Correlation of Three-Dimensional Roughness Parameters With the Crater Dimensions in μED-Milling of Cryogenic-Treated Tool and Workpiece

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
J. M. Jafferson ◽  
P. Hariharan ◽  
J. Ramkumar
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
Three Dimensional ◽  
Flow Characteristics ◽  
Roughness Parameters ◽  
Machining Performance ◽  
Electric Discharge Milling

Abstract Microfluidics is one of the rapidly growing markets in the present era of miniaturization. Microchannels have wide applications in various fields such as biomedical, mechanical, electrical, and chemical sciences. Machining microfeatures with high aspect ratio in metals is difficult by mechanical and lithography-based processes. Micro-electric discharge milling is a suitable process to machine microcavities and microchannels in all electrically conductive materials. The main disadvantage of this process is its very low material removal rate. Improving the machining performance of micro-electric discharge machining (μEDM) is a research area that attracts researchers and remains as an unfulfilled agenda. The aim of this study is to improve the machining performance of micro-electric discharge milling process by investigating the performance of cryogenically treated tool and workpiece materials. Since surface roughness determines the minimum feature size machinable by any micromachining process and also it is an important factor in determining the flow characteristics of microchannels, a detailed comparative study was conducted on the three-dimensional (3D) surface quality parameters along with machining performance while using all four different combinations of untreated and cryogenically treated tool and workpiece, and the roughness parameters are correlated with the erosion behavior. The study revealed significant change in material removal rate and erosion pattern due to cryogenic treatment.

Machining performance of cryogenically treated Ti–5Al–2.5Sn titanium alloy in electric discharge machining: A comparative study

2016 ◽  
Vol 231 (11) ◽  
pp. 2017-2024 ◽  
Author(s):  
Sanjeev Kumar ◽  
Ajay Batish ◽  
Rupinder Singh ◽  
TP Singh
Keyword(s):  
Titanium Alloy ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Machined Surface ◽  
Pulse On Time

In the present study, the effect of cryogenic treatment on the machining performance of Ti–5Al–2.5Sn alpha titanium alloy was investigated during electric discharge machining. Untreated, shallow cryogenically treated (−110 ℃), and deep cryogenically treated (−184 ℃) titanium alloys were machined by varying current and pulse-on-time. The machining performance was measured in terms of higher material removal rate and microhardness and low tool wear rate and surface roughness. The results showed a significant improvement in the machining performance with deep cryogenically treated alloy when compared with shallow and untreated alloy. Current and pulse-on-time also affected the machinability of titanium alloy. Higher material removal rate and microhardness were observed when titanium alloy was machined at high current and pulse-on-time. During machining, carbon was deposited on the machined surface due to the breakdown of hydrocarbon dielectric at high temperature thereby, affecting its properties.

High-Throughput Picosecond Laser Machining of Aerospace Nickel Superalloy

2021 ◽  
pp. 095440542110288
Author(s):  
Sundar Marimuthu ◽  
Bethan Smith
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Thermal Damage ◽  
Removal Rate ◽  
Picosecond Laser ◽  
Nickel Superalloy ◽  
Laser Machining ◽  
Process Conditions ◽  
Machining Performance

This manuscript discusses the experimental results on 300 W picosecond laser machining of aerospace-grade nickel superalloy. The effect of the laser’s energetic and beam scanning parameters on the machining performance has been studied in detail. The machining performance has been investigated in terms of surface roughness, sub-surface thermal damage, and material removal rate. At optimal process conditions, a picosecond laser with an average power output of 300 W can be used to achieve a material removal rate (MRR) of ∼140 mm3/min, with thermal damage less than 20 µm. Shorter laser pulse widths increase the material removal rate and reduce the resultant surface roughness. High scanning speeds improve the picosecond laser machining performance. Edge wall taper of ∼10° was observed over all the picosecond laser machined slots. The investigation demonstrates that high-power picosecond lasers can be used for the macro-machining of industrial components at an acceptable speed and quality.

Modeling of Material Removal Mechanism in Micro Electric Discharge Milling of Ti-6Al-4V

2014 ◽  
Vol 592-594 ◽  
pp. 516-520 ◽  
Author(s):  
Basil Kuriachen ◽  
Jose Mathew
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Electric Discharge Milling

Micro EDM milling process is accruing a lot of importance in micro fabrication of difficult to machine materials. Any complex shape can be generated with the help of the controlled cylindrical tool in the pre determined path. Due to the complex material removal mechanism on the tool and the work piece, a detailed parametric study is required. In this study, the influence of various process parameters on material removal mechanism is investigated. Experiments were planned as per Response Surface Methodology (RSM) – Box Behnken design and performed under different cutting conditions of gap voltage, capacitance, electrode rotation speed and feed rate. Analysis of variance (ANOVA) was employed to identify the level of importance of machining parameters on the material removal rate. Maximum material removal rate was obtained at Voltage (115V), Capacitance (0.4μF), Electrode rotational Speed (1000rpm), and Feed rate (18mm/min). In addition, a mathematical model is created to predict the material removal

Intelligent Modeling and Optimization of Material Removal Rate in Electric Discharge Diamond Grinding

2012 ◽  
Author(s):  
Pankaj Kumar Shrivastava ◽  
Avanish Kumar Dubey
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Iron Carbide ◽  
Hybrid Approach ◽  
Weight Ratio ◽  
Manufacturing Industries ◽  
Machining Process ◽  
Diamond Grinding

Metal matrix composites (MMCs) have wide applications in modern manufacturing industries due to their specific and improved technological characteristics such as high strength to weight ratio, high hardness, high thermal, corrosion and wear resistances. Such characteristics are highly demanded in automobile, aircraft and space research organizations. Shaping of MMCs has been a big challenge for manufacturing industries due to their superior mechanical properties and the peculiar microstructure composed of different phases in MMCs poses machining challenges. Unconventional machining methods have become an alternative to give desired shapes with intricate profiles and stringent design requirements. The aim of present research is to investigate the machining performance of copper-iron-carbide MMC using hybrid machining process, electric discharge diamond grinding (EDDG). A hybrid approach of neural network and genetic algorithm has been used to develop the intelligent model for material removal rate (MRR) and subsequent optimization with the experimental data obtained by scientifically designed experimentation.

scholarly journals An Experimental Study on the Precision Abrasive Machining Process of Hard and Brittle Materials with Ultraviolet-Resin Bond Diamond Abrasive Tools

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 125 ◽  
Author(s):  
Lei Guo ◽  
Xinrong Zhang ◽  
Shibin Chen ◽  
Jizhuang Hui
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Manufacturing Process ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Ultraviolet Curable

Ultraviolet-curable resin was introduced as a bonding agent into the fabrication process of precision abrasive machining tools in this study, aiming to deliver a rapid, flexible, economical, and environment-friendly additive manufacturing process to replace the hot press and sintering process with thermal-curable resin. A laboratory manufacturing process was established to develop an ultraviolet-curable resin bond diamond lapping plate, the machining performance of which on the ceramic workpiece was examined through a series of comparative experiments with slurry-based iron plate lapping. The machined surface roughness and weight loss of the workpieces were periodically recorded to evaluate the surface finish quality and the material removal rate. The promising results in terms of a 12% improvement in surface roughness and 25% reduction in material removal rate were obtained from the ultraviolet-curable resin plate-involved lapping process. A summarized hypothesis was drawn to describe the dynamically-balanced state of the hybrid precision abrasive machining process integrated both the two-body and three-body abrasion mode.

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