Additive manufacturing technology provides a gateway to completely new horizons for producing a wide range of components, such as manufacturing, medicine, aerospace, automotive, and space explorations, especially in non-conventional manufacturing processes. The present study analyzes the influence of the additive manufactured tool in electrochemical micromachining (ECMM) on machining beta titanium alloy. The influence of different machining parameters, such as applied voltage, electrolytic concentration, and duty ratio on material removal rate (MRR), overcut, and circularity was also analyzed. It was inferred that the additive manufactured tool can produce better circularity and overcut than a bare tool due to its higher corrosion resistance and localization effect. The additive manufactured tool can remove more material owing to its strong atomic bond of metals and higher electrical conductivity.
Electrochemical machining (ECM) is a preferred advanced machining process for machining Monel 400 alloys. During the machining, the toxic nickel hydroxides in the sludge are formed. Therefore, it becomes necessary to determine the optimum ECM process parameters that minimize the nickel presence (NP) emission in the sludge while maximizing the material removal rate (MRR). In this investigation, the predominant ECM process parameters, such as the applied voltage, flow rate, and electrolyte concentration, were controlled to study their effect on the performance measures (i.e., MRR and NP). A meta-heuristic algorithm, the grey wolf optimizer (GWO), was used for the multi-objective optimization of the process parameters for ECM, and its results were compared with the moth-flame optimization (MFO) and particle swarm optimization (PSO) algorithms. It was observed from the surface, main, and interaction plots of this experimentation that all the process variables influenced the objectives significantly. The TOPSIS algorithm was employed to convert multiple objectives into a single objective used in meta-heuristic algorithms. In the convergence plot for the MRR model, the PSO algorithm converged very quickly in 10 iterations, while GWO and MFO took 14 and 64 iterations, respectively. In the case of the NP model, the PSO tool took only 6 iterations to converge, whereas MFO and GWO took 48 and 88 iterations, respectively. However, both MFO and GWO obtained the same solutions of EC = 132.014 g/L, V = 2406 V, and FR = 2.8455 L/min with the best conflicting performances (i.e., MRR = 0.242 g/min and NP = 57.7202 PPM). Hence, it is confirmed that these metaheuristic algorithms of MFO and GWO are more suitable for finding the optimum process parameters for machining Monel 400 alloys with ECM. This work explores a greater scope for the ECM process with better machining performance.
The present study deals with the process optimization of printing parameters for fabricating gyroid TPMS (triply periodic minimal surface) lattice structure incorporated compression samples on the polylactic Acid polymeric material for obtaining the maximum compressive strength. The design of experiments is followed for the process parameter optimization. The experiment was carried out by varying three printing process parameters and four levels such as printing speed (10 mm/sec, 20 mm/sec, 30 mm/sec, and 40 mm/sec), layer height (0.10 mm, 0.15 mm, 0.20 mm, and 0.25 mm), and nozzle temperature (190°C, 200°C, 210°C, and 220°C). The L16 orthogonal array is employed for the experimental procedure and the Taguchi optimization technique is utilized for the optimization of the printing process parameters for obtaining maximum compressive strength for the fabricated gyroid TPMS lattice structure incorporated compression samples. The experimental results confirm that printing speed and layer height have major influence of 57.28% and 30.92% on the compressive properties of the fabricated samples. Based on the regression analysis results, it can be concluded that the proposed mathematical model has observed an error percentage of 2.1% and a good fit has been observed with the experimental results. The macroscopic view of the fractured samples depicts that the sample fabricated at a nominal printing speed of 20 mm/sec and layer height of 0.10 mm has obtained the highest compressive strength and lower buckling during compression test. The optimized combination of printing process parameters for obtaining maximum compressive strength is 20 mm/sec, 0.10 mm, and 210°C.
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