Pub Date : 2021-07-28DOI: 10.1177/25165984211031687
Abhinav Kumar, H. Yadav, Manjesh Kumar, M. Das
Electrochemical micromachining (EMM) uses anodic dissolution in the range of microns to remove material. Complex shapes that are difficult to machine on hard materials can be fabricated easily with the help of EMM without any stresses on the workpiece surface and no tool wear. Fabrication of microfeatures on microdevices is a critical issue in modern technologies. For the fabrication of microfeatures, precise micro-tools have to be fabricated. In this present study, EMM milling is used for the fabrication of micro-tools. For this, an EMM setup has been designed. Tungsten carbide tools with an initial diameter of 520 µm have been selected and are electrochemically machined to reduce their diameter. The tool and workpiece are connected as anode and cathode, respectively. The electrolyte solution used for this investigation is sodium nitrate. A comparative analysis of the effect of tool rotation over both machining accuracy and surface finish has been performed.
{"title":"Effect of tool rotation on the fabrication of micro-tool by electrochemical micromachining","authors":"Abhinav Kumar, H. Yadav, Manjesh Kumar, M. Das","doi":"10.1177/25165984211031687","DOIUrl":"https://doi.org/10.1177/25165984211031687","url":null,"abstract":"Electrochemical micromachining (EMM) uses anodic dissolution in the range of microns to remove material. Complex shapes that are difficult to machine on hard materials can be fabricated easily with the help of EMM without any stresses on the workpiece surface and no tool wear. Fabrication of microfeatures on microdevices is a critical issue in modern technologies. For the fabrication of microfeatures, precise micro-tools have to be fabricated. In this present study, EMM milling is used for the fabrication of micro-tools. For this, an EMM setup has been designed. Tungsten carbide tools with an initial diameter of 520 µm have been selected and are electrochemically machined to reduce their diameter. The tool and workpiece are connected as anode and cathode, respectively. The electrolyte solution used for this investigation is sodium nitrate. A comparative analysis of the effect of tool rotation over both machining accuracy and surface finish has been performed.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"4 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117260010","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-07-27DOI: 10.1177/25165984211033427
S. Bhandari, Shivani Gupta, R. Mishra, A. Sharma, N. Arora
In the current experimental work, an effort has been made to explore the feasibility of fusion joints of 21-4-N nitronic steel employing microwave heating. These fusion joints were developed inside a domestic microwave applicator operating at 900 W. Microwave energy was used to fabricate the joints in hybrid heating mode by converting electromagnetic energy into heat at 2.45 GHz. Charcoal and SiC plates were used as susceptor and separator, respectively, and nickel powder was used as the interface material. The developed joints were characterized for their microstructural and mechanical properties. The microstructures indicate a complete fusion of nickel interfacing powder with the faying surfaces. XRD results show the formation of metallic nitrides and carbide phases (Cr2N, Fe3N, and Fe2C) and the FeNi phase at the weld zone. Furthermore, the observed average tensile strength of the fusion joints was approximately 61% of base metal. The reduction in the stress and elongation compared to the base metal were 38.67% and 12.68%, respectively. The average microhardness of the microwave joints was monitored as 407 ± 69.27 HV. The results indicate the feasibility of fusion joints of nitronic steel using microwave energy.
{"title":"On microstructural and mechanical properties of 21-4-N nitronic steel joint developed using microwave energy","authors":"S. Bhandari, Shivani Gupta, R. Mishra, A. Sharma, N. Arora","doi":"10.1177/25165984211033427","DOIUrl":"https://doi.org/10.1177/25165984211033427","url":null,"abstract":"In the current experimental work, an effort has been made to explore the feasibility of fusion joints of 21-4-N nitronic steel employing microwave heating. These fusion joints were developed inside a domestic microwave applicator operating at 900 W. Microwave energy was used to fabricate the joints in hybrid heating mode by converting electromagnetic energy into heat at 2.45 GHz. Charcoal and SiC plates were used as susceptor and separator, respectively, and nickel powder was used as the interface material. The developed joints were characterized for their microstructural and mechanical properties. The microstructures indicate a complete fusion of nickel interfacing powder with the faying surfaces. XRD results show the formation of metallic nitrides and carbide phases (Cr2N, Fe3N, and Fe2C) and the FeNi phase at the weld zone. Furthermore, the observed average tensile strength of the fusion joints was approximately 61% of base metal. The reduction in the stress and elongation compared to the base metal were 38.67% and 12.68%, respectively. The average microhardness of the microwave joints was monitored as 407 ± 69.27 HV. The results indicate the feasibility of fusion joints of nitronic steel using microwave energy.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"74 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-07-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116254142","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-07-21DOI: 10.1177/25165984211031115
Shrikrishna Pawar, D. Dolas
Fused deposition modeling (FDM) is one of the most commonly used additive manufacturing (AM) technologies, which has found application in industries to meet the challenges of design modifications without significant cost increase and time delays. Process parameters largely affect the quality characteristics of AM parts, such as mechanical strength and surface finish. This article aims to optimize the parameters for enhancing flexural strength and surface finish of FDM parts. A total of 18 test specimens of polycarbonate (PC)-ABS (acrylonitrile–butadiene–styrene) material are printed to analyze the effect of process parameters, viz. layer thickness, build orientation, and infill density on flexural strength and surface finish. Empirical models relating process parameters with responses have been developed by using response surface regression and further analyzed by analysis of variance. Main effect plots and interaction plots are drawn to study the individual and combined effect of process parameters on output variables. Response surface methodology was employed to predict the results of flexural strength 48.2910 MPa and surface roughness 3.5826 µm with an optimal setting of parameters of 0.14-mm layer thickness and 100% infill density along with horizontal build orientation. Experimental results confirm infill density and build orientation as highly significant parameters for impacting flexural strength and surface roughness, respectively.
{"title":"Effect of process parameters on flexural strength and surface roughness in fused deposition modeling of PC-ABS material","authors":"Shrikrishna Pawar, D. Dolas","doi":"10.1177/25165984211031115","DOIUrl":"https://doi.org/10.1177/25165984211031115","url":null,"abstract":"Fused deposition modeling (FDM) is one of the most commonly used additive manufacturing (AM) technologies, which has found application in industries to meet the challenges of design modifications without significant cost increase and time delays. Process parameters largely affect the quality characteristics of AM parts, such as mechanical strength and surface finish. This article aims to optimize the parameters for enhancing flexural strength and surface finish of FDM parts. A total of 18 test specimens of polycarbonate (PC)-ABS (acrylonitrile–butadiene–styrene) material are printed to analyze the effect of process parameters, viz. layer thickness, build orientation, and infill density on flexural strength and surface finish. Empirical models relating process parameters with responses have been developed by using response surface regression and further analyzed by analysis of variance. Main effect plots and interaction plots are drawn to study the individual and combined effect of process parameters on output variables. Response surface methodology was employed to predict the results of flexural strength 48.2910 MPa and surface roughness 3.5826 µm with an optimal setting of parameters of 0.14-mm layer thickness and 100% infill density along with horizontal build orientation. Experimental results confirm infill density and build orientation as highly significant parameters for impacting flexural strength and surface roughness, respectively.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"99 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127163645","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-06-14DOI: 10.1177/25165984211015413
H. Singh, B. Dewangan, P. Jain
Natural fibre composites have received worldwide attention due to their good mechanical properties, lightweight and low density. Due to these advantages, the natural fibre composites have been used in various engineering applications. Drilling is one of the most frequent machining operations performed on hybrid sisal–jute polymer composites, to assemble the numerous structural components by using mechanical joining process. Furthermore, the machining of fibre reinforced composite material has attracted several researchers because of its non-homogeneous and anisotropic structure. The present research work concerns with the experimental studies on the drilling process of hybrid sisal–jute epoxy composite, using three different types of drill geometry (twist drill, step drill and core drill). The significance of the current work aims to reveal the effect of drill geometry configuration and drilling parameters in terms of drilling-induced force and damages (delamination and surface roughness) for the drilling of hybrid natural fibre composites. Drilling forces, drilling-induced damages and hole quality attributes were experimentally investigated for different drill geometries. The delamination and surface roughness type damages are revealed by microscopic analysis with the help of scanning electron microscope (SEM). The results show that twist drill is best suited for the hole- and force-induced damages.
{"title":"Experimental study on drilling characteristics of the hybrid sisal–jute fibre epoxy composites","authors":"H. Singh, B. Dewangan, P. Jain","doi":"10.1177/25165984211015413","DOIUrl":"https://doi.org/10.1177/25165984211015413","url":null,"abstract":"Natural fibre composites have received worldwide attention due to their good mechanical properties, lightweight and low density. Due to these advantages, the natural fibre composites have been used in various engineering applications. Drilling is one of the most frequent machining operations performed on hybrid sisal–jute polymer composites, to assemble the numerous structural components by using mechanical joining process. Furthermore, the machining of fibre reinforced composite material has attracted several researchers because of its non-homogeneous and anisotropic structure. The present research work concerns with the experimental studies on the drilling process of hybrid sisal–jute epoxy composite, using three different types of drill geometry (twist drill, step drill and core drill). The significance of the current work aims to reveal the effect of drill geometry configuration and drilling parameters in terms of drilling-induced force and damages (delamination and surface roughness) for the drilling of hybrid natural fibre composites. Drilling forces, drilling-induced damages and hole quality attributes were experimentally investigated for different drill geometries. The delamination and surface roughness type damages are revealed by microscopic analysis with the help of scanning electron microscope (SEM). The results show that twist drill is best suited for the hole- and force-induced damages.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"61 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115898368","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-06-13DOI: 10.1177/25165984211021010
A. Petare, N. Jain, I. Palani
This article reports on influence of extrusion pressure, abrasive particle size and volumetric concentration on simultaneous reduction of surface roughness and microgeometry errors of spur and straight bevel gear by abrasive flow finishing (AFF) process. A vertical configured experimental apparatus was developed for two-way AFF and developed fixtures for finishing gears. Experimental investigations were conducted to identify optimum parametric combination, using response surface methodology, based on Box–Behnken design approach. Results revealed that higher values of abrasive particle size and volumetric concentration yield more percentage decrease in surface roughness and microgeometry error. Roughness profile, bearing area curve, microhardness, surface morphology, and wear resistance of the gear having best quality finishing were studied. Surface morphology analysis of the flank regions of the best finished spur and straight bevel gears found them to be smooth and free from cracks and burrs. Reciprocating wear test results revealed higher wear resistance of the AFF finished gears as compared to the unfinished gears. AFF also enhanced microhardness of the finished gears, which would enhance their operating performance and service life. This study shows that AFF is a flexible, economical, productive, easy to operate, and sustainable nontraditional process for precision finishing of gear that can simultaneously improve microgeometry, surface finish, microhardness, surface morphology, wear resistance, and residual stresses of the finished gears. Gear manufacturers and users will be benefited by the outcome of this study. JEL codes: C00, C20
{"title":"Simultaneous improvement of microgeometry and surface quality of spur and straight bevel gears by abrasive flow finishing process","authors":"A. Petare, N. Jain, I. Palani","doi":"10.1177/25165984211021010","DOIUrl":"https://doi.org/10.1177/25165984211021010","url":null,"abstract":"This article reports on influence of extrusion pressure, abrasive particle size and volumetric concentration on simultaneous reduction of surface roughness and microgeometry errors of spur and straight bevel gear by abrasive flow finishing (AFF) process. A vertical configured experimental apparatus was developed for two-way AFF and developed fixtures for finishing gears. Experimental investigations were conducted to identify optimum parametric combination, using response surface methodology, based on Box–Behnken design approach. Results revealed that higher values of abrasive particle size and volumetric concentration yield more percentage decrease in surface roughness and microgeometry error. Roughness profile, bearing area curve, microhardness, surface morphology, and wear resistance of the gear having best quality finishing were studied. Surface morphology analysis of the flank regions of the best finished spur and straight bevel gears found them to be smooth and free from cracks and burrs. Reciprocating wear test results revealed higher wear resistance of the AFF finished gears as compared to the unfinished gears. AFF also enhanced microhardness of the finished gears, which would enhance their operating performance and service life. This study shows that AFF is a flexible, economical, productive, easy to operate, and sustainable nontraditional process for precision finishing of gear that can simultaneously improve microgeometry, surface finish, microhardness, surface morphology, wear resistance, and residual stresses of the finished gears. Gear manufacturers and users will be benefited by the outcome of this study. JEL codes: C00, C20","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"75 2 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134065638","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-06-04DOI: 10.1177/25165984211016323
N. Kadam, G. Karthikeyan, D. Kulkarni
Thermal barrier coatings (TBCs) are favorable for better protection of gas turbines and aero engines at high temperatures. The TBCs were fabricated using NiCrAlY bond coat and 8% wt. yttria-stabilized zirconia (YSZ) topcoat onto the nickel-based superalloy Inconel 800 by atmospheric plasma spray. In this article, the investigation of microstructural and mechanical properties of 8YSZ TBCs with the effect of spray angle has been discussed. The microstructural and elemental analyses were conducted by scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDS). The porosity analysis was conducted based on SEM image analysis using a gray scale threshold. Mechanical properties such as coating hardness, surface roughness, and thickness are measured by indentation, surface profilometer, and optical microscopy. The result shows the effect of the spray angle over the coating surface in terms of pores and microcracks. The influence of the spray angle leads to different grain growth resulting in the shadow region. A large number of defects and a decrease in coating hardness were observed for 60 degrees pray angle compared to the 90 degrees pray angle. A large number of defects led to developing rough surfaces, resulting in low hardness and increased porosity. The experimental results showed that the plasma sprayed 8YSZ TBC with a 90 degree spray angle can improve the durability and performance of the TBCs, as it has better microstructural and mechanical properties.
{"title":"The effect of spray angle on the microstructural and mechanical properties of plasma sprayed8YSZ thermal barrier coatings","authors":"N. Kadam, G. Karthikeyan, D. Kulkarni","doi":"10.1177/25165984211016323","DOIUrl":"https://doi.org/10.1177/25165984211016323","url":null,"abstract":"Thermal barrier coatings (TBCs) are favorable for better protection of gas turbines and aero engines at high temperatures. The TBCs were fabricated using NiCrAlY bond coat and 8% wt. yttria-stabilized zirconia (YSZ) topcoat onto the nickel-based superalloy Inconel 800 by atmospheric plasma spray. In this article, the investigation of microstructural and mechanical properties of 8YSZ TBCs with the effect of spray angle has been discussed. The microstructural and elemental analyses were conducted by scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDS). The porosity analysis was conducted based on SEM image analysis using a gray scale threshold. Mechanical properties such as coating hardness, surface roughness, and thickness are measured by indentation, surface profilometer, and optical microscopy. The result shows the effect of the spray angle over the coating surface in terms of pores and microcracks. The influence of the spray angle leads to different grain growth resulting in the shadow region. A large number of defects and a decrease in coating hardness were observed for 60 degrees pray angle compared to the 90 degrees pray angle. A large number of defects led to developing rough surfaces, resulting in low hardness and increased porosity. The experimental results showed that the plasma sprayed 8YSZ TBC with a 90 degree spray angle can improve the durability and performance of the TBCs, as it has better microstructural and mechanical properties.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"30 4 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125699507","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-06-02DOI: 10.1177/25165984211015785
C. Kumari, S. K. Chak
Magneto-rheological abrasive honing (MRAH) is an unconventional surface finishing technique that relies on abrasives mixed with a unique finishing fluid, which changes its characteristics on magnetic field application. This process imparts nanometric-level surface finish with a significant amount of uniformity. Rotating motion of the workpiece and continuous reciprocation of the finishing fluid in the MRAH process are recognized as the major aspects for adopting this process in finishing non-magnetic materials. The finishing obtained through the MRAH process relies on the workpiece’s material properties and process parameters such as concentration of abrasives in finishing fluid, rotational speed of the workpiece, and magnetic field strength/magnetizing current. To study the efficacy of MRAH process, a parametric study was conducted by performing few experiments on a brass workpiece. Design of experiment approach was adopted to plan the experiments, and the effect of different values of magnetizing current, the concentration of abrasives, and rotational speed on the surface finish were analyzed through the application of analysis of variance (ANOVA). From ANOVA, the rotational speed was found as the most significant parameter with a contribution of 48.90% on % reduction in roughness value (%∇Ra). Around 57% of roughness reduction was obtained at the optimized value of process parameters.
{"title":"Experimental investigations on finishing of a brass specimen by magneto-rheological honing technique","authors":"C. Kumari, S. K. Chak","doi":"10.1177/25165984211015785","DOIUrl":"https://doi.org/10.1177/25165984211015785","url":null,"abstract":"Magneto-rheological abrasive honing (MRAH) is an unconventional surface finishing technique that relies on abrasives mixed with a unique finishing fluid, which changes its characteristics on magnetic field application. This process imparts nanometric-level surface finish with a significant amount of uniformity. Rotating motion of the workpiece and continuous reciprocation of the finishing fluid in the MRAH process are recognized as the major aspects for adopting this process in finishing non-magnetic materials. The finishing obtained through the MRAH process relies on the workpiece’s material properties and process parameters such as concentration of abrasives in finishing fluid, rotational speed of the workpiece, and magnetic field strength/magnetizing current. To study the efficacy of MRAH process, a parametric study was conducted by performing few experiments on a brass workpiece. Design of experiment approach was adopted to plan the experiments, and the effect of different values of magnetizing current, the concentration of abrasives, and rotational speed on the surface finish were analyzed through the application of analysis of variance (ANOVA). From ANOVA, the rotational speed was found as the most significant parameter with a contribution of 48.90% on % reduction in roughness value (%∇Ra). Around 57% of roughness reduction was obtained at the optimized value of process parameters.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"16 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125334342","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-06-02DOI: 10.1177/25165984211015410
P. Abhilash, D. Chakradhar
This study aims to create an image processing algorithm that categorises the wire electric discharge machine (WEDM) processed finish cut surfaces, based on surface microdefects. The algorithm also detects the defect locations and suggests alternate parameter settings for improving the surface integrity. The proposed automated analysis is more precise, efficient and repeatable compared to manual inspection. Also, the method can be used for automatic data generation to suggest parameter changes in closed loop systems. During the training phase, mean, standard deviation and defect area fraction of enhanced binary images are extracted and stored. The training dataset consists of 27 WEDM finish cut surface images with labels, ‘coarse’, ‘average’ and ‘smooth’. The trained model is capable of categorising any machined surface by detecting the microdefects. If the machined surface image is not classified as a smooth image, then alternate input parameter settings will be suggested by the model to minimise the microdefects. This is done based on the Euclidean distance between the current image datapoint and the nearest ‘smooth’ class datapoint.
{"title":"Image processing algorithm for detection, quantification and classification of microdefects in wire electric discharge machined precision finish cut surfaces","authors":"P. Abhilash, D. Chakradhar","doi":"10.1177/25165984211015410","DOIUrl":"https://doi.org/10.1177/25165984211015410","url":null,"abstract":"This study aims to create an image processing algorithm that categorises the wire electric discharge machine (WEDM) processed finish cut surfaces, based on surface microdefects. The algorithm also detects the defect locations and suggests alternate parameter settings for improving the surface integrity. The proposed automated analysis is more precise, efficient and repeatable compared to manual inspection. Also, the method can be used for automatic data generation to suggest parameter changes in closed loop systems. During the training phase, mean, standard deviation and defect area fraction of enhanced binary images are extracted and stored. The training dataset consists of 27 WEDM finish cut surface images with labels, ‘coarse’, ‘average’ and ‘smooth’. The trained model is capable of categorising any machined surface by detecting the microdefects. If the machined surface image is not classified as a smooth image, then alternate input parameter settings will be suggested by the model to minimise the microdefects. This is done based on the Euclidean distance between the current image datapoint and the nearest ‘smooth’ class datapoint.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"69 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126231083","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-05-31DOI: 10.1177/25165984211015761
Himanshu Kumar, S. Shiva
In this article, Al7075 matrix with SiC as reinforcement particle was developed and the mechanical properties such as tensile strength, hardness, and impact strength was investigated. Aluminum is preferred as a matrix phase because Al alloys have low density and good ductility. Silicon carbide is chosen as a reinforcement phase due to its brittle and hard properties to enhance the wear properties. Mechanical properties of aluminum metal matrix have been tested at different temperatures and holding time. It shows an ultimate tensile strength of 121 N/mm2 at 800°C processing temperature and 20 mins of holding time. At a processing temperature of 850°C, it shows maximum hardness and impact strength. Among all the fabrication processes, stir casting is chosen because stir casting process is the simplest and cheapest for fabricating metal matrix composites (MMCs). Microelectronic and aerospace packaging industry requires a material with optimum hardness and impact strength to prevent the material from wear and impact during material handling. These MMCs will be a replacement for traditionally used materials such as W-Cu, BeO, and Kovar in packaging application.
{"title":"Experimental investigation on stir casting of a metal matrix composite material","authors":"Himanshu Kumar, S. Shiva","doi":"10.1177/25165984211015761","DOIUrl":"https://doi.org/10.1177/25165984211015761","url":null,"abstract":"In this article, Al7075 matrix with SiC as reinforcement particle was developed and the mechanical properties such as tensile strength, hardness, and impact strength was investigated. Aluminum is preferred as a matrix phase because Al alloys have low density and good ductility. Silicon carbide is chosen as a reinforcement phase due to its brittle and hard properties to enhance the wear properties. Mechanical properties of aluminum metal matrix have been tested at different temperatures and holding time. It shows an ultimate tensile strength of 121 N/mm2 at 800°C processing temperature and 20 mins of holding time. At a processing temperature of 850°C, it shows maximum hardness and impact strength. Among all the fabrication processes, stir casting is chosen because stir casting process is the simplest and cheapest for fabricating metal matrix composites (MMCs). Microelectronic and aerospace packaging industry requires a material with optimum hardness and impact strength to prevent the material from wear and impact during material handling. These MMCs will be a replacement for traditionally used materials such as W-Cu, BeO, and Kovar in packaging application.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-05-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132350126","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-05-29DOI: 10.1177/25165984211016445
Arun Kumar Rouniyar, P. Shandilya
Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) has emerged as hybrid electrical discharge machining (EDM) technique which improves machining performance by the addition of powder in dielectric and under the influence of magnetic field. In the present article, Aluminium 6061 alloy was machined through fabricated MFAPM-EDM set-up considering the one-parameter-at-a-time method. The individual effect of process parameters, namely pulse on duration (PON), pulse off duration (POFF), discharge current (IP), magnetic field strength (MF) and powder concentration (PC) on surface crack density (SCD) and micro hardness (MH) has been studied. Pulse on duration was observed as the most dominating process parameter accompanied by peak current, powder concentration and magnetic field for both SCD and MH. Lower SCD (0. 0063 µm/µm 2 ) and higher MH (188. 21 HV) on machined surface were observed at PON= 90 µsec, POFF=45 µsec, IP=13 A, PC =10 g/l and MF= 0. 3 T. Machining of AA6061 with MFAPM-EDM process revealed 85% and 76% improvement in SCD and MH, respectively. XRD analysis witness an increase in MH due to the presence of oxide as well as carbide layer on machined surface.
磁场辅助粉末混合电火花加工(MFAPM-EDM)是一种通过在介质中加入粉末并在磁场作用下提高加工性能的混合电火花加工技术。本文以6061铝合金为研究对象，采用一参数一次加工的方法，采用MFAPM-EDM加工装置进行加工。研究了脉冲开启时间(PON)、脉冲关闭时间(POFF)、放电电流(IP)、磁场强度(MF)和粉末浓度(PC)等工艺参数对表面裂纹密度(SCD)和显微硬度(MH)的个别影响。在SCD和MH中，脉冲持续时间是最主要的工艺参数，伴随着峰值电流、粉末浓度和磁场。0063µm/µm 2)和更高的MH(188。在PON= 90µsec, POFF=45µsec, IP=13 A, PC =10 g/l, MF= 0时，对加工表面的影响达到21 HV。采用MFAPM-EDM工艺加工AA6061, SCD和MH分别提高了85%和76%。XRD分析表明，由于加工表面存在氧化物和碳化物层，MH含量增加。
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