing on the Plane Surface

2010 ◽  
Vol 426-427 ◽  
pp. 409-412
Author(s):  
Pai Shan Pa
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Feed Rate ◽  
Rotational Speed ◽  
Plane Surface ◽  
Negative Electrode ◽  
Experimental Results ◽  
High Rotational Speed ◽  
Small Thickness ◽  
Off Time

For the purpose of elevating the efficiency of the finish effect to reach the fast improvement of the surface roughness of the plane surface, so as to reduce the residual stress on the surface efficiently. This study discusses the plane surface after traditional grinding machining, of which the plane surface used a new design of finish-tool includes a nonconductive burnishing-tool and a negative electrode to execute the simultaneous processes of burnishing and electrofinishing. In the experiment, the use of the small thickness of the negative electrode is advantageous to the finish effect. High rotational speed of the finish-tool produces better polishing. Higher current rating with quicker workpiece feed rate effectively reaches the fast improvement of the surface roughness of the workpiece. The finishing effect is better with longer off-time because discharge of the electrofinishing dregs becomes easier. The experimental results show that the supply of current rating is near concern with the position of the negative electrode and the burnishing-tool.

scholarly journals Effects of hybrid Al2O3–CuO nanofluids on surface roughness and machining forces during turning AISI 4340

2021 ◽  
Vol 3 (2) ◽  
Author(s):  
Shahin Haghnazari ◽  
Vahid Abedini
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Rotational Speed ◽  
Minimum Quantity Lubrication ◽  
Weight Percent ◽  
Cutting Fluid ◽  
Hybrid Nanofluid ◽  
Workpiece Material ◽  
Machining Forces ◽  
Aisi 4340

AbstractThis paper presents an effort to model the process parameters involved in turning of alloy steel AISI 4340 workpiece material with Al2O3 and CuO hybrid nanofluids using the minimum quantity lubrication (MQL) method. In this paper, the effect of mixing two nanoparticles (Al2O3 and CuO) with different weight percent in environmentally friendly water-based cutting fluid, the rotational speed, and the feed rate has been investigated on the surface roughness and the machining forces using the response surface method. The results of the experiments show that the hybrid nanofluid containing 0.75 CuO with 0.25 Al2O3 has the best output for the machining forces and the surface roughness. Also, in the best composition of the nanoparticles (0.75 CuO with 0.25 Al2O3), the lowest value of machining forces has been achieved at a feed rate of 0.08 mm per revolution and the rotational speed 1000 rpm as well as the lowest value of the surface roughness at a feed rate of 0.08 mm per revolution and the rotational speed 710 rpm.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

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