Pub Date : 2022-03-04DOI: 10.1080/10910344.2022.2044853
Ashwani Sharma, M. Z. Khan Yusufzai, M. Vashista
Abstract Difficult-to-cut material, i.e., AISI D2 tool steel, has been widely adopted in metalworking industries to manufacture dies for piercing, blanking, drawing and thread rolling due to its excellent wear resistance and non-deforming properties. This article attempts an experimental study to determine the effect of cryogenic coolant (liquid nitrogen) on the grindability of AISI D2 tool steel as work material and its results are compared with the conventional dry and wet grinding methods. The effects of the cryogenic coolant on force components (i.e., tangential force, Ft and normal force, Fn ), specific grinding energy (u), force ratio, surface roughness parameters (Ra and Rz ) and microstructure were observed. The comparison results indicate a significant reduction in grindability indices such as 64% and 44% in Ft , 54% and 34% in Fn , 46% and 30% in Ra and 40% and 34% in Rz , respectively under cryogenic grinding at higher downfeed as followed to dry and wet grinding. The grinding performance in Ft , Fn , u and Ra was also improved with an increased delivery pressure of the liquid nitrogen (LN2). From the results, it is concluded that cryogenic coolant offers an influential method to improve grinding performance and surface integrity of AISI D2 tool steel.
{"title":"A comparative analysis of grinding of AISI D2 tool steel under different environments","authors":"Ashwani Sharma, M. Z. Khan Yusufzai, M. Vashista","doi":"10.1080/10910344.2022.2044853","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044853","url":null,"abstract":"Abstract Difficult-to-cut material, i.e., AISI D2 tool steel, has been widely adopted in metalworking industries to manufacture dies for piercing, blanking, drawing and thread rolling due to its excellent wear resistance and non-deforming properties. This article attempts an experimental study to determine the effect of cryogenic coolant (liquid nitrogen) on the grindability of AISI D2 tool steel as work material and its results are compared with the conventional dry and wet grinding methods. The effects of the cryogenic coolant on force components (i.e., tangential force, Ft and normal force, Fn ), specific grinding energy (u), force ratio, surface roughness parameters (Ra and Rz ) and microstructure were observed. The comparison results indicate a significant reduction in grindability indices such as 64% and 44% in Ft , 54% and 34% in Fn , 46% and 30% in Ra and 40% and 34% in Rz , respectively under cryogenic grinding at higher downfeed as followed to dry and wet grinding. The grinding performance in Ft , Fn , u and Ra was also improved with an increased delivery pressure of the liquid nitrogen (LN2). From the results, it is concluded that cryogenic coolant offers an influential method to improve grinding performance and surface integrity of AISI D2 tool steel.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"183 - 202"},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43784485","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: 10.1080/10910344.2022.2044856
P. Abhilash, D. Chakradhar
Abstract This study aims to develop a pulse classification algorithm to understand wire electric discharge machining (wire EDM) process stability and performance based on the discharge pulse characteristics. Also, a process data driven failure prediction system is proposed. The wire EDM monitoring system includes high sampling rate differential probes and current probes. The features extracted through pulse train analysis were spark discharge energy, ignition delay time, spark frequency and proportion of various discharges. A pulse discrimination algorithm was proposed, which classifies the discharges into open circuit sparks, arc discharges, short circuit sparks and normal sparks. It was observed that higher proportions of short circuit pulses resulted in inferior part quality. The differences in the pulse cycle during stable and unstable machining were studied based on the extracted features. It was found that the discharge frequency and the proportion of arc and short circuit pulses were extremely high before the wire breakages. An artificial neural network (ANN) model was developed to predict the process responses, like cutting speed and surface roughness, from the process data. Also, an intelligent algorithm was developed based on the extracted in-process data to predict the unstable conditions, leading to machining failures. The accuracy of the algorithm was confirmed to be very high by conducting confirmation tests.
{"title":"Performance monitoring and failure prediction system for wire electric discharge machining process through multiple sensor signals","authors":"P. Abhilash, D. Chakradhar","doi":"10.1080/10910344.2022.2044856","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044856","url":null,"abstract":"Abstract This study aims to develop a pulse classification algorithm to understand wire electric discharge machining (wire EDM) process stability and performance based on the discharge pulse characteristics. Also, a process data driven failure prediction system is proposed. The wire EDM monitoring system includes high sampling rate differential probes and current probes. The features extracted through pulse train analysis were spark discharge energy, ignition delay time, spark frequency and proportion of various discharges. A pulse discrimination algorithm was proposed, which classifies the discharges into open circuit sparks, arc discharges, short circuit sparks and normal sparks. It was observed that higher proportions of short circuit pulses resulted in inferior part quality. The differences in the pulse cycle during stable and unstable machining were studied based on the extracted features. It was found that the discharge frequency and the proportion of arc and short circuit pulses were extremely high before the wire breakages. An artificial neural network (ANN) model was developed to predict the process responses, like cutting speed and surface roughness, from the process data. Also, an intelligent algorithm was developed based on the extracted in-process data to predict the unstable conditions, leading to machining failures. The accuracy of the algorithm was confirmed to be very high by conducting confirmation tests.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"245 - 275"},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46110530","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: 10.1080/10910344.2022.2044855
Ü. Şimşek, C. Çoğun, Ziya Esen
Abstract The most important cost element of electric discharge machining (EDM) is the production of tool electrode (shortly electrode). In the EDM process, copper and its alloys are often used as electrode materials. The machining with EDM without increasing the costs can be achieved by selecting the proper electrode with low production and material costs as well as high workpiece material removal rate (MRR), low electrode wear rate (EWR), and relative wear (RW = MRR/EWR). In this study, the EDM performance outputs, namely, MRR and RW were experimentally investigated for electrolytic copper, CuCr1Zr (with and without aging treatment) and CuCo2Be alloy electrode materials for varying machining parameters. The performance outputs were affected by the electrode material and the applied aging treatment. The aged CuCr1Zr alloy electrodes had higher electrical conductivity and better machining performance than the as-received alloy. The CuCo2Be alloy electrodes exhibited moderate to high MRR; however, their RW was the highest. Although the electrolytic copper has moderate MRR performance compared to the investigated alloys, its low cost increased its performance index, making it a more suitable electrode material for EDM applications.
{"title":"Effects of electrolytic copper and copper alloy electrodes on machining performance in electrical discharge machining (EDM)","authors":"Ü. Şimşek, C. Çoğun, Ziya Esen","doi":"10.1080/10910344.2022.2044855","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044855","url":null,"abstract":"Abstract The most important cost element of electric discharge machining (EDM) is the production of tool electrode (shortly electrode). In the EDM process, copper and its alloys are often used as electrode materials. The machining with EDM without increasing the costs can be achieved by selecting the proper electrode with low production and material costs as well as high workpiece material removal rate (MRR), low electrode wear rate (EWR), and relative wear (RW = MRR/EWR). In this study, the EDM performance outputs, namely, MRR and RW were experimentally investigated for electrolytic copper, CuCr1Zr (with and without aging treatment) and CuCo2Be alloy electrode materials for varying machining parameters. The performance outputs were affected by the electrode material and the applied aging treatment. The aged CuCr1Zr alloy electrodes had higher electrical conductivity and better machining performance than the as-received alloy. The CuCo2Be alloy electrodes exhibited moderate to high MRR; however, their RW was the highest. Although the electrolytic copper has moderate MRR performance compared to the investigated alloys, its low cost increased its performance index, making it a more suitable electrode material for EDM applications.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"229 - 244"},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42654031","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 The polycrystalline cubic boron nitride (PCBN) insert has been widely used in machining high chromium white cast iron (HCCI), which has the high hardness and abrasiveness. The aim of this article is to reveal that micro-mechanical properties play an essential role in assessing the machinability of high chromium cast iron. Grid nanoindentation is applied to measure the micro-hardness distribution. Based on grid nanoindentation results, the micro-hardness distribution is proposed to study the machinability. After the machining test of HCCI by the PCBN insert, the cutting force, tool wear, surface roughness, and chip formation showed that the micro-hardness distribution of materials has the better results than macro-hardness in machinability evaluation, and abrasive wear occurred on the rake and flank face of the cutting tool. The abrasiveness index that is related with the micro-hardness distribution and the abrasive wear effect in machining, for the most of high abrasion materials, has the possible to evaluate the dynamic cutting process and tool life in dry machining by using the PCBN insert. The micro-hardness distribution imported into the machinability model may propose a new way to improve the data exchange capability in the modern manufacturing process.
{"title":"Machinability study on dry machining of white cast iron by polycrystalline cubic boron nitride inserts","authors":"Xin Guo, Ling Chen, Wu Zhao, Hao Wan, Huiting Wen, Jinming Zhou","doi":"10.1080/10910344.2022.2044851","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044851","url":null,"abstract":"Abstract The polycrystalline cubic boron nitride (PCBN) insert has been widely used in machining high chromium white cast iron (HCCI), which has the high hardness and abrasiveness. The aim of this article is to reveal that micro-mechanical properties play an essential role in assessing the machinability of high chromium cast iron. Grid nanoindentation is applied to measure the micro-hardness distribution. Based on grid nanoindentation results, the micro-hardness distribution is proposed to study the machinability. After the machining test of HCCI by the PCBN insert, the cutting force, tool wear, surface roughness, and chip formation showed that the micro-hardness distribution of materials has the better results than macro-hardness in machinability evaluation, and abrasive wear occurred on the rake and flank face of the cutting tool. The abrasiveness index that is related with the micro-hardness distribution and the abrasive wear effect in machining, for the most of high abrasion materials, has the possible to evaluate the dynamic cutting process and tool life in dry machining by using the PCBN insert. The micro-hardness distribution imported into the machinability model may propose a new way to improve the data exchange capability in the modern manufacturing process.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"137 - 159"},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47305942","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 : 2021-12-23DOI: 10.1080/10910344.2021.1971707
Q. Niu, L. Jing, Z. Yu, C. P. Li, X. Qiu, T. Ko
Abstract Silicon carbide particulate-reinforced aluminum (SiCp/Al) composites is one of the typical difficult-to-cut materials, which are not suitable well for traditional machining any more. In order to explore new processing technology and verify its feasibility, this paper discussed the effects of cryogenic assisted milling with liquid nitrogen (LN2) coolant on the machinability of SiCp/Al composites. The effects of cryogenic milling were also compared with that of conventional dry milling. The results showed that cryogenic milling of 20% SiCp/Al composites would increase the surface hardness of the material, causing 15% higher amount of cutting force in cryogenic milling as compared to dry milling. In addition, there were serious tool feed marks on the machined surface under cryogenic condition because of the secondary cutting mechanism, which resulted in high surface roughness and poor surface quality. Overall, 46.73% higher roughness Ra and 31.53% roughness Rz were seen for cryogenic milling in comparison with dry milling technique respectively. The dish angle of milling tool and processing environment plays important roles in machined surface. Chip brittleness increased and short arc chips were formed in cryogenic milling. It was suggested that milling SiCp/Al composites under cryogenic condition had negative effects on the machinability of the material.
{"title":"Experimental study on cryogenic milling performance of SiCp/Al composites with liquid nitrogen","authors":"Q. Niu, L. Jing, Z. Yu, C. P. Li, X. Qiu, T. Ko","doi":"10.1080/10910344.2021.1971707","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971707","url":null,"abstract":"Abstract Silicon carbide particulate-reinforced aluminum (SiCp/Al) composites is one of the typical difficult-to-cut materials, which are not suitable well for traditional machining any more. In order to explore new processing technology and verify its feasibility, this paper discussed the effects of cryogenic assisted milling with liquid nitrogen (LN2) coolant on the machinability of SiCp/Al composites. The effects of cryogenic milling were also compared with that of conventional dry milling. The results showed that cryogenic milling of 20% SiCp/Al composites would increase the surface hardness of the material, causing 15% higher amount of cutting force in cryogenic milling as compared to dry milling. In addition, there were serious tool feed marks on the machined surface under cryogenic condition because of the secondary cutting mechanism, which resulted in high surface roughness and poor surface quality. Overall, 46.73% higher roughness Ra and 31.53% roughness Rz were seen for cryogenic milling in comparison with dry milling technique respectively. The dish angle of milling tool and processing environment plays important roles in machined surface. Chip brittleness increased and short arc chips were formed in cryogenic milling. It was suggested that milling SiCp/Al composites under cryogenic condition had negative effects on the machinability of the material.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"1 - 17"},"PeriodicalIF":2.7,"publicationDate":"2021-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49081336","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 : 2021-12-21DOI: 10.1080/10910344.2021.1998829
A. Hassouna, S. Mzali, F. Zemzemi, S. Mezlini
Abstract Short glass fiber composites, particularly sheet molding compound (SMC) materials, are becoming increasingly important alternative in various contemporary aerospace, automotive, and electronic applications. For these manufacturing industries, the quality of the machined SMC composite is still a challenging target. The article proposes a new tool design with an offset between teeth to minimize friction, limit damage and promote chip removal when drilling composite materials. The effects of the tool’s geometric parameters, especially the rake, the inclination and the complementary side cutting edge angles on the material removal process, as well as the cutting and thrust forces, are investigated. A 3D finite element model of a representative multi-tooth tool is developed using the ABAQUSExplicit code. The results show that fine-tuning the geometric parameters of the tool reduces the induced machining damage and enhances the chip removal and the flow evolution. The rake angle has a significant influence on the cutting and thrust forces. However, both forces are insensitive to the inclination angle. The complementary side cutting edge angle influences only the thrust force. The presented outcomes not only give insights into the cutting process, but also improve the SMC machinability.
{"title":"Effect of geometrical parameters and tool pattern of multi-tooth sawing on cutting of sheet molding compound composite: FE study","authors":"A. Hassouna, S. Mzali, F. Zemzemi, S. Mezlini","doi":"10.1080/10910344.2021.1998829","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998829","url":null,"abstract":"Abstract Short glass fiber composites, particularly sheet molding compound (SMC) materials, are becoming increasingly important alternative in various contemporary aerospace, automotive, and electronic applications. For these manufacturing industries, the quality of the machined SMC composite is still a challenging target. The article proposes a new tool design with an offset between teeth to minimize friction, limit damage and promote chip removal when drilling composite materials. The effects of the tool’s geometric parameters, especially the rake, the inclination and the complementary side cutting edge angles on the material removal process, as well as the cutting and thrust forces, are investigated. A 3D finite element model of a representative multi-tooth tool is developed using the ABAQUSExplicit code. The results show that fine-tuning the geometric parameters of the tool reduces the induced machining damage and enhances the chip removal and the flow evolution. The rake angle has a significant influence on the cutting and thrust forces. However, both forces are insensitive to the inclination angle. The complementary side cutting edge angle influences only the thrust force. The presented outcomes not only give insights into the cutting process, but also improve the SMC machinability.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"95 - 119"},"PeriodicalIF":2.7,"publicationDate":"2021-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43040204","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 : 2021-12-21DOI: 10.1080/10910344.2021.1998107
E. Tascioglu, Y. Kaynak, S. Sharif, Fatih Pitir, M. A. Suhaimi
Abstract Parameters used in laser powder bed fusion (LPBF) process are key factors that influence the surface integrity and thus mechanical properties of Inconel 718 components fabricated by additive manufacturing (AM) technique. For this reason, various parameters with different settings through trial and error approach have used by AM community to fabricate Inconel 718 components. These AM fabricated components generally required post treatment or processing including finish machining, to enhance their surface properties. This study presents a systematic investigation on the effect of volumetric energy density, and various LPBF processing parameters including laser power, layer thickness, and scanning speed on the as-printed specimens and the surface integrity aspects, namely surface quality, porosity, and microhardness. Furthermore, using machining operations specifically finish milling on these specimens under constant machining parameters, the effect of as-printed conditions on the machinability responses including burr formation, cutting forces are evaluated accordingly. Moreover, the interrelationship between LPBF processing parameters-machining-surface and subsurface aspects are also examined. This study reveals that LPBF additive manufacturing parameters have remarkable influence on the printed Inconel 718 specimens. Results also showed that parameters including laser power, scanning speed and layer thickness also have an effect on both the machinability and final surface and subsurface properties of the AM fabricated Inconel 718 specimens. It should be also noted that there is a notable relationship between volumetric energy density and the machinability of the AM printed Inconel 718.
{"title":"Machining-induced surface integrity of Inconel 718 alloy fabricated by powder bed fusion additive manufacturing under various laser processing parameters","authors":"E. Tascioglu, Y. Kaynak, S. Sharif, Fatih Pitir, M. A. Suhaimi","doi":"10.1080/10910344.2021.1998107","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998107","url":null,"abstract":"Abstract Parameters used in laser powder bed fusion (LPBF) process are key factors that influence the surface integrity and thus mechanical properties of Inconel 718 components fabricated by additive manufacturing (AM) technique. For this reason, various parameters with different settings through trial and error approach have used by AM community to fabricate Inconel 718 components. These AM fabricated components generally required post treatment or processing including finish machining, to enhance their surface properties. This study presents a systematic investigation on the effect of volumetric energy density, and various LPBF processing parameters including laser power, layer thickness, and scanning speed on the as-printed specimens and the surface integrity aspects, namely surface quality, porosity, and microhardness. Furthermore, using machining operations specifically finish milling on these specimens under constant machining parameters, the effect of as-printed conditions on the machinability responses including burr formation, cutting forces are evaluated accordingly. Moreover, the interrelationship between LPBF processing parameters-machining-surface and subsurface aspects are also examined. This study reveals that LPBF additive manufacturing parameters have remarkable influence on the printed Inconel 718 specimens. Results also showed that parameters including laser power, scanning speed and layer thickness also have an effect on both the machinability and final surface and subsurface properties of the AM fabricated Inconel 718 specimens. It should be also noted that there is a notable relationship between volumetric energy density and the machinability of the AM printed Inconel 718.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"49 - 71"},"PeriodicalIF":2.7,"publicationDate":"2021-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49034215","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 : 2021-12-21DOI: 10.1080/10910344.2021.1998828
Wenbo Bie, Bo Zhao, Xiaobo Wang, Yi Wang, Baoqi Chang
Abstract In ultrasonic vibration-assisted drilling (UVAD), the processing stability is strongly influenced by the ultrasonic vibration system's vibrational characteristics. The effect of tool parameters on UVAD's vibrational characteristic was experimentally studied and theoretically analyzed in this paper. Firstly, a measurement experiment was designed to assess the above effect in three various tools under different loads. The relationship between the ultrasonic power and amplitude was used to indirectly monitor the ultrasonic amplitude variation, which was corroborated by the UVAD test results. The ultrasonic amplitude and power were mainly controlled by the stiffness coefficient, while the damping coefficient effect could be ignored. Furthermore, the tool vibration frequency exhibited an increasing trend with the load value. Finally, the effects of the stiffness coefficient and damping coefficient on the vibrational characteristics were theoretically substantiated. The results of this study are considered instrumental in selecting tool and process parameters in ultrasonic machining.
{"title":"Experimental study on the effect of tool parameters on the vibrational characteristic of ultrasonic vibration-assisted drilling system","authors":"Wenbo Bie, Bo Zhao, Xiaobo Wang, Yi Wang, Baoqi Chang","doi":"10.1080/10910344.2021.1998828","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998828","url":null,"abstract":"Abstract In ultrasonic vibration-assisted drilling (UVAD), the processing stability is strongly influenced by the ultrasonic vibration system's vibrational characteristics. The effect of tool parameters on UVAD's vibrational characteristic was experimentally studied and theoretically analyzed in this paper. Firstly, a measurement experiment was designed to assess the above effect in three various tools under different loads. The relationship between the ultrasonic power and amplitude was used to indirectly monitor the ultrasonic amplitude variation, which was corroborated by the UVAD test results. The ultrasonic amplitude and power were mainly controlled by the stiffness coefficient, while the damping coefficient effect could be ignored. Furthermore, the tool vibration frequency exhibited an increasing trend with the load value. Finally, the effects of the stiffness coefficient and damping coefficient on the vibrational characteristics were theoretically substantiated. The results of this study are considered instrumental in selecting tool and process parameters in ultrasonic machining.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"72 - 94"},"PeriodicalIF":2.7,"publicationDate":"2021-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46368322","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 : 2021-12-02DOI: 10.1080/10910344.2021.1998830
I. Prasanth, D. Ravishankar, M. Manzoor Hussain, Chandra Mouli Badiganti
Abstract The anisotropic nature of polymer composites presents many challenges for manufacturers to adopt appropriate machining processes. In the present investigation, end milling experiments were conducted on glass fiber reinforced polymer laminates with five varieties of customized cutting tools with different angles of rake and clearance. The performance of the tools was evaluated in terms of their machining force, surface roughness and delamination factor at spindle speeds in the range of 690–2500 rpm. From the observations, relatively high rake and angled clearance tools performed better than the rest of the tools under consideration in terms of delamination and machined surface finishing. The milling operations performed at a spindle speed of 1950 rpm produced better surface quality. Observations from SEM graphs, exposed surface defects due to milling, generated at lower spindle speeds of 690 rpm and at higher spindle speeds of 2500 rpm with the tool signature of low angle rake and angled clearance tools out of all five tools considered for the experiments.
{"title":"Influence of milling process parameters and significance of tools to improve the surface quality of GFRP composites","authors":"I. Prasanth, D. Ravishankar, M. Manzoor Hussain, Chandra Mouli Badiganti","doi":"10.1080/10910344.2021.1998830","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998830","url":null,"abstract":"Abstract The anisotropic nature of polymer composites presents many challenges for manufacturers to adopt appropriate machining processes. In the present investigation, end milling experiments were conducted on glass fiber reinforced polymer laminates with five varieties of customized cutting tools with different angles of rake and clearance. The performance of the tools was evaluated in terms of their machining force, surface roughness and delamination factor at spindle speeds in the range of 690–2500 rpm. From the observations, relatively high rake and angled clearance tools performed better than the rest of the tools under consideration in terms of delamination and machined surface finishing. The milling operations performed at a spindle speed of 1950 rpm produced better surface quality. Observations from SEM graphs, exposed surface defects due to milling, generated at lower spindle speeds of 690 rpm and at higher spindle speeds of 2500 rpm with the tool signature of low angle rake and angled clearance tools out of all five tools considered for the experiments.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"120 - 136"},"PeriodicalIF":2.7,"publicationDate":"2021-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42368532","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 : 2021-11-08DOI: 10.1080/10910344.2021.1971713
K. Mishra, B. Sarkar, B. Bhattacharyya
Abstract Fabrication of high aspect ratio (HAR) complex micro features on high strength temperature resistant (HSTR) alloys is challenging by any conventional or non-conventional machining methods. In this study blind, HAR and complex micro features have been fabricated by micro electrochemical milling (MEM) on HSTR Cobalt alloy (Haynes-188) introducing a new strategic approach with novel flushing technique which could get rid of the need of pulsed DC power supply. Multiphysics simulation of the rotating micro-tool at different rpm and its impact on effective sludge removal has been analyzed and verified experimentally. In this study, most influencing parameters of MEM like voltage, feed rate, rpm of tool and milling layer depth have been selected to investigate their effects on the machining responses like width overcut, machined depth and surface roughness on Haynes-188 alloy. Comparison has also been made with constant and pulsed DC power source to know the influence of these process parameters on the MEM responses. Finally, several linear and non-linear blind, HAR (AR > 11) and intricate micro features have been fabricated successfully on cobalt alloy at the most suitable parametric combination, i.e., 7.5 V of machining voltage, feed rate of 0.3 mm/min, and tool rotation of 750RPM with 0.5 M of NaNO3 electrolyte.
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