An Investigation of Material Removal Mechanisms in Lapping with Grain Size Transition

2000 ◽  
Vol 122 (3) ◽  
pp. 413-419 ◽  
Author(s):  
Y. P. Chang ◽  
M. Hashimura ◽  
D. A. Dornfeld
Keyword(s):  
Material Removal ◽  
Model Verification ◽  
Time Dependent ◽  
Depth Of Cut ◽  
Statistical Nature ◽  
Material Removal Mechanisms ◽  
Effective Inclusion ◽  
Three Body Abrasion ◽  
Three Body ◽  
Abrasive Size

The mechanical material removal (MRR) mechanisms in lapping were investigated, using concepts of two-body vs. three-body abrasion and ductile vs. brittle machining. The statistical nature of the depth of cut in the lapping process was described using distribution of abrasive sizes in the slurry. Through the change in abrasive size distribution, the time dependent characteristic of MRR was captured in the model. Experiments were conducted for model verification. It was found that a constant 60 deg effective inclusion angle allowed the model to fit measurement well. [S1087-1357(00)00504-9]

Material Removal Model of Sapphire Substrate in Double-Side Lapping Process

2009 ◽  
Vol 407-408 ◽  
pp. 460-464 ◽  
Author(s):  
Cong Da Lu ◽  
Dong Min Qian ◽  
Shao Fei Jiang
Keyword(s):  
Sapphire Substrate ◽  
Material Removal ◽  
Material Removal Mechanisms ◽  
Removal Mechanisms ◽  
Ductile Machining ◽  
Material Removal Model ◽  
Three Body Abrasion ◽  
Three Body ◽  
Processing Mechanisms ◽  
Removal Model

The material removal mechanisms of sapphire substrate in double-side lapping process were studied. The concepts of brittle vs. ductile machining and two-body vs. three-body abrasion were used to classify the processing mechanisms. The material removal models of double-side lapping process in different mechanisms were analyzed and researched. The experiment showed that the material removal model can describe double-side lapping process of sapphire qualitatively.

Studies on the Lapping of Polycrystalline Diamond Compact (PDC)

2011 ◽  
Vol 325 ◽  
pp. 495-501 ◽  
Author(s):  
Jason Sowers ◽  
Alex Fang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Size Distributions ◽  
Design Constraints ◽  
Material Removal Mechanisms ◽  
Removal Mechanisms ◽  
Polycrystalline Diamond Compact ◽  
Abrasive Size

Researching the effect that certain parameters have on the lapping process is crucial to understanding the fundamental material removal mechanisms and implementing a procedure that most efficiently produces desired results. This study examines the lapping procedure for polycrystalline diamond compacts (PDCs). Tests were conducted using different sample carriers, PDC arrangements, and abrasive size distributions. Previous studies have focused on the material removal rate (MRR), which is of interest, but this study also examines the MRR uniformity within a group of PDCs lapped together. The goal of this research was to determine the optimal lapping conditions and PDC arrangement required to achieve the highest productivity. Results indicate that a hard specimen carrier is necessary to produce PDCs with uniform MRRs, and the number of PDC samples in a carrier can be increased with certain design constraints kept in mind.

scholarly journals A Nanomechanical Analysis of Deformation Characteristics of 6H-SiC Using an Indenter and Abrasives in Different Fixed Methods

Micromachines ◽  
2019 ◽  
Vol 10 (5) ◽  
pp. 332 ◽  
Author(s):  
Jisheng Pan ◽  
Qiusheng Yan ◽  
Weihua Li ◽  
Xiaowei Zhang
Keyword(s):  
Single Crystal ◽  
Material Removal ◽  
Elastic Moduli ◽  
Deformation Characteristics ◽  
Static Stiffness ◽  
Magnetorheological Finishing ◽  
Material Removal Mechanisms ◽  
Single Crystal Sic ◽  
Three Body ◽  
Precise Theory

The super-precise theory for machining single crystal SiC substrates with abrasives needs to be improved for its chemical stability, extremely hard and brittle. A Berkovich indenter was used to carry out a systematic static stiffness indentation experiments on single crystal 6H-SiC substrates, and then these substrates were machined by utilizing fixed, free, and semi-fixed abrasives, and the nanomechanical characteristics and material removal mechanisms using abrasives in different fixed methods were analyzed theoretically. The results indicated that the hardness of C faces and Si faces of single crystal 6H-SiC under 500 mN load were 38.596 Gpa and 36.246 Gpa respectively, and their elastic moduli were 563.019 Gpa and 524.839 Gpa, respectively. Moreover, the theoretical critical loads for the plastic transition and brittle fracture of C face of single crystal 6H-SiC were 1.941 mN and 366.8 mN, while those of Si face were 1.77 mN and 488.67 mN, respectively. The 6H-SiC materials were removed by pure brittle rolling under three-body friction with free abrasives, and the process parameters determined the material removal modes of 6H-SiC substrates by grinding with fixed abrasives, nevertheless, the materials were removed under full elastic-plastic deformation in cluster magnetorheological finishing with semi-fixed abrasives.

Experimental Investigation on Two-Body Abrasion of Cast Aluminum–Alumina Composites: Influence of Abrasive Size and Reinforcement Content

2019 ◽  
Vol 142 (3) ◽  
Author(s):  
Santanu Sardar ◽  
Santanu Kumar Karmakar ◽  
Debdulal Das
Keyword(s):  
Stir Casting ◽  
Matrix Composites ◽  
Cast Aluminum ◽  
Alloy Matrix ◽  
Test Configuration ◽  
Alumina Composites ◽  
Al Matrix Composites ◽  
Three Body Abrasion ◽  
Three Body ◽  
Abrasive Size

Abstract The occurrence of abrasion is inevitable in most engineering systems. Abrasive wear specifically two-body causes higher material and dimensional loss than other modes of wear. Two-body abrasion is yet to be fully comprehended as it is governed by several intrinsic and extrinsic variables. In this article, tribo-performances of Al-composites were experimentally studied with specific emphasis on the role of abrasive size and amount of reinforcement. AA7075 alloy matrix composites with different amounts of alumina particles were fabricated by the advanced stir-casting method. Besides measurements of density, porosity, and Vickers hardness, in-depth characterizations of microstructures were performed. Specific wear-rate (SWR), coefficient of friction (COF), and abraded surface roughness (SR) of developed materials were measured under two-body abrasion over a vast range of distance, load, velocity, and abrasive size. Under all abrasion conditions, composites exhibited higher SR but lower SWR and COF over alloy; the differences increased with reinforcement quantity. SWR, COF, and SR rose with an increase in abrasive size; however, only SR varied with sliding distance for any material. The effects of different variables on the recorded tribo-performances were explained through identification of various micro-mechanisms of abrasion via extensive post wear characterizations and microstructural features. Finally, the criteria for the occurrence of three-body abrasion even in two-body test configuration were highlighted. The wear coefficient value of 10 × 10−3 was identified as the demarcation between two-body and two-body plus three-body abrasion for Al-matrix composites.

Energy and Material Removal Mechanisms for the Grinding of Cemented Carbide with Brazed Diamond Wheels

2011 ◽  
Vol 175 ◽  
pp. 58-66 ◽  
Author(s):  
You Ji Zhan ◽  
Yuan Li ◽  
Hui Huang ◽  
Xi Peng Xu
Keyword(s):  
Material Removal ◽  
Diamond Wheel ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Material Removal Mechanisms ◽  
Vacuum Brazing ◽  
Unit Width ◽  
Removal Mechanisms ◽  
Video Microscope ◽  
Grinding Conditions

An investigation was undertaken to explore the specific energy and material removal mechanisms involved in the grinding of cemented carbide with vacuum brazing diamond wheels. A mathematical model, relating to the grinding parameters such as wheel velocity, workpiece feedrate and depth of cut, was proposed to predict specific grinding energy, and was verified by experimental data. This verification came as a result of surface grinding two typical cemented carbides (YG8 and YG30) with a vacuum brazing diamond wheel under various grinding conditions. The earlier model’s prediction shows a direct correlation with the experimental results. Good relationships between the consumed power per unit width with the plowed face areas generated by all cutting points per unit width were obtained. Microscopic examination of the ground surfaces and the grinding detritus by a digital and video microscope system also revealed that material removal occurred mainly by flow-type chip formation (plastic flow) while grinding YG8 and by blocky fracture particles formation (brittle fracture) while grinding YT30.

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.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

Material removal mechanisms by EDM of zirconia reinforced MWCNT nanocomposites

2016 ◽  
Vol 42 (5) ◽  
pp. 5792-5801 ◽  
Author(s):  
Latifa Melk ◽  
Marta-Lena Antti ◽  
Marc Anglada
Keyword(s):  
Material Removal ◽  
Material Removal Mechanisms ◽  
Removal Mechanisms
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