Barrel Chamber Polishing, Using Electrochemical Theories

2007 ◽  
Vol 364-366 ◽  
pp. 272-279
Author(s):  
Ramezan Ali Mahdavinejad
Keyword(s):  
Surface Quality ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Point Of View ◽  
Electrochemical Polishing ◽  
Machining Time ◽  
High Surface Quality ◽  
Surface Polishing ◽  
Complex Shapes ◽  
Complex Parts

Electrochemical polishing is a well-known method in finishing of complex shapes with high surface quality. Inner surface polishing of complex parts with high precision can also be easily done by this method. In this research, barrel chamber’s surface, with numerous serial surface angles, is analyzed so that, according to the various set ups, the optimized polishing parameters are obtained. The comparison between electrochemical polishing and conventional methods from this point of view, shows good advantages of this method, so that, the machining time is more than thirty times less and produces very high surface quality. Besides, the dimensional accuracy of the workpiece repeatability process in this polishing method is noticeable.

Machining Characteristics of Electrochemical Polishing Using Ultrasonic Vibration for Nanoscale High Surface Quality

2021 ◽  
Vol 21 (9) ◽  
pp. 4891-4896
Author(s):  
Uk Su Kim ◽  
Seung-Yub Baek ◽  
Tae-Wan Kim ◽  
Jeong Woo Park
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Surface Defects ◽  
High Current Density ◽  
Removal Rate ◽  
High Surface ◽  
Electrochemical Polishing ◽  
High Surface Quality ◽  
Surface Polishing ◽  
Work Material

This study demonstrates a method to improve the surface quality by adding artificial vibration to the electrolyte in electrochemical polishing (ECP, electropolishing). ECP is a typical non-contact surface polishing process that has been used to improve surface quality without leaving any of the mechanical scratch marks that can arise when applying mechanical processes. ECP can polish work material via electrochemical dissolution between the surfaces of an anode and a cathode, and irregular defects are generated on the surface by impurities and bubbles generated during machining. This study confirms that our novel ECP method yields improved results over conventional ECP based on experiments using vibration electrochemical polishing (VECP) with ultrasonic vibrations. VECP minimizes nanoscale surface defects, improves surface roughness, makes it possible to quickly remove materials at nanoscale by increasing the material removal rate (MRR). Under high current density, where the electrochemical relatively reaction is active, value of the current is increased when ultrasonic vibration is added. The localized roughness of the work material was measured by atomic force microscopy (AFM) according to various electrical conditions. In addition, we also compared the overall surface quality and productivity to those obtained by conventional ECP.

Influence of Manufacturing Process on the Fatigue Strength of Gears

2014 ◽  
Vol 1018 ◽  
pp. 269-276
Author(s):  
Andrea Reiß ◽  
Ulf Engel
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Fatigue Behavior ◽  
High Surface ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Cold Forging ◽  
Hardness Distribution ◽  
Forming Process ◽  
High Surface Quality

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between manufacturing parameters on the one side, strength and other properties like hardness distribution and surface quality of the component on the other side. The research work covered in this paper focuses on the correlation of the components properties influenced by its manufacturing history and their fatigue strength. The used component is a gear produced by a lateral cold forging process. For the investigations an experimental setup has been designed. The aim for the design of the setup is to reproduce the real contact condition for the contact of two gears. To obtain different component properties the production process of the gear was varied by producing the parts by a milling operation. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

scholarly journals Optimization of Ceramic Shells for Contact with Reactive Alloys

2008 ◽  
Vol 587-588 ◽  
pp. 157-161 ◽  
Author(s):  
Teresa P. Duarte ◽  
Rui J.L. Neto ◽  
Rui Félix ◽  
F. Jorge Lino
Keyword(s):  
Mechanical Properties ◽  
Surface Quality ◽  
Investment Casting ◽  
Chemical Reactivity ◽  
High Surface ◽  
Casting Process ◽  
Ceramic Shell ◽  
High Surface Quality ◽  
Complex Shapes ◽  
Investment Casting Process

Companies are continuously under pressure to innovate their products and processes. In Portugal, there are already several examples of enterprises that have chosen research groups, associated to universities, to straighten collaboration seeking the development of new materials and advanced technological processes, to produce components with complex shapes, high surface quality, and others, at low cost, for continuously more demanding applications. Unfortunately, these cases are still a very small number, and many efforts have to be done to enlarge the collaboration university-companies. Ti and other reactive alloys are important groups of metals that are under intense and continuous research and development. For example, the high mechanical properties, low density, osteointegration behavior, corrosion resistance to fluids and tissues of the human body, the ability to be sterilized, and the possibility to obtain complex shapes, makes Ti a very attractive material for medical applications. The investment casting process, using lost wax or lost rapid prototyping models, allows designers a great amount of freedom and capacity to quickly produce castings of high dimensional accuracy and excellent surface quality suitable for different applications. Many of the castings obtained by this process are immediately ready for use, avoiding costly machining operations and joining processes, making the process very attractive to produce precision parts in Ti and other reactive alloys. However, the high reactivity of the Ti raises several compatibility problems with the traditional materials employed on the ceramic shells for casting steels and non ferrous alloys. The fragile surface layer obtained on the interface Ti-ceramic shell, result of the Ti reaction with oxygen and nitrogen of the shell, significantly reduces the mechanical properties of the cast parts, making them useless. The aim of the present work is the study of the interface properties of the Ti-ceramic shell, in order to be able to manufacture ceramic shells of low chemical reactivity for the investment casting process of reactive alloys, namely; titanium alloys, inconel, aluminotitanates, and others. Ceramic shells manufactured with calcium and yttria stabilized zirconia and other non reactive ceramics were employed and the metallic interface characterized in terms of microscopic and microhardness properties.

scholarly journals Experimental investigation of the machining characteristics in diamond wire sawing of unidirectional CFRP

2021 ◽  
Author(s):  
Lukas Seeholzer ◽  
Stefan Süssmaier ◽  
Fabian Kneubühler ◽  
Konrad Wegener
Keyword(s):  
Surface Quality ◽  
Influencing Factors ◽  
Material Properties ◽  
High Surface ◽  
Workpiece Surface ◽  
High Surface Quality ◽  
High Productivity ◽  
Surface Temperatures ◽  
Process Forces ◽  
The Wire

AbstractEspecially for slicing hard and brittle materials, wire sawing with electroplated diamond wires is widely used since it combines a high surface quality with a minimum kerf loss. Furthermore, it allows a high productivity by machining multiple workpieces simultaneously. During the machining operation, the wire/workpiece interaction and thus the material removal conditions with the resulting workpiece quality are determined by the material properties and the process and tool parameters. However, applied to machining of carbon fibre reinforced polymers (CFRP), the process complexity potentially increases due to the anisotropic material properties, the elastic spring back potential of the material, and the distinct mechanical wear due to the highly abrasive carbon fibres. Therefore, this experimental study analyses different combinations of influencing factors with respect to process forces, workpiece surface temperatures at the wire entrance, and the surface quality in wire sawing unidirectional CFRP material. As main influencing factors, the cutting and feed speeds, the density of diamond grains on the wire, the workpiece thickness, and the fibre orientation of the CFRP material are analysed and discussed. For the tested parameter settings, it is found that while the influence of the grain density is negligible, workpiece thickness, cutting and feed speeds affect the process substantially. In addition, higher process forces and workpiece surface temperatures do not necessarily deteriorate the surface quality.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

Benchmark test artifacts for selective laser melting – a critical review

2021 ◽  
Vol 15 ◽  
Author(s):  
Weishi Li ◽  
Kuanting Wang ◽  
Shiaofen Fang
Keyword(s):  
Selective Laser Melting ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Melting Process ◽  
Design Guidelines ◽  
Laser Melting ◽  
Specific Test ◽  
Benchmark Test ◽  
High Surface Quality ◽  
Machine Performance

Background: Selective laser melting is the best-established additive manufacturing technology for high-quality metal part manufacturing. However, the widespread acceptance of the technology is still underachieved, especially in critical applications, due to the absence of a thorough understanding of the technology, although several benchmark test artifacts have been developed to characterize the performance of selective laser melting machines. Objective: The objective of this paper is to inspire new designs of benchmark test artifacts to understand the selective laser melting process better and promote the acceptance of the selective laser melting technology. Method: The existing benchmark test artifacts for selective laser melting are analyzed comparatively, and the design guidelines are discussed. Results: The modular approach should still be adopted in designing new benchmark test artifacts in the future, and task-specific test artifacts may also need to be considered further to validate the machine performance for critical applications. The inclusion of the design model in the manufactured artifact, instead of the conformance to the design specifications, should be evaluated after the artifact is measured for the applications requiring high-dimensional accuracy and high surface quality. Conclusion: The benchmark test artifact for selective laser melting is still under development, and a breakthrough of the measuring technology for internal and/or inaccessible features will be beneficial for understanding the technology.

Variothermal Foam Injection Molding - Dimensional Stability with High Surface Quality

2017 ◽  
Vol 36 (3) ◽  
pp. 151-166 ◽  
Author(s):  
Christian Hopmann ◽  
Nicolai Lammert ◽  
Yuxiao Zhang
Keyword(s):  
Surface Quality ◽  
Surface Defects ◽  
Control Strategies ◽  
High Surface ◽  
Skin Layer ◽  
High Surface Quality ◽  
Major Disadvantage ◽  
Scope Of Application ◽  
Specific Material ◽  
Foam Injection Molding

Thermoplastic foam injection moulding offers various advantages for both processing and product design. Despite its many benefits, the moderate surface quality still constitutes a major disadvantage of this process. The mould temperature can be controlled dynamically to improve the surface quality. Different dynamic temperature control strategies are employed and analysed regarding their effectiveness and scope of application. Mould temperatures above the specific material transition temperatures allow the surface defects to be cured and enable the production of foamed thermoplastic parts with surface qualities comparable to those of the compact reference samples. The high mould temperatures during the injection phase alter the foam structure and the skin layer thicknesses, which impacts the mechanical properties.

scholarly journals Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Machines ◽  
2021 ◽  
Vol 9 (12) ◽  
pp. 325
Author(s):  
Muslim Mahardika ◽  
Martin Andre Setyawan ◽  
Tutik Sriani ◽  
Norihisa Miki ◽  
Gunawan Setia Prihandana
Keyword(s):  
Taguchi Method ◽  
Surface Quality ◽  
Process Parameters ◽  
Applied Voltage ◽  
High Surface ◽  
Machining Process ◽  
Machining Parameters ◽  
Pareto Analysis ◽  
High Surface Quality

Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.

scholarly journals Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3505
Author(s):  
Basem M. A. Abdo ◽  
Syed Hammad Mian ◽  
Abdualziz El-Tamimi ◽  
Hisham Alkhalefah ◽  
Khaja Moiduddin
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Thermal Damage ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Machining Time ◽  
Laser Beam Machining ◽  
Wide Range

Micromachining has gained considerable interest across a wide range of applications. It ensures the production of microfeatures such as microchannels, micropockets, etc. Typically, the manufacturing of microchannels in bioceramics is a demanding task. The ubiquitous technologies, laser beam machining (LBM) and rotary ultrasonic machining (RUM), have tremendous potential. However, again, these machining methods do have inherent problems. LBM has issues concerning thermal damage, high surface roughness, and vulnerable dimensional accuracy. Likewise, RUM is associated with high machining costs and low material-removal rates. To overcome their limits, a synthesis of LBM and RUM processes known as laser rotary ultrasonic machining (LRUM) has been conceived. The bioceramic known as biolox forte was utilized in this investigation. The approach encompasses the exploratory study of the effects of fundamental input process parameters of LBM and RUM on the surface quality, machining time, and dimensional accuracy of the manufactured microchannels. The performance of LRUM was analyzed and the mechanism of LRUM tool wear was also investigated. The results revealed that the surface roughness, depth error, and width error is decreased by 88%, 70%, and 80% respectively in the LRUM process. Moreover, the machining time of LRUM is reduced by 85%.

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