Support Vector Fuzzy Adaptive Network in the Modeling of Material Removal Rate in Rotary Ultrasonic Machining

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
Judong Shen ◽  
Z. J. Pei ◽  
E. S. Lee
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Support Vector ◽  
Adaptive Networks ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Adaptive Network ◽  
Fuzzy Adaptive

Rotary ultrasonic machining (RUM) is one of the cost-effective machining methods for machining difficult to process material. It is a hybrid machining process that combines the material removal mechanisms of diamond grinding with ultrasonic machining. However, due to the lack of understanding of the mechanisms of these operations, models for these machining processes are difficult to establish. In this paper, the support vector fuzzy adaptive network (SVFAN), a parameter free nonlinear regression technique, is used to model the material removal rate in RUM. The SVFAN retains the advantages of both the fuzzy adaptive networks and the support vector machines. The former possesses the linguistic representation ability and the latter is a very effective learning machine. The results are compared with that obtained by the use of fuzzy adaptive network and it is shown that the combined approach is a more effective algorithm for the modeling of complex manufacturing processes.

A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

1995 ◽  
Vol 117 (2) ◽  
pp. 142-151 ◽  
Author(s):  
Z. J. Pei ◽  
D. Prabhakar ◽  
P. M. Ferreira ◽  
M. Haselkorn
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Diamond Particle ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Stabilized Zirconia ◽  
Mechanistic Approach ◽  
Wide Range

An approach to modeling the material removal rate (MRR) during rotary ultrasonic machining (RUM) of ceramics is proposed and applied to predicting the MRR for the case of magnesia stabilized zirconia. The model, a first attempt at predicting the MRR in RUM, is based on the assumption that brittle fracture is the primary mechanism of material removal. To justify this assumption, a model parameter (which models the ratio of the fractured volume to the indented volume of a single diamond particle) is shown to be invariant for most machining conditions. The model is mechanistic in the sense that this parameter can be observed experimentally from a few experiments for a particular material and then used in prediction of MRR over a wide range of process parameters. This is demonstrated for magnesia stabilized zirconia, where very good predictions are obtained using an estimate of this single parameter. On the basis of this model, relations between the material removal rate and the controllable machining parameters are deduced. These relationships agree well with the trends observed by experimental observations made by other investigators.

An experimental study on rotary ultrasonic machining of Macor ceramic

2016 ◽  
Vol 232 (7) ◽  
pp. 1221-1234 ◽  
Author(s):  
Ravi Pratap Singh ◽  
Sandeep Singhal
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Desirability Approach ◽  
Index Value ◽  
The Impact ◽  
Desirability Index

Macor ceramic has been well recognized as an eminent engineering material which possesses enlarged industrial usage owing to its excellent and versatile properties. However, its fruitful and economic processing is still unanswered. This article has targeted to experimentally investigate the influence of numerous process variables on machining characteristics in rotary ultrasonic machining of Macor ceramic. The impact of different input factors, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power has been appraised on process responses of interest, that is, material removal rate and chipping size. The experimental plan was designed by employing response surface methodology through central composite rotatable design. The variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominated brittle fracture that caused removal of material along with the thin plastic deformation in rotary ultrasonic machining of Macor ceramic. The reliability and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are 0.4762 mm3/s and 0.3718 mm, respectively, with the combined desirability index value of 0.937.

Experimental investigation of machining characteristics in rotary ultrasonic machining of quartz ceramic

2016 ◽  
Vol 232 (10) ◽  
pp. 870-889 ◽  
Author(s):  
Ravi Pratap Singh ◽  
Sandeep Singhal
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Quartz Ceramic ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Desirability Approach ◽  
Desirability Index ◽  
Machining Characteristics

Quartz ceramic has been well observed as one of the highly demanded advanced ceramics which is receiving enlarging industrial approbation owing to its excellent and superior properties. However, its fruitful processing with traditional and non-traditional machining methods is still a challenge. The current article has aimed to experimentally investigate the influence of several process variables, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power on machining characteristics of interest, i.e. chipping size, and material removal rate in rotary ultrasonic machining of quartz ceramic. Response surface methodology has been employed to design the experiments and the variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominating brittle fracture that caused removal of material along with the slighter plastic deformation in rotary ultrasonic machining of quartz ceramic. The soundness and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are, 0.6437 mm3/s and 1.3326 mm, respectively, with the combined desirability index value of 0.949.

Analysis of the Material Removal Rate of Micro-Hole Machining of Ceramic Materials

2011 ◽  
Vol 347-353 ◽  
pp. 1572-1575 ◽  
Author(s):  
Shu Lung Wang ◽  
Ting Yu Chueh
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Rotation Speed ◽  
Removal Rate ◽  
Tool Geometry ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Related Factors ◽  
Drill Diameter

This study discussed what rotary ultrasonic machining (RUM) and tool geometry parameters combination can obtain bigger material removal rate (MRR) in drilling. The experimental configuration of this study was planned using Taguchi orthogonal array, where the drill diameter, rotation speed, power and feed rate were taken as the experimental factors. A relation model among the MRR and standard deviation of the holes walls and processing parameters and tool geometry was established, so as to achieve maximum MRR of the overall deep holes walls. The experimental results proved that application of the optimized parameters combination in rotary ultrasonic machining of holes processing can obtain bigger and better removal rate of holes walls. The effect of control factors on the holes quality was discussed from the straightness deviation and maximum material removal rate of related factors on the holes when the Taguchi method was used in rotary ultrasonic machining of holes drilling. The results showed that rotation speed, power, and feed rate under bigger level have a larger MRR than that of other level in a fixed drill diameter.

Rotary Ultrasonic Machining of Advanced Ceramics

2006 ◽  
Vol 532-533 ◽  
pp. 361-364 ◽  
Author(s):  
Wei Min Zeng ◽  
Xi Peng Xu ◽  
Zhi Jian Pei
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Cost Effective ◽  
Machining Process ◽  
Future Research ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Advanced Ceramics ◽  
Material Removal Mechanisms ◽  
Removal Mechanisms

Rotary ultrasonic machining (RUM) is one of the cost-effective machining methods for advanced ceramics, which is a hybrid machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining (USM). This paper presents an overview of the investigations on RUM of advanced ceramics. The issues about the material removal mechanisms, process modeling, material removal rate, and tool wear in RUM are reviewed. Directions of future research on RUM are also presented.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Schruppfräsbearbeitung von Verdichterscheiben/Milling of compressor disk - Identification of a cutting material and coating combination for high process reliability

2017 ◽  
Vol 107 (09) ◽  
pp. 674-680
Author(s):  
E. Prof. Abele ◽  
C. Hasenfratz ◽  
C. Praetzas ◽  
G. M. Schüler ◽  
C. Stark ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Manufacturing Technology ◽  
Machining Process ◽  
Complex Task ◽  
Eine Hohe ◽  
Process Reliability ◽  
Rough Milling ◽  
Compressor Disk

Die Herstellung von Verdichterscheiben stellt hohe Ansprüche an die Fertigungstechnik. Neue, schwer zu zerspanende Materialien und Integralkonstruktionen erzeugen eine hohe Komplexität bei der Ausführung. Das Projekt „SchwerSpan“ stellt sich dieser Herausforderung und entwickelt einen Prozess zur Schruppfräsbearbeitung von Verdichterscheiben. Ziel des Projekts ist eine Reduktion der Werkzeugkosten bei erhöhtem Zeitspanvolumen.   The production of compressor disks places high demands on the manufacturing technology. A very complex task is created by new difficult-to-cut materials and integral components. The project “SchwerSpan” is taking on this task by developing a machining process for rough milling in the production of compressor disks. The aim of the process is to reduce the tool costs by increasing material removal rate.

Effect of Frequency to Ultrasonic Vibration-Assisted Wire-EDM

2019 ◽  
Vol 814 ◽  
pp. 127-131
Author(s):  
Patittar Nakwong ◽  
Apiwat Muttamara
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Machining Process ◽  
Wire Electrode ◽  
Ultrasonic Machine ◽  
Lower Amplitude ◽  
Wedm Process

Wire electrical discharge machine (WEDM) is non-conventional machining process. It can be used for hard cutting material. The study has been presented the combining WEDM with an ultrasonic machine (USM) with brass and tungsten were used as a wire electrode and workpiece respectively. The experiment was carried out with an ultrasonic transducer at 40, 80 kHz. The results were observed with the material removal rate (MRR) and surface roughness (Ra). This research introduced the method of USM setup and described the effected of vibration with the wire electrode on the displacement of amplitude. The result shows that the WEDM process with USM at 40 kHz can be more improved with the material removal rate and surface roughness than that of USM at 80 kHz. This can be explained that higher frequency affected to vibration displacement which makes lower amplitude.

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