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":"26 1","pages":"571 - 594"},"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":"26 1","pages":"396 - 427"},"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":"26 1","pages":"377 - 395"},"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":"26 1","pages":"486 - 513"},"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.
{"title":"A comprehensive review of magnetorheological fluid assisted finishing processes","authors":"A. Rajput, M. Das, S. Kapil","doi":"10.1080/10910344.2022.2129982","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129982","url":null,"abstract":"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.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"339 - 376"},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49384479","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: 10.1080/10910344.2022.2129984
A. L. Pissolatti, A. Magri, A. Antonialli, A. Diniz
Abstract Regarding milling of dies and molds, there are several geometric requirements, and it is absolutely not trivial to machine complex either concave or convex surfaces. Since the contact between tool and workpiece changes all the time, making the components of the milling forces also to change, it is fundamental to find the correct milling strategies which cause the smallest variation of cutting forces (amplitude and sense) in order to obtain the best possible workpiece surface quality. In this work, four different machining strategies for finish milling of D6 tool steel were studied. They were compared in terms of surface roughness, cutting force, and tool wear at the end of tool life. Results show that lower surface roughness was obtained using descending down milling and ascending up milling because the sense of the cutting force components, specially the one that is normal to the machined surface on the most critic region of the workpiece, pulled the workpiece against the tool and the tool against the workpiece. On the other hand, descending up milling and ascending down milling did not present good results because the sense of the force components was responsible for excessive tool bending moving the tool and workpiece apart.
{"title":"Comparing surface roughness and tool wear when milling convex surface of hardened steel using different milling strategies","authors":"A. L. Pissolatti, A. Magri, A. Antonialli, A. Diniz","doi":"10.1080/10910344.2022.2129984","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129984","url":null,"abstract":"Abstract Regarding milling of dies and molds, there are several geometric requirements, and it is absolutely not trivial to machine complex either concave or convex surfaces. Since the contact between tool and workpiece changes all the time, making the components of the milling forces also to change, it is fundamental to find the correct milling strategies which cause the smallest variation of cutting forces (amplitude and sense) in order to obtain the best possible workpiece surface quality. In this work, four different machining strategies for finish milling of D6 tool steel were studied. They were compared in terms of surface roughness, cutting force, and tool wear at the end of tool life. Results show that lower surface roughness was obtained using descending down milling and ascending up milling because the sense of the cutting force components, specially the one that is normal to the machined surface on the most critic region of the workpiece, pulled the workpiece against the tool and the tool against the workpiece. On the other hand, descending up milling and ascending down milling did not present good results because the sense of the force components was responsible for excessive tool bending moving the tool and workpiece apart.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"460 - 485"},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44780956","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: 10.1080/10910344.2022.2129983
Van Tao Le
Abstract In the literature, investigations on the electrical discharge machining (EDM) process with Tungsten carbide powder mixed into dielectric fluid, also called PMEDM, are still limited. In this study, machining performances of PMEDM, including material removal rate (MRR) of AISI H13 steel and tool wear rate (TWR), were investigated in the semi-finishing process. Thereafter, recast layer properties of AISI H13 steel, including composition and content of chemical elements, recast layer thickness (RLT), and acreage percentage of micro-cracks on surfaces (APCS), were evaluated and discussed. Quantitative methods of MRR, TWR, RLT, APCS, and the composition and content of chemical elements on machined surfaces have been proposed. The results revealed that machining performances and recast layer properties were influenced by peak current (Ip), pulse on time (Ton), and powder concentration (Cp). MRR and TWR have been changed in an uptrend when Ip, Ton, and Cp increased. The chemical composition of machined surfaces was modified. APCS and RLT formed by PMEDM are notably decreased as compared with EDM, with a reduction of 41.093% and 48.982%, respectively. In addition, the changing trend of machining performances and recast layer properties were also explored.
{"title":"The evaluation of machining performances and recast layer properties of AISI H13 steel processed by tungsten carbide powder mixed EDM process in the semi-finishing process","authors":"Van Tao Le","doi":"10.1080/10910344.2022.2129983","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129983","url":null,"abstract":"Abstract In the literature, investigations on the electrical discharge machining (EDM) process with Tungsten carbide powder mixed into dielectric fluid, also called PMEDM, are still limited. In this study, machining performances of PMEDM, including material removal rate (MRR) of AISI H13 steel and tool wear rate (TWR), were investigated in the semi-finishing process. Thereafter, recast layer properties of AISI H13 steel, including composition and content of chemical elements, recast layer thickness (RLT), and acreage percentage of micro-cracks on surfaces (APCS), were evaluated and discussed. Quantitative methods of MRR, TWR, RLT, APCS, and the composition and content of chemical elements on machined surfaces have been proposed. The results revealed that machining performances and recast layer properties were influenced by peak current (Ip), pulse on time (Ton), and powder concentration (Cp). MRR and TWR have been changed in an uptrend when Ip, Ton, and Cp increased. The chemical composition of machined surfaces was modified. APCS and RLT formed by PMEDM are notably decreased as compared with EDM, with a reduction of 41.093% and 48.982%, respectively. In addition, the changing trend of machining performances and recast layer properties were also explored.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"428 - 459"},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47915006","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044857
Tarlochan Singh, J. Arab, P. Dixit
Abstract Continuous demands to develop advanced radio-frequency transmission at higher frequencies have initiated glass-based materials as a substrate in radio-frequency micro-electro-mechanical-systems (MEMS) applications. Due to its superior electrical insulation characteristics, glass has lower substrate losses than silicon when an electrical signal is transmitted at higher frequencies. The optical transparent nature of glass substrate makes it an attractive choice for microfluidics and Bio-MEMS applications. Despite having superior properties, glass usage has remained limited mainly due to the lack of suitable micromachining processes. Due to its hard and brittle nature, creating microfeatures by conventional methods has been a challenge. To date, laser ablation and plasma etching have been employed to create micro-size through-holes in glass substrate; however, both have severe process limitations. Electrochemical discharge drilling (ECDD) is an emerging method that possesses similar capabilities as existing technologies at a low cost. Therefore, this manuscript is presented to describe the ECDD process's potential and their hybrid methods in the direction of fabricating micro-holes for MEMS applications. This manuscript includes the fundamental aspects of the ECDD process and a detailed description of components used to develop its various configurations. ECDD-based hybrid methods have also been presented along with their mechanisms and capabilities. The existing challenges and the possible research potentials have been derived based on previously reported capabilities to establish the correlation between the ECDD process and MEMS devices.
{"title":"A review on microholes formation in glass-based substrates by electrochemical discharge drilling for MEMS applications","authors":"Tarlochan Singh, J. Arab, P. Dixit","doi":"10.1080/10910344.2022.2044857","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044857","url":null,"abstract":"Abstract Continuous demands to develop advanced radio-frequency transmission at higher frequencies have initiated glass-based materials as a substrate in radio-frequency micro-electro-mechanical-systems (MEMS) applications. Due to its superior electrical insulation characteristics, glass has lower substrate losses than silicon when an electrical signal is transmitted at higher frequencies. The optical transparent nature of glass substrate makes it an attractive choice for microfluidics and Bio-MEMS applications. Despite having superior properties, glass usage has remained limited mainly due to the lack of suitable micromachining processes. Due to its hard and brittle nature, creating microfeatures by conventional methods has been a challenge. To date, laser ablation and plasma etching have been employed to create micro-size through-holes in glass substrate; however, both have severe process limitations. Electrochemical discharge drilling (ECDD) is an emerging method that possesses similar capabilities as existing technologies at a low cost. Therefore, this manuscript is presented to describe the ECDD process's potential and their hybrid methods in the direction of fabricating micro-holes for MEMS applications. This manuscript includes the fundamental aspects of the ECDD process and a detailed description of components used to develop its various configurations. ECDD-based hybrid methods have also been presented along with their mechanisms and capabilities. The existing challenges and the possible research potentials have been derived based on previously reported capabilities to establish the correlation between the ECDD process and MEMS devices.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"276 - 337"},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44359640","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044852
V. M, Ramanujam R, Gururaj Parande, M. Gupta
Abstract Advanced machining has become one of the inevitable processes for the fabrication of miniature industrial components that demands high dimensional accuracy. Magnesium (Mg) and its composites have widespread applications in the areas of aerospace, medical, and automobile sectors. The objective of this work is to analyze the machinability of Mg—rare earth (RE) alloy (Mg3Al2.5La)-based nanocomposites using wire electrical discharge turning (WEDT), a variant of EDM process. Y2O3 (0.6 and 1.9%) reinforced magnesium composites are prepared through disintegrated melt deposition technique. SEM and XRD analyses confirmed the intermetallic phase formation, such as Al11La3, and Al2La. Machining experiments are conducted with input parameters: discharge ON time, wire feed and spindle rotational speed each varied at three levels to study surface roughness (Ra) and volume of material removed (MRR). Results showed that Ra of the machined samples increases and MRR decreases, with the increase in % reinforcement and discharge ON time. The lower Ra value of 2.985 µm and higher MRR of 34.85 mm3/min are observed for the Mg3Al2.5La sample. This result is attributed to the absence of particle pullout and increased thermal conductivity of magnesium alloy during machining. Prediction analysis based on mean values is carried out to confirm the accuracy of the experimental results at optimal parametric levels.
{"title":"Machining of Y2O3 reinforced magnesium rare earth alloys using wire electrical discharge turning process","authors":"V. M, Ramanujam R, Gururaj Parande, M. Gupta","doi":"10.1080/10910344.2022.2044852","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044852","url":null,"abstract":"Abstract Advanced machining has become one of the inevitable processes for the fabrication of miniature industrial components that demands high dimensional accuracy. Magnesium (Mg) and its composites have widespread applications in the areas of aerospace, medical, and automobile sectors. The objective of this work is to analyze the machinability of Mg—rare earth (RE) alloy (Mg3Al2.5La)-based nanocomposites using wire electrical discharge turning (WEDT), a variant of EDM process. Y2O3 (0.6 and 1.9%) reinforced magnesium composites are prepared through disintegrated melt deposition technique. SEM and XRD analyses confirmed the intermetallic phase formation, such as Al11La3, and Al2La. Machining experiments are conducted with input parameters: discharge ON time, wire feed and spindle rotational speed each varied at three levels to study surface roughness (Ra) and volume of material removed (MRR). Results showed that Ra of the machined samples increases and MRR decreases, with the increase in % reinforcement and discharge ON time. The lower Ra value of 2.985 µm and higher MRR of 34.85 mm3/min are observed for the Mg3Al2.5La sample. This result is attributed to the absence of particle pullout and increased thermal conductivity of magnesium alloy during machining. Prediction analysis based on mean values is carried out to confirm the accuracy of the experimental results at optimal parametric levels.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"160 - 182"},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44249634","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044854
Cheng Fan, Kunshan Xu, Lei Zhang, Qiang Yuan, Qian Wang, Kejun Wang, Lining Sun
Abstract An integrated polishing and in-situ measurement machine tool with seven-axis and five-linkage is developed for manufacturing and measuring the complex curved surface such as blisk. Firstly, this paper introduces the structure and configuration of the machine tool. Then, the kinematic analyses of the polishing side and measuring side of the machine tool are carried out respectively and the inverse kinematic solutions of them are derived. The motion of each axis can be calculated based on the tool location of the complex curved surface through the inverse kinematic solution. Aiming at the in-situ measurement of parts with complex curved surfaces, the forward kinematic solution, the processing of measured data of blade surface and the calculation algorithm of the machining allowance are developed in the paper. Finally, the above algorithms are verified by polishing the experimental stainless-steel sample.
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