Material Removal Rate

Metal-bonded diamond wheels, due to its strong grain retention and thermal conductivity properties, are generally used for grinding difficult-to-cut materials, such as high-performance ceramics. On the other hand, the poor dressability of this type of bond limits its application. This study aims to evaluate the use of a wire electrical discharge machining (EDM) principle for truing and dressing metal-bonded grinding wheels. Through the EDM process, the electrically conductive grinding bond is eroded, so that grain protrusion can be generated. For evaluating this dressing process, a wire electrical discharge dressing unit was designed, manufactured, and integrated into a universal cylindrical grinding machine. The dressing process is carried out using the grinding oil also as dielectric fluid. High material removal rates were achieved. Cylindrical plunge grinding tests on silicon nitride workpieces indicated that in comparison to conventionally dressed wheels, smaller cutting forces and wheel wear are achieved by using EDM-dressed grinding wheels.

Nanopowder mixed Electrical discharge machining (NPMEDM) is a non-conventional machining process used to manufacture intricate profiles, complex cavities in dies and molds, machining of advanced materials that are extremely difficult to machine by conventional machining processes. In recent years, researches have emphasized on machining of workpiece material after the addition of nano particles into the dielectric fluid of EDM. This technology is termed as NPMEDM. This article presents a review of ongoing research and development in NPMEDM. The critical analysis of the use of powders for micro and nano machining is also presented. The last part of the article discusses the future research directions.

Machinability aspect is of considerable importance for efficient process planning in manufacturing. Machinability of an engineering material may be evaluated in terms of the process output variables like material removal rate, processed surface finish, cutting forces, tool life, specific power consumption, etc. In this paper, graph theoretic approach (GTA) is proposed to evaluate the machinability of tungsten carbide composite. Material removal rate is considered as a machinability attribute of tungsten carbide to evaluate the effect of several factors and their subfactors. Factors affecting the machinability and their interactions are analyzed by developing a mathematical model using digraph and matrix method. Permanent function or machinability index is obtained from the matrix model developed from the digraphs. This index value helps in quantifying the influence of considered factors on machinability. In the present illustration, factors affecting machinability of tungsten carbide are grouped into five broad factors namely work material, machine tool, tool electrode, cutting conditions, and geometry to be machined. GTA methodology reveals that the machine tool has highest index value. Therefore, it is the most influencing factor affecting machinability.

It is well known that the chemical reaction between an oxide layer and a water-based slurry produces a softer hydroxylated interface layer. During chemical-mechanical polishing (CMP), it is assumed that material removal occurs by the plastic deformation of this interface layer. In this paper, the behavior of the hydroxylated layer is modeled as a perfectly plastic, material, and a mechanistic model for material removal rate (MRR) in CMP is developed. The deformation profile of the soft pad is approximated as the bending of a thin elastic beam. In addition to the dependence of MRR on pressure and relative velocity, the proposed plasticity-based model is also capable of delineating the effects of pad and slurry properties. The plasticity-based model is utilized to explore the effects of various design parameters (e.g., abrasive shape, size and concentration, and pad stiffness) on the MRR. Model predictions are compared with existing experimental observations from glass polishing, lapping, and CMP

In this paper wire cut electro discharge process parameters are optimized by using Taguchi method. Process parameters considered for the study are pulse on time, pulse off time and current. High Carbon high Chromium (HCHCr-D3) steel is high tensile strength alloy which is mostly used in cold dies and tooling application that where high degree and dimensional accuracy is required. HCHCr-D3 alloy steel plate of rectangular shape has been used for machining operation. Performance of wire cut electro discharge machine (WEDM) with a molybdenum wire has been measured by material removal rate (MMR) and surface roughness (SR). In Taguchi method L9 orthogonal array has been selected. The analysis of variance (ANOVA) has been used to determine effect of each parameter on material removal rate (MRR) and surface roughness (SR).

To optimize cylindrical grinding operation using four process parameters as Job Speed, Feed Depth of Cut (DOC) and Grinding Wheel. The two main objectives for optimization are Material Removal Rate (MRR) and Surface Roughness. The experiments are designed using Taguchi method, along with Principal Component Analysis (PCA) to formulate the results. The grinding operations are conducted on Stainless Steel (SS410) Shaft. Thus, the process parameters are experimentally investigated in order to minimize Surface Roughness (RA) and maximize Material Removal Rate (MRR) simultaneously.

In this project work machining of the EN-36 Alloy Steel (with hardening and without hardening) with the help of coated carbide tool is perform on CNC Turing machine. Material Removal Rate (MRR), the experiment is carried out as per Box Behnken Design under Response Surface Methodology (RSM). Analysis of the Material removal rate is done The experimental study of material removal rate which is perform on CNC machine of EN-36(with hardening and without hardening) material using coated carbide cutting tool by various cutting parameters like feed, cutting speed and depth of cut and determine optimum cutting parameters of material removal rate. The help Minitab 16 software and ANOVA (Analysis of Variance), the most effective parameter selected from the input to obtain the optimal combination for Material removal rate

Laser drilling is increasingly becoming the method of choice for precision drilling for variety of components. However, a number of defects such as spatter, recast, heat-affected zone (HAZ), and taper limit the application. Elimination of these defects is the subject of intense research. This paper presents a grey relational optimization approach for the determination of the optimum process parameters which minimize the HAZ and hole circularity and maximize material removal rate in a Pulsed Nd:YAG laser micro-drilling in high carbon steel within existing resources. The input process parameters considered are pulse width, number of pulses, assist gas (oxygen) flow rate, and its supply pressure. A higher resolution-based L25 orthogonal array has been used for conducting the experiments. The designed experimental results are used in grey relational analysis and the weights of the quality characteristics are determined optimizing the parameters. On the basis of optimization results, it has been found that the optimal parameter level gives a small HAZ, fine hole, and maximum material removal rate. Subsequently, the results are also verified and found appropriate by running confirmation tests.

In present's days MQL in green environments turning of steels is highly interested for scientific research and manufacturing sectors. GMQL offers number of advantages over dry, wet with pollutant environments like higher material removal rate, high surface finish, greater part geometry flexibility, no need of used cutting fluid hence reducing the Environmental investigation to study the effect of machining parameters on Material Removal rate in GMQL turning of medium carbon steel EN19. Taguchi's single objective optimization method was used to find the effect of input parameters on the responses were prepared by using MINITAB-16 software. Analysis of variance (ANOVA) was used to find the influence of machining parameters on the responses .From the ANOVA results, it is clear that spindle speed has influence followed by feed and depth of cut has very low influence in achieving the optimum values for Material Removal Rate.

— Electro discharge machining (EDM) is nontraditional machining process which is used to remove the material by thermal energy of the spark. All electrically conductive materials can be machined. EDM is a capable of machining hard material components or geometrically complex. As there is no direct contact between tool and work piece, no physical cutting forces are present between tool and workpiece. In recent years to enhance process capabilities, powder mixed electric discharge machining (PMEDM) is used as new technique. In PMEDM dielectric fluid is mixed with additive powder. For Experimentation parameters selected are peak current, pulse on time, duty cycle and different dielectric media. Material removal rate, tool wear rate and surface roughness are taken as the output parameter.

Present manufacturing industries are facing challenges for advanced material like super alloy, ceramics and composite, that have more hardness and difficult to machine using conventional machining. The literature review has been carried out on studying the material removal rate (MRR) and surface roughness (SR) behaviour in particular rotary EDM. Most publications on the EDM process are directed in non-rotational tools. But rotation of tool gives better MRR and provides a good flushing in the machining zone. The present work would be carried out on an Electronica EDM. The rotary mechanism was developed and attached on EDM. The experiment are carried out under various combinations of current, pulse on time, gap voltage and tool rotational speed. Inconel 600 have wide application in aerospace, nuclear engineering, gas turbine components. Due to its high hardness, EDM with tool rotation is used in current study. The analysis is carried out with Inconel 600 as a workpiece material with negative polarity, ETP grade copper tool with positive polarity and kerosene as a dielectric fluid. Response surface method was used for experimentation. It was seen from the results and main effects plots that with increase in rotational speed MRR also increases. for the values of MRR, the maximum and minimum error for regression model was 4.54% & 0.73%, respectively.

In this work, the influence of lightning-strike-induced electric current and surface heat flux on the thermal response and thermal ablation of a carbon fiber polymer matrix composite laminated panel is studied. A coupled electric-thermal model for an anisotropic plate exposed to the lightning-strike-induced electric current and surface heat flux is formulated.  Temperature-dependent material properties of the carbon fiber polymer matrix composites, including electrical conductivity, thermal conductivity, and specific heat, are used. A coupled electric-thermal finite element analysis (FEA) is conducted using a MATLAB-ABAQUS integrated numerical procedure, which enables progressive element deletion to accurately model the lightning-strike-induced continuous surface recession (thermal ablation) in the composite panel. The obtained thermal response and thermal ablation using the proposed numerical procedure are compared with those obtained using existing solution procedures without progressive element deletion.

Drilling is an important process for making and assembling components made from Glass Fiber Reinforced Plastic (GFRP). Various processes like conventional drilling, vibration assisted drilling and ultrasonic assisted drilling have been attempted in order to maintain the integrity of the material and obtain the necessary accuracy in drilling of GFRP. In conventional machining feed rate, tool material and cutting speed are the most influential factor in the machining of GFRP. This paper attempts to show effect of material thickness and ultrasonic machine parameters like amplitude and pressure on material removal rate while ultrasonic machining of glass fiber reinforced plastic.