Tool Wear and Form Accuracy in Ultrasonic-Assisted Milling of Soda-Lime Glass

2018 ◽  
Vol 786 ◽  
pp. 206-214
Author(s):  
Yasmine El-Taybany ◽  
Mohab Hossam ◽  
Hassan El-Hofy
Keyword(s):  
Tool Wear ◽  
Brittle Materials ◽  
Soda Lime ◽  
Machining Process ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Form Accuracy ◽  
Ultrasonic Assisted ◽  
Hard And Brittle Materials ◽  
Vibration Assistance

Machining of hard and brittle materials is inherently involved with tool wear, which influences the dimensional and form accuracy of the machined product. Ultrasonic-assisted machining process is suitable for hard-to-cut materials such as ceramics, glass, and metal matrix composites, etc. In the current study, the mechanism of tool wear is investigated during ultrasonic-assisted milling of soda-lime glass as one of hard and brittle materials. Ultrasonic-Assisted Milling (UAM) combines the material removal mechanism of grinding and the milling kinematics with ultrasonic assistance. The effect of different process parameters, i.e. feed rate, depth of cut, cutting fluid, and ultrasonic vibration assistance on the tool wear behavior are investigated. Form accuracy of the machined slots is also investigated. The results showed that UAM produces less tool wear than conventional milling (CM). However, CM gives less error in the slot dimensions than UAM.

Grey Relation Approach in Abrasive Jet Machining Process

2019 ◽  
Author(s):  
Lijo Paul ◽  
J. Babu
Keyword(s):  
Removal Rate ◽  
Brittle Materials ◽  
Soda Lime ◽  
Machining Process ◽  
Soda Lime Glass ◽  
Abrasive Particles ◽  
Abrasive Jet Machining ◽  
Conducting Materials ◽  
Hard And Brittle Materials ◽  
Relation Approach

Abstract Micro machining of conducting and non-conducting materials with high accuracy has great demand in industries especially in machining of ceramic, brittle materials. Abrasive Jet Machining (AJM) has shown tremendous application especially in machining of hard and brittle materials. In the present paper drilling of soda lime glass has been carried out to determine the machinability under different controlling parameters. A set of L9 series experiments were carried out by varying process parameters such as Stand Off Distance (SOD), Silicon carbide abrasive particles mesh sizes and jet pressure. Material Removal Rate (MRR) and Radial Over Cut (ROC), were taken as the output responses and are optimised with multi objective optimisation.

Influence of Ultrasonic Assistance on Material Removal Mechanism of Hard and Brittle Materials Based on Single-Point Scratch

2011 ◽  
Vol 487 ◽  
pp. 413-418 ◽  
Author(s):  
Feng Jiao ◽  
Bo Zhao
Keyword(s):  
Material Removal ◽  
Single Point ◽  
Brittle Materials ◽  
Shielding Effect ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Critical Cutting Depth ◽  
Material Hardness ◽  
Ultrasonic Assisted ◽  
Hard And Brittle Materials

In order to deeply study the influence of ultrasonic assistance on material removal characteristics of hard and brittle materials, a series of ultrasonic assisted single-point scratch experiments have been carried out in this paper. Experimental results show that the assisted ultrasonic vibration is benefit to increase the critical cutting depth and enlarge the ductile regime of material removal. The main reason can be explained as the influences of blank cutting phenomenon, the decrease of the normal cutting force under the same depth of cut, the decrease of the material hardness under ultrasonic excitation and the shielding effect of lateral crack.

Ultraprecision Ductile-Regime Cutting of Brittle Materials

2007 ◽  
Vol 339 ◽  
pp. 395-399 ◽  
Author(s):  
Ming Zhou ◽  
X.D. Liu ◽  
S.N. Huang
Keyword(s):  
Ultrasonic Vibration ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Diamond Cutting ◽  
Vibration Cutting ◽  
Ductile Regime Machining ◽  
Critical Depth Of Cut ◽  
Micro Deformation ◽  
Micro Indentation

Soda-lime glass is a typical brittle material, which is difficult to realize ductile-regime machining by using conventional cutting technology due to the extremely small critical depth of cut. In this work, the micro-deformation characteristics of this kind of materials were analyzed by micro indentation. Ultrasonic vibration assisted diamond cutting was performed in order to investigate the effect of tool vibration on material removal process and surface quality. The profiles of cut surfaces were measured and compared with those obtained by conventional diamond cutting. Real depths of cut in ultrasonic vibration cutting correspond well with the nominal ones. The change in the tribology of the cutting process as well as the alteration of the deformation mechanism of the work material might be responsible for the reduction in tool wear in vibration cutting.

Werkzeuge der ultraschallunterstützten Bearbeitung*/Modelling of an Actorsystem - Development of a tool for ultrasonic assisted machining with an axial-tangential vibration vector

2018 ◽  
Vol 108 (01-02) ◽  
pp. 53-57
Author(s):  
K. Drewle ◽  
T. Stehle ◽  
H: Möhring
Keyword(s):  
Contact Zone ◽  
Brittle Materials ◽  
Wird Eine ◽  
Alternative Method ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Hard And Brittle Materials ◽  
Feed Axis

Die schwingungsunterstützte Bearbeitung hat sich bereits bei der Zerspanung von hartspröden Werkstoffen mit einer einachsigen Schwingung in der Kontaktzone bewährt. Untersuchungen zu schwingungsunterstützten Bohrprozessen beschränken sich bisher auf eine Schwingungserzeugung, die entlang der Vorschubachse ausgerichtet ist. Für alternative Schwingungsrichtungen fehlt in erster Linie die geeignete Aktorik. In diesem Beitrag wird eine alternative Methode zur Erzeugung einer axial-tangentialen Schwingung in der Kontaktzone untersucht.   Ultrasonic assisted machining with uniaxial vibration is a well-proven process for machining hard and brittle materials. Existing investigations of vibration assisted drilling and boring processes so far are limited to an oscillation along the feed axis, which primarily due to nonexistent actuators. This contribution will present investigations into an alternative method for creating axial-tangential vibrations in the tool contact zone.

scholarly journals Tool Wear Mechanisms during Cutting of Soda Lime Glass

2018 ◽  
Vol 290 ◽  
pp. 012039
Author(s):  
Mohamed Konneh ◽  
Mst. Nasima Bagum ◽  
Mohammad Yeakub Ali ◽  
Tasnim Firdaus Bt. Mohamed Arif
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Tool Wear Mechanisms

Characterisation, Performance and Optimisation of Nanocellulose Metalworking Fluid (MWF) for Green Machining Process

2021 ◽  
Vol 18 (4) ◽  
pp. 9188-9207
Author(s):  
Mahendran Samykano ◽  
J. Kananathan ◽  
K. Kadirgama ◽  
A. K. Amirruddin ◽  
D. Ramasamy ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Machining Process ◽  
Alumina Nanoparticles ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Nanoparticle Concentration

The present research attempts to develop a hybrid coolant by mixing alumina nanoparticles with cellulose nanocrystal (CNC) into ethylene glycol-water (60:40) and investigate the viability of formulated hybrid nanocoolant (CNC-Al2O3-EG-Water) towards enhancing the machining behavior. The two-step method has been adapted to develop the hybrid nanocoolant at various volume concentrations (0.1, 0.5, and 0.9%). Results indicated a significant enhancement in thermal properties and tribological behaviour of the developed hybrid coolant. The thermal conductivity improved by 20-25% compared to the metal working fluid (MWF) with thermal conductivity of 0.55 W/m℃. Besides, a reduction in wear and friction coefficient was observed with the escalation in the nanoparticle concentration. The machining performance of the developed hybrid coolant was evaluated using Minimum Quantity Lubrication (MQL) in the turning of mild steel. A regression model was developed to assess the deviations in the tool flank wear and surface roughness in terms of feed, cutting speed, depth of the cut, and nanoparticle concentration using Response Surface Methodology (RSM). The mathematical modeling shows that cutting speed has the most significant impact on surface roughness and tool wear, followed by feed rate. The depth of cut does not affect surface roughness or tool wear. Surface roughness achieved 24% reduction, 39% enhancement in tool length of cut, and 33.33% improvement in tool life span. From this, the surface roughness was primarily affected by spindle cutting speed, feed rate, and then cutting depth while utilising either conventional water or composite nanofluid as a coolant. The developed hybrid coolant manifestly improved the machining behaviour.

Modeling and Optimization of Ultrasonic Machining Process Using a Novel Evolutionary Algorithm

2019 ◽  
pp. 153-174
Author(s):  
Mantra Prasad Satpathy ◽  
Bharat Chandra Routara
Keyword(s):  
Evolutionary Algorithm ◽  
Removal Rate ◽  
Ceramic Matrix Composites ◽  
Imperialist Competitive Algorithm ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Ultrasonic Machining ◽  
Hard And Brittle Materials ◽  
Experimental Values ◽  
Single Response

Ultrasonic machining (USM) is one of the non-conventional techniques for machining of hard and brittle materials like glass, ceramics, and ceramic matrix composites. The objective of the study includes the investigation of material removal rate (MRR), hole oversize (HOS), and circularity of holes (COH) during USM of soda lime glass and finding out the optimal parametric condition by an evolutionary algorithm. Taguchi philosophy was employed to carry out experiments using the process parameters such as power rating, abrasive slurry concentration, and static load. A novel optimization algorithm called imperialist competitive algorithm (ICA) was used to obtain maximum MRR and minimum HOS and COH. This algorithm is inspired by the imperialistic competition and has several advantages over other evolutionary algorithms like its simplicity, less computational time, and accuracy in predicting the results. The Technique for order of preference by similarity to ideal solution (TOPSIS) is utilized to convert these multiple performance characteristics to a single response. Moreover, the prediction outcomes of this TOPSIS integrated ICA methodology demonstrates excellent conformity with the experimental values and can be applied to solve complex problems.

scholarly journals Optimization of Power Consumption Associated with Surface Roughness in Ultrasonic Assisted Turning of Nimonic-90 Using Hybrid Particle Swarm-Simplex Method

Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3418 ◽  
Author(s):  
Khanna ◽  
Airao ◽  
Gupta ◽  
Song ◽  
Liu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Fitness Function ◽  
Particle Swarm ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Hybrid Particle ◽  
Ultrasonic Assisted

These days, power consumption and energy related issues are very hot topics of research especially for machine tooling process industries because of the strict environmental regulations and policies. Hence, the present paper discusses the application of such an advanced machining process i.e., ultrasonic assisted turning (UAT) process with the collaboration of nature inspired algorithms to determine the ideal solution. The cutting speed, feed rate, depth of cut and frequency of cutting tool were considered as input variables and the machining performance of Nimonic-90 alloy in terms of surface roughness and power consumption has been investigated. Then, the experimentation was conducted as per the Taguchi L9 orthogonal array and the mono as well as bi-objective optimizations were performed with standard particle swarm and hybrid particle swarm with simplex methods (PSO-SM). Further, the statistical analysis was performed with well-known analysis of variance (ANOVA) test. After that, the regression equation along with selected boundary conditions was used for creation of fitness function in the subjected algorithms. The results showed that the UAT process was more preferable for the Nimconic-90 alloy as compared with conventional turning process. In addition, the hybrid PSO-SM gave the best results for obtaining the minimized values of selected responses.

An Experimental Approach to Determine the Critical Depth of Cut in Brittle-to-Ductile Phase Transition During End Milling of Soda-Lime Glass

2016 ◽  
Vol 41 (11) ◽  
pp. 4553-4562 ◽  
Author(s):  
A. K. M. Nurul Amin ◽  
Mst. Nasima Bagum ◽  
Noor Fathiah ◽  
Mohamed Konneh ◽  
Tasnim Firdaus Bt. Mohamed Ariff
Keyword(s):  
Phase Transition ◽  
Experimental Approach ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Critical Depth ◽  
Ductile Phase ◽  
Critical Depth Of Cut
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