Papers by Keyword: Material Removal Rate (MRR)

Abstract: In this work, Abrasive Water Jet Machining (AWJM) on aluminum based hybrid composite with Silicon Carbide (SiC) and Boron Carbide (B₄C) reinforcement particles are investigated. Two different abrasive grain sizes of 80 mesh and 120 mesh are selected to carry out the experiments. The cutting parameters namely pressure, standoff distance (SOD) and traverse speed are assessed in terms of the kerf angle, Material Removal Rate (MRR) and Surface Roughness (Ra). The result shows that the coarse abrasive particle has a favorable effect on the MRR, while the fine grained abrasive particle produced minimum kerf angle and good surface finish.

Abstract: The Electrical Discharge Machine (EDM), parameters are investigated during the machining of Inconel 825 by using different tool geometry of zirconium copper electrode. Demand for better MRR, SR, and lower Tool Wear Rate are increasing recently for all materials, the low rigidity and high material removal rate of Inconel alloy offers a challenging task in obtaining output responses. The analysis of output responses such as Metal Removal Rate (MRR) of Inconel 825 material is carried out an excellent result can be obtained by using Taguchi L16 Orthogonal Array under different conditions of Parameters. The response of MRR is considered for improving machining efficiency. Optimal combination of parameters was obtained Taguchi optimization technique. The confirmation experiments results shows that the significant improvement in output responses was obtained. ANOVA have been used to analyze the contribution of individual parameters on Material Removal Rate. The experimental result demonstrates that the Taguchi method satisfies the practical requirements.

Abstract: Improving the Material Removal Rate (MRR), reduce Tool Wear Rate (TWR), achieve the good Surface Finish (SF) and Over Cut (OC) are very demanding in Electrical Discharging Machining (EDM). This paper focused on performance of Silicon powder mixed with kerosene servotherm dielectric medium in EDM of Monel 400. The optimum range of Silicon powder, Graphite powder 6g mixes with the dielectric medium of kerosene servotherm (75:25) were developed experimentally. It was reported slightly more MRR, very low TWR, better OC and good surface finish (SF) in Monel 400.

Abstract: In the present study, the aluminum based hybrid composite with Silicon Carbide (SiC) and Boron Carbide (B₄C) particles are prepared through the stir casting process and subjected to Abrasive Water Jet Machining (AWJM). The pressure, standoff distance and traverse speed are considered as the input process parameters and the output response such as Kerf angle, Material Removal Rate (MRR) and Surface Roughness (Ra) are measured and optimized using Grey Relational Analysis (GRA). The Analysis of Variance (ANOVA) and the F-test are performed to understand the contribution and the significant level of importance of each input parameter over the output response. The experimental result shows that the traverse speed and the standoff distance contributed more on affecting the performance, with a contribution of 62.14% and 18.43% respectively.

Abstract: The effect of machining parameters on machining characteristics for aluminium alloy LM6 (Al-Sil2) in Electrical Discharge Machining (EDM) die-sinking is studied. The objective of this project is to determine the relationship between the machining parameters including pulse-on time, pulse-off time, peak current and voltage with the machining characterictics such as Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (Ra). Copper materials having diameter 15mm was chosen as the electrode tool. Design of experimenent using Taguchi technique was employed to design experimental matrix that was used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that current and pulse off time significantly affect MRR, EWR and Ra while pulse on time and voltage are less significant in their effect on machining responses. Results show that using Taguchi as a design matrix, the best setting of optimum value for machining parameters to find the required machining responses can be obtained.

Abstract: Through experimental study on the role of the free abrasive in chemical mechanical polishing, in this paper, four different types of abrasive which were chosen were used for the research of material removal rate(MRR) and surface quality of SiC single crystal . Finally ,Diamond abrasive which is considered was the most suitable for chemical mechanical polishing(CMP) abrasive of SiC Crystal Substrate. With diamond Particle polish pad polishing, it is draw a comparison result on the influence of the free abrasive and consolidation abrasive for the material removal rate and surface quality of 6H-SiC. The results showed that: the MRR is 140nm / min, the material removal rate if fixed abrasive chemical mechanical polishing(FA-CMP) more than three times that of traditional CMP, fixed abrasive chemical mechanical polishing pad, are involved in a large proportion of micro abrasive cutting, can greatly improve the material removal efficiency. And results from the test procedure, the FA-CMP surface has scratches after more technical problems for the polishing pad, the surface damage is relatively free of abrasive chemical mechanical polishing is more serious.

Abstract: Electrochemical Machining is one of established non-traditional machining process which is widely used in micro machining parts. Purpose of this research paper is to investigate effect of Electrochemical Machining under low voltage and relatively high current rating on concentrated or masked work piece of Copper and Carbon Steel EN9. Developing Machine set up with the help of PLC and SCADA device for Accurate Positioning and reliable data supervising which includes ECM, basic working principle of ECM, selection and development of components, implementation and to analyze the effect of change in the parameters of the process. Selection and development part will cover design of frame, fixture, pump, filter, tool, electrolyte, and work piece material as a mechanical part, selection of electric drive system and PLC. PLC programming and hardware circuit as electrical and programming part.

Abstract: The machining ability of Electrical Discharge Machining (EDM) die-sinking on material characteristics of LM6 (Al-Sil2) is studied. This is due to the machining process on sharp edge, pocket, deep slot and micro hole cannot be performed by milling and turning machine. The objective of this paper is to determine the relationship between the machining parameters such as pulse on time, pulse off time, peak current and voltage on material removal rate (MRR) that are electrode wear rate (EWR) and surface roughness (Ra). Graphite tool of diameter 15mm was chosen as an electrode. Taguchi method is used as analysis technique to develop experimental matrix that is used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that the current and pulse off time are significantly effected the MRR, EWR and Ra while pulse on time and voltage are less significant factors that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.

Abstract: Advancing of micro-milling process via ultrasonic vibration assist has been proven able to improve machining characteristics such as surface roughness quality and dimension accuracy. The improvement is due to the cutting motion of Vibration Assisted Machining (VAM) process. Thus, for every vibration motion manner, the cutting characteristic of the VAM system will be difference from one to another. This paper presents the development approach of ultrasonic vibration assisted micro-milling (UVAM) using tilted 45° XY stage. It covers theoretical perspective and the influence of Minimum Quantity Lubrication (MQL) system as cutting fluid. It will emphasize on the theory of surface roughness, dimension tolerance and cutting tool life. Piezo-actuator is used as fast servo vibration mechanism in specific axis input with controlled signal. The input signal is sine wave with controllable frequency and amplitude to allow mechanism control algorithms to be develop during the process. In addition, the effect of cutting fluid was be analyzed to understand the potential capabilities of this aid on UVAM process.

Abstract: This study presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of Electrical Discharge Machining (EDM) input parameters on characteristics of EDM process. The machining parameters include peak current, servo voltage, pulse ON time and pulse OFF time. The study was conducted using 2 levels of Full Factorial Method in Design of Experiments. The design expert software employed to perform all the data analysis for Full Factorial and Central Composite Design (CCD) experiments. This study evaluates the machining performance of the Stainless Steel 316L using Sodick EDM linear motor series AM3L which employed Copper impregnated graphite diameter 7.0 mm as the tool electrode. The response variables are material removal rate (MRR), electrode wear rate (EWR), surface roughness (SR) and dimensional accuracy. The result shows that the peak current was the most significant factors to all variable responses. The servo voltage does not have significant effects to the machining responses in RSM. Higher current produced higher MRR, EWR, SR and Dimensional Accuracy. Maximum MRR was obtained at peak current range from 27amp to 38amp, pulse on time range from 120μs to 145μs and 60μs of pulse off time. Maximum EWR was obtained at peak current range from 27amp to 37amp, pulse on time range from 140μs to 160μs and 60μs of pulse off time. High probably, the minimum EWR only can be obtained if peak current parameter sets greater than 45amp. Lower dimensional accuracy and SR obtain at 5amp of pulse on time. Higher pulse off time produced lower MRR and EWR.Keywords: EDM Die sinking, Stainless Steel 316L, Copper Impregnated Graphite Electrode, Response Surface Methodology, Surface Roughness, Material Removal Rate, Electrode Wear Rate, Dimensional Accuracy