Experimental Study of Machining of Smart Materials Using Submerged Abrasive Waterjet Micromachining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Anurag Mahajan
Keyword(s):  
Experimental Study ◽  
Smart Materials ◽  
Thermal Stresses ◽  
Piezoelectric Materials ◽  
High Hardness ◽  
Machining Process ◽  
Critical Parameters ◽  
Abrasive Waterjet ◽  
Parameter Study ◽  
Wide Range

Smart materials are new generation materials which possess great properties to mend themselves with a change in environment. Smart materials find applications in a wide range of industries including biomedical, aerospace, defense and energy sector and so on. These materials possess unique properties including high hardness, high strength, high melting point and low creep behavior. Manufacturing of these materials is a huge challenge, particularly at the micron scale. Abrasive waterjet micromachining (AWJMM) is a non-traditional material removal process which has the capability of machining extremely hard and brittle materials such as glasses and ceramics. AWJMM process is usually performed with nozzle and workpiece placed in air. However, machining in the air causes spreading of the waterjet resulting in low machining quality. Performing the AWJMM process with a submerged nozzle and workpiece could eliminate this problem and also reduce noise, splash, and airborne debris particles during the machining process. This research investigates Submerged Abrasive Waterjet Machining (SAWJMM) process for micromachining smart ceramic materials. The research involves experimental study on micromachining of smart materials using an in-house fabricated SAWJMM setup. The effect of critical parameters including stand-off distance, abrasive grain size and material properties on the cavity size, kerf angle and MRR during SAWJMM and AWJMM processes are studied. The study found that SAWJMM process is capable of successfully machining smart materials including shape memory alloys and piezoelectric materials at the micron scale. The machined surfaced are free of thermal stresses and did not show any cracking around the edges. The critical process parameter study revealed that stand-off distance and abrasive grit size significantly affect the machining results.

Experimental Study on Machining of Hybrid Composite Stacks Using Submerged Abrasive Waterjet Machining Process

2018 ◽  
Author(s):  
Mayur Narkhede ◽  
Sagil James
Keyword(s):  
Experimental Study ◽  
Grain Size ◽  
Hybrid Composite ◽  
Machining Process ◽  
Critical Parameters ◽  
Abrasive Waterjet ◽  
Precision Machining ◽  
Abrasive Waterjet Machining ◽  
Abrasive Grain ◽  
Waterjet Machining

The research involves experimental study on precision machining of hybrid composite stacks using Submerged Abrasive Waterjet Machining (SAWJM) process. In this study, an in-house fabricated SAWJM setup is used to machine a stack of Carbon Fiber Reinforced Polymer (CFRP) and Titanium. The effect of critical parameters including stand-off distance and abrasive grain size on the size of the cavity machined during SAWJM and Abrasive Waterjet Machining (AWJM) processes are studied. The study found that SAWJM process is capable of successfully machining CFRP/Titanium composites with high precision. The machined surface is free of thermal stresses and did not show any delamination or cracking around the edges. The study suggested that the stand-off distance and abrasive grain size has significant influence on the machining process. The cavities machined on both CFRP and titanium during SAWJM process are smaller and more circular than that produced during AWJM process. The results of this study provide deeper insight into precision machining of hybrid composite stacks.

Preliminary Experimental Study of SMA Knitted Actuation Architectures

Aerospace ◽  
2006 ◽  
Author(s):  
Julianna Evans ◽  
Diann Brei ◽  
Jonathan Luntz
Keyword(s):  
Experimental Study ◽  
Smart Materials ◽  
Material Properties ◽  
Geometric Parameters ◽  
Design Parameters ◽  
Static Force ◽  
Vast Array ◽  
Material Parameters ◽  
Wide Range ◽  
And Control

Nature builds an immense set of materials exhibiting a wide range of behaviors using only a small number of basic compounds. The range of materials comes about through architecture, giving functional structure to the basic materials. Analogously, a new genre of actuators can be derived from existing smart materials through architecture. This paper presents a preliminary experimental study of knitted actuation architectures that yield high strains (up to 73%) with moderate forces (tens of Newtons or more) from basic contracting smart material fibers. By different combinations of the two primary knit loops – purl and knit – a variety of behaviors can be achieved including contraction, rolling, spirals, accordions, arching, and any combination of these across the fabric. This paper catalogs several basic knit stitches and their actuated form: garter, stockinette, seed, rib and I-cord. These knitted architectures provide performance tailorability (force, strain, stiffness, and motion) by manipulation of key design parameters such as the material properties of the wire, the geometric parameters (wire diameter, loop size, and gauge), and architectural parameters (stitch type and orientation). This is demonstrated via a quasi-static force-deflection experimental study with several shape memory alloy garter prototypes with varying geometric parameters. While the basic architecture of a knit is simple, it affords a vast array of architectural combinations and control of geometrical and material parameters that generate a myriad of gross motion capabilities beyond that of current day actuation strategies.

An Experimental Study of Radial-Mode Abrasive Waterjet Turning of Steels

2011 ◽  
Vol 697-698 ◽  
pp. 166-170 ◽  
Author(s):  
W.Y. Li ◽  
Jun Wang ◽  
Yasser M. Ali
Keyword(s):  
Experimental Study ◽  
Tilt Angle ◽  
Material Removal ◽  
High Surface ◽  
Machining Process ◽  
Radial Mode ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Statistical Experimental Design

An experimental study of a radial-mode abrasive waterjet (AWJ) turning of AISI4340 high tensile steel is presented. The major process parameters, i.e. feed speed, waterjet pressure, abrasive flow rate, nozzle tilt angle, and workpiece surface speed, are considered in a statistical experimental design. The advantages of the radial-mode AWJ turning over the offset-mode turning include maximum jet energy utilization, high surface speed, a variety of nozzle tilt angles and small nozzle standoff distance, to enable high material removal rate (MRR). It is found that the depth of cut is considerably increased when large nozzle tilt angle and high surface speed are used. It also shows that feed speed and waterjet pressure are the two most significant parameters to control the MRR. This preliminary study suggests that the radial-mode AWJ turning is feasible and can yield high material removal rates. Future research to advance the knowledge about this new machining process is also proposed.

scholarly journals Behavior of Rotary Ultrasonic Machining of Ceramic Materials at a Wide Range of Cutting Speeds

Machines ◽  
2021 ◽  
Vol 9 (8) ◽  
pp. 164
Author(s):  
Marcel Kuruc ◽  
Jozef Peterka
Keyword(s):  
Surface Roughness ◽  
Cutting Parameters ◽  
Ceramic Materials ◽  
Machining Process ◽  
Critical Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Zirconia Ceramics ◽  
Wide Range ◽  
Cutting Speeds

The paper deals with the behavior of the rotary ultrasonic machining process at different cutting speeds of ceramic materials. This process is relatively new; therefore, there are gaps in information about its behavior at near-critical parameters. We adjusted cutting speeds 10 times lower and 10 times higher than the recommended one. The observed parameters were machine load, tool wear, and surface roughness. Alumina and zirconia ceramics were used as materials. The results will help with the optimization of the cutting parameters of the rotary ultrasonic machining process.

scholarly journals The Tribaloy T-800 Coatings Deposited by Laser Engineered Net Shaping (LENSTM)

Materials ◽  
2019 ◽  
Vol 12 (9) ◽  
pp. 1366 ◽  
Author(s):  
Durejko ◽  
Łazińska ◽  
Dworecka-Wójcik ◽  
Lipiński ◽  
Varin ◽  
...  
Keyword(s):  
Brittle Fracture ◽  
Thermal Stresses ◽  
High Hardness ◽  
High Sensitivity ◽  
Laves Phase ◽  
Direct Result ◽  
Laser Engineered Net Shaping ◽  
Wide Range ◽  
Net Shaping ◽  
Technological Limitations

A Tribaloy family of alloys (CoMoCrSi) are characterized by a substantial resistance to wear and corrosion within a wide range of temperatures. These properties are a direct result of their microstructure including the presence of Laves phase in varying proportions. Tribaloy T-800 exhibits the highest content of Laves phase of all other commercial Tribaloy alloys, which provides high hardness and wear resistance. On the other hand, a large content of the Laves phase brings about a high sensitivity to brittle fracture of this alloy. The main objective of this work was a development of the Tribaloy T-800 coatings on the Ni-based superalloy substrate (RENE 77), which employs a Laser Engineered Net Shaping (LENSTM) technique. Technological limitations in this process are susceptibility of T-800 to brittle fracture as well as significant thermal stresses due to rapid cooling, which is an inherent attribute of laser techniques. Therefore, in this work, a number of steps that optimized the LENSTM process and improved the metallurgical soundness of coatings are presented. Employing volume and local substrate pre-heating resulted in the formation of high quality coatings devoid of cracks and flaws.

scholarly journals A Review of Piezoelectric Material-Based Structural Control and Health Monitoring Techniques for Engineering Structures: Challenges and Opportunities

Actuators ◽  
2021 ◽  
Vol 10 (5) ◽  
pp. 101
Author(s):  
Abdul Aabid ◽  
Bisma Parveez ◽  
Md Abdul Raheman ◽  
Yasser E. Ibrahim ◽  
Asraar Anjum ◽  
...  
Keyword(s):  
Structural Health Monitoring ◽  
Health Monitoring ◽  
Smart Materials ◽  
Structural Control ◽  
Piezoelectric Materials ◽  
Sensors And Actuators ◽  
Engineering Structures ◽  
Structural Health ◽  
Wide Range ◽  
Challenges And Opportunities

With the breadth of applications and analysis performed over the last few decades, it would not be an exaggeration to call piezoelectric materials “the top of the crop” of smart materials. Piezoelectric materials have emerged as the most researched materials for practical applications among the numerous smart materials. They owe it to a few main reasons, including low cost, high bandwidth of service, availability in a variety of formats, and ease of handling and execution. Several authors have used piezoelectric materials as sensors and actuators to effectively control structural vibrations, noise, and active control, as well as for structural health monitoring, over the last three decades. These studies cover a wide range of engineering disciplines, from vast space systems to aerospace, automotive, civil, and biomedical engineering. Therefore, in this review, a study has been reported on piezoelectric materials and their advantages in engineering fields with fundamental modeling and applications. Next, the new approaches and hypotheses suggested by different scholars are also explored for control/repair methods and the structural health monitoring of engineering structures. Lastly, the challenges and opportunities has been discussed based on the exhaustive literature studies for future work. As a result, this review can serve as a guideline for the researchers who want to use piezoelectric materials for engineering structures.

Experimental Study on 3-Phase Abrasive Waterjet Deburring

2011 ◽  
Vol 411 ◽  
pp. 335-338 ◽  
Author(s):  
Qing Hua Wang ◽  
Dong Hua Deng ◽  
Bo Huang
Keyword(s):  
Experimental Study ◽  
Product Quality ◽  
Surface Quality ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Product Cost ◽  
Additional Equipment ◽  
By Products

Burrs are unnecessary by-products produced by cutting metal in a machining process. It greatly affects product quality and assembly efficiency, and also affects product cost. Therefore, burrs must be removed and the surface quality must be maintained. Contrary to abrasive waterjet, 3-phase abrasive waterjet has same machining effect on a workpiece without an additional equipment to meet its circulatory requirement. An experiment was performed to analyze the effect of the 3-phase abrasive waterjet parameters on burr removal and surface quality.

An Experimental Study of Abrasive Waterjet for Deburring

2011 ◽  
Vol 411 ◽  
pp. 311-314 ◽  
Author(s):  
Zhi Min Hou ◽  
Wei Xia ◽  
Dong Hua Deng ◽  
Qing Hua Wang
Keyword(s):  
Experimental Study ◽  
Stainless Steel ◽  
Surface Quality ◽  
Orthogonal Experiment ◽  
Grit Size ◽  
Abrasive Waterjet ◽  
Wide Range ◽  
Manufacturing Organizations ◽  
Milled Surface ◽  
Major Bottleneck

Deburring is a major bottleneck in manufacturing organizations. Burrs on the milled surface need to be removed and the surface quality must be maintained. Abrasive waterjet (AWJ) has been used in various operation for a wide range of materials. But no detailed investigations are known to be carried out on AWJ deburring. An orthogonal experiment is designed to investigate the effects of the AWJ parameters on burr removal and on surface quality. The results show that AWJ can remove the burrs from the stainless-steel specimens effectively under the condition of proper parameters, and the parameters such as abrasive grit size and stand-off distance are important not only for burr removal but also for surface quality, and slurry concentration is another important factor for surface quality.

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