Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129990
S. Paswan, Anant Kumar Singh
Abstract A new in-situ rotary magnetorheological honing (RMRH) approach has been developed in this study to fine-finish the machined inner surface of cylindric workpieces with increased productivity and dimensional accuracy. A single in-situ honing tool is used for performing both traditional as well as magnetorheological (MR) honing. The tool is fabricated based on the designed tool through magnetostatic analysis. In this work, the final MR finished surface is achieved up to 60 nm from the original machined surface roughness of 510 nm with the expense of 40 min of traditional honing and 60 min of MR finishing. Also, the great improvement in surface waviness is confirmed through the final surface waviness is achieved as 50 nm from the initial surface waviness of 1460 nm. The improvement in circularity is confirmed through the circularity test performed in this work. The improvement in surface texture has been analyzed through the scanning electron microscope images. As a result of the finishing capability of the currently designed in-situ tool, it is useful in a variety of industrial applications such as oil pipes, bearings, hydraulic cylinders, cylindrical molds, cylindrical barrels of injection molding machines, compressor bodies, valve bodies, etc.
{"title":"Development of a new in-situ rotating magnetorheological honing technique for fine finishing the inner cylindric surfaces","authors":"S. Paswan, Anant Kumar Singh","doi":"10.1080/10910344.2022.2129990","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129990","url":null,"abstract":"Abstract A new in-situ rotary magnetorheological honing (RMRH) approach has been developed in this study to fine-finish the machined inner surface of cylindric workpieces with increased productivity and dimensional accuracy. A single in-situ honing tool is used for performing both traditional as well as magnetorheological (MR) honing. The tool is fabricated based on the designed tool through magnetostatic analysis. In this work, the final MR finished surface is achieved up to 60 nm from the original machined surface roughness of 510 nm with the expense of 40 min of traditional honing and 60 min of MR finishing. Also, the great improvement in surface waviness is confirmed through the final surface waviness is achieved as 50 nm from the initial surface waviness of 1460 nm. The improvement in circularity is confirmed through the circularity test performed in this work. The improvement in surface texture has been analyzed through the scanning electron microscope images. As a result of the finishing capability of the currently designed in-situ tool, it is useful in a variety of industrial applications such as oil pipes, bearings, hydraulic cylinders, cylindrical molds, cylindrical barrels of injection molding machines, compressor bodies, valve bodies, etc.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43447879","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129989
G. Toker, J. Schoop, H. Karaca
Abstract In this study, the effects of cryogenic and flood cooling on the surface integrity of Inconel 718 are investigated for face turning with four selected cutting speeds of 25, 50, 75 and 100 m/min. Surface integrity of machined samples was characterized in terms of surface morphology, sub-surface microstructure, microhardness, x-ray diffraction textures, and residual stresses. While the differences between cryogenic and flood cooling were relatively limited for the majority of surface integrity metrics, a substantially increased (+80% vs flood condition) nanolayer depth was observed at the highest cutting speed of 100 m/min with cryogenic cooling. Additionally, cryogenic cooling resulted in slightly improved surface roughness and slightly increased compressive residual stress, particularly at elevated cutting speeds. Nb-rich secondary phases were detected after machining for all conditions, however, cryogenic cooling and low cutting speed led to reduced mixing of these nanocrystalized phases in the recrystallized surface layer. Based on these observations a and qualitative model for surface generation and nanocrystallization under flood and cryogenic machining conditions was proposed. Overall, the effect of cryogenic cooling on nanolayer generation was most pronounced at elevated speeds, suggesting the potential for cryogenic cooling to allow for more aggressive, yet sustainable, processing strategies with improved surface integrity.
{"title":"Machining-induced surface integrity and nanocrystalline surface layers in cryogenic finishing turning of Inconel 718","authors":"G. Toker, J. Schoop, H. Karaca","doi":"10.1080/10910344.2022.2129989","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129989","url":null,"abstract":"Abstract In this study, the effects of cryogenic and flood cooling on the surface integrity of Inconel 718 are investigated for face turning with four selected cutting speeds of 25, 50, 75 and 100 m/min. Surface integrity of machined samples was characterized in terms of surface morphology, sub-surface microstructure, microhardness, x-ray diffraction textures, and residual stresses. While the differences between cryogenic and flood cooling were relatively limited for the majority of surface integrity metrics, a substantially increased (+80% vs flood condition) nanolayer depth was observed at the highest cutting speed of 100 m/min with cryogenic cooling. Additionally, cryogenic cooling resulted in slightly improved surface roughness and slightly increased compressive residual stress, particularly at elevated cutting speeds. Nb-rich secondary phases were detected after machining for all conditions, however, cryogenic cooling and low cutting speed led to reduced mixing of these nanocrystalized phases in the recrystallized surface layer. Based on these observations a and qualitative model for surface generation and nanocrystallization under flood and cryogenic machining conditions was proposed. Overall, the effect of cryogenic cooling on nanolayer generation was most pronounced at elevated speeds, suggesting the potential for cryogenic cooling to allow for more aggressive, yet sustainable, processing strategies with improved surface integrity.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47118001","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129991
Sahil Sharma, Tarlochan Singh, A. Dvivedi
Abstract The requirement to fabricate the micro features in difficult-to-machine materials has increased the demand for new micro-machining processes. Over the years, various micro-machining processes have emerged, such as non-conventional, hybrid, and tandem micro-machining processes. Recently, among all of these processes, the tandem micro-machining processes have gained substantial attention. In these processes, two machining methods are arranged tandemly to mitigate the drawbacks of the primary one. This manuscript presents a comprehensive systematic review of the recent developments carried out in the novel tandem micro-machining processes. After conducting a literature review, the existing tandem micro-machining processes have been classified into four categories: Thermo plus Electrochemical, Thermo plus Mechanical, Thermo plus Thermo, and Hybrid plus Mechanical/Thermal. This work includes a detailed description of process conceptualization, process mechanisms, current development and capabilities of tandem micro-machining processes regarding work material and machined features. The manuscript’s originality illustrates how combining two processes could effectively produce intricate shapes in difficult-to-cut materials. Furthermore, the various steps involved in developing a tandem process from the idea formulation to the implementation stage have been discussed in the manuscript. The future opportunities in tandem micro-machining processes have also been identified and presented as research potential. While motivated by the systematic investigation, initial experimental results obtained from the in-house developed micro tandem machining processes such as W-EDM plus W-ECM and Laser plus W-ECM have also been included.
{"title":"Developments in tandem micro-machining processes to mitigate the machining issues at micron level: a systematic review, challenges and future opportunities","authors":"Sahil Sharma, Tarlochan Singh, A. Dvivedi","doi":"10.1080/10910344.2022.2129991","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129991","url":null,"abstract":"Abstract The requirement to fabricate the micro features in difficult-to-machine materials has increased the demand for new micro-machining processes. Over the years, various micro-machining processes have emerged, such as non-conventional, hybrid, and tandem micro-machining processes. Recently, among all of these processes, the tandem micro-machining processes have gained substantial attention. In these processes, two machining methods are arranged tandemly to mitigate the drawbacks of the primary one. This manuscript presents a comprehensive systematic review of the recent developments carried out in the novel tandem micro-machining processes. After conducting a literature review, the existing tandem micro-machining processes have been classified into four categories: Thermo plus Electrochemical, Thermo plus Mechanical, Thermo plus Thermo, and Hybrid plus Mechanical/Thermal. This work includes a detailed description of process conceptualization, process mechanisms, current development and capabilities of tandem micro-machining processes regarding work material and machined features. The manuscript’s originality illustrates how combining two processes could effectively produce intricate shapes in difficult-to-cut materials. Furthermore, the various steps involved in developing a tandem process from the idea formulation to the implementation stage have been discussed in the manuscript. The future opportunities in tandem micro-machining processes have also been identified and presented as research potential. While motivated by the systematic investigation, initial experimental results obtained from the in-house developed micro tandem machining processes such as W-EDM plus W-ECM and Laser plus W-ECM have also been included.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42424111","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abstract Carbon fiber reinforced polymer (CFRP) is prone to surface damage such as delamination, uncut fibers and tear during the process of hole-making in aerospace field. Helical milling greatly improves the exit damage of CFRP holes, but the entrance damage will further deteriorate. To further diminish hole entrance damage and enhance hole machining quality, this paper proposed a longitudinal torsional ultrasonic assisted helical milling method to investigate the formation mechanism of hole entrance damage based on a cutting fracture mechanism with a fiber angle of 0° to 180°. The differences of hole entrance damage between longitudinal torsional ultrasonic helical milling (LTUHM) and traditional helical milling (THM) were analysed by a series of comparative experiments. The results showed that longitudinal torsional ultrasonic machining significantly reduced the damage of CFRP holes compared to THM. The delamination damage factor and uncut fibers factor of the hole entrance are reduced to 24.92% and 20.28%, respectively, and the fiber fracture surface is flatter under LTUHM. The study provides a production guide for efficient hole-making of CFRP.
{"title":"The hole entrance damage in longitudinal torsional ultrasonic helical milling of CFRP composites","authors":"Xue Wang, Feng Jiao, Shun Zhang, Yuanxiao Li, J. Tong, Zhibin Feng","doi":"10.1080/10910344.2022.2129988","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129988","url":null,"abstract":"Abstract Carbon fiber reinforced polymer (CFRP) is prone to surface damage such as delamination, uncut fibers and tear during the process of hole-making in aerospace field. Helical milling greatly improves the exit damage of CFRP holes, but the entrance damage will further deteriorate. To further diminish hole entrance damage and enhance hole machining quality, this paper proposed a longitudinal torsional ultrasonic assisted helical milling method to investigate the formation mechanism of hole entrance damage based on a cutting fracture mechanism with a fiber angle of 0° to 180°. The differences of hole entrance damage between longitudinal torsional ultrasonic helical milling (LTUHM) and traditional helical milling (THM) were analysed by a series of comparative experiments. The results showed that longitudinal torsional ultrasonic machining significantly reduced the damage of CFRP holes compared to THM. The delamination damage factor and uncut fibers factor of the hole entrance are reduced to 24.92% and 20.28%, respectively, and the fiber fracture surface is flatter under LTUHM. The study provides a production guide for efficient hole-making of CFRP.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43914177","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129987
Gaopan Lei, D. Zhu, Mingzhu Ren, Dihua Zhu
Abstract The structure of the blades on a blisk is generally characterized by spatial distortion and spatial bending. Electrochemical trepanning (ECTr) is an effective roughing method in blisk manufacturing. To improve the structural characteristics and the allowance distribution uniformity manufactured by ECTr, a new feeding strategy, in which the relative motion of the cathode and the workpiece is due to simultaneous rotational feeding (RF) and shift feeding (SF), is proposed. The approach is called the rotational feeding combined with shift feeding (RF-SF) strategy. A parametric model and an optimized method for calculating the feeding trajectory (FT) under the RF-SF strategy are presented. To assess the effectiveness of the proposed method, the FTs for a twisted blade with variable cross section and a degree of bending were calculated and simulated for the RF and RF-SF strategies. Compared with the RF strategy, the uniformity of the allowance distribution under the RF-SF strategy was improved by 60.4% and 50.3% at the concave and convex parts, respectively. A blade was machined with RF-SF ECTr. The deviations between the experimental and simulated results were 7.1% and 8.1%, respectively, thereby verifying the effectiveness of the proposed method.
{"title":"Rotational feeding combined with shift feeding in the electrochemical trepanning of a blisk","authors":"Gaopan Lei, D. Zhu, Mingzhu Ren, Dihua Zhu","doi":"10.1080/10910344.2022.2129987","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129987","url":null,"abstract":"Abstract The structure of the blades on a blisk is generally characterized by spatial distortion and spatial bending. Electrochemical trepanning (ECTr) is an effective roughing method in blisk manufacturing. To improve the structural characteristics and the allowance distribution uniformity manufactured by ECTr, a new feeding strategy, in which the relative motion of the cathode and the workpiece is due to simultaneous rotational feeding (RF) and shift feeding (SF), is proposed. The approach is called the rotational feeding combined with shift feeding (RF-SF) strategy. A parametric model and an optimized method for calculating the feeding trajectory (FT) under the RF-SF strategy are presented. To assess the effectiveness of the proposed method, the FTs for a twisted blade with variable cross section and a degree of bending were calculated and simulated for the RF and RF-SF strategies. Compared with the RF strategy, the uniformity of the allowance distribution under the RF-SF strategy was improved by 60.4% and 50.3% at the concave and convex parts, respectively. A blade was machined with RF-SF ECTr. The deviations between the experimental and simulated results were 7.1% and 8.1%, respectively, thereby verifying the effectiveness of the proposed method.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47276520","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129986
M. Imad, H. Kishawy, N. Z. Yussefian, A. Hosseini
Abstract This work investigated the impact of cutting tools varying edge radii by presenting a 3-dimensional finite element analysis (3D FEA) model during the milling of hardened steels. The proposed numerical model was able to capture the effect of micro geometrical changes between cutting tools of five different edge radii (25 30 35 40 and 45 ). Experimental milling tests were performed to validate the numerical model and close agreement was reported between the experimentally acquired cutting forces and the numerically simulated ones. Results concluded that experimental and numerical cutting forces increased with the increase of edge radius. Furthermore, the effect of the five different edge radii and cutting conditions on the integrity of machined surfaces were studied. The integrity parameters of choice were surface roughness, feed marks pattern, subsurface plastic deformation, and subsurface microhardness. Results indicated that the surface roughness increased with increasing the feed rate and decreasing the cutting speed, and vice versa. However, altering the edge radius did not introduce a significant impact on the surface roughness. Results also revealed that increasing the edge radius made feed marks more visible and increased the subsurface plastic deformation and microhardness beneath the machined surface.
{"title":"Effect of cutting edge radius when milling hardened steels: a finite element analysis and surface integrity investigation","authors":"M. Imad, H. Kishawy, N. Z. Yussefian, A. Hosseini","doi":"10.1080/10910344.2022.2129986","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129986","url":null,"abstract":"Abstract This work investigated the impact of cutting tools varying edge radii by presenting a 3-dimensional finite element analysis (3D FEA) model during the milling of hardened steels. The proposed numerical model was able to capture the effect of micro geometrical changes between cutting tools of five different edge radii (25 30 35 40 and 45 ). Experimental milling tests were performed to validate the numerical model and close agreement was reported between the experimentally acquired cutting forces and the numerically simulated ones. Results concluded that experimental and numerical cutting forces increased with the increase of edge radius. Furthermore, the effect of the five different edge radii and cutting conditions on the integrity of machined surfaces were studied. The integrity parameters of choice were surface roughness, feed marks pattern, subsurface plastic deformation, and subsurface microhardness. Results indicated that the surface roughness increased with increasing the feed rate and decreasing the cutting speed, and vice versa. However, altering the edge radius did not introduce a significant impact on the surface roughness. Results also revealed that increasing the edge radius made feed marks more visible and increased the subsurface plastic deformation and microhardness beneath the machined surface.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43402752","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-05-04DOI: 10.1080/10910344.2022.2129981
G. Sonawane, V. Sargade
Abstract The present study is an extension of our previous work. Performance evaluation of single-layer AlTiN coating deposited by Scalable Pulse Power Plasma (S3p) and High Power Impulse Magnetron Sputtering (HiPIMS), with multi-layer TiN/TiAlN and AlTiN/TiAlN coating deposited by Cathodic Arc Evaporation (CAE) is carried out. Taguchi’s full factorial design with L9 orthogonal array was used for machining. AlTiN (S3p) coating exhibited a tool life of 111 min, 1.5 times as much as AlTiN (HiPIMS) coating. Multi-layer coatings could not offer comparable performance with single-layer coatings. Among the multi-layer coatings’ tools having the top layer of Al performed better. Surface roughness exhibited by AlTiN (S3p) tool was 1.2 µm compared to 1.8 µm by AlTiN (HiPIMS) tools. The rate of reduction of cutting force for AlTiN (HiPIMS) and AlTiN (S3p) tools was found to be 5% and 11%, respectively. Multi-layer TiN/TiAlN-coated tool exhibited 2.5 times higher surface roughness compared to single-layer AlTiCrN coated tool. Empirical models showed predictability of 5% and 20% for cutting force and surface roughness respectively. The higher predictability range for surface roughness is due to influence of both cutting speed and feed. The developed models can be used for selection among AlTiN (S3p) and AlTiN (HiPIMS) coated tools.
{"title":"Performance evaluation of HiPIMS, S3p and CAE deposited coatings during dry turning of Dss2205","authors":"G. Sonawane, V. Sargade","doi":"10.1080/10910344.2022.2129981","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129981","url":null,"abstract":"Abstract The present study is an extension of our previous work. Performance evaluation of single-layer AlTiN coating deposited by Scalable Pulse Power Plasma (S3p) and High Power Impulse Magnetron Sputtering (HiPIMS), with multi-layer TiN/TiAlN and AlTiN/TiAlN coating deposited by Cathodic Arc Evaporation (CAE) is carried out. Taguchi’s full factorial design with L9 orthogonal array was used for machining. AlTiN (S3p) coating exhibited a tool life of 111 min, 1.5 times as much as AlTiN (HiPIMS) coating. Multi-layer coatings could not offer comparable performance with single-layer coatings. Among the multi-layer coatings’ tools having the top layer of Al performed better. Surface roughness exhibited by AlTiN (S3p) tool was 1.2 µm compared to 1.8 µm by AlTiN (HiPIMS) tools. The rate of reduction of cutting force for AlTiN (HiPIMS) and AlTiN (S3p) tools was found to be 5% and 11%, respectively. Multi-layer TiN/TiAlN-coated tool exhibited 2.5 times higher surface roughness compared to single-layer AlTiCrN coated tool. Empirical models showed predictability of 5% and 20% for cutting force and surface roughness respectively. The higher predictability range for surface roughness is due to influence of both cutting speed and feed. The developed models can be used for selection among AlTiN (S3p) and AlTiN (HiPIMS) coated tools.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45129426","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-05-04DOI: 10.1080/10910344.2022.2129980
Seyyed Sajjad Ahmadpoor, M. Khajehzadeh, M. Razfar
Abstract In this study, an experimental study and three-dimensional finite element simulation of ultrasonic elliptical vibration-assisted turning (UEAT) are investigated. In addition, the comparison of this process with ultrasonic-assisted turning (UAT) and conventional turning (CT) is also provided. First, a three-dimensional FEM has been developed to study the cutting forces, friction coefficient, and residual stresses in CT, UAT, and UEAT. For the experimental tests, a special design of elliptical vibration tool with two bending modes (along feed and cutting speed) is proposed and fabricated. Then, the effect of vibration amplitude, cutting speed, and feed on the machining residual stresses during hard turning of AISI4340 steel has been explored. Finally, the developed FEM is validated with the experimental test results. According to the obtained results, by applying elliptical vibrations on the cutting tool in UEAT, machining residual stresses became more compressive on averagely by 49%. Moreover, the application of elliptical ultrasonic vibrations with amplitudes of 6 and 12 μm had made machining residual stresses 34 and 64% more compressive, respectively.
{"title":"Finite element simulation and experimental investigation of machining induced residual stresses in ultrasonic elliptical vibration-assisted turning","authors":"Seyyed Sajjad Ahmadpoor, M. Khajehzadeh, M. Razfar","doi":"10.1080/10910344.2022.2129980","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129980","url":null,"abstract":"Abstract In this study, an experimental study and three-dimensional finite element simulation of ultrasonic elliptical vibration-assisted turning (UEAT) are investigated. In addition, the comparison of this process with ultrasonic-assisted turning (UAT) and conventional turning (CT) is also provided. First, a three-dimensional FEM has been developed to study the cutting forces, friction coefficient, and residual stresses in CT, UAT, and UEAT. For the experimental tests, a special design of elliptical vibration tool with two bending modes (along feed and cutting speed) is proposed and fabricated. Then, the effect of vibration amplitude, cutting speed, and feed on the machining residual stresses during hard turning of AISI4340 steel has been explored. Finally, the developed FEM is validated with the experimental test results. According to the obtained results, by applying elliptical vibrations on the cutting tool in UEAT, machining residual stresses became more compressive on averagely by 49%. Moreover, the application of elliptical ultrasonic vibrations with amplitudes of 6 and 12 μm had made machining residual stresses 34 and 64% more compressive, respectively.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44128557","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-05-04DOI: 10.1080/10910344.2022.2129985
S. Aravind, S. Hiremath
Abstract This article presents a comprehensive study on the machining and characterization of the holes machined on a biomaterial Ti-6Al-4V ELI of 350 µm thickness with hollow stainless steel tool electrode of outside diameter 250 µm using the tailor-made µ-ECM experimental setup. The distinct feature of the experimental unit is an indigenously made pulse generator circuit and a closed-loop tool feed circuit made from a current-based sensor to retain a constant inter-electrode gap (IEG) between the tool electrode and the workpiece electrode during the machining operation. The machining process parameters are electrolyte concentration (wt % C), voltage (V) and duty factor (% DF). The output responses of interest are Circularity (C), Material Removal Rate (MRR), Taper Angle (TA), Stray Corrosion Zone (SCZ) Width and Radial Over Cut (ROC) of the hole machined. The maximum MRR obtained is 7.2 µg/s at the parametric combination of 12 V, 15 wt % C and 50% DF. The maximum circularity of 0.989 and minimum SCZ width of 309.796 µm is produced by the combination of 8 V, 15 wt % C and 30% DF. The minimum ROC of 181.091 µm is generated by the combination of 10 V, 20 wt % C and 50% DF. The combination of 12 V, 25 wt % C and 40% DF resulted a minimum TA of 0.235 degrees. The machined hole topography study based on the High Resolution Scanning Electron Microscope (HRSEM) images of all the machined holes revealed that the parametric combination of 8 V, 15 wt % C and 30% DF yielded uniform microstructure in the SCZ no pitting corrosion, smooth and precise hole edge. The presence of sodium and bromine is found in Energy Dispersive Spectroscopy (EDS) analysis of the machined hole surface. In addition to these elements, titanium and vanadium are found in the used tool electrode.
{"title":"Machining and characterization of holes machined on a biomaterial Ti-6Al-4V ELI using an indigenously developed electrochemical machining cell with IEG control mechanism","authors":"S. Aravind, S. Hiremath","doi":"10.1080/10910344.2022.2129985","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129985","url":null,"abstract":"Abstract This article presents a comprehensive study on the machining and characterization of the holes machined on a biomaterial Ti-6Al-4V ELI of 350 µm thickness with hollow stainless steel tool electrode of outside diameter 250 µm using the tailor-made µ-ECM experimental setup. The distinct feature of the experimental unit is an indigenously made pulse generator circuit and a closed-loop tool feed circuit made from a current-based sensor to retain a constant inter-electrode gap (IEG) between the tool electrode and the workpiece electrode during the machining operation. The machining process parameters are electrolyte concentration (wt % C), voltage (V) and duty factor (% DF). The output responses of interest are Circularity (C), Material Removal Rate (MRR), Taper Angle (TA), Stray Corrosion Zone (SCZ) Width and Radial Over Cut (ROC) of the hole machined. The maximum MRR obtained is 7.2 µg/s at the parametric combination of 12 V, 15 wt % C and 50% DF. The maximum circularity of 0.989 and minimum SCZ width of 309.796 µm is produced by the combination of 8 V, 15 wt % C and 30% DF. The minimum ROC of 181.091 µm is generated by the combination of 10 V, 20 wt % C and 50% DF. The combination of 12 V, 25 wt % C and 40% DF resulted a minimum TA of 0.235 degrees. The machined hole topography study based on the High Resolution Scanning Electron Microscope (HRSEM) images of all the machined holes revealed that the parametric combination of 8 V, 15 wt % C and 30% DF yielded uniform microstructure in the SCZ no pitting corrosion, smooth and precise hole edge. The presence of sodium and bromine is found in Energy Dispersive Spectroscopy (EDS) analysis of the machined hole surface. In addition to these elements, titanium and vanadium are found in the used tool electrode.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43141041","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-05-04DOI: 10.1080/10910344.2022.2129982
A. Rajput, M. Das, S. Kapil
Abstract In today’s manufacturing sector, it is required to manufacture products that have an exceptionally low tolerance. The desired high precision (or low tolerance) can be obtained through various finishing processes, which consist of bonded (honing, grinding, lapping, etc.) or unbonded (abrasive flow finishing) forms of the tool. An unbonded form of tool is more reliable and beneficial because it helps to achieve a highly polished surface without affecting the material topography of the product. The literature survey shows that an effective unbonded form of finishing tool can be produced through the assistance of Magnetorheological (MR) Fluid, as it has in-situ control on its rheological properties. The MR fluid is mainly composed of abrasives and ferromagnetic powder mixed in a viscoplastic base medium. The unbonded multipoint cutting tool is generated during the finishing operations, which produces a mirror-like polished surface. Several MR fluid-assisted finishing processes have been developed in the last few decades. This article explores the evolution of MR fluid-assisted finishing processes, along with their development, applications, influencing process parameters, the composition of MR fluids, and governing analytical models. The key capabilities and limitations of different MR fluid-assisted finishing processes are also discussed, and a comparison is made to provide an overview at a glance.
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