Surface finish and material removal rate are two important factors in the manufacturing which affect acceptability of the product which in turn reflects on the profitability of the organization. The worth of the production setup to produce the components with high material removal rate (MRR) without sacrificing the surface requirements can play vital role in sustainability and profitability of the organization. In this paper, the effect of process parameters on metal removal rate and surface roughness has been investigated in milling of Al7075-MMC with WC as reinforcement element. Cutting speed, feed and depth of cut have been taken as input factors in three level response surface methodologies used for experimentation. Mathematical models have been developed using response surface methodology to predict surface finish, and metal removal rate in term of machining parameters. Depth of cut and feed rate are found to be a dominant parameter for surface roughness; whereas feed rate mainly affects the metal removal rate. The results of mathematical models have been compared with the experimental and found to be in good agreement. The results of predicted model can be used in selection of process parameters to insure desired quality and improved productivity
In recent times, nonlinear ultrasonic inspection has become a very reliable technique to characterize micro-scale cracks and small-scale delaminations. In this paper, an analytical framework is developed for the orthotropic composite plate to calculate the variation of relative acoustic nonlinearity parameter, a quantitative measurement of nonlinearity at the delamination region. The analytical investigation is justified with numerical and experimental research using a carbon fiber-reinforced polymer (CFRP) plate with three delaminations. Two incident waves are used for excitation, out of which the first wave frequency is varied as local defect resonance (LDR) frequency ( fd), subharmonic LDR frequency (2 fd), second-order superharmonic LDR frequency ( fd/2), and third-order superharmonic LDR frequency ( fd/3) while the second incident wave is taken as a single periodic frequency. Different delamination sizes, positions, and depths were used to understand the second-order relative acoustic nonlinearity parameter ( β2) with other LDR frequencies as well as its harmonics. It has been observed from analytical, numerical, and experimental results that the relative acoustic nonlinearity parameter is maximum at LDR frequencies. It increases in case of surface level delaminations.
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