Papers by Keyword: MRR

Abstract: Because of their extraordinary qualities, titanium alloys are very sought-after materials that can be applied to a wide range of sectors. Excellent mechanical and chemical qualities, including a high strength-to-weight ratio and resistance to corrosion, are present in it. The special properties of these alloys make machining them extremely difficult. As frequent tool wear occurs throughout the machining process, Computer Numerical Control (CNC) milling has become a potential method for machining titanium alloys due to its precision and versatility. This review article provides a comprehensive overview of the development of titanium alloy CNC milling, with an emphasis on the effects of cutting tool geometries and materials on machining efficiency. The process examines several aspects of cutting circumstances, including depth of cut, speed, feed rate, and lubrication techniques, and optimizes machining parameters and procedures to achieve the best results. Surface integrity and quality, surface roughness, residual stresses, and microstructural changes brought about by CNC milling are the main points of evaluation.

Abstract: Transition metal ion was added to CMP (chemical-mechanical polishing) slurry without abrasive particle to solve the problem of CMP. MRR (material removal rate) value of SiC substrate processed using non-abrasive slurry was comparable to MRR values of SiC substrates using abrasive slurries. The scratch formation was successfully suppressed in SiC substrate polished with using non-abrasive slurry and no residual particle resulting from agglomeration of abrasive particles could suppress scratches and forms a good quality of SiC substrate surface. Uniform and high-quality SiC substrates could be prepared through the non-abrasive CMP process.

Abstract: Commercial applications for Ti 6Al 4V, an alloy composed of titanium, aluminium, and vanadium, are possible. The features of titanium alloy include: Lightweight, non-magnetic, high melting point, outstanding fatigue strength, superior specific strength, great corrosion resistance, and biocompatibility. Reviewing the electro-discharge machining of titanium alloy (Ti 6Al 4V) as a workpiece, silicon carbide particle combined with EDM oil, and coated tungsten carbide electrode, this research examines this process. Dielectric fluid's impact on microhardness, surface finishing, TWR, and MRR. MRR is raised by silicon particles and coated tungsten carbide electrodes with EDM fluid. According to the study, the most important input parameters for determining TWR, MRR, surface finishing, and micro-hardness are voltage, current, pulse on time (Tonne), and pulse off time (Toff).

Abstract: An extensive examination of the effect of dielectric properties of the Electrical Discharge Machining (EDM) operation machining variables is being done in the present study. Irrespective of the material's hardness, an EDM is an unconventional thermo-erosion machining procedure. It gave the workpiece a better and more detailed surface topography. Dielectric is an essential EDM component that typically affects the operation's high material removal rate and surface integrity. The dielectric fluid acts as a medium that modulates electrical sparks and traps energy due to the operation. It cleans up the trash and cools the workpiece. Whenever powders like Ti, Si, graphite, Cu, Al₂O₃, and others are added to the dielectric fluid, the fluid's conductivity increases the micro-hardness of the substance. For executing studies in EDM, choosing a proper dielectric from the number of fluids now offered is crucial. Adopting different additives in the dielectric fluid impacts the optimization of machining parameters and related characteristics are addressed in this study in light of existing research. The studies show the effect on various output parameters.

Abstract: Composites are being used since decades and imparting excellent properties comparatively. It may be used in numerous industries because of its light weight and specific strength. Machinability of these materials is a concerned aspect. Conventional and The composites have been machined using unconventional machining techniques. Conventional methods are less suitable than non-conventional quoting the best surface finish and ability to machine complex parts. This article investigates the suitability of thermo-electric process for the machining of composites for higher surface quality and material removal. It includes the study of machining by die sinking, wire cut, powder mixed electric discharge machine in different matrix based composites along with the variation of reinforcement. Electric Discharge Machining (EDM) finds its suitability in machining of different metal matrix composites (MMC) more than the Polymer Matrix Composite (PMC) and Ceramic Matrix Composites (CMC). Variation in input parameters listed as Pulse duration, Voltage, Peak Current and Polarity is studied to obtain the optimum resulting parameters as Material Removal Rate (MRR), Surface Roughness (SR), Electrode Wear Rate (EWR) and Kerf Width. Material removal in PMC is 16% more in parallel fibre direction than with perpendicular. Low electrical conductance and high hardness of CMCs limits the use of EDM while natural ceramics are found more suitable for machining. Gap voltage, pulse on time and current are found most crucial in machining MMCs while quantifying material removal and surface roughness.

Abstract: The Al-B₄C composites are exclusively applicable in the structural components of automobiles and aerospace. It is also termed a hard-to-cut material. Hence, the Machining of such materials with firm design and close tolerance is a key concern in the present era of the manufacturing world, particularly through the conventional machining process. The prime motive of this paper is to evaluate the Machinability performance in terms of MRR and SR of the AA7050-7.5% B4C-T6 Composite using die-sinking EDM. The Taguchi L9 DOE was employed for the execution of experiments to assess the machinability performance of the composite in terms of MRR and Ra, with the simultaneous effect of input parameters such as Ip, Ton, and sand parking voltage (Sv). Further, the parameters were optimized using the Taguchi Analysis. ANOVA analysis was performed to evaluate the significance and contribution of the input parameters toward performance measures.

Abstract: The CNC milling process is one of the most valuable traditional machining processes for machining hardened material by using various coated end mill tools. The attention of the current study has been done on end milling of hardened AISI D2 tool steel which is a commonly used tool steel grade in a press machine. The material removal rate is an essential aspect of improving productivity and reducing lead time and production costs. MRR has been considered as a response in this experimental work. A number of experiments were conducted using the design of the experiment via response surface methodology (RSM). MRR was calculated for each machining performance. A mathematical model of MRR was found using response surface methodology.

Abstract: The current research paper is focused on investigating the influence of Laser beam machining process parameters on surface roughness and kerf width of HSLA steel. Taguchi’s L₁₈ orthogonal array is adopted to conduct the machining studies. MOORA method is used to evaluate the suitable combination of the LBM process parameters. The combined effect of machining performance measures is analysed using analysis of variance to identify the significance of the result. Consequently, the influence of the parameters on machining responses were explored. The surface morphology of the machined surface of the optimal set of parameters has been studied.

Abstract: WEDM is an unconventional method of thermal machining that produces products with irregular shapes. The results of milling titanium (TI-6242) under various machining conditions that affect the WEDM process are provided. Pulse on time (Ton), pulse off time (Toff), peak current (Ip), voltage (V), wire tension (Wt), and wire feed are all considered machining parameters (Wf). They are established using an experimental design and the Box–Behnken approach to optimize the machining factors. The optimization goal is to attain the highest Material Removal Rate (MRR) and the least amount of recast layer (RL). ANOVA determines the most important factor. Moreover, a regression analysis is used to predict MRR and RL based on defined machining parameters. Ton = 120s, Toff = 50s, Ip = 11 A, Wt = 1kg, and V = 50 volt are the optimal regulatory factors for obtaining the highest MRR, depending on the consequences. Ton = 130s, Toff = 60s, Ip = 12 A, Wt = 3 kilogram, and V= 30 volt are the best control variables for achieving the lowest RL. Ton = 120s, Toff = 50s, Ip=10 A, and Wt=1kg are thought to be the ideal control parameters for achieving minimum RL and greatest MRR. In ideal machining circumstances, the microstructure of the machined surface exhibits a recast layer on the machined surface.

Abstract: Dry EDM is a variation of the standard EDM method in which the liquid dielectric is replaced with a gaseous medium during the machining process. This paper presents comparative analysis of stationary and rotary electrode on Dry EDM in machining of Hastelloy C276 using copper EC grade rod as electrode and air as dielectric medium. Solid cylindrical (stationary and rotary) tool electrodes are used, and high-velocity gas is fed between the electrode and the workpiece through it into the discharge gap. The high-velocity gas flow into the gap assists debris clearance and reduces tool and workpiece overheating at the discharge areas. The dry EDM technique is currently known to have reduced tool wear, a smaller discharge gap, fewer residual stresses, a smaller white layer, and a smaller heat-affected zone, in addition to being ecologically friendly. To improve response factors such as material removal rate (MRR), surface roughness (Ra), and tool wear rate (TWR), Taguchi's L9 orthogonal array approach is utilised to design the trials and study the effects of different process parameters. Discharge current (I), pulse on time (Ton), Voltage (V), pressure (P), and tool rotational speed (N) were the varied input parameters. It is observed that the rotary electrode gives better MRR compared to stationary. The analysis of results show that current (I), pulse on time (Ton) and pulse off time (Toff) are the dominant factors that influence MRR and EWR.