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Reduced computational time in 3D finite element simulation of high speed milling of 6061-T6 aluminum alloy Mach. Sci. Tech. (IF 2.071) Pub Date : 2021-01-15 Guohe Li; Meng Liu; Shanshan Zhao
Abstract The finite element method is an important supplement to the experiment on the research of metal cutting mechanism. A 3D thermo-mechanical coupling model was established based on ABAQUS, in which a model of the tool with real structure and a simplified model of the work-piece based on the cutting zone were established. It can greatly improve the computational efficiency because the volume of
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Tool condition monitoring: unscented Kalman filter for tool flank wear estimation in turning of Inconel 718 Mach. Sci. Tech. (IF 2.071) Pub Date : 2021-01-15 Chandrani Sadhukhan; Swarup Kumar Mitra; Ranjib Biswas; Mrinal Kanti Naskar
Abstract This article presents flank wear estimation during the turning process of Inconel 718 in dry cutting condition using unscented Kalman filter (UKF). A discrete flank wear model is developed where two components of flank wear due to abrasion and diffusion are considered as state variables and the cutting force is taken as the output variable. The proposed model can be implemented for online
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Performance analysis of copper-based MWCNT composite coated 316L SS tool in electro discharge machining Mach. Sci. Tech. (IF 2.071) Pub Date : 2021-01-11 Prosun Mandal; Subhas Chandra Mondal
Abstract The tool material properties are essential key factors for the enhancement of electro discharge machining performance mainly, resistance to the wear of tool, removal of material from workpiece, and machined surface quality. In this study, copper-based multi-wall carbon nanotube (MWCNT) composite coated 316 L stainless steel electrode was fabricated by electrodeposition method and used in EDM
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Surface modeling and analysis of high-speed ultrasonic vibration cutting Mach. Sci. Tech. (IF 2.071) Pub Date : 2021-01-04 He Sui; Xiangyu Zhang; Deyuan Zhang
Abstract High-speed ultrasonic vibration cutting has been proven to be effective in prolonging tool life, as well as reducing cutting force and cutting temperature at certain cutting speeds, which is higher than both the critical cutting speed of traditional ultrasonic vibration cutting and the range of conventional high-speed cutting in recent research. However, the surface topography results from
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On the temperature analysis of magnetic abrasive finishing of aluminum 6060 using finite element method Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-11-26 Rajneesh Kumar Singh; Swati Gangwar; D. K. Singh
Abstract Magnetic abrasive finishing (MAF) process is the superfinishing process used to enhance the surface quality of metallic and nonmetallic materials such as alloys, composites and ceramics etc. This process erodes material from a workpiece surface in the form of micro-chips with the help of flexible magnetic abrasive brush (FMAB) in working gap with the presence of a magnetic field. This process
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Hard milling of carburized and waterjet peened 18CrNiMo7-6 steel Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-11-25 Yongtao Ma; Yongbin Zhang; Jiancheng Liu; Lanrong Liu; Junzhen Gong
Abstract Post-mixed waterjet peening is an effective treatment method for compressive residual stress field. After peening, the surface quality of the parts is low, and the hardness is usually higher than 60HRC. A fine manufacturing process should be carried out to obtain a satisfactory surface roughness without side effect on existing residual stress. In this article, the 18CrNiMo7-6 steel after carburization
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Tool nose radius effects in turning process Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-11-13 Lefi Abdellaoui; Hassen Khlifi; Wassila Bouzid Sai; Hedi Hamdi
Abstract The main goal of this article is to study the effects of tool nose radius on some performances in turning process. An analytical approach is developed and adapted for cutting with round inserts or when only the round edge was engaged in the metal. The uncut chip area is evaluated as function to tool nose radius and discretized into some elements which are defined by their average uncut chip
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Investigation of the chip adhesion mechanisms in micro-drilling of high ceramic-content particle-filled GFRPs Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-09 Xin Huang; Chengyong Wang; Tao Yang; Bingmiao Liao; Xingrong He; Lijuan Zheng
Abstract Glass-fiber reinforced polymers (GFRP) are widely used for printed circuit boards (PCBs) in automotive and aircraft structural applications. The performance of micro-drilling in high ceramic-content particle-filled GFRP heavily influences the signal transmission quality and speed available from these PCBs. Chip adhesion is one of the biggest obstacles to high-performance micro-drilling especially
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Study on the constitutive model of anisotropic aluminum alloy in high speed cutting Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-21 Xiuli Fu; Bin Zhou; Ying Meng; Yongzhi Pan
Abstract In order to construct the constitutive model for high speed machining of aviation aluminum alloy with different forming directions, the Split Hopkinson Pressure Bar (SHPB) impact compression experiment and the high speed orthogonal cutting experiment are carried out in the normal direction (ND), rolling direction (RD) and transverse direction (TD) of aviation aluminum alloy 7050-T7451 rolling
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Identifying the effectiveness of manner of cryogenic coolant supply in different cryogenic cooling techniques in turning process—a review Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-10-26 P. Sivaiah; D. Chakradhar
Abstract Cryogenic machining is one of the emerging manufacturing techniques in the field of metal cutting industries due to the new stringent environmental regulations in terms of utilization and disposal of chemically contaminated conventional coolants. The method of supply of cryogenic coolants at the machining zone significantly influences the machined product functional performance. In this context
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Effect of rotational speed ratio between platen and work piece on lapping processes Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-10-28 Tufa Habtamu Beri; Yang Ling; Min Liu; Wei Hang; Julong Yuan
Abstract Process parameters that are addressed in literature to affect lapping process includes, abrasive grain size, types of abrasive, concentration of abrasives, viscosity of the compound, lapping pressure, lapping speed, lapping time, and lap material/disc material. However, a trajectory analysis of a single fixed abrasive particle shows various paths for different rotational speed ratio between
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Effect of cryogenic oils-on-water compared with cryogenic minimum quantity lubrication in finishing turning of 17-4PH stainless steel Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-17 Zhiwei Lai; Chengyong Wang; Lijuan Zheng; Haisheng Lin; Yaohui Yuan; Jianzhang Yang; Weiqiang Xiong
Abstract 17-4PH stainless steel is widely used for applications of critical importance owing to its favorable property profile. However, the great mechanical performance of 17-4PH stainless steel is at the cost of its unsatisfied machinability. Exploring suitable cooling method becomes an effective way to improve its machinability. This study aims to explore the applicability and feasibility of oils-on-water
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Research on the evolution of serrated chips in high-speed cutting based on digital microscope Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-10-21 Guohe Li; Yujun Cai; Houjun Qi; Meng Liu; Xiaole Qi
Abstract Serrated chip is a typical characteristic of high-speed cutting. It is an important aspect of high-speed cutting mechanism, and has significant influence on cutting force, cutting temperature and tool wear. For the observation of serrated chip, optical microscope (OM) and scanning electron microscope (SEM) are usually used. The main problem of OM observation is time-consuming and that of SEM
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Investigation on performance characteristics of micro-EDM dressing for the fabrication of micro-rod(s) on Ti-6Al-7Nb biomedical material Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-10-13 Md Shamim Shah; Probir Saha
Abstract The performance characteristics of micro-EDM dressing were investigated based on some real-time and offline responses for the fabrication of micro-rod(s) on a novel Ti-6Al-7Nb biomedical material. These characteristics evaluated along the micro-rod length at three different discharge energy settings were analyzed by monitoring the discharge gap condition captured through an in house developed
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Mechanical properties of helical milling deep hole on QFRP using cryogenic cooling process Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-29 Fengbiao Wang; Yongqing Wang
Abstract The structure and physical properties of quartz fiber reinforced polyimide composite (QFRP) lead to the milling hole defects of crimp, ablation and delamination, as well as serious tool wear and limited hole making depth. Based on three kinds of defects of helical milling holes of composite materials, the cutting force model was constructed considering the cutting micro-zone temperature. This
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Characterization of machinability of sintered steel foams having different porosities during drilling operations Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-28 Nuray Bekoz Ullen
Abstract Steel foams are a new class of engineering materials with exceptional structure and properties. Foams produced by powder metallurgy generally have a near-net shape, however, sometimes machining operations may be required. The presence of porosity in steel foams significantly affects the cutting process and causes poor machinability. This study deals with the evaluation of the machinability
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Effect of magneto rheological minimum quantity lubrication on machinability, wettability and tribological behavior in turning of Monel K500 alloy Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-22 Arul Kulandaivel; Senthil Kumar
The proposed work deals with the investigation of magnetorheological based minimum quantity lubrication of graphene oxide (GO) based jojoba oil as bio-lubricant on machinability and tool wear mechanism of turning Monel K500 alloy. Experiments were carried out for dry, flooded, minimum quantity lubrication (MQL) and magnetorheological (MR–MQL) conditions using medium duty lathe. The process parameters
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Investigation into the error compensation method of the surface form based on feed rate optimization in deterministic polishing Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-17 Cheng Fan; Yucheng Xue; Lei Zhang; Qizhi Zhao; Yao Lu; Qian Wang
As the final step to fabricate the optical parts, the deterministic polishing process is usually used to reduce the roughness and correct the surface form. In this article, a new compensation method of the surface form error was proposed by optimizing the feed rate of the polishing process. The local material removal was described as the polished depth orthogonal to the tool path, and the local material
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Influence of cutting tool material on machinability of Inconel 718 superalloy Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-17 Thrinadh Jadam; Saurav Datta; Manoj Masanta
Appropriate selection of tool material is very important for effective machining of ‘difficult-to-cut’ aerospace superalloy Inconel 718, especially, under dry condition. Present work aims at investigating performance of physical vapor deposition (PVD) multi-layer (TiN/TiCN/TiN) coated cermet, and PVD TiAlN coated PCBN (Polycrystalline Cubic Boron Nitride) brazed tipped carbide inserts on machinability
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Force prediction in ultrasonic vibration-assisted milling Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-17 Yixuan Feng; Fu-Chuan Hsu; Yu-Ting Lu; Yu-Fu Lin; Chorng-Tyan Lin; Chiu-Feng Lin; Ying-Cheng Lu; Steven Y. Liang
The use of ultrasonic vibration on milling has several benefits including reduction of the machining forces. However, the mechanism behind this phenomenon is unclear, and reported analytical studies are quite limited. An analytical predictive modeling work is presented in the current study. To describe the intermittent contact between tool and workpiece due to vibration, conditions of tool-workpiece
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A combined numerical and experimental investigation of minimum quantity lubrication applied to end milling of Ti6Al4V alloy Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-16 Sabarish V. Narayanan; Mark Benjamin D.; Hariharan M. V.; Raja Keshav; D. Samuel Raj
Minimum Quantity Lubrication (MQL) has increased in popularity over the last two decades, owing to its economic and environmental benefits over flood cooling. But there are still challenges in the form of mist formation, an inability to carry away chips, and contradicting results in terms of surface roughness and tool wear. This study is a combined experimental and computational investigation to compare
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Studies on chip morphology and modes of tool wear during machining of Ti-6Al-4V using uncoated carbide tool: application of multi-walled carbon nanotubes added rice bran oil as nanocutting fluid Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-09-14 Thrinadh Jadam; Saurav Datta; Manoj Masanta
In this work, machining performance of Ti-6Al-4V is studied in consideration with cutting force, tool-tip temperature, tool wear mechanisms, chip morphology and roughness of the machined surface. Machining experiments are carried out by varying cutting speed (Vc) with constant feed and depth-of-cut. Uncoated WC-Co insert is used as cutting tool. Multi-walled carbon nanotubes (MWCNTs) added rice bran
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Rheological study of the developed medium and its correlation with surface roughness during abrasive flow finishing of micro-slots Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-07-16 Sachin Singh; Mamilla Ravi Sankar
Abstract Abrasive flow finishing (AFF) is an advanced finishing process employed for finishing macro- to micro-features of workpieces. Finishing improves the functioning of the components by reducing their surface roughness. AFF process uses a polymer-based flexible medium containing abrasive particles as a finishing tool. Medium used during the AFF process plays a vital role in deciding the final
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Effect of MQL flow rate on machinability of AISI 4140 steel Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-06-27 Hüseyin Gürbüz; Yunus Emre Gönülaçar; Şehmus Baday
Many studies were performed about the influence of minimum quantity lubrication (MQL) technique on cutting performance in the literature, but there is no paper examining the effect of different MQL flow rates and cutting parameters on machinability of AISI 4140 material as a whole. In this study, the effects of different MQL flow rates and cutting parameters on surface roughness, main cutting force
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Micro-end milling of biomedical Tz54 magnesium alloy produced through powder metallurgy Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-06-11 Ali Erçetin; Kubilay Aslantas; Özgür Özgün
Abstract In this study, micro machinability of Mg5Sn4Zn (TZ54) alloy produced by a hot-pressing process (one of the powder metallurgy methods) is investigated. For this purpose, micro-milling experiments were carried out, considering different cutting parameters. In order to determine the appropriate cutting parameters, the variation of cutting forces, surface quality and burr width were investigated
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Dry turning performance of TiN–WSx/TiN hard-lubricious bilayer composite coating Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-06-04 Tushar Banerjee; A. K. Chattopadhyay
Abstract Dry machining is receiving immense attention worldwide to eliminate or minimize the harmful environmental effects of cutting fluids. The present work investigates dry machining performance of a bilayer coating with top-layer of hard-lubricious TiN–WSx, supported by a hard TiN under layer. During dry turning of AISI 1060 steel, the bilayer coated carbide tool registered significantly less cutting
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Investigation of roughness, topography, microhardness, white layer and surface chemical composition in high speed milling of Ti-6Al-4V using minimum quantity lubrication Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-05-18 Hamed Hassanpour; Amir Rasti; Mohammad Hossein Sadeghi; Javad Hashemi Khosrowshahi
In this research, the effects of high speed milling on the main surface integrity characteristics, including surface roughness and topography, microhardness, white layer thickness, and surface chemical composition of Ti-6Al-4V were empirically studied. Totally, 18 experiments were carried out using a full factorial design of experiments method in the presence of minimum quantity lubricant. The results
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An improved decomposition algorithm of surface topography of machining Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-05-18 Gaiyun He; Hongliang Wang; Yicun Sang; Yiqian Lv
In order to accurately decompose the surface morphology of machined surface and trace the potential errors of the machine, a comprehensive improved algorithm is proposed, which combines wavelet packet decomposition (WPD) and improved complete ensemble empirical modal decomposition of adaptive noise (Improve CEEMDAN). Firstly, the cost function is used to find the optimal wavelet packet base and the
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Sustainable electrochemical discharge machining process: Characterization of emission products and occupational risks to operator Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-04-23 Manpreet Singh; Sarbjit Singh
Electrochemical discharge machining (ECDM) process is prominent machining process for processing of composites, glass, ceramics, and super-alloys. In the recent years, the ECDM process has attained popularity due to its applicability to generate micro-holes, micro-channels on different materials irrespective to their properties. This study presents the various environmental aspects of ECDM process
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New predictor-corrector methods based on piecewise polynomial interpolation for milling stability prediction Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-04-20 Yi Wu; Youpeng You; Jianjun Jiang
Chatter frequently occurs during cutting operations, which seriously restricts the machining productivity and workpiece accuracy. Consequently, accurate and efficient stability prediction is of great significance to determine stable machining parameters. A cubic Hermite–Newton approximation method which can determine the chatter stability boundaries more efficiently is presented in this paper. The
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Tool wear rate prediction in ultrasonic vibration-assisted milling Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-04-19 Yixuan Feng; Fu-Chuan Hsu; Yu-Ting Lu; Yu-Fu Lin; Chorng-Tyan Lin; Chiu-Feng Lin; Ying-Cheng Lu; Steven Y. Liang
In the current study, a predictive model on tool flank wear rate during ultrasonic vibration-assisted milling is proposed. One benefit of ultrasonic vibration is the frequent separation between tool and workpiece as the cutting time is reduced. In order to account for this effect, three types of tool–workpiece separation criteria are checked based on the tool center instantaneous position and velocity
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Investigation on the effect of EDM process variables and environments on acoustic emission signals Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-04-19 R. Dwaraka; N. Arunachalam
The performance of electrical discharge machining (EDM) primarily depends on the spark quality generated in the inter-electrode gap (IEG) between the tool and workpiece. A method for obtaining accurate information about the spark gap is required to effectively monitor the EDM process. The rise and fall of thermal energy in the discharge zone at a rapid rate during the dielectric breakdown produces
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Numerical investigation of surface topography and residual stress after abrasive water jet sequential peening (AWJSP) Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-04-19 Zhanshu He; Shusen Zhao; Chao Li; Dalei Li; Yuanxi Zhang; Ting Fu; Huixin Yu
This article reveals the formation mechanism of surface topography and the formation and coupling mechanism of residual stress field (RSF) after abrasive water jet sequential peening (AWJSP) that can sequential peening on the material surface at a certain distance interval, and proposes a mathematical model of surface dimple characteristic verified by simulation results. In addition, the influences
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Combined rough and finish machining of Ti–6Al–4V alloy by electrochemical mill-grinding Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-04-19 Shen Niu; Ningsong Qu; Xiaokang Yue; Gangqiang Liu; Hansong Li
This study proposes a combined method for the electrochemical mill-grinding of Ti–6Al–4V alloy to achieve a high material removal rate, high machining accuracy and good surface quality based on rough and finish machining. In the rough machining stage, a maximum feed rate of 2.7 mm min−1 and a material removal rate of 248.3 mm3 min−1 were achieved experimentally at a 10 mm cut depth using an abrasive
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Fabrication of micro-end mill tool by EDM and its performance evaluation Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-02 Ganesh Malayath; Ajay M. Sidpara; Sankha Deb
Micro-milling is a fast, cheap and controlled process compared to other micro-fabrication processes such as lithography, laser/electron/ion beam machining, etc. However, scarcity of cutting tools of very small dimensions often results in limited application of micro-milling. In the present study, electro discharge machining (EDM) is used for fabrication of micro-end mill tool. To ensure high dimensional
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Experimental investigations into rotary mode electrochemical discharge drilling (RM-ECDD) of metal matrix composites Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-02 Tarlochan Singh; Rajendra Kumar Arya; Akshay Dvivedi
In the present work, rotary mode electrochemical discharge drilling (RM-ECDD) was employed to machine the Al-6063 SiCp metal matrix composites (MMC’s). The effect of various process parameters such as applied voltage, pulse on time, tool rotation rate, electrolyte concentration and current on quality characteristics (hole over cut and depth of penetration) of the drilled holes was investigated. The
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Effect of machining parameters on the milling process of 2.5D C/SiC ceramic matrix composites Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-14 Xuewei Zhang; Tianbiao Yu; Ming Li; Zixuan Wang
The C/SiC ceramic matrix composites are widely used for high-value components in the nuclear, aerospace and aircraft industries. The cutting mechanism of machining C/SiC ceramic matrix composites is one of the most challenging problems in composites application. Therefore, the effects of machining parameters on the machinability of milling 2.5D C/SiC ceramic matrix composites is are investigated in
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Finishing performance of die-sinking EDM with ultrasonic vibration and powder addition through pulse train studies Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-06 R. Rajeswari; M. S. Shunmugam
Die-sinking electrical discharge machining (EDM) is widely used in die and mold-making industry. Finish EDM conditions are often selected to produce good quality surfaces. Attempts to enhance the finishing capabilities using ultrasonic vibration and powder-added dielectric medium have been reported in the literature. However, the changes in the gap phenomena with ultrasonic assistance and powder addition
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Analysis of subsurface defects occurrence in abrasion resistant Creusabro steel after WEDM including the study of morphology and surface topography Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-10-03 K. Mouralova; T. Prokes; L. Benes; P. Sliwkova
Unconventional wire electrical discharge machining technology is an indispensable part of the production of many industrial devices. Material separation takes place at very high local temperatures, and therefore, some undesirable surface and sub-surface defects are formed. Not only the occurrence of defects but also the quality of the machined surface is very important for the end customer, so it is
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Effect of MQL and nanofluid on the machinability aspects of hardened alloy steel Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-09-30 Anshuman Das; Sudhansu Ranjan Das; Saroj Kumar Patel; Bibhuti Bhusan Biswal
The current research comprises of various machinability aspects of 4340 hardened alloy steel which are scrutinized with in context of improvements in main cutting force, tool flank wear, crater wear, surface roughness, micro-hardness, machined surface morphology, chip morphology, chip reduction coefficient and apparent coefficient of friction under three different cutting fluid applications i.e. compressed
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Cryogenic drilling of aluminum-based printed circuit boards: a review and analysis Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-11-05 Dantian Lin; Chengyong Wang; Xin Huang; Yong Ke; Lijuan Zheng
An aluminum-based printed circuit board (Al-PCB) is a composite material comprising a copper layer, an insulating layer, and an aluminum base layer. In the drilling of Al-PCBs, exit burrs are formed because of the plastic deformation of the remnant aluminum under high drilling temperatures. In this work, a new method using cryogenic media is suggested to prevent exit burrs in Al-PCB drilling. The effects
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Experimental investigation and economic analysis of surfactant (Span-20) in powder mixed electrical discharge machining (PMEDM) of AISI D2 hardened steel Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-03-11 Nor Ain Jamil Hosni; Mohd Amri Lajis
Powder mixed EDM (PMEDM) is recognized as an advanced and innovative technique with enhanced performance and limited drawbacks in comparison to conventional EDM method. This study investigates the effect of powder particle size, various powder concentrations (Cp), and surfactant concentrations (Cs) on the performance of EDM. Since the machining characteristics are highly dependent on the dielectric
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Deformation characteristics and grain size effect of thin silicon steel sheet during shearing Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-02-06 Yiwei Zhu; Qiusheng Yan; Jiabin Lu
The characteristics of shearing force and shearing surface, working hardening at the shearing edge, and structural evolution of microstructures during the transverse shearing of thin silicon steel sheet (SSS) were explored. On this basis, the influences of the thickness and grain size of the thin SSS and lateral clearance of the tool on shearing deformation processes were further analyzed. The results
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Thermal modeling of drilling process in titanium alloy (Ti-6Al-4V) Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-01-25 Ankit Kumar; Rajneesh Bhardwaj; Suhas S. Joshi
In drilling in titanium alloys, heat trapped in a hole adversely affects tool life, hole surface quality and integrity. Therefore, modeling temperature distribution in drilling is vital for effective heat dissipation and improving quality of drilled surfaces. The existing numerical and finite element models consider only frictional heat, whereas the effect of shear heat generation and tertiary heat
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A 2D finite element analysis of the effect of numerical parameters on the reliability of Ti6Al4V machining modeling Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-01-25 Mariem Yaich; Yessine Ayed; Zoubeir Bouaziz; Guénaël Germain
The numerical analysis, based on the finite element modeling (FEM), presents nowadays an efficient computational tool. It allows a better understanding of several thermo-mechanical phenomena involved during the machining process. However, its reliability heavily depends on the accurate definition of the numerical model. In this regard, a FE analysis focused on the 2D modeling of the Ti6Al4V dry orthogonal
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Surface integrity study of WEDM with various wire electrodes: experiments and analysis Mach. Sci. Tech. (IF 2.071) Pub Date : 2020-01-13 Ruma Sen; Bikash Choudhuri; John Deb Barma; Prasun Chakraborti
Wire electrical discharge machining (WEDM) is always significant for its high-precision machining. However, due to the generation of high discharge energy during machining, machined surfaces are often got distorted. These might be upgraded by choosing the correct tool with proper machining condition. The effects of the electrode materials and process parameters on different responses of WEDM like average
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Investigation into the blade-formation process in electrochemical trepanning of diffusers Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-12-26 Zhu Dong; Hu Xingyan; Lin Jiahao; Xu Zhengyang; Liu Jia
Electrochemical trepanning process is an advanced manufacturing technology suitable for the machining of aero-engine components such as blades and diffusers. Tool-electrode (cathode) with special electrical isolation is adopted in the experimental investigations of this article using the electrochemical trepanning to produce a flow mode in which the electrolyte is supplied evenly to the blade being
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Correlation between different cutting conditions, surface roughness and dimensional accuracy when ball end micro milling material measures with freeform surfaces Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-12-12 K. Klauer; M. Eifler; B. Kirsch; J. Seewig; J. C. Aurich
Material measures are used to calibrate topography measuring instruments. Micro-milling is a suitable process for the manufacturing of areal material measures in particular of material measures featuring freeform surfaces. To improve their surface quality and to minimize their deviations from the target geometry, the cutting parameters feed per tooth respectively feed rate and spindle speed are examined
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Experimental and numerical investigation of cutting forces in micro-milling of polycarbonate glass Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-12-10 Muhammad Pervej Jahan; Jianfeng Ma; Craig Hanson; Xingbang Chen; Greg K. Arbuckle
Polycarbonates have found important applications in various types of industries including optical, automotive, aerospace, biomedical, and defense manufacturing industries. Conventional mechanical machining has the capability to create complex multi-scale parts and components for various materials including polymeric materials. This study investigates the cutting forces generated during the machining
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Tool wear estimation in machining based on the flank wear inclination angle changes using the FE method Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-12-10 Ramin Yousefi Nooraie; Mehdi Safari; Abbas Pak
In this study, a FEM-based tool wear approach with a focus on the geometry of the worn tool, especially the changes of flank wear land inclination angle, was developed. The relationship between the variables of the wear rate equation and the average nodal temperature on the flank wear land through integrating FE-simulations of the cutting process and Response Surface Methodology (RSM) was determined
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Investigation of surface integrity in end milling of 55NiCrMoV7 die steel under the cryogenic environments Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-12-10 M. Jebaraj; M. Pradeep Kumar; N. Yuvaraj; R. Anburaj
Cryogenic assisted machining is experiencing growing popularity and acceptance as a toxic-free, eco-friendly, hazardless process producing improved structural components. This article deals with the analysis of 3D and 2D roughness profiles, surface morphology, residual stress and microhardness of 55NiCrMoV7 die steel after end milling operation under dry, wet, cryogenic CO2 and LN2 cooling environments
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Experimental research on the MRR of ultrasonic vibration aided electric discharge milling of ceramic materials using deionized water as processing medium Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-11-01 Weijie Chang; Yanying Xi; Haowei Li; Shunhua Chen; Bolin Dong; Qin Yang; Jianhua Zhang
Abstract Electric Discharge Milling Machining (EDMM) simplifies the electrode manufacturing process and reduces the cost. However, the introducing of new parameters, such as the three-dimensional motion and the electrode rotation speed, results in a periodic change of control state that can reduce the control performance and processing efficiency. In this work, ultrasonic vibration of tool electrode
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Feature extraction method of abrasive belt wear state for rail grinding Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-10-10 Meng Nie, Liu Yueming, Li Jianyong
Abrasive belt has the advantages of high removal efficiency and high waste collection; furthermore, it does not easily damage the rail when applied in rail grinding. However, the poor wear consistency and short service life restrict its development in this field. It is important to explore the theory and technology of monitoring the abrasive belt wear condition to evaluate the means of improving the
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Robust control synthesis for CNC machine spindle Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-09-24 Nguyen Ngoc Nam, Sam-Sang You, Boc Minh Hung, Pham Dinh Tung, Hwan-Seong Kim
This paper aims to analyze the dynamic stability and build the robust controller for motorized spindle system under parametric variations, external disturbances and measurement noises. A nonlinear model has been established for the machine tool spindles. The phase portrait and bifurcation analyses are provided to show dynamical behaviors for spindle machining. The spindle operations can be dynamically
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Evaluation of machinability and economic performance in cryogenic-assisted hard turning of α-β titanium: a step towards sustainable manufacturing Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-09-23 Muhammad Jamil; Aqib Mashood Khan; Ning He; Liang Li; Asif Iqbal; Mozammel Mia
Abstract Titanium, a difficult-to-cut material, consumes higher time and cost in removing material by machining to produce parts. Machining of Ti alloys has got serious attention owing to its reactive nature with tool materials at elevated temperature that aggravates tool wear. Reportedly, effective and efficient cooling and lubrication at the tool–work interface can ameliorate the machinability of
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Investigate on effect of cryogenic cooling on oxidation wear of WC-Co carbide tool milling titanium alloy Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-09-03 Fengbiao Wang, Yongqing Wang
For titanium alloy at high cutting speed, the severe tool wear will ineluctably take place diminishing the available tool life because of the high instantaneous temperature rise. Especially the WC-Co material in carbide tool will be reacted with the oxygen element in the air and generate oxide, and the tool oxidation wear is inevitable. In milling Ti–6Al–4V alloy operations, this article presents the
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Edge micro-creation of Ti(C, N) cermet inserts by micro-abrasive blasting process and its tool performance Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-26 Xiangsong Fu; Bin Zou; Yanan Liu; Chuanzhen Huang; Peng Yao
Abstract In this study, the cutting edge passivation by a micro-abrasive blasting method for cermet inserts and its machining performance were investigated. The micro-abrasive blasting parameters for cermet inserts were optimized and the micro-creation of cutting edge was determined with detail. A Back Propagation (BP) neural network prediction model was further established based on our micro-abrasive
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Finite element modeling of ultrasonic-assisted turning: cutting force and heat generation Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-07 B. Gholamzadeh; H. Soleimanimehr
Abstract Adding ultrasonic vibrations to conventional turning can improve the process in terms of cutting force, surface finish and so on. One of the most important factors in machining is the heat generation during the cutting process. In ultrasonic-assisted turning (UAT) the tool tip also vibrates at very high frequency and this sinusoidal motion causes complexity in heat modeling of the cutting
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A Predictive Model of the Optimal Tool Edge Geometry for Veneer Cutting Processes Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-06 Fatma Zohra Bouarab; Abdelhamid H. Aknouche; Abderrachid Hamrani
Abstract Veneer cutting is a specific machining process, where the chip is the final product. The objective of this article is to investigate on the optimal tool edge geometry, using particle swarm optimization (PSO) algorithm, to obtain the desired veneer thickness. The challenge is to maintain the best quality of veneer product with the control of pre-splitting condition and thickness variation.
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Investigation on thrust force in rotary ultrasonic drilling of CFRP using Brad drill Mach. Sci. Tech. (IF 2.071) Pub Date : 2019-08-05 Kan Zheng; Song Dong; Wenhe Liao
Abstract The carbon fiber reinforced plastic (CFRP) has been widely used in manufacturing industry due to its excellent mechanical and physical properties. Brad drill, as a representative of new-type structural drills, is applied in processing of CFRP. Meantime, rotary ultrasonic drilling (RUD) is regarded as a superior method for machining composite materials, due to its outstanding performance in
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