Advances in Unconventional Machining and Composites (eBook)

Proceedings of AIMTDR 2018

M. S. Shunmugam, M. Kanthababu (Herausgeber)

eBook Download: PDF

2019
XXI, 783 Seiten
Springer Singapore (Verlag)
978-981-329-471-4 (ISBN)

Infos

This volume presents research papers on unconventional machining (also known as non-traditional machining and advanced manufacturing) and composites which were presented during the 7th International and 28th All India Manufacturing Technology, Design and Research conference 2018 (AIMTDR 2018). The volume discusses improvements on well-established unconventional machining processes and novel or hybrid machining processes as well as properties, fabrication techniques and machining of composite materials. This volume will be of interest to academicians, researchers, and practicing engineers alike.

M.S. Shunmugam is a Professor (Emeritus) in the Manufacturing Engineering Section in the Department of Mechanical Engineering, Indian Institute of Technology (IIT) Madras. After receiving his PhD in Mechanical Engineering from IIT Madras in 1976, he has worked in IIT Bombay (from 1977 to 1980) and in IIT Madras from 1980 onwards. He was a visiting faculty member at Michigan Technological University during 1989-1991 and was a member in the board of governors of IIT Madras during 2012-2013. Dr. Shanmugam's research interests include metrology, machine tools, manufacturing, gears, micro-machining and computer applications in manufacturing. He has published about 130 peer-reviewed international journal papers, 15 peer-reviewed national journal papers, 75 international conferences and about 80 national conferences.

M. Kanthababu is a Professor in the Department of Manufacturing Engineering in Anna University, Chennai, India and the Director of the Centre for Intellectual Property Right and Trade Marks in Anna University. He has completed his MS in Mechanical engineering and PhD in Advanced Manufacturing Technology from IIT Madras. Prof Kanthababu's research interests include manufacturing technology, composite materials and machining, and automation in manufacturing. He has published more than 30 peer reviewed international journal papers and 2 books, and holds one patent. 

Inhalt

AIMTDR 2018 Conference’s Core Organizing Committee 6
Patrons 6
President (NAC-AIMTDR) 6
Vice-President (NAC-AIMTDR) 6
Co-patrons 6
Chairman 7
Co-chairman 7
Organizing Secretary 7
Joint Organizing Secretaries 7
International Scientific Committee 7
National Advisory Committee 8
Foreword 10
Preface 11
Contents 12
About the Editors 19
Unconventional Machining 20
1 Powder Mixed Near Dry Electric Discharge Machining Parameter Optimization for Tool Wear Rate 21
1.1 Introduction 21
1.2 Indigenous Developed Setup for Powder Mixed Near Dry EDM 22
1.3 Working Principle of PMND-EDM 22
1.4 Process Parameters Selection and Experimentation 23
1.4.1 Selection of Workpiece and Tool 23
1.4.2 Response Characteristic (Tool Wear Rate) 24
1.4.3 Scheme of Experiments 25
1.5 Results and Discussion 26
1.5.1 Effect of Machining Parameters on TWR 26
1.5.2 Taguchi Analysis 29
1.5.3 Estimation of Optimum Performance Characteristics (TWR) 29
1.5.4 Confirmation of Tests 32
1.6 Conclusions 33
References 34
2 Comparative Study of Dielectric and Debris Flow in Micro-Electrical Discharge Milling Process Using Cylindrical and Slotted Tools 35
2.1 Introduction 35
2.2 CFD Model 37
2.3 Boundary Conditions 37
2.4 Results and Discussion 38
2.4.1 Dielectric Fluid Flow 38
2.4.2 Debris Particle 41
2.5 Conclusions 43
References 43
3 Parametric Investigation into Electrochemical Micromachining for Generation of Different Micro-surface Textures 45
3.1 Introduction 45
3.2 Experimental Procedure 47
3.3 Results and Discussion 48
3.3.1 Influences of EMM Parameters 49
3.3.2 Analysis of Micrographs 51
3.4 Conclusions 56
References 57
4 Investigations into Wire Electrochemical Machining of Stainless Steel 304 58
4.1 Introduction 58
4.2 Experimental Setup 61
4.3 Design of Experiments 61
4.4 Results and Discussions 62
4.4.1 Effect of Process Parameters on Fillet Radius (FR) 62
4.4.2 Effect of Process Parameters on Corner Radius (CR) 64
4.4.3 Effect of Process Parameters on Kerf Width (S) 64
4.5 Generation of Different Features on Stainless Steel 304 67
4.6 Conclusions 67
References 68
5 Nanofinishing of External Cylindrical Surface of C60 Steel Using Rotating Core-Based Magnetorheological Finishing Process 70
5.1 Introduction 70
5.2 Design of Experiment 72
5.2.1 Response Surface Regression Analysis 75
5.3 Results and Discussion 76
5.3.1 Effect of Current 76
5.3.2 Effect of Rotational Speed of Tool Core 77
5.3.3 Effect of Workpiece Rotational Speed 77
5.3.4 Effect of Abrasives Concentration 79
5.3.5 Effect of Interaction of Current and Workpiece Rotation 79
5.3.6 Effect of Interaction of Current and Abrasives Concentration 80
5.3.7 Confirmation Experiments for Validation of the Model 81
5.4 Conclusions 82
References 83
6 Effect of Laser Parameters on Laser-Induced Plasma-Assisted Ablation (LIPAA) of Glass 84
6.1 Introduction 84
6.2 Experimental 85
6.2.1 Experimental Setup 85
6.2.2 Materials 86
6.3 Results and Discussion 87
6.3.1 Effect of Laser Parameters on Ablated Crater Width by LIPAA 88
6.4 Conclusions 92
References 93
7 An Experimental Study of Electrochemical Spark Drilling (ECSD) 94
7.1 Introduction 94
7.2 Working Principle of ECDM 96
7.3 Experimental Setup 97
7.4 Results and Discussion 97
7.4.1 Effect of Voltage on MRR 100
7.4.2 Effect of Duty Cycle on MRR 101
7.4.3 Effect of Tool Rpm on MRR 102
7.5 Conclusions 102
References 104
8 Development and Experimental Study of Ultrasonic Assisted Electrical Discharge Machining Process 105
8.1 Introduction 105
8.2 Ultrasonic-Assisted Electrical Discharge Machining (UAEDM) Process 106
8.3 Development of Experimental Setup for UAEDM 108
8.4 Experimental Details 109
8.4.1 Selection of Workpiece and Tool Material 109
8.4.2 Selection of Machining Process Parameters 111
8.5 Results and Discussion 111
8.5.1 Effect of Pulse Current on MRR 112
8.5.2 Effect of Pulse-on-Time on MRR 112
8.5.3 Effect of Pulse-off-Time on MRR 113
8.5.4 Effect of Ultrasonic Power on MRR 114
8.6 Conclusions 115
References 115
9 Effect of Finishing Time on Surface Finish of Spur Gears by Abrasive Flow Finishing (AFF) Process 116
9.1 Introduction 116
9.2 Details of Experimentation 118
9.2.1 Experimental Setup and Fixture 118
9.2.2 Gear Materials and Specification 118
9.2.3 Medium Preparation 119
9.2.4 Details of Process Parameters and Responses 120
9.2.5 Measurement of Responses 121
9.3 Results and Discussions 121
9.4 Conclusions 125
References 126
10 Experimental Study on Improving Material Removal Rate and Surface Roughness in Wire-Cut EDM of Low Conductive Material 127
10.1 Introduction 127
10.2 Experimental Details 129
10.2.1 Machining Performance Evaluation 130
10.2.2 Data Collection 131
10.2.3 Methodology 131
10.3 Results and Discussion 132
10.3.1 Analysis of MRR 133
10.3.2 Analysis of SR 134
10.3.3 Optimization Using Response Surface Methodology 135
10.4 Conclusions 138
References 139
11 Machining Performance Evaluation of Al 6061 T6 Using Abrasive Water Jet Process 141
11.1 Introduction 141
11.2 Experimental Study 143
11.2.1 Design of Experiment 143
11.3 Results and Discussions 144
11.3.1 Calculation of Grey Relational Coefficient (GRC) 146
11.3.2 Grey-Fuzzy Logic System 146
11.3.3 Analysis of MRR and SR with Process Parameters 147
11.3.4 Analysis of Variance 148
11.3.5 Characteristics of Machined Surface 150
11.4 Artificial Neural Network (ANN) Prediction 152
11.4.1 Forward Mapping 152
11.4.2 Reverse Mapping 152
11.5 Conclusion 153
References 153
12 Formulating Empirical Model of MRR in Near-Dry EDM 154
12.1 Introduction 154
12.2 Experimental Setup and Methodology 155
12.3 Results and Analysis 157
12.3.1 Analysis of MRR 158
12.4 Conclusions 161
References 161
13 A Model for Average Surface Roughness for Abrasive Waterjet Cut Metal Matrix Composites 162
13.1 Introduction 162
13.2 Experimentation 164
13.2.1 AWJ Cutting 165
13.2.2 Measurement of DOP and Ra 166
13.2.3 Modeling of Ra 166
13.2.4 Development of Ra Model 166
13.2.5 Model Verification 167
13.3 Results and Discussions 168
13.3.1 DOP Results 168
13.3.2 Ra Results 169
13.3.3 Validation of the Ra Model 170
13.4 Conclusions 173
References 173
14 Abrasive Jet Machining of Soda Lime Glass and Laminated Glass Using Silica Sand 175
14.1 Introduction 176
14.2 Experimental Investigation 177
14.2.1 Experimental Conditions and Process Parameters 177
14.2.2 Procedures for Experiments 178
14.2.3 Flow Rate Calculation of Silica Sand 178
14.2.4 Drilling of Soda Lime Glass Using Silica Sand (Exp. I) 179
14.2.5 Drilling of Laminated Glass Using Silica Sand (Exp. II) 181
14.3 Result and Discussions 183
14.3.1 Discussion on Experiment Set I 183
14.3.2 Discussion on Experiment Set II 186
14.3.3 Observation on Reusability of Silica Sand 188
14.4 Conclusions 189
References 189
15 A Novel Magnetorheological Grinding Process for Finishing the Internal Cylindrical Surfaces 191
15.1 Introduction 191
15.2 Design of the Magnetorheological Grinding Tool 193
15.3 Experimentation 197
15.4 Results and Discussion 198
15.5 Conclusions 200
References 201
16 A Study on Micro-tool and Micro-feature Fabrication in Micro-EDM 202
16.1 Introduction 202
16.2 Micro-tool Fabrication and Micro-feature Fabrication in Micro-EDM 204
16.3 Experimental Procedure 204
16.3.1 Experimental Setup 204
16.3.2 Experimental Scheme 204
16.4 Results and Discussion 207
16.5 Conclusions 212
References 212
17 Influence of Graphite Nanopowder-Mixed Dielectric Fluid on Machining Characteristics of Micro Electric Discharge Milling 214
17.1 Introduction 214
17.2 Experimentation Details 215
17.3 Results and Discussion 217
17.4 Conclusions 220
References 221
18 Realization of Green Manufacturing Using Citric Acid Electrolyte for WC–Co Alloy Micro-tool Fabrication in Micro-WECM 222
18.1 Introduction 222
18.2 Materials and Methods 223
18.2.1 Materials 223
18.2.2 Methods 224
18.3 Experimental Setup 224
18.4 Results and Discussion 227
18.4.1 Cyclic Voltammetry 227
18.4.2 Effect of Process Parameters on Material Removal Rate (MRR) 228
18.4.3 Optimization of Process Parameters 232
18.5 Conclusions 232
References 234
19 Effect of Powder Mix and Ultrasonic Assistance on Pulse Train-Based Specific Energy in EDM of D3 Steel 235
19.1 Introduction 235
19.2 Experimental Details 237
19.3 Pulse Train Analyses 239
19.3.1 Pulse Characteristics 239
19.3.2 Pulse Types 242
19.3.3 Specific Energy 243
19.4 Results and Discussion 244
19.5 Conclusions 246
References 246
20 Performance Evaluation of Si–Cu-Hybrid Dust as a Powder Additive of EDM Dielectrics to Machine Ti6Al4V with Copper Electrode 248
20.1 Introduction 249
20.2 Literature Review and Motivation of the Work 250
20.3 Experimental Methodology 253
20.4 Results and Discussions 254
20.4.1 Effects of Process Parameters on Material Removal Rate 254
20.4.2 Effects of Process Parameters on Surface Roughness 257
20.4.3 Analysis of the Micro-structure 258
20.5 Conclusions 261
References 263
21 Experimental Study on Material Removal Rate and Over-Cut in Electrochemical Machining of Monel 400 Alloys with Coated Tools 264
21.1 Introduction 265
21.2 Preparation of Insulated and Abrasive Tools 266
21.3 Equipment and Experimentation 268
21.4 Results and Discussions 271
21.4.1 Material Removal Rate 271
21.4.2 Over-Cut 272
21.5 Conclusions 277
References 277
22 Experimental Investigations into Ultrasonic-Assisted Magnetic Abrasive Finishing of Freeform Surface 278
22.1 Introduction 278
22.2 Experimental Design and Setup 280
22.2.1 Preparation of Bonded Abrasive 280
22.2.2 Experimental Setup 282
22.2.3 Design of Experiment and Selection of Process Parameters 283
22.2.4 Experimentation 285
22.2.5 Statistical Modeling of % ?Ra 285
22.3 Results and Discussion 289
22.3.1 Effect of Process Parameters 289
22.3.2 Interaction Effects 291
22.4 Surface Generation in UAMAF of Freeform Surface 292
22.5 Conclusions 293
References 294
23 Fiber Laser Cutting of Nimonic C263 Alloy and Investigation of Surface Integrity 296
23.1 Introduction 296
23.2 Materials and Methods 298
23.2.1 Workpiece Preparation 298
23.2.2 Experimental Setup 298
23.2.3 Experimentation 298
23.2.4 Characterization Procedure 299
23.3 Results and Discussions 299
23.3.1 Microstructure and EDS Analysis 301
23.4 Conclusions 305
References 306
24 Generation of Three-Dimensional Features on Ti6Al4V by EC Milling 308
24.1 Introduction 308
24.2 Experimental Setup 310
24.3 Experimental Planning 311
24.4 Experimental Methodology 312
24.5 Results and Discussion 313
24.5.1 Influence of Feed Rate and MLD on Overcut 313
24.5.2 Influence of Feed Rate and MLD on Average Machining Depth 314
24.5.3 Influence of Feed Rate and MLD on Side Angle 315
24.5.4 Influence of Feed Rate and MLD on Radius of Curvature 316
24.5.5 Influence of Tool Rotation on Machining Quality 317
24.6 Selection of Best Parametric Combination by Analyzing Experimental Results 318
24.7 Generation of Various Three-Dimensional Features 320
24.8 Conclusions 320
References 321
25 Enhancement in Machining Efficiency and Accuracy of ECDM Process Using Hollow Tool Electrode 322
25.1 Introduction 322
25.2 Material and Method 324
25.2.1 Experimental Setup 324
25.2.2 Mechanism of Material Removal Using Solid and Hollow Tool Electrode 326
25.2.3 Experimental Procedure 326
25.3 Results and Discussion 328
25.4 Conclusions 331
References 331
26 Evaluation of Cutting Force and Surface Roughness of Inconel 718 Using a Hybrid Ultrasonic Vibration-Assisted Turning and Minimum Quantity Lubrication (MQL) 333
26.1 Introduction 333
26.2 Materials and Methods 336
26.3 Results and Discussion 337
26.3.1 Cutting Forces 337
26.3.2 Average Surface Roughness 339
26.4 Conclusions 340
References 340
27 On Performance Evaluation of Helical Grooved Tool During Rotary Tool Micro-ultrasonic Machining 342
27.1 Introduction 342
27.2 Materials and Methods 344
27.3 Discussion of Experimental Results 347
27.3.1 Process Parameters Effect on WOC and Edge Chipping 347
27.4 Conclusions 350
References 351
28 Experimental Investigation on Surface Topography of the Natural Ceramics in Abrasive Water Jet Cutting and Its Optimization Validation by Formulated Model 353
28.1 Introduction 354
28.2 Materials and Methods 355
28.3 Results and Discussion 358
28.3.1 Model Fitting and Statistical Analysis 358
28.3.2 Mathematical Model Formulation 364
28.4 Conclusions 365
References 366
29 Prediction and Comparison of Vision Parameter of Surface Roughness in WEDM of Al-6%Si3N4 and Al-10%Si3N4 Using ANN 367
29.1 Introduction 368
29.2 Experimental Work 369
29.2.1 Surface Roughness Measurement 370
29.3 Introduction to Artificial Neural Network (ANN) 371
29.4 Results and Discussion 373
29.5 Conclusion 374
References 377
30 Performance Study of Electrical Discharge Drilling of Metal Matrix Composite 378
30.1 Introduction 378
30.2 Experimental Procedure 379
30.2.1 Fabrication of MMC 379
30.2.2 Experimental Setup for EDD 380
30.2.3 Selection of Tool Electrode 381
30.3 Experimental Conditions 382
30.3.1 Evaluation of Response Variables 382
30.4 Results and Discussion 383
30.4.1 Effect of Discharge Current 383
30.4.2 Effect of Pulse Duration 384
30.4.3 Effect of Pulse Interval 385
30.4.4 Effect of Tool Rotation 385
30.4.5 Effect of Flushing Pressure 386
30.5 Conclusions 386
References 388
31 Multi-objective Optimisation of Electro Jet Drilling Process Parameters for Machining of Crater in High-Speed Steel Using Grey Relational Analysis 389
31.1 Introduction 389
31.2 Problem Definition 390
31.3 Experimental Details 391
31.4 Result and Discussion 392
31.4.1 Effect of Process Parameters on Mass Removal Rate 392
31.4.2 Effect of Process Parameters on Roundness Error of Top of the Crater 394
31.4.3 Effect of Process Parameters on Mean Diameter-to-Height Ratio of the Crater 395
31.4.4 Optimization of Process Parameters Using Grey Relational Analysis 396
31.5 Conclusions 398
References 399
32 Machining of Bio-Implant Materials Using WEDM and Optimization of Process Parameters 400
32.1 Introduction 400
32.2 Literature Review and Objective 401
32.2.1 Objectives 401
32.3 Work Materials 402
32.3.1 Mg AZ31b 402
32.3.2 SS 316L 402
32.4 Experimental Work 402
32.4.1 Design of Experiments 403
32.4.2 Experimental Methodology 403
32.5 Antlion Optimization (ALO) 405
32.5.1 ALO Algorithm 407
32.5.2 Random Walks of Ants 408
32.5.3 Trapping Antlion Pits 408
32.5.4 Proposed Algorithm 408
32.5.5 Proposed Path 409
32.6 Results and Discussions 409
32.6.1 Material Removal Rate 409
32.6.2 Surface Roughness 410
32.6.3 Kerf 411
32.7 Regression Analysis 412
32.8 Conclusions 413
References 414
33 Experimental Investigations of Abrasive Waterjet Machining Parameters on Titanium Alloy Ti-6Al-4V Using RSM and Evolutionary Computational Techniques 415
33.1 Introduction 415
33.2 Experimental Setup and Material 417
33.3 Response Surface Methodology (RSM) 419
33.3.1 Analysis of Surface Roughness 419
33.3.2 Analysis of Kerf Taper Angle 419
33.3.3 Single Objective Optimization Using RSM 421
33.4 Evolutionary Optimization Techniques 422
33.4.1 Particle Swarm Optimization (PSO) 423
33.4.2 Cuckoo Search Algorithm (CSA) 423
33.4.3 Simulated Annealing (SA) 424
33.5 Conclusions 426
References 427
34 Design of Fixture for Trimming of a Composite Material Shim by Abrasive Water Jet Machining 428
34.1 Introduction 428
34.2 Fixture Design Requirements 430
34.3 Design of Composite Shim Cutting Fixture 430
34.4 Design Analysis 435
34.5 Results 436
34.6 Conclusions 436
References 437
35 Fabrication and Characterization of Helical Grooved Cylindrical Electrodes Generated by WED Turning Process 438
35.1 Introduction 438
35.2 Material Removal Mechanism in WEDT 440
35.3 Machining of Electrodes 441
35.4 Results and Discussions 442
35.4.1 Evaluation of Helical Geometry Machined on the Electrode 443
35.4.2 The Surface Roughness of the Helical Grooves 446
35.5 Conclusions 447
References 450
36 A Study of Wire Electrical Discharge Machining of Carbon Fibre Reinforced Plastic 451
36.1 Introduction 451
36.2 Materials and Methods 452
36.2.1 Fabrication of CFRP Laminate 452
36.2.2 Experimental Work 453
36.3 Results and Discussion 454
36.3.1 Mechanisms of Material Removal 454
36.3.2 Effect of Input Factors on Machining Time 457
36.4 Conclusions 458
References 459
37 Development of a Bore Using Jet Electrochemical Machining (JECM) in SS316 Alloy 461
37.1 Introduction 462
37.2 Experimental Procedure 462
37.2.1 Experimental Setup 462
37.2.2 Selection of Tool, Workpiece, and Electrolyte 463
37.2.3 Design of Experiments 463
37.3 Results and Discussion 464
37.3.1 Without Flushing Experiment 464
37.3.2 Flushing Experiment 466
37.4 Comparison of with and Without Flushing Experiment 466
37.4.1 Effect of Flushing on MRR 466
37.4.2 Effect of Flushing on Circularity 468
37.4.3 Effect of Flushing Experiment in Conicity 469
37.5 Conclusions 471
References 471
38 Machining and Characterization of Channels on Quartz Glass using Hybrid Non-conventional Machining Process µ-ECDM 472
38.1 Introduction 473
38.2 Experimentation 475
38.3 Results and Discussion 476
38.4 Conclusion 478
References 479
39 Parametric Study of a Newly Developed Magnetorheological Honing Process 481
39.1 Introduction 481
39.2 MR Honing Process Variables 482
39.3 Design of Experiments 483
39.4 Response Surface Regression Analysis 484
39.5 Results and Discussion 485
39.5.1 Effect of Mesh Sizes of SiC Abrasive Particles 485
39.5.2 Effect of Mesh Sizes of CIPs 485
39.5.3 Effect of Magnetizing Currents 486
39.5.4 Effect of Tool Rotational Speeds 486
39.5.5 Effect of Tool Linear Speeds 487
39.6 Confirmatory Experiments for Validating Results 487
39.7 Optimization of Process Parameters 488
39.8 Conclusions 488
References 489
40 Investigation on Surface Roughness During Finishing of Al-6061 Hybrid Composites Tube with Traces of Rare Earth Metals Using Magnetic Abrasive Flow Machining 490
40.1 Introduction 491
40.2 Experimental Details 492
40.2.1 Material Selection 492
40.2.2 Stir Casting 492
40.3 Finishing Mechanism of Magnetic Abrasive Finishing Process 493
40.4 Results and Discussions 494
40.4.1 Results from Optical Micrograph 496
40.5 Conclusions 497
References 498
41 Part Program-Based Process Control of Ball-End Magnetorheological Finishing 499
41.1 Introduction 499
41.2 i5-B CNC BEMRF Machine Tool 500
41.2.1 The Surface Finishing Cycle 500
41.2.2 Work Piece Cleaning Cycle 501
41.2.3 Roughness Measurement Cycle 501
41.3 Manual Controls of the Developed System 501
41.4 CNC Part Program Control of Each Cycle 502
41.4.1 Part Program Codes for Finishing Cycle 502
41.4.2 Part Program Codes for Work Piece Cleaning Cycle 503
41.4.3 Part Program Codes for Roughness Measurement Cycle 505
41.4.4 Integrated CNC Part Program for All Three Cycles 506
41.5 Testing and Results 507
41.6 Conclusions 509
References 509
42 Modelling and Analysis of Change in Shape of sintered Cu–TiC tool tip during Electrical Discharge Machining  process 511
42.1 Introduction 512
42.2 Experimental Procedure 513
42.3 Dimensional Analysis for Electrode Shape Using Buckingham’s ?-Theorem 514
42.3.1 Buckingham’s ?-Theorem 514
42.3.2 Modelling for Electrode Shape Using Buckingham’s ?-Theorem 514
42.3.3 Dimensionless Products 517
42.4 Results 517
42.5 Conclusions 521
References 521
43 Experimental Investigations on C-263 Alloy by Electrochemical Milling 522
43.1 Introduction 522
43.1.1 Scheme of EC Milling 523
43.2 Experimental Details 524
43.2.1 Experimental Setup 524
43.2.2 Scheme of Experiments 525
43.2.3 Evaluation of Response Variables 526
43.3 Experimental Investigations 526
43.3.1 Influence of Tool Feed Rate and Milling Layer Depth with Tool Rotation on Width Overcut 526
43.3.2 Influence of Feed Rate and Milling Layer Depth with Tool Rotation on Surface Roughness 527
43.3.3 Influence of Tool Rotation on Quality of the Machined Surface 528
43.4 Conclusions 530
References 530
44 Influence of Discharge Energy on Electrical Discharge Machining of Ti-Foam Material 531
44.1 Introduction 531
44.2 Experimentation 533
44.3 Results and Discussion 534
44.3.1 Effect of Process Parameters on Discharge Energy 534
44.3.2 Effect of Discharge Energy on Hole Dimension 538
44.4 Conclusions 540
References 540
45 Gang Drilling of Square Micro-Holes on Glass Using USM 542
45.1 Introduction 542
45.2 Methodology and Experimentation 544
45.3 Results and Discussion 546
45.4 Conclusions 549
References 549
46 Parametric Optimization of Micro Ultrasonic Drilling of Quartz Based on RSM 551
46.1 Introduction 551
46.2 Fundamentals of Micro USM 552
46.3 Experimental Planning and Methods 553
46.3.1 Empirical Model 554
46.4 Parametric Analysis Found on Response Surface Plots 555
46.4.1 Parametric Effects on Material Removal Rate (MRR) 556
46.4.2 Parametric Effects on Overcut of Micro Hole 557
46.4.3 Parametric Effects on Taper Angle of Micro Hole 558
46.5 Multi Objective Optimization of Micro Ultrasonic Machining of Quartz 559
46.6 Conclusions 560
References 561
47 Investigations into the Effect of Varying Electrode Diameter on Cutting Rate and Kerf Width in WEDM of Varying Thickness Inconel718 562
47.1 Introduction 562
47.2 Materials and Methods 565
47.3 Results and Discussions 566
47.4 Conclusions 572
47.5 Future Scope 572
References 573
48 Comparative Evaluation of Drilling on GFRP Made by Different Fabrication Techniques 574
48.1 Introduction 574
48.2 Materials and Methods 575
48.2.1 Manual Layup Process 576
48.2.2 Compression Molding 576
48.2.3 Vertical Machining Center 577
48.2.4 Delamination Factor 579
48.2.5 Design of Experiment 579
48.2.6 Manual Layup Method 583
48.2.7 Compression Molding Method 583
48.3 Results and Discussion 584
48.3.1 SEM Images 585
48.4 Conclusions 587
References 588
49 An Experimental Analysis of Square Stepped Hole Fabrication on Zirconia Bio-Ceramics 589
49.1 Introduction 589
49.2 Details of Experimental Setup of USM 590
49.3 Experimentation 591
49.3.1 Basic Influences of USM Process Parameters on Responses of Square-Shaped Stepped Hole Production on Zirconia 593
49.3.2 Influences of USM Process Parameters on MRR 593
49.3.3 Influences of USM Process Parameters on Circularity Error 598
49.4 Conclusions 600
References 600
50 Pulse and Work Revolution Parameters of Wire Electrical Discharge Turning on Ti-6Al-4V Alloy 601
50.1 Introduction 601
50.2 Materials and Methods 602
50.3 Experimental Results and Discussion 604
50.3.1 Effect of Process Parameters on MRR 604
50.3.2 Effect of Process Parameters on Ra 604
50.3.3 3D Surface Analysis Plots for MRR 604
50.3.4 3D Surface Analysis Plots for Ra 607
50.3.5 Regression Analysis of MRR and Ra 608
50.4 Conclusion 609
References 610
51 Modeling of Areal Surface Roughness Using Soft-Computing-Based ANN and GA to Estimate Optimal Process Parameters During Wire Electrical Discharge Turning of Inconel 825 611
51.1 Introduction 611
51.2 Experimental Details 613
51.2.1 Experimental Setup 613
51.2.2 Design of Experiments 613
51.2.3 ANN Modeling 616
51.3 Results and Discussion 616
51.4 GA Optimization Solution 617
51.5 Conclusions 618
References 619
52 Investigation on the Influence of Process Parameters on Surface Roughness and Kerf Properties in Abrasive Water Jet Machining of Carbon Fibre Vinyl Ester Composite 620
52.1 Introduction 620
52.2 Experimental Setup 621
52.3 Experimental Design 622
52.4 Results and Discussion 623
52.5 Conclusion 626
References 628
53 Fluidized Bed Hot Abrasive Jet Machining (FB-HAJM) of K-60 Alumina Ceramic 629
53.1 Introduction 629
53.2 Experimental Setup and Procedure 631
53.3 Results and Discussion 632
53.3.1 Design of Experiment (DOE) 632
53.3.2 Regression Analysis 632
53.3.3 Analysis of Surface Plots 635
53.4 Conclusions 637
References 637
54 Performance Evaluation of Abrasive Water Jet Machining on AA6061-B4C-HBN Hybrid Composites Using Taguchi Methodology 639
54.1 Introduction 639
54.2 Materials and Methods 641
54.2.1 Materials 641
54.2.2 Experimental Setup 641
54.2.3 Measurement of Kerf Taper Angle and Roughness 642
54.2.4 Taguchi Methodology 642
54.3 Results and Discussion 643
54.3.1 Experimental Results and Data Analysis 643
54.3.2 Analysis of Variance (ANOVA) 643
54.4 Conclusions 647
References 647
55 Empirical Modelling and Optimisation of Bio-Micromachining on Antimicrobial Copper to Fabricate Micromixing System 649
55.1 Introduction 650
55.2 Experimental Details 650
55.2.1 Culturing of Microorganism 650
55.2.2 Sample Preparation 651
55.3 Experimental Plan 652
55.4 Result and Discussion 653
55.4.1 Material Removal 653
55.5 Conclusion 657
References 658
56 Investigation on Magnetic Field-assisted Near-dry Electrical Discharge Machining of Inconel 600 659
56.1 Introduction 659
56.2 Experimental Details 661
56.3 Results and Discussion 663
56.3.1 Effect of Process Parameters on Material Removal Rate 663
56.3.2 Effect of Process Parameters on Surface Roughness 665
56.3.3 Effect of Process Parameters on Surface Morphology 667
56.3.4 Tool Wear Rate 669
56.4 Conclusion 671
References 671
Composites 673
57 Selection of Aluminum Hybrid Metal Matrix Composite Material Using Additive Ratio Assessment Approach and Comparing with the Experimental Results Varying Different Weight Percentage of the Reinforcements 674
57.1 Introduction 675
57.2 Additive Ratio Assessment Method 676
57.3 Experimental Setup 677
57.3.1 Material Library 677
57.3.2 Composite Development 678
57.3.3 Porosity Analysis 679
57.3.4 Corrosion Test 679
57.4 Results and Discussion 679
57.4.1 Evaluation of Mechanical Properties 679
57.4.2 Porosity Analysis and Corrosion Rate 681
57.5 Conclusion 681
References 682
58 The Role of HBN Solid Lubricant Reducing Cutting Forces of Dry Machined Al-B4C Composite 683
58.1 Introduction 684
58.2 Experimental Procedure 685
58.2.1 Composite Fabrication 685
58.2.2 Machining 685
58.3 Results and Discussion 686
58.3.1 Microstructure of Composite 686
58.3.2 Effect of Cutting Force to Cutting Speed in Minimum and Maximum Feed and Depth of Cut 686
58.3.3 Effect of Cutting Force to Feed Rate in Minimum and Maximum Speed and Depth of Cut 687
58.3.4 Effect of Cutting Force to Depth of Cut in Minimum and Maximum Cutting Speed and Feed 688
58.3.5 Flank Wear Analysis 689
58.4 Conclusions 689
References 690
59 Experimental Investigation on Influence of Process Parameters of Abrasive Water Jet Machining on Kerf Taper of Glass Fiber-Reinforced Polymer Composites 692
59.1 Introduction 692
59.2 Experimental Work 694
59.3 Results and Discussion 697
59.4 Conclusions 698
References 699
60 WEDM Studies on TiB2-15% SiC Ceramic Composite Processed Through SPS Process 700
60.1 Introduction 700
60.2 Experimental Details 702
60.2.1 Synthesis of Composite 702
60.2.2 Wire EDM Study 702
60.3 Results and Discussions 705
60.3.1 Microstructure Analysis 705
60.3.2 Effect of Input Variables on MRR 706
60.3.3 Effects of Input Variables on Kerf 707
60.4 Conclusions 707
References 708
61 Study of Mechanical Properties and Thermal Conductivity of Carbon and Basalt Fibre-Reinforced Hybrid Polymer Composites 709
61.1 Introduction 710
61.2 Preparation of Carbon–Basalt Hybrid Composites 712
61.2.1 Vacuum Bagging Process 712
61.3 Experimentation 714
61.3.1 Tensile Test 714
61.3.2 Hardness Test 714
61.3.3 Thermal Conductivity Test 716
61.4 Results and Discussion 716
61.4.1 SEM Analysis of Fractured Specimen of Tensile Test 719
61.5 Conclusions 719
References 721
62 Design and Fabrication of Aluminium/Alumina Ultra-fine Composite and Functionally Graded Material Using Powder Metallurgy Route 723
62.1 Introduction 724
62.2 Methodology 726
62.2.1 Raw Material 726
62.2.2 Mechanical Milling 726
62.3 Experimental Method 726
62.3.1 Testing 728
62.4 Results and Discussion 728
62.5 Conclusions 729
References 730
63 Mechanical and Crystallization Behaviour of Sisal Fiber and Talc Reinforced Polylactic Acid Composites 732
63.1 Introduction 732
63.2 Experimental Work 733
63.2.1 Materials 733
63.2.2 Fabrication of Composites 734
63.2.3 Tensile Test 734
63.2.4 Impact Test 734
63.2.5 Water Absorption Test 735
63.2.6 Differential Scanning Calorimetry 735
63.3 Results and Discussions 736
63.3.1 Tensile Properties of Composites 736
63.3.2 Impact Strength of Composites 736
63.3.3 Water Absorption Behaviour of Composites 737
63.3.4 Crystallization Behaviour of Composites 737
63.4 Conclusions 738
References 739
64 Assessment on Hole Quality During Drilling of Al/CFRP Stack 740
64.1 Introduction 740
64.2 Experimental Procedure 742
64.2.1 Machine, Workpiece, and Cutting Tool Details 742
64.2.2 Parameters for Performance Evaluation 743
64.3 Result and Discussions 746
64.3.1 Delamination 746
64.3.2 Circularity 747
64.3.3 Surface Roughness 749
64.4 Conclusion 752
References 752
65 Experimental and Analytical Outcomes of Carbon Fiber Orientation in Epoxy Resin Composite Laminate Under Tensile Loading 754
65.1 Introduction 754
65.2 Fabrication of Laminate Composite and Specimen Preparation 755
65.3 Experiments and Modeling 758
65.3.1 Experimental Outcomes from Tensile Loading Experiments 759
65.3.2 Analytical Observations from Finite Element (FE) Model Using ANSYS—Academic Version 761
65.4 Results and Discussion 765
References 766

Produkt-Details

• Erscheint lt. Verlag: 22.11.2019
• Reihe/Serie: Lecture Notes on Multidisciplinary Industrial Engineering
• Reihe/Serie: Lecture Notes on Multidisciplinary Industrial Engineering
• Zusatzinfo: XXI, 783 p. 515 illus., 424 illus. in color.
• Sprache: englisch
• Themenwelt: Technik ► Maschinenbau
• Schlagworte: Advanced Machining Technology • Composites • material processing • Micro and Nano Manufacturing • Modeling • Optimization • Product Design & Development • Surface Engineering • sustainable manufacturing • Unconventional Machining
• ISBN-10: 981-329-471-X / 981329471X
• ISBN-13: 978-981-329-471-4 / 9789813294714