Material Removal Rate

Since machine tools are used extensively throughout their functional life and consequently consuming valuable natural resources and emitting harmful pollutants during this time, this study reviews strategies for characterizing and reducing the energy consumption of milling machine tools during their use. The power demanded by a micromachining center while cutting low carbon steel under varied material removal rates was measured to model the specific energy of the machine tool. Thereafter the power demanded was studied for cutting aluminum and polycarbonate work pieces for the purpose of comparing the difference in cutting power demand relative to that of steel.

Material with unique metallurgical properties such as Titanium, Haynes-25, Molybdenum, Columbium C-103, hardened steels, and other superalloys was developed to meet the demands of extreme applications in aerospace, automobile, and nuclear reactor industries. Machining these materials using a conventional machining process is a challenging task. Electrical discharge machining (EDM) is one of the most suitable non-conventional processes to achieve precise quality components with optimum tooling cost. EDM process becomes a natural choice for machining of superalloys; its low machining removal rate and poor surface quality have been the key problems restricting its development. To overcome these drawbacks, the nanopowder suspended dielectric oil is used, which increases its conductive strength and increases the discharge gap between the tool and workpiece. This newly developed material removal process is called Powder Mixed Electrical Discharge Machining (PMEDM). This paper presents the review work done to improve the performance characteristics of machining like MRR, TWR, EWR, SR, Microhardness, and SCD for different Machining parameters. This paper also reviewed the industrial and academic work performed by various researchers from the origin to the development of PMEDM over the past decades. The research findings with major challenges along with the future scope have also been paved out.

By means of the improvement and growths in new machineries, low weight- high strength, high hardness and temperature resistant materials have been advanced for distinctive applications which include aerospace, medical, automobile and more. In the machining of hard and metal matrix composite materials, outdated manufacturing processes are being more and more changed by more non-traditional machining processes which include Electrical Discharge Machining (EDM). The work piece material designated in this experiment is Inconel 925 taking into interpretation its wide usage in industrial applications. In today’s world stainless steel provides to nearly half of the world’s production and consumption for industrial determinations. In this experiment the input variable factors are voltage, current and pulse on time. As we know that Taguchi method is functional to produce an L9 orthogonal array of input variables by means of the Design of Experiments (DOE). So, Taguchi method is used to analysis the output data. The consequence of the compliant parameters stated overhead upon machining characteristics such as Material Removal Rate (MRR) and Tool Wear Rate (TWR) is considered and examined. In this we are focused on to analysis minimum TWR and maximum MRR based on control factors and response parameters.

Purpose: The purpose of this paper is to study and analyse the possible impact of International Financial Reporting Standards on the level of earnings management. The paper includes a review of all such studies from around the world. Design/Methodology: Existing studies available on the topic are systematically reviewed. Different journals, periodicals and websites were used to gather the information. Time period considered for the study is from 2005 to 2019. Although most of the papers relate to foreign countries as not much research is available in the Indian context. Overall, 60 papers were considered, but out of them only 40 were found to be suitable for the present study. The review has been segregated into 3 parts. 30% of the paper focus on the meaning and determinants of earnings management, 20% of the studies relate to IFRS adoption around the world. Remaining research tries to analyse the connection between adoption of international standards and level of earnings management. Findings: The adoption of IFRS standards has no significant impact on the level of earnings management of any country. In fact, the level has increased in some countries after the compulsory adoption. However, if certain other factors are taken into account along with IFRS like audit quality, corporate governance practices, board management, R&D disclosure, enforcement mechanism, investor protection regime etc., the combined effect have yielded different results for different countries. Research Limitations and Implications: The study focuses only on one major area related to IFRS i.e., its impact on earnings management of a firm. Although there are many other determinants of earnings management and also IFRS had its impact on various other areas. But due to certain research limitations those are not considered Purpose: The purpose of this paper is to study and analyse the possible impact of International Financial Reporting Standards on the level of earnings management. The paper includes a review of all such studies from around the world. Design/Methodology: Existing studies available on the topic are systematically reviewed. Different journals, periodicals and websites were used to gather the information. Time period considered for the study is from 2005 to 2019. Although most of the papers relate to foreign countries as not much research is available in the Indian context. Overall, 60 papers were considered, but out of them only 40 were found to be suitable for the present study. The review has been segregated into 3 parts. 30% of the paper focus on the meaning and determinants of earnings management, 20% of the studies relate to IFRS adoption around the world. Remaining research tries to analyse the connection between adoption of international standards and level of earnings management. Findings: The adoption of IFRS standards has no significant impact on the level of earnings management of any country. In fact, the level has increased in some countries after the compulsory adoption. However, if certain other factors are taken into account along with IFRS like audit quality, corporate governance practices, board management, R&D disclosure, enforcement mechanism, investor protection regime etc., the combined effect have yielded different results for different countries. Research Limitations and Implications: The study focuses only on one major area related to IFRS i.e., its impact on earnings management of a firm. Although there are many other determinants of earnings management and also IFRS had its impact on various other areas. But due to certain research limitations those are not considered

This Experimental study mainly focus on the Optimization of the cutting parameters on MRR of EN 41 alloy steel with carbide tool. The input parameters like cutting speed, Depth of Cut (DOC), feed rate and coolant flow rate are influencing in Material Removal Rate (MRR) using Taguchi method. The contribution and significant parameter are determined by using the Taguchi Design of Experiments (DOE) method. A number of turning experiments were conducted using the L9 orthogonal array on a CNC machine. In this paper analysis is based on Taguchi method of optimization and experimental design and further analysis is carried out with the help of statistical software MINITAB-17.

By means of the improvement and growths in new mechanisms, low weight-high strength, high hardness and temperature resistant materials have been advanced for distinctive applications which include aerospace, medical, automobile and more. In the machining of hard and metal matrix composite materials, outdated manufacturing processes are being more and more changed by more non-traditional machining processes which include Electrical Discharge Machining (EDM). The work piece material designated in this experiment is Inconel 925 taking into interpretation its wide usage in industrial applications. In today's world stainless steel provides to nearly half of the world's production and consumption for industrial determinations. In this experiment the input variable factors are voltage, current and pulse on time. As we know that Taguchi method is functional to produce an L9 orthogonal array of input variables by means of the Design of Experiments (DOE). So, Taguchi method is used to analysis the output data. The consequence of the compliant parameters stated overhead upon machining characteristics such as Material Removal Rate (MRR) and Tool Wear Rate (TWR) is considered and examined. In this we are focused on to analysis minimum TWR and maximum MRR based on control factors and response parameters.

Carbon footprint is defined as the total sets of greenhouse gases that are emitted by a product, organization, services or an organization. This is a recent area of development on the field of climate change and global warming, where a base line for carbon dioxide equivalent emissions are calculated that are useful in tracking the future emissions. The greenhouse gases are to be reduced to the maximum as it is a threat to the global mean temperature's increase and it destroys sustainability. In this study different star categories of hotels in a metropolitan city are taken as the fields of study, whose carbon footprint is calculated so that it will give an idea of what carbon emissions is happening actually in a metropolitan city due to these hotels. It is a comparative study which gives light on which type of hotels can be chosen for a long run so that the environmental sustainability is achieved and the emissions are to a minimum level. The area chosen for this study is Chennai, which has a various attraction for tourists and business people all over the year, and always there is a high demand for the hospitality sector to cater the needs of the customers. All the three scopes of Carbon emissions according to the greenhouse gas protocol has been taken into account for the calculation of emissions which are direct, indirect and other indirect emissions. Thus by arriving at a base line it will be useful to measure the further reductions on a yearly or monthly basis. Suitable energy conservation measures are also given accordingly to address the areas where energy can be conserved and best practices are also discussed so that energy optimization is possible.

It has been a challenge to finish optical glass surface due to their hard and brittle nature. Moreover tight tolerances of surface figure and finish make polishing a more critical operation. This work reports the results of an experimental study performed for full aperture polishing of BK7 optical glass. Flat samples of BK7 glass are polished using optical pitch polisher and cerium oxide slurry. Taguchi’s L9 orthogonal array is used for design of experiments. Abrasive concentration, pressure and overarm speed are taken as variable process parameters. Polishing is performed for duration of 120 minutes for each combination of parameters. Material removal is measured using the precision weighing balance. Surface roughness was measured using Form Talysurf PGI 120 profiler. Abrasive slurry concentration is observed to be one of the most significant parameters in optical polishing process. It affects material removal rate as well as surface roughness. Pressure applied at workpiece-polisher interface affects material removal rate but variation of pressure is not found to affect surface roughness significantly. Relative motion at workpiece-polisher interface is also observed to be significant in defining final polishing outputs.

Wire Electrical Discharge machining process is extensively used in mechanical industry to manufacture
geometrically complex, intricate shape and very hard material parts that are extremely difficult to machine by
conventional machining process. The objective of the present work is to investigate the effects of the various
WEDM process parameters like pulse on time (TON), pulse off time (TOFF), peak current (IP), Servo voltage (SV) on
material removal rate(MRR) and surface roughness (SR) of Monel K-500 by using Ultima-1F wire-cut EDM
machine.The experimentation has been done by using Taguchi’
s
L27 Orthogonal Array. Multi response optimization
method using grey relation analysis is proposed for optimization of parameters.
Keywords: WEDM, Material removal rate, Surface roughness, GRA.

One of the main goals of the metal-mechanical industries is the reduction of the production costs through the productivity increase. In the attempt to reach this goals, many researchers have been used the hot machining method. This method consists, basically, in the heating of the work piece hundreds of degrees Celsius above room temperature with aid of an external source of heat. Thus, the reduction of the shear stress of the material of the piece is gotten and, hence, is possible to obtain a smaller wear of cutting tool in relation to the conventional machining. This paper presents a review of hot machining, where the different techniques are presented together their results. This review paper presents a survey on variation in process parameter i.e. temperature, cutting speed, feed etc. and their effect on surface roughness, hardness, material removal rate, tool wear, tool life.

This paper deals with the effect of copper tool vibration with ultrasonic (US) frequency on the electrical discharge machining (EDM) characteristics of cemented tungsten carbide (WC-Co). It was found that ultrasonic vibration of the tool (USVT) was more effective in attaining a high material removal rate (MRR) when working under low discharge currents and low pulse times (finishing regimes). In general, the surface roughness and the tool wear ratio (TWR) were increased when ultrasonic vibration was employed. It was observed that application of ultrasonic vibration significantly reduced arcing and open circuit pulses, and the stability of the process had a remarkable improvement. This study showed that, there were optimum conditions for ultrasonic assisted machining of cemented tungsten carbide, although the conditions may vary by giving other input parameters for those which had been set constant in the present work.

In this investigation, the effect of wire electrical discharge machining (WEDM) parameters such as pulse-on time (T ON), pulse-off time (T OFF), gap voltage (V) and wire feed (F) on material removal rate (MRR) and surface roughness (R a) in metal matrix composites (MMCs) consisting of aluminium alloy (Al6063) and silicon carbide (SiCp) is discussed. The Al6063 is reinforced with SiCp in the form of particles with 5%, 10% and 15% volume fractions. The experiments are carried out as per design of experiments approach using L9 orthogonal array. The results were analysed using analysis of variance and response graphs. The results are also compared with the results obtained for unreinforced Al6063. From this study, it is found that different combinations of WEDM process parameters are required to achieve higher MRR and lower R a for Al6063 and composites. Generally, it is found that the increase in volume percentage of SiC resulted in decreased MRR and increased R a. Regression equations are developed based on the experimental data for the prediction of output parameters for Al6063 and composites. The results from this study will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine MMCs of Al6063 reinforced with SiCp at various proportions.

EDM is a non- conventional machining process in which the material is removed by erosive effect. Arc is established between the electrode and tool both should be electrical conductive. There is no direct contact between the two. It is useful for machining hard, difficult to machine materials such as heat resistant alloys, super alloys and carbides which can’t be easily machined with conventional once. Its unique feature of using thermal energy to machine electrically conductive parts regardless of its hardness. It is commonly used in mould, die making industry and in manufacturing of automotive, aero-space surgical components. However, EDM suffers few limitations such as low machining efficiency and poor surface finish. To overcome these limitations the electrically conductive powder particles are mixed in the dielectric fluid, which reduces its insulating strength and increases the spark gap distance between the tool and workpiece. This new hybrid material removal process is called Powder mixed EDM (PM-EDM). From the point of view of industrial applications, die steel is a very important material and that’s why for the purpose of experimentation D3 die steel with copper electrode and IPOL oil as dielectric has been used. PMEDM is very complex in nature and controlled by a large number of parameters, which are having impact on various responses. The present study is an attempt to investigate the potential of PMEDM for increasing material removal rate (MRR), decrease in tool wear rate (TWR) with improved surface roughness (SR) of Die steel. In previous research work Kerosene is used as dielectric fluid. Kerosene has adverse impact on the environment as well as health of the operator. So in this experimental method commercially available EDM oil will be used. The research outcome will identify the important parameters and their effect on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) in the presence of suspended powder in a IPOL oil as dielectric of EDM. Experiments is designed using Design of Experiment so that effect of all the parameters could be studied with minimum possible number of experiments. Results of the experimentation is analyze analytically as well as graphically using ANOVA and main effect-interaction plots, respectively. ANOVA has determined the percentage contribution of all factors upon each response individually.

Electrical discharge machining (EDM) process is one of the most commonly used nonconventional precise material removal processes. This paper presents the modeling of material removal rate and surface roughness of Electrical discharge machining process and their variation with circuit parameters. For carrying out the experiments, a numerically controlled electrical discharge machine was used. The paper also briefly describes the current techniques and trends in EDM and its applications in the field of aerospace.

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 this research paper, the different process parameters of wire cut electrical discharge machining process are studied. And work piece material for which parameters are to be optimized is H 13 Hot die tool steel material with a 0.25 mm coated wire by using Taguchi methodology. The selection of machining parameters in any machining process significantly affects surface finish, production rate and production cost of a finished one component. The experiment has been formulated with the help of Design of experiment and grey relational analysis. The Taguchi method is used to formulate the experimental layout, to analyse the effect of each parameter on the machining characteristics, and to predict the optimal choice for each WEDM parameter. Experimentation is planned as per Taguchi's L8 Orthogonal Array (OR).In this experiment optimize the input process parameters Pulse on time (T ON), Pulse off time (T OFF), peak current (IP), Wire feed rate (WF), Wire tension (WT), Servo voltage (SV) of a WEDM process for a response parameters Surface Roughness (SR), Material Removal Rate (MRR) and Kerf Width (KW) for a H 13 HOT DIE TOOL STEEL. The experimental results are to be analysed using analysis of variance (ANOVA) to find out significant contribution of machining parameters over response parameters and the optimal combinations of the parameters are to be determined.

The use of titanium alloys is increasing rapidly nowadays. Simultaneously the requirement for machining of titanium alloys is also increasing. The present research work deal with the optimization of process parameters such as spindle speed, feed rate, depth of cut, MRR and surface roughness value for titanium alloy by using Advanced cutting Tools. Hence the present study uses titanium Grade 12 as work piece material and CBN and carbide as tool material and focusses on the optimum value of material removal rate and surface roughness. In this paper, Taguchi Method has been used to identify the optimal combination of influential factors in the milling process. Milling experiment has been performed on titanium Grade 12 material, according to Taguchi orthogonal array (L9) for various combinations of controllable parameters viz. speed, feed and depth of cut. The surface roughness (Ra) is measured and recorded for each experimental run and analyzed using Taguchi S/N ratios and the optimum controllable parameter combination is identified.

NITINOL is a newly developed material. It possesses the properties as high fatigue strength, high malleability and high toughness. So machining of such materials is very difficult due to above properties .Thus there is necessary to study the machining methods which use appropriate feed , cutting speed and also considering the machining parameters. A non-conventional machining method Wire electrical discharge machining (WEDM) is used to cut hard to machine materials which are difficult to machine by traditional processes. WEDM is thermal machining process capable of accurately machining parts with difficult shapes and more hardness, which have sharp edges that are very difficult to be machined by the traditional machining processes. WEDM is worked on sparking phenomenon of EDM and used as non-contact type material removal process.

Heat Assisted Drilling Machine (HADM) is a new technique to drill hard, brittle and ceramic materials. This system is hybrid of conventional and non-conventional manufacturing processes, In which conventional radial drilling machine were used and non-conventional heating source used. Heat source decreases the hardness and brittleness of material by thermally softening phenomenon. Ti6Al4V has been used as the working material in this research. HSS M42 has been used as the tool material for drilling operation. It has been demonstrated that HADM process can improves the material removal rate and surface finish

Abstract The present paper outlines an experimental study to investigate the effects of cutting parameters on finish and power consumption by employing Taguchi techniques. The high speed machining of AISI 1045 using coated carbide tools was investigated. A combined tech- ...

In recent years, many cooling lubricants are classified as health hazards, while their end-of-life treatment poses numerous ecological threats. Dry machining is a solution for greener production and also is a favorable process from an economical point of view. However, compared to other machining processes, conventional grinding has a low material removal rate and involves high specific energy. A major part of the specific energy in grinding is changed to heat that makes harmful effect on surface quality. Therefore, in conventional dry grinding, as there are no cutting fluids to transfer the heat from the contact zone, the temperature of workpiece surface and grinding wheel surface will be increased resulted to thermal damage and poor surface integrity, increasing of wheel wear and inefficient grinding compared to conventional grinding. To make a step forward to pure dry grinding and to eliminate the negative environmental impact of the cutting fluids, a new technique called ultrasonic assisted dry grinding has been used. The advantages of ultrasonic assisted grinding were proved mostly for the brittle material. Our investigations show the improvement on the surface roughness, considerable reduction of the normal grinding force, and thermal damage in case of using ultrasonic assisted dry grinding compared to conventional dry grinding for a soft material, 42CrMo4. A decrease of up to 60% of normal grinding forces has been achieved.

The cylindrical wire electrical discharge turning (CWEDT) process was developed to generate precise cylindrical forms on hard, difficult to machine materials. A precise, flexible, and corrosion-resistant submerged rotary spindle was designed and added to a conventional five-axis CNC wire electrical discharge machine (EDM) to enable the generation of free-form cylindrical geometries. The hardness and strength of the work material are no longer the dominating factors that affect the tool wear and hinder the machining process. In this study, the effect of machining parameters on surface roughness (R a) and roundness in cylindrical CWEDT of a AISI D3 tool steel is investigated. The selection of this material was made taking into account its wide range of applications in tools, dies, and molds and in industries such as punching, tapping, reaming, and so on in cylindrical forms. Surface roughness and roundness are chosen as two of the machining performances to verify the process. In addition, power, pulse off-time, voltage, and spindle rotational speed are adopted for evaluation by full factorial design of experiments. In this case, a 22 × 32 mixed full factorial design has been selected considering the number of factors used in the present study. The main effects of factors and interactions were considered in this paper, and regression equations were derived using response surface methodology. Finally, the surfaces of the CWEDT parts were examined using scanning electron microscopy (SEM) to identify the macro-ridges and craters on the surface. Cross sections of the EDM parts were examined using the SEM and microhardness tests to quantify the sub-surface recast layers and heat-affected zones under specific process parameters.