Non-traditional Micromachining Processes: Opportunities and Challenges

Debnath, Sudipta; Kunar, S.; Anasane, Sandip S.; Bhattacharyya, B.

doi:10.1007/978-3-319-52009-4_1

Cited by 12 publications

(6 citation statements)

References 137 publications

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“…The main parameters of the study are shown in Table 2. They are chosen according to values successfully applied in previous work [1][2][3][4][5][6]14,15 and some preliminary experiments.…”

Section: Methodsmentioning

confidence: 99%

“…It has long been adapted for use in regrinding of cutting and turning tools. [1][2][3][4][5][6][7] Enhancing the efficiency of the material removal rate and improving the surface quality of the machining processes can be achieved by applying different cutting actions on the material being machined. In particular, the electrochemical and mechanical actions that applied in the ECG can be combined with respective mechanical interaction used in another unconventional machining processes like ultrasonic machining (USM) or abrasive water jet machining, jet electrochemical micro-drilling.…”

Section: Introductionmentioning

confidence: 99%

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Effect of the Al₂O₃ powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Yehia

El-Assal

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The integrated electrochemical grinding machining has received wide acceptance in the aircraft turbine industry for the machining of blades, vanes, and honeycomb seal rings. Also, medical devices, instruments and forceps, shells, precision nozzles, instrument coupling, and air rotor motors that produced from stainless steel and new materials have all successfully been accomplished with electrochemical grinding. To improve the metal removal rate and to reduce the surface roughness ( Ra) of the electrochemical grinding at high voltages, an integration between the alumina abrasive jet and the electrochemical grinding machining has been performed. The effect of the Al2O3 abrasive content on the metal removal rate and the Ra of the K110 alloy steel using Everite electrochemical grinding 618 at different voltages, different feed rates, different electrolyte NaCl concentrations, and different depths of the cut were successfully investigated. The results revealed that the abrasive electrochemical grinding was better than the electrochemical grinding results. The maximum effect of the Al2O3 on the metal removal rate was achieved at 5 wt.%. The current density in the machining gap was affected by the addition of the Al2O3, where it was decreased at percentages over 5-wt.% Al2O3. The abrasive electrochemical grinding resulted in lower surface roughness than the electrochemical grinding process.

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“…The main parameters of the study are shown in Table 2. They are chosen according to values successfully applied in previous work [1][2][3][4][5][6]14,15 and some preliminary experiments.…”

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of the Al₂O₃ powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Yehia

El-Assal

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…These applications are accompanied by a number of technical difficulties that need to be resolved [ 31 , 32 ]. These problems result in the new challenges that await scientists in this area [ 33 , 34 ]. One of the main problems concerns the sucking of the abrasive material in the very fine fraction (typically, at least MESH 200 and higher), because the abrasive material tends to clog the feed tubes.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Several Physical Phenomena Measured on the Metallic Materials Cut by Abrasive Water Jets (AWJ)

et al. 2022

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Cutting using an abrasive water jet is a complex process involving several physical phenomena. This research studies some of them, mostly the influence of selected variables on the measured forces and vibrations. The traverse speed represents one of the key parameters when cutting using the AWJ. In the presented research, a set of experiments was performed on twelve different metal samples, while the force sensor measured the exerted forces and accelerometers measured the vibrations. Ten different types of steel samples of the same dimensions were cut applying five different traverse speeds. The data obtained during these measurements show that an increase in the traverse speed leads to an increase in the measured forces and vibrations. An analogous experiment performed on bronze and duralumin samples of the same dimensions, having applied higher speeds to compensate for the difference in the material structure and properties, completes the presented data. The most important results of the research are that exerted forces in the z-axis are higher than those in the x-axis, whereas measured vibrations are higher in the x-axis. According to our research, the elemental structure, especially the carbide formation, affects the measured forces and vibrations substantially.

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“…Nontraditional machining process changed the current trend of manufacturing industries. For achieving better production rate with accuracy, conventional machining processes are replaced by nontraditional machining processes [1]. WEDM process is basically a Thermo-Electrical process which falls under the category of unconventional machining process, practiced extensively in industries to machine high hardness materials for complex geometry in electrically conductive materials [2].…”

Section: Introductionmentioning

confidence: 99%

Enhancing the Tool Die Steel P rofile C utting P erformance in WEDM P rocess

Saravanan*¹,

Thiagarajan²,

Somasundaram³

2019

IJEAT

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This work elaborates the experimental work on Material Removal Rate (MRR) and Surface Roughness (SR) output conditions of Wire-Electrical Discharge Machining (WEDM) and finding the optimal input conditions through Taguchi method coupled with Grey relational analysis for lower SR and higher MRR during profile cutting of high strength D3 tool steel, which is the need of the hour in industries. The machining factors considered for investigation which influences MRR and SR were: cutting speed, pulse on-time and off-time, input current, wire tension and feed and servo feed and voltage. A L18 orthogonal array was considered for mixed-level experimental design through Taguchi’s approach and for multi-criteria optimization Grey Relational Analysis was applied. Outcome shows that SR increases with the increase of pulse on-time and decreases with increase in pulse off-time and MRR increases as the pulse on-time increases due to longer spark duration. Both SR and MRR are well within the control limits and servo voltage is the most influential parameter contributing by 48.48%, followed by wire feed rate, input current and servo feed rate with an R2 value of 95.85%, identified through Analysis of Variance (ANOVA). With obtained optimum conditions, a validation experiment was conducted to authenticate the results, which indicates a worthy agreement with predicted output characteristics.

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Non-traditional Micromachining Processes: Opportunities and Challenges

Cited by 12 publications

References 137 publications

Effect of the Al₂O₃ powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Effect of the Al₂O₃ powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Analysis of Several Physical Phenomena Measured on the Metallic Materials Cut by Abrasive Water Jets (AWJ)

Enhancing the Tool Die Steel P rofile C utting P erformance in WEDM P rocess

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Non-traditional Micromachining Processes: Opportunities and Challenges

Cited by 12 publications

References 137 publications

Effect of the Al2O3 powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Effect of the Al2O3 powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Analysis of Several Physical Phenomena Measured on the Metallic Materials Cut by Abrasive Water Jets (AWJ)

Enhancing the Tool Die Steel P rofile C utting P erformance in WEDM P rocess

Contact Info

Product

Resources

About

Effect of the Al₂O₃ powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Effect of the Al₂O₃ powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining