Utilizing Small External Vibrational Sources to Increase Polishing Material Removal Rates

2015 ◽  
Author(s):  
M. Mainuddin ◽  
R. Keanini ◽  
B. Mullany
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Low Cost ◽  
Power Input ◽  
Fused Silica ◽  
Removal Rates ◽  
Dc Motors ◽  
Scientific Attention

Although precision polishing of optical grade components using pitch based tools is still common practice, the process has not received the same level of scientific attention as other precision material removal processes. Building on previous research results, this paper demonstrates the relationship between low amplitude, broad spectrum vibrational power input and fused silica material removal rates obtained with different tool-polishing machine combinations. A low cost, easy to implement method of increasing vibrational power is presented and verified through polishing tests. The method uses small, off the shelf, high speed (>10 krpm), DC motors with eccentric masses (0.5 g and 4 g). Attachment of the battery driven motors to the underside of the platen and the workpiece holder increased the vibrational input from 0.7 W to 0.22 W resulting in an increase in the material removal rate from 0.96 mg/hr to 1.10 mg/hr. A method to attenuate process generated vibrations, and thus material removal rates, is also outlined. To achieve this the tool construction is modified by the addition of a cork layer between the substrate and the pitch layer. While this approach is not as flexible as that for increasing the vibrational power input, it successfully attenuated process vibrations (0.2 W to 0.14 W) and reduced the associated material removal rate (9.67 mg/hr to 6.13 mg/hr). The results outlined this paper demonstrate that recording and controlling process vibrations provides practitioners with viable process monitoring and optimization options.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

Effect of Lubricant in Output Parameters of Milling

2010 ◽  
Vol 44-47 ◽  
pp. 335-339
Author(s):  
Ramezan Ali Mahdavinejad
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Surface Finishing ◽  
Machining Parameters ◽  
Machining Processes ◽  
High Speed Milling ◽  
Cooling Lubricant ◽  
Machined Surfaces

The usage of lubrication in machining processes especially in high speed milling is very important. In this research, some steel samples are machined with and without cooling lubricant conditions. In these cases, the material removal rate and surface finishing of machined surfaces are analyzed. The comparison between two conditions shows that the usage of lubricant as coolant material, improves the output machining parameters significantly.

scholarly journals Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3749 ◽  
Author(s):  
Adel T. Abbas ◽  
Neeraj Sharma ◽  
Saqib Anwar ◽  
Faraz H. Hashmi ◽  
Muhammad Jamil ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

High-Speed EDM Milling Using Rotating Short Arcs Under Composite Field

2021 ◽  
Author(s):  
Jin Zhang ◽  
Fuzhu Han
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Comparative Experiment ◽  
Composite Field

Abstract This paper proposed a new method of high-speed electrical discharge machining (EDM) using rotating short arcs under composite field. By the Lorentz force, the electric force and the high-speed rotation of the tool electrode, rotating short arcs are generated between the tool electrode and the workpiece, which can greatly improve the material removal rate of difficult-to-cut materials such as titanium alloys and superalloys. Firstly, the machining equipment used to generate rotating short arcs was constructed. Secondly, single arc discharge experiment was carried out to investigate the motion characteristics of rotating short arcs. The result shows that the arcs can rotate between the tool electrode and workpiece under composite field. Then, the experiment of processing GH4169 was conducted to explore the machining characteristics of rotating short arcs milling, which indicated that rotating short arcs can achieve a much higher material removal rate (MRR). Additionally, it’s found that the magnetic field also has influence on debris, which is beneficial to debris removal. Finally, a comparative experiment was carried out. The MRR of rotating short arcs milling was three times than that of traditional EDM, and the tool electrode wear rate (TEWR) is only one-fifth of that of traditional EDM. The comparative experiment further verified that rotating short arcs milling can achieve higher MRR and lower TEWR.

Process Research on High-Speed Small Hole Drilling by EDM Combined with Magnetic Field and Water Dispersant

2011 ◽  
Vol 189-193 ◽  
pp. 269-272 ◽  
Author(s):  
Ming Rang Cao ◽  
Xiao Di Geng
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Hole Drilling ◽  
Tool Wear Rate ◽  
The Magnetic Field

The mechanism that the magnetic field and the dispersant are helpful to chip removal, to improve the material removal rate (MRR) and to reduce the tool wear rate (TWR) was analyzed in detail.The corresponding experiments were conducted based on theoretical analysis. The experimental results show that adding a certain proportion of dispersant into the dielectric fluid and introducing the magnetic field for high speed small hole drilling by EDM can greatly improve the material removal rate and significantly decrease the tool wear rate.

Study on Force Characteristics for High Speed Sawing of Quartz Glass with Diamond Blade

2014 ◽  
Vol 800-801 ◽  
pp. 144-149 ◽  
Author(s):  
Bo Jiang ◽  
Jian Yun Shen ◽  
Xi Peng Xu
Keyword(s):  
Quartz Glass ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Processing Parameters ◽  
High Productivity ◽  
Diamond Blade ◽  
Force Ratio ◽  
Advanced Machining

High speed sawing is an advanced machining technique for sawing of brittle materials with good component quality and high productivity. In the paper, sawing experiments were carried out to investigate the characteristics of sawing forces by altering many processing parameters in high speed sawing of quartz glass with a diamond blade. The sawing forces and force ratio were analyzed. The conclusions present that in the fixed material removal rate, the increasing of periphery speed can help to lower sawing forces and force ratio; sawing forces increase with material removal rate; in the high speed sawing, the effect of material removal rate on sawing forces is smaller than the one in the low speed.

EXPERIMENTAL INVESTIGATION OF EFFECT OF CRYO-TREATMENT ON MICROMILLING OF INCONEL 718

2020 ◽  
Vol 27 (11) ◽  
pp. 2050001
Author(s):  
PADMAJA TRIPATHY ◽  
KALIPADA MAITY
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Inconel 718 ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
High Speed Steel ◽  
End Mill ◽  
Micro End Mill

In this paper, the effect of cutting parameters during micromilling on surface finish and material removal rate is presented. Inconel 718 alloy and high-speed steel micro end mill are used as work material and cutting tool, respectively. High-speed steel end mill of 1 mm diameter is subjected to cryogenic treatment. Machining studies are performed on Inconel alloy using untreated and cryogenic treated cutters. The milling tests are conducted at three different values of feed rate, cutting speed and depth of cut. Also, tool wear, microstructure and microhardness of different treated and untreated end mill are investigated and discussed in detail. The results showed that cryogenic treatment significantly improved the tool wear. The surface finish produced on machining the work-piece is better with the cryogenic treated tools than when compared with the untreated tools. The material removal rate is better with the cryogenic treated tools than when compared with the untreated tools. Improvement in tool life was up to 53.16% for Inconel 718 material when machined with cryogenically treated micro end mill.

Modeling Material Removal Rate of Heavy Belt-Grinding in Manufacturing of U71Mn Material

2016 ◽  
Vol 693 ◽  
pp. 1082-1089 ◽  
Author(s):  
Rong Quan Wang ◽  
Jian Yong Li ◽  
Yue Ming Liu ◽  
Wen Xi Wang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Low Cost ◽  
Belt Grinding ◽  
Abrasive Particles ◽  
Grinding Conditions ◽  
Modeling Material ◽  
Abrasive Cutting

The heavy belt-grinding is a new machining method, which combined the characters of heavy-duty grinding and belt-grinding together, with high efficiency and low cost. In the present paper the removal rate model of heavy belt-grinding in manufacturing of U71Mn steel is established. It is assumed that the distribution of the abrasive particles protrusion height of the abrasive belt surface closes to Gaussian distribution. The model is presented by calculating the removal volumes of all abrasive grains contributing to cutting action based on the probability theory, elastic-plastic mechanics and abrasive cutting theory. It is analysis that the material removal rate depends essentially on the mechanical properties of the workpiece and the belt and the grinding conditions. It is proportional to the average pressure, belt velocity and the indentation depth and is inverse proportion to the grain size.

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