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1
Ezeora, B. U., and B. C. Nwafor. "Effect of Non – Conventional Machining Principles Instruction on Craft Students' Achievement and Retention in Machining Practice in Government Technical Colleges in Enugu State, Nigeria." Contemporary Journal of Social Science and Humanities 3, no. 2 (2022): 1–17. https://doi.org/10.5281/zenodo.7213557.
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<strong>ABSTRACT</strong> This study empirically investigated the effect of Non-Conventional Machining Principles Instruction Model (NMPIM) on students’ achievement and retention in machining. The study was carried out with respect to the principles of arc length. The effect of NMPIM and the conventional method were studied. A research question and a null hypothesis guided the study. A non-equivalent pretest-posttest non randomized parallel group quasi experimental design was adopted for the study. The study was conducted in Government Technical Colleges in Enugu State, Nigeria. The population of the study was 1761-year two machining craft students. Intact classes of the only two technical colleges offering Machining Craft practice were used as subjects, with 85 and 36 students for experimental and control groups respectively. A structured instrument constructed by the researcher was validated by five experts, one from University of Nigeria, Nsukka (UNN) and four from Enugu State University of Science and Technology (ESUT). The validated instrument when subjected to item stability and internal consistency tests yielded 0.87 and 0.98, using Pearson product moment correlation coefficient formula, and Kuder Richardson (K-R 20) formulae respectively. The trial testing of the instrument by test retest was carried out in Government Technical College, Abakaliki, Ebonyi state, Nigeria. The research question was answered using Mean and Standard Deviation while the null hypothesis was analysed and tested using Analysis of Covariance (ANCOVA) at .05 level of significance. The results showed that year two machining students taught Machining with NMPIM achieved higher and retained higher in the principle learned when compared with those who were taught with the conventional method. There was no significant difference in the mean achievement and retention scores of Males over Females in the study. It was recommended that the TVET curriculum should be reviewed in line with the current technological realities with provision for 21st century equipment and training materials. The 21st century employers of labour (manufacturers) should be appointed as Technical colleges’ board members so they could advice the management on the current emerging technologies and possibly donate the state-of-the-art equipment to the colleges. Therefore, NMPIM should be adopted in teaching Machining to keep the students abreast of the 21st century technology which is ever evolving.
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Song, J. L., and Guang Jun Chen. "The Study of Computer Simulation on Vibratory Metal Machining with Low Frequency." Applied Mechanics and Materials 10-12 (December 2007): 286–90. http://dx.doi.org/10.4028/www.scientific.net/amm.10-12.286.
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Vibratory cutting is one of the newly developed machining techniques and theories in recent years. Insight into the machining mechanism and the chip formation process in metal vibratory cutting has yet to be carried out for this technique to be used widely and efficiently. But with conventional investigation, it is much difficult, and time and energy consuming to analyze and study such principles quantitatively. A system of the computer simulation has been established and based on FEM the chip formation process was emulated. The cutting forces and temperature distribution were imitated under condition of a variety of vibratory frequencies and turning engagements. ANSYS is utilized for the quantitative analysis. Contrast and comparison experiments between vibratory and the conventional metal machining are done, revealing a good agreement between the simulation and the experiment and the inborn nature and the principles of the vibratory metal cutting.
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Sterle, Luka, Damir Grguraš, Matjaž Kern, and Franci Pušavec. "Sustainability Assessment of Advanced Machining Technologies." Strojniški vestnik – Journal of Mechanical Engineering 65, no. 11-12 (2019): 671–79. http://dx.doi.org/10.5545/sv-jme.2019.6351.
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Efficient cooling and lubrication techniques are required to obtain sustainable machining of difficult-to-cut materials, which are the pillars of aerospace, automotive, medical and nuclear industries. Cryogenic machining with the assistance of lubricated Liquid Carbon Dioxide (LCO2) is a novel approach for sustainable manufacturing without the use of harmful water-based metalworking fluids (MWFs). In case of unavoidable use of MWFs under high pressure, such as turning finishing processes of difficult-to-cut materials, the pulsating high pressure delivery of MWFs prolongs the tool life and enables the control over chip length to prevent surface damage of high value-added parts. In this paper, sustainability assessment of both advanced principles was carried out, considering overall costs and operational safety. Experimental tests were executed on difficult-to-cut materials in comparison to conventional flood lubrication. For both techniques, longer tool life compared to flood lubrication was observed additional cleaner production and higher part quality led to reduced long-term overall costs. These advanced machining technologies are also operation safe, proving to be a sustainable alternative to conventional machining.
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Popov, K., S. Dimov, D. T. Pham, and A. Ivanov. "Micromilling strategies for machining thin features." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 220, no. 11 (2006): 1677–84. http://dx.doi.org/10.1243/09544062jmes192.
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Micromilling of metal structures with ‘thin’ features represents a major challenge towards broadening the use of this technology in a range of microengineering applications, for example in producing multi-channel microstructures, housing for mechanical microdevices, and surgical instruments. The most common thin features seen in microengineering products are ribs and webs. This research identifies the main factors affecting the reliability of micromilling technology when employed for the machining of microcomponents incorporating thin features. The general principles that should be followed in designing machining strategies for such features are discussed in this article. Taking these general principles into account, new strategies are proposed to reduce the negative effects of identified factors on part quality and, at the same time, to overcome some of the problems associated with the use of conventional machining strategies for micromilling of ribs and webs. To implement and verify them, initially the milling operations were programmed manually, and then a special CAM module was developed for their automatic generation. Finally, this article reports the validation of the proposed strategies for machining thin features, which was carried out on a specially designed test part.
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Walczyk, D. F., and D. E. Hardt. "Rapid Tooling for Sheet Metal Forming Using Profiled Edge Laminations—Design Principles and Demonstration." Journal of Manufacturing Science and Engineering 120, no. 4 (1998): 746–54. http://dx.doi.org/10.1115/1.2830215.
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Sheet metal forming dies constructed of laminations offer advantages over more conventional tooling fabrication methods (e.g. CNC-machining) in terms of tooling accessibility, reduced limitations on die geometry and faster fabrication with harder die materials. Furthermore, the recently introduced Profiled Edge Lamination (PEL) tooling method improves upon other lamination-based tooling methods. Adoption of this promising rapid tooling method by industry is being hindered by the lack of formal analysis, design principles, and manufacturing requirements needed to construct dies in such a manner. Therefore, the propensity for delamination of the die is discussed and preventive measures are suggested. The basic machining instructions, i.e., an array of points and directional vectors for each lamination, are outlined for both compound and planar profiled-edge bevels. Laser, AWJ and flute-edge endmilling are experimentally identified as the most promising methods for machining bevels. Development of a stand-alone PEL fabrication machine is suggested over retrofitting commercially-available 5-axis machines. Finally, the general procedure for creating PEL dies is implemented in the construction of a matched set of sheet metal forming tools. These tools are used to successfully stamp a sheet metal part out of draw-quality steel.
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Martins, Henrique, and Hélder Puga. "Ultrasonic Assisted Machining Overview: Accessing Feasibility and Overcoming Challenges for Milling Applications." Metals 13, no. 5 (2023): 908. http://dx.doi.org/10.3390/met13050908.
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Machinability, along with its associated facets, is a critical parameter that ultimately determines the cost of machining. Its optimization, however, is inherently limited by the current technology. To surmount such limitations, novel alternative machining technologies, such as Ultrasonic Assisted Machining (UAM), have emerged. The present study introduces UAM, the technology’s underlying principles, and general considerations for vibration application (harmonic waves, eigenfrequencies, resonance). The influence of ultrasonic application on the key parameters of conventional machining processes is studied and relevant research data are presented to support UAM benefits. Following, a comprehensive kinematic examination of vibration application to the milling process is conducted, accounting for various possible vibration modes. A detailed analysis of the requisite system components and their technical specifications is presented, followed by identifying common issues within such systems. Solutions for the identified limitations are proposed, acting as design guidelines for future technological advancements. Finally, based on the conducted research, conclusions are drawn and future directions for UAM are suggested.
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Lee, E. S., C. H. Lee, and Sung Chung Kim. "Machining Accuracy Improvement by Automatic Tool Setting and On Machine Verification." Key Engineering Materials 381-382 (June 2008): 199–202. http://dx.doi.org/10.4028/www.scientific.net/kem.381-382.199.
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This paper proposes a methodology for improving the machining accuracy based on auto tool setting & work-piece measuring on the machine using laser tool setting system & inspection probe. In this study, laser tool setting systems were analyzed as considering principles, convenience and efficiency and auto tool setting method and operating macro software were developed. As compared with conventional manual tool setting and touch-type auto tool setting, the importance of automatic non-contact tool setting using laser tool setter has been discussed. Also correct tool-setting methods in accordance with different tool shapes and sizes were defined and pocket features were machined by each of setting tools and measured by the inspection probe system to verify machining accuracy. Lastly we tried to demonstrate the superiority of laser tool setting systems by analyzing the cutting results when the CNC machining center was fitted with laser tool setting system.
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Li, Zhi Yang, Ming Yu Huang, Hong Ju Hu, et al. "Design and Manufacturing of Complex Surface Impeller Based on RE." Advanced Materials Research 328-330 (September 2011): 619–23. http://dx.doi.org/10.4028/www.scientific.net/amr.328-330.619.
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Based on the instance of collection the data of complex surface impeller and reconstruction the three-dimensional model, it describes the concepts and basic principles of Reverse Engineering, and discusses the entire process in detail, which are from the data of impeller collected, the impeller three-dimensional model re-Construction, fixture design to NC simulation machining. Solved the design and manufacturing problems of complex surface parts, which can not be solved by the conventional methods.
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Batke, Christoph, Karl Heinz Wurst, Armin Lechler, and Alexander Verl. "The Printed Machine Tool for Micro Machining." Advanced Materials Research 1018 (September 2014): 433–40. http://dx.doi.org/10.4028/www.scientific.net/amr.1018.433.
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Machine tools for micro machining are so far not adapted to work piece sizes and process forces. They feature hardly any modularity and do not allow reconfiguration in a significant process change. One possibility to adapt the machines is to produce them from plastic or composite materials through generative methods. This “printed” machine is a reconfigurable, monolithic module, in which drives are integrated. By a cooperative motion generation, larger workspaces can be realized while the installation spaces decreases. This gives the possibility to use alternative drive technologies for example piezo-drives. Based on these methods, two small generatively produced machine tools are designed. These machine tools use two different drive principles. The first machine tool is equipped with ball screw drives which are cost efficient and space saving. The second machine tool uses piezo-actuators, which are very dynamic in motion generation. Further has to be examined, which tolerances and rigidities are needed at critical points and which parts can be produced generatively and which in a conventional way.
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Ma, Nan, Stephen Monk, and David Cheneler. "Collaborative Continuum Robots for Remote Engineering Operations." Biomimetics 8, no. 1 (2022): 4. http://dx.doi.org/10.3390/biomimetics8010004.
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In situ repair and maintenance of high-value industrial equipment is critical if they are to maintain the ability to continue vital operations. Conventional single-arm continuum robots have been proven numerous times to be successful tools for use in repair operations. However, often more than one arm is needed to ensure successful operation within several scenarios; thus, the collaborative operation of multiple arms is required. Here, we present the design and operating principles of a dual-arm continuum robot system designed to perform critical tasks within industrial settings. Here, presented are the design principle of the robotic system, the optimization-based inverse kinematic calculation of the 6-DoF continuum arms, and the collaborative operation strategy. The collaborative principle and algorithms used have been evaluated by a set of experiments to demonstrate the ability of the system to perform in situ machining operations. With the developed prototype and controller, the average error between planned and real toolpaths can be within 2.5 mm.
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Kozak, J., K. P. Rajurkar, and B. Wei. "Modelling and Analysis of Pulse Electrochemical Machining (PECM)." Journal of Engineering for Industry 116, no. 3 (1994): 316–23. http://dx.doi.org/10.1115/1.2901947.
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A small interelectrode gap in Electrochemical Machining (ECM) results in improved dimensional accuracy control and simplified tool design. However, using a small gap with conventional ECM equipment adversely affects the electrolyte flow or mass transport conditions in the gap, leading to process instability. The most remarkable breakthrough in this regard is the development of ECM using pulsed current. Pulse Electrochemical Machining (PECM) involves the application of a voltage pulse at high current density in the anodic dissolution process. PECM allows for more precise monitoring and control of machining parameters than ECM using continuous current. Small interelectrode gap, low electrolyte flow rate, gap state recovery during the pulse-off times and improved anodic dissolution efficiency features encountered in PECM lead to improved workpiece precision and surface finish when compared with ECM using continuous current. This paper presents mathematical models for the PECM process which take into consideration the nonsteady physical phenomena in the gap between the electrodes, including the conjugate fields of electrolyte flow velocities, pressure, temperature, gas concentrations, current densities and anodic material removal rates. The principles underlying higher dimensional accuracy and simpler tool design attainable with optimum pulse parameters are also discussed. Experimental studies indicate the validity of the proposed PECM models.
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Kumar, Jogendra, Kumar Abhishek, Jinyang Xu, and Rajesh Kumar Verma. "Experimental Investigation on Machine-Induced Damages during the Milling Test of Graphene/Carbon Incorporated Thermoset Polymer Nanocomposites." Journal of Composites Science 6, no. 3 (2022): 77. http://dx.doi.org/10.3390/jcs6030077.
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The fiber laminate composites are extensively used in aerospace, aircraft, automotive components due to their high stiffness, corrosion, moisture resistance, low weight, and durability features. These fiber composites are modified with nanomaterials to acquire the desired manufacturing properties. The complex structure and anisotropic features differ from metals and their alloys. Additionally, the machining principles of fiber laminates significantly differ from conventional engineering materials. The present work investigates the machining behavior and permeates the damage generated while milling of graphene-modified carbon-fiber reinforced polymer nanocomposites (G/C@FRNC). The surface damages and defects caused in the milling samples have been examined through the high-resolution spectroscopy test. The influence of machining constraints such as cutting speed (N), feed rate (F), depth of cut (D), and graphene oxide weight % (GO) has been investigated to achieve the desired milling performances viz. material removal rate (MRR), cutting force (Fc), surface roughness (Ra), and delamination factor (Fd). The outcomes indicated that the cutting parameters and graphene nanomaterial prominently affects the milling responses. The addition of graphene improves the machinability of proposed nanocomposites with lesser defects generated. However, its higher addition can lead to the phenomenon of agglomeration that can reduce the machining efficiency. The damages and delamination generated in the machined sample are low at a higher cutting speed. This work suggests a new system to control the damage and defects to enhance the laminate samples’ quality and productivity.
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Ding, Song Lin, John Mo, and D. Yang. "HSM Strategies of CAD/CAM Systems — Part I Tool Path Generation." Key Engineering Materials 426-427 (January 2010): 520–24. http://dx.doi.org/10.4028/www.scientific.net/kem.426-427.520.
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Owning to the ultra high feed rate and spindle speed, tool path patterns which are less important in conventional metal cutting processes becomes critical in High Speed Machining (HSM). Without an appropriate tool path strategy HSM can not be fully implemented even though the CNC machine has HSM potentials. In practice attentions are usually drawn to advanced hardware components; tool path pattern catering to HSM is often overlooked. This paper introduces the principles of tool path generation for HSM. Essential properties of HSM and its technical requirements on the CAD/CAM system are summarized. The state-of-the-art technologies and practice-oriented tool path generation methodologies are presented.
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Grădinaru, Cosmin-Gabriel, and Gheorghe Nagîţ. "Some Aspects Regarding the Design of Tools for Superficial Cold Plastic Deformation of Internal Cylindrical Surfaces." Bulletin of the Polytechnic Institute of Iași. Machine constructions Section 70, no. 4 (2024): 83–94. https://doi.org/10.2478/bipcm-2024-0023.
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Abstract Surface cold deformation is an alternative to traditional machining processes used for finishing and hardening the surfaces of components in mechanical assemblies. One of the key advantages of cold deformation is that it allows for producing high-quality surfaces using tools mounted on conventional machines‒tools commonly found in most mechanical workshops. The resultant surface quality can rival with the one achieved through superfinishing processes, such as finishing grinding or honing. Additionally, this method hardens a sufficiently thick surface layer, enabling the machined parts to function properly without the need for conventional heat treatment. However, specialized tools are necessary for these surface hardening processes, and their proper design is crucial for achieving the desired characteristics in the finished components. This paper proposes an analysis of the different tools utilized for superficial cold plastic deformation of inner cylindrical surfaces, based on logical principles for identifying technical solutions. Using decision support systems (DSS), the adjustment mechanisms for cold surface plastic deformation heads that use roller burnishing have been analyzed. Ultimately, this analysis identified a tool that best meets the specified requirements.
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McKeown, P. A. "High Precision Manufacturing and the British Economy." Proceedings of the Institution of Mechanical Engineers, Part B: Management and engineering manufacture 200, no. 3 (1986): 147–65. http://dx.doi.org/10.1243/pime_proc_1986_200_066_02.
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In Industry Year, this James Clayton Lecture appropriately addresses the field of manufacturing engineering and aims to contribute to a wider understanding of how our economy and standard of living critically depend on those who design, manufacture and sell the products of high quality necessary to compete in world markets. The two main thrusts worldwide, in manufacturing engineering are: Automation—in particular, computer integrated, flexible manufacture to reduce overall cost and lead time and in which CADCAM, FMS and CIM are crucially important technologies Manufacture with higher precision—on which a wide range of advanced technology products are totally dependent—and in which precision engineering, micro-engineering and nanotechnology are generally less well understood and practised than by our main international competitors The paper traces recent developments in precision engineering in general and several new and non-conventional high precision ‘machining’ processes in particular, including those by which ‘atomic-bit machining’ is possible. Principles and modern techniques for controlling the accuracy of tool to workpiece in two- and three-dimensional work-zones of high precision production machines are reviewed and illustrated. Today's precision engineering, which can be defined as work at the forefront of design and manufacturing technology, can also be expected to become the general engineering of tomorrow. Its importance to the future of the UK economy cannot be overstated.
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Žmak, Irena, and Lidija Ćurković. "Improving Sustainability of Technical Ceramics Production: Synergistic Approach." ENTRENOVA - ENTerprise REsearch InNOVAtion 7, no. 1 (2021): 376–84. http://dx.doi.org/10.54820/jojw7514.
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Sustainable development is a concept focused on preserving current resources for them to be available to future generations as well, while at the same time fulfilling current human needs and facilitating adequate levels of development. Nowadays, there are many possible applications of sustainability principles, such as in the fields of the economy, agriculture, environment, energy, transport, architecture, and production. Sustainable production of materials and goods aims at improving the processes which are less damaging to the environment, which conserve natural resources and use low levels of energy, possibly derived from sustainable sources. One of the intensive energy- and resource-consuming industries is the conventional production of technical ceramics. Although non-toxic, ceramic waste is generated during the machining of the green bodies and is typically landfilled. To improve the sustainability of technical ceramics production, methods of recycling ceramic waste need to be developed and applied.
 This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
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Liu, Lei, and Jinzhao Zhang. "Meshing characteristics of a sphere–face gear pair with variable shaft angle." Advances in Mechanical Engineering 11, no. 6 (2019): 168781401985951. http://dx.doi.org/10.1177/1687814019859510.
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This article presents a sphere–face gear pair by substituting the convex spherical gear for the pinion of a conventional face gear pair. The sphere–face gear pair not only maintains the advantages of the face gear pair with a longitudinally modified pinion but also allows variable shaft angles or large axial misalignments. Meshing characteristics of the proposed gear pair are studied in this article. The mathematical models of the sphere–face gear pair are derived based on machining principles. The tooth contact analysis (TCA) and curvature interference check are conducted for the sphere–face gear pair with variable shaft angles. The loaded TCA is also implemented utilizing the finite element method. The results of numerical examples show that proposed gear pair has the following features. Geometrical transmission error of constant shaft angle or varying shaft angle is zero; contact points of the sphere–face gear set with variable shaft angle are located near the centre region of face gear tooth surface; there is no curvature interference in meshing; and transmission continuity of the gear pair can be guaranteed in meshing.
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Dubey, A. K. "Experimental investigations on electrochemical honing." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 222, no. 3 (2008): 413–26. http://dx.doi.org/10.1243/09544054jem905.
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Electrochemical honing (ECH) is an electrolytic precision mircofinsihing technology based on the hybridization of the electrochemical machining and conventional honing process principles to provide the controlled functional surface generation and fast material removal capabilities in a single action. This paper presents the distinctive findings of comprehensive experimental investigations designed to explore the influence of key ECH process parameters on the work surface microgeometrical, part-macrogeometrical, and material removal aspects. The current intensity, electrolyte concentration, stick-out pressure, and stick grit size are found to be the major players in the process. Interactions between current intensity, electrolyte concentration, and speed ratio play a vital role, specifically for macrogeometrical performance. Proper electrolyte composition and stick grit-size selections and a distinct coordination of electrolytic dissolution and mechanical scrubbing are crucial for the optimal performance. Work surface characterization reveals a nano-finished plateau-honed work surface featured with a uniform roughness value, impressive surface characteristic parameters, no trace of cold-worked material, or any adverse effect of the process. This, accompanied with precise part macro- geometry, can result in an unexcelled tribological performance of the components. Key features of an ECH set-up that was designed and developed incorporating several unique features are also highlighted.
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Xiao, Qiang. "Research on the Machining Principle and Experinment of Ultrasonic Machining." Applied Mechanics and Materials 373-375 (August 2013): 1983–86. http://dx.doi.org/10.4028/www.scientific.net/amm.373-375.1983.
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Ultrasonic machining is a non-conventional machining process. Ultrasonic machining offers an effective alternative for ultra precision machining of hard and brittle materials due to its unique characteristics. This paper did a comprehensive analysis on ultrasonic machining mechanism in theory. The experiment compared this ultrasonic machining process with the common machining process in surface quality is done and the experimental result show that the smooth high quality surface can be obtained under ultrasonic machining.
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Xu, Cun Shan. "Working Principle and Performance of Wire Electrical Discharge Machining." Advanced Materials Research 507 (April 2012): 180–83. http://dx.doi.org/10.4028/www.scientific.net/amr.507.180.
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Wire electrical discharge machining (WEDM) is an advanced thermal machining process capable of accurately machining parts with complicated shapes, especially for the parts that are very difficult to be machined by traditional machining processes. WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. This author reviews the vast array of research work carried out from the EDM process to the development of the WEDM, also highlights the working principle and mechanical performance of machining conditions. A wide range of WEDM industrial applications are reported together with the development of the hybrid machining processes. The final part of the paper discusses these developments and outlines the possible trends for future WEDM research.
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Schimmelpfennig, Tassilo Maria, Ivan Perfilov, Jan Streckenbach, and Eckart Uhlmann. "Comparison of Conventional and Dry Electrical Discharge Machining." Applied Mechanics and Materials 794 (October 2015): 278–84. http://dx.doi.org/10.4028/www.scientific.net/amm.794.278.
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For manufacturing of micro holes ElectricalDischarge Machining (EDM) can be used, which is well-established due toits thermal working principle that allows almost force free machining independent of the material’s mechanical properties. The importance of this production technology is increasing, especially for the machining of ceramic materials, which are required in many applications within the field of microtechnology. However, the production of precise micro holes with complex geometries and high aspect ratios is associated with a many challenges. Hightool electrode wear, low material removal rate and small gap widths are observed in the process. This paper presents an optimized dry EDM technology for the manufacturing of micro holes in Si3N4-TiNceramic. The experiments were carried out with different energy influencing process parameters for the spark discharge and flushing pressure, which were systematically evaluated by methods of statistical Design of Experiments. Subsequently dry EDM and conventional EDM micro drilling processes were compared and the differences between both processes were evaluated. The influences of liquid and gaseous dielectric are analyzed in terms of process stability and axis movements.
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Mr., Mayur N. Patel* Mr. Viren B. Bagadiya Mr.Manish M. Maisuria. "PARAMETRIC OPTIMIZATION TECHNIQUE IN WIRE CUT ELECTRICAL DISCHARGE MACHINING: AN OVERVIEW." INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY 5, no. 10 (2016): 721–25. https://doi.org/10.5281/zenodo.163281.
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Electro Discharge Machining (EDM) is an emerging technology in the field of machining to fabricate very complex micro products. Wire EDM is a very complex process involving the different process parameters. The experiments are often time consuming and costly. It is used to manufacture geometrically intricate shapes with great accuracy and good surface finish that are difficult to machine with the help of conventional machining processes,but recent development in material have become a difficult task for WEDM process to be used for machining alternative in future,so there is need to make continuous improvement in current WEDM process to increase their productivity and efficiency in WEDM have directly contributed to increased cutting speed and dimensional accuracy. This paper reviews the various notable works in the field of WEDM and emphasis is made on optimization of machining parameters.
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Vishwasrao, Pratik R. "Optimization of Process Parameter in Wire Electrical Discharge Machining of H11 Tool Steel Using Response Surface Methodology." International Journal for Research in Applied Science and Engineering Technology 9, no. 12 (2021): 2150–57. http://dx.doi.org/10.22214/ijraset.2021.39693.
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Abstract: Conventional machining is now being superseded by non-conventional machining to cope up with increased demand of machining of complex shapes with high surface finish machining and dimensional accuracy. Wire electric discharge machining (WEDM) is electro-thermal principle based nontraditional machining, widely used for machining of electrically conductive materials. This paper summarized, the parametric influence of Pulse-on duration (Ton), Pulse-off duration (Toff) and Pulse peak current (Ip) on material removal rate (MRR), surface roughness (SR) of H11 tool steel. Response surface methodology (RSM) is used for modelling and optimization. ANOVA has been carried out to identify importance of the machining parameters on the performance characteristics considered. Further the verification experiment has been carried out to confirm the performance of optimum parameters. The results from this study will be useful for selecting appropriate set of process parameters to WEDM machining of H11 tool steel.
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Di, Shi Chun, Dong Bo Wei, Guan Xin Chi, Zhen Long Wang, and J. T. Jiang. "Research on Energy Saving EDM Pulsed Power Supply with Cyclically Superimposed Chopper Circuit." Key Engineering Materials 315-316 (July 2006): 516–20. http://dx.doi.org/10.4028/www.scientific.net/kem.315-316.516.
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This paper presents an energy saving electrical discharge machining (EDM) pulsed power supply, the principle of which is introduced. This pulsed power supply possesses no current-limiting resistors used in conventional EDM pulsed power supplies and no energy storage inductors applied in most other energy saving pulsed power supplies. Direct current from DC power supply is chopped to form many branches of paralleling spike pulse currents and the current branches are then combined into the desired pulse current for EDM machining through cyclic superimposition. The calculation method of energy loss is then analyzed. The short-circuit and contrastive machining experiments proved that the new pulsed power supply was capable of performing stable machining with higher machining efficiency and less main-machining-circuit energy loss than those of conventional EDM pulsed power supplies.
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MOKROVA, Natalia, Viktor ARTEMYEV, and Anar HAJIYEV. "DESIGN OF REVERSIBLE THYRISTOR FEED DRIVE WITH PROPORTIONAL-INTEGRAL CONTROLLERS." Machine Science Journal 4, no. 2 (2024): 13–28. https://doi.org/10.61413/iynu7656.
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This paper presents a detailed analysis of a reversible thyristor feed drive for industrial metalworking systems, oriented for application in machine tools with position or contour numerical control, as well as in copying and milling machines. The drive under consideration is based on a three-phase zeroreversing scheme, providing a wide dynamic speed control range of the executive motor speed not less than 10000 revolutions, which allows effectively adapting to changes in technological parameters and various production modes. The application of proportional-integral speed and current regulators in the control loop contributes to the accuracy, stability and speed of the system under various mechanical loads and transient modes. The paper offers a comprehensive consideration of structural features, principles of operation and performance characteristics of reversible thyristor feed drive with PI controllers. The obtained results allow to optimize the drive operation in conditions of high precision machining, to expand the functional capabilities of the machine tool equipment, to reduce the influence of external disturbances and to increase the reliability of the industrial system as a whole. The basis of the hardware configuration of the drive consists of thyristor block (BT), control unit (CU), stabilized power supply of control circuits, as well as synchronization transformer, interacting by means of functional blocks: regulator block (RB), phase shifting device (PSD), logic block (BL), stabilized power supply block (SPB) and correction block (BC). The described functional structure simplifies the procedure of initial setting of the drive, tightening the interaction of the system elements and reducing the risk of uneven operation modes. It is possible to use both conventional electric motors with normal inertia-torque ratio and motors with increased torque overload capacity or reduced inertia. An important feature of the proposed solution is a built-in system of protection of power keys against short circuits by using high-speed maximum protection automatics (MPA), which contributes to increased reliability of operation and reduces the risk of failure of expensive elements. Additional stability of thyristor switching process is achieved by using transistor electronic keys, whose operation is synchronized with the supply network due to a special transformer winding, providing fast and accurate transition between positive and negative half-periods.
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Wang, Shi Ying, Ming Lv, and Gang Ya. "Research on System Design of Ultrasonic-Assisted Honing of Gears." Advanced Materials Research 53-54 (July 2008): 191–96. http://dx.doi.org/10.4028/www.scientific.net/amr.53-54.191.
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Ultrasonic vibration can reduce honing forces efficiently. As the honing wheel can be washed by ultrasonic cavitations of cutting fluids, its jams are decreased and the higher honing efficiency has been obtained. Therefore, gear honing combined with ultrasonic machining honing is a method for gear finish machining with its wide application future. Ultrasonic-assisted honing of gears is firstly proposed, its machining devices are manufactured based upon the design parameters derived by four-terminal network principle. Experiments of gear honing show that the machining traces on the tooth flanks in ultrasonic and traditional honing are different. The ultrasonic honing can produce a better tooth surface roughness (Ra 0.45 μm) than one obtained conventional honing (Ra 0.72 μm).
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Zou, Yan Hua, and Takeo Shinmura. "A New Internal Magnetic Field Assisted Machining Process Using a Magnetic Machining Jig-Machining Characteristics of Inside Finishing of a SUS304 Stainless Steel Tube." Advanced Materials Research 69-70 (May 2009): 143–47. http://dx.doi.org/10.4028/www.scientific.net/amr.69-70.143.
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This paper proposes a new magnetic field assisted machining process using a magnetic machining jig (permanent magnet tool) to finish the internal surface of thick tubing 5~30 mm in thickness. Because the magnetic machining jig consists of permanent magnets, it can generate a higher magnetic force (finishing force) than conventional magnetic abrasives, and makes possible the internal finishing of thick non-ferromagnetic tubing. First, the principle and the feature of this process were examined. It was compared that the difference of the mechanism of using the conventional magnetic abrasives and magnetic machining jig (magnet tool) was clarified. Next, a processing unit and magnetic machining jig were made, and the processing unit was set on a lathe machine. An experiment was performed on a thick SUS304 stainless steel tubing 5 mm in thickness. In this study, it was clarified that this processing method can improve the roundness of the inside tubing while improving the surface roughness. The results showed that the initial surface roughness of 6.5 μm Ra can be improved to 0.06 μm Ra, and the roundness of the inside tubing can be improved from 187 μm to 89 μm.
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Sen, Binayak, Mozammel Mia, G. M. Krolczyk, Uttam Kumar Mandal, and Sankar Prasad Mondal. "Eco-Friendly Cutting Fluids in Minimum Quantity Lubrication Assisted Machining: A Review on the Perception of Sustainable Manufacturing." International Journal of Precision Engineering and Manufacturing-Green Technology 8, no. 1 (2019): 249–80. http://dx.doi.org/10.1007/s40684-019-00158-6.
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AbstractIn modern days, the conception of sustainability has progressively advanced and has begun receiving global interest. Thus, sustainability is an imperative idea in modern research. Considering the recent trend, this review paper presents a summary of the previously published research articles on minimum quantity lubrication (MQL) assisted machining. The requirement to stir towards sustainability motivated the researchers to revise the effects of substitute lubrication methods on the machining. Conventional lubri-cooling agents are still extensively employed when machining of engineering alloys, but the majority of the recent papers have depicted that the utilization of vegetable oil, nanofluids, and nanoplatelets in MQL system confers superior machining performances as compared to conventional lubrication technology. In actual, the definite principle of this manuscript is to re-examine modern advancements in the MQL technique and also explore the benefits of the vegetable oil and nanofluid as a lubricant. In brief, this paper is a testimony to the advancing capabilities of eco-friendly MQL technique which is a viable alternative to the flood lubrication technology, and the outcomes of this review work can be contemplated as a movement towards sustainable machining.
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Zhang, Qin He, Jian Hua Zhang, Q. B. Zhang, and Shu Peng Su. "Experimental Research on Technology of Ultrasonic Vibration Aided Electrical Discharge Machining (UEDM) in Gas." Key Engineering Materials 315-316 (July 2006): 81–84. http://dx.doi.org/10.4028/www.scientific.net/kem.315-316.81.
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Ultrasonic vibration aided electrical discharge machining (UEDM) in gas is an electrical discharge machining (EDM) technology, in which gases such as air and oxygen are used as dielectrics and ultrasonic vibration is applied. UEDM in gas can avoid environment pollution, the most serious disadvantage of conventional EDM in kerosene-based oil or other dielectric fluids, and it is environmental-friendly. The technology also possesses virtues of wide applications, high machining efficiency and simple tool electrodes and so on. The principle of UEDM in gas is introduced in this paper. Experiments have been carried out to study the effects of machining parameters on material removal rate (MRR), surface roughness of the workpiece and tool electrode wear ratio (TWR), and the experiments results have also been analyzed.
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Zhu, Xuyang, Guangxian Li, John Mo, and Songlin Ding. "Multi-channel electrical discharge machining of titanium alloy Ti-6Al-4V with semiconductor electrodes." Journal of Physics: Conference Series 2612, no. 1 (2023): 012011. http://dx.doi.org/10.1088/1742-6596/2612/1/012011.
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Abstract Titanium alloys are extensively used in aerospace and medical engineering owing to their exceptional mechanical properties and biocompatibility. For a long time, the low thermal conductivity of titanium alloys has made them difficult to machine with conventional approaches. Electrical discharge machining (EDM) is a nonconventional method for machining difficult-to-cut materials. However, it is not possible to achieve high-quality surface finish while simultaneously maintain high machining efficiency. This paper introduced a new EDM approach to obtain high surface quality in machining titanium alloy Ti-6Al-4V with discrete semiconductor electrodes by utilising a new multi-channel discharge principle to disperse the discharge energy. To explore the dissimilarities in discharge characteristics between semiconductor electrodes and traditional copper electrodes, continuous discharge waveforms of both electrodes were compared. Through modelling the discharge equivalent circuit and analysing workpiece surface using scanning electron microscopy (SEM), it was discovered that, due to the unique electrical properties of the semiconductor, it is possible for semiconductor electrodes to form multiple discharge channels. The outcomes reveal that the utilization of semiconductor electrodes can disperse discharge energy and enhance surface quality without sacrificing material removal rate compared to the use of conventional copper electrodes.
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Wang, Yu Kui, Bo Yan Song, and Wan Sheng Zhao. "Research on Highly Efficient EDM Pulse Power Supply and Its Experiments." Key Engineering Materials 291-292 (August 2005): 567–72. http://dx.doi.org/10.4028/www.scientific.net/kem.291-292.567.
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Their efficiency and their power factor of conventional independent electrical discharge machining (EDM) pulse power supplies with the current-limiting-resistor circuit is so low that they do not meet the need of advanced EDM technologies. The design of highly efficient EDM pulse power supply based on switching circuit pulse width modulation current closed-loop principle has been initiated. It is composed of such three stages as a single-phase active power factor correction preregulator, a full-bridge phase shift resonant converter based on machining current closed-loop control and a pulse generator based on machining sequence control. Therefore, the efficiency of the new system is considerably increased to about 70%, its weight and size is decreased much. Its power factor is a great deal increased to about 0.95. Experiment results have demonstrated that the highly efficient EDM pulse power supply is capable of low electrode wear, high speed, stable machining.
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Qiang, Xiao. "Study of the Machining Principle and Influencing of Ultrasonic Lapping on SiC Single Crystal." Advanced Materials Research 411 (November 2011): 102–6. http://dx.doi.org/10.4028/www.scientific.net/amr.411.102.
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In order to resolve precision machining problem for SiC single crystal, a new ultrasonic lapping method is proposed. According to the brittle and hardness character of SiC single crystal, the principle of ultrasonic lapping is firstly introduced, and then parameters of experimental for ultrasonic lapping, such as wheel speed, grit size, vibration amplitude, frequency are given. Lastly, experimental result is analyzed by comparing ultrasonic lapping process with the conventional lapping process in the MRR and surface quality.
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Shuai, Mo, Ma Shuai, Jin Guoguang, Gong Jiabei, Zhang Ting, and Zhu Shengping. "Design principle and modeling method of asymmetric involute internal helical gears." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 1 (2018): 244–55. http://dx.doi.org/10.1177/0954406218756443.
Full textAbstract:
In the field of mechanical engineering, involute helical gears are widely used. Compared with the involute spur gear, helical gears have a high bearing strength, more smooth transmission, less impact and less noise. The internal gear pairs have the features of large transmission ratio, low vibration, low noise and low wear and hence are widely used in planetary gear transmission systems. In order to meet the requirements of high strength, high speed of the modern gear transmission systems, a new type of asymmetric involute internal helical gears is designed based on conventional involute gears. This paper discusses the gear shaper cutter modeling for machining this new gear, analyzes the formation principle of asymmetric tooth profile and establishes a three-dimensional modeling by SolidWorks. Through MATLAB simulation, pressure angle, tooth number, coefficient of displacement and contact ratio of conventional and asymmetric gear are compared and analyzed. Using ANSYS, two types of gears are compared on strength in order to demonstrate superiority of asymmetric tooth and further study about the asymmetric internal helical gears.
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Nayak, Prasmit Kumar, and MS Shunmugam. "CAD simulation and generation machining of discrete ring-involute spherical segment gear pair." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 226, no. 7 (2011): 1832–44. http://dx.doi.org/10.1177/0954406211427833.
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A spherical segment gear pair is useful in robotic wrist and similar such applications that require two degrees of freedom. From the first principle, tooth surface of spherical gear can be mathematically derived from a rack-cutter profile using the coordinate transformation and one-parameter family of envelope theory. Alternatively, the spherical gear tooth surface is obtained as an envelope of a series of cutter surfaces formed during the kinematic motion between work blank and cutter. Conventional gear cutting machines cannot be used to generate the spherical gears and hence the spherical gears have remained a conceptual mechanism. In order to establish the feasibility of generation machining, a CAD-based simulation is carried out first where work blank and cutter are taken as solid models and the simulation is performed using the Boolean operation to remove the interfered material in an incremental manner, maintaining the kinematic relationship. The actual machining of the spherical segment gear is then carried out on a five-axis CNC machining centre using a specially developed conical end-mill cutter having a semi-cone angle of 20°. The script file for the CAD simulation has also been used for creating the program for CNC machining.
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Zou, Ping, Yingshuai Xu, Yu He, Mingfang Chen, and Hao Wu. "Experimental Investigation of Ultrasonic Vibration Assisted Turning of 304 Austenitic Stainless Steel." Shock and Vibration 2015 (2015): 1–19. http://dx.doi.org/10.1155/2015/817598.
Full textAbstract:
This research study focuses on the experimental analysis of the three-dimensional (3D) surface topography and surface roughness of the workpiece machined with ultrasonic vibration assisted turning (UAT) in comparison to conventional turning (CT). For the challenge that machining difficulties of 304 austenitic stainless steel (ASS 304) and high demands for the machined surface quality and machining precision represent, starting with cutting principle and processing technology, the ultrasonic vibration method is employed to scheme out a machining system of ultrasonic vibration assisted turning (MS-UAT). The experiments for turning the workpiece of ASS 304 are conducted with and without ultrasonic vibration using the designed MS-UAT, and then the 3D morphology evaluation parametersSaandSqare applied to characterize and analyse the machined surface. The experimental results obtained demonstrate that the process parameters in UAT of ASS 304 have obvious effect on the 3D surface topography and surface roughness of machined workpiece, and the appropriate choice of various process parameters, including ultrasonic amplitude, feed rate, depth of cut, and cutting speed, can enhance the machined surface quality efficiently to make the machining effect of UAT much better than that of CT.
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MISRA, J. P., P. K. JAIN, and D. K. DWIVEDI. "PRECISION FINISHING OF GEARS BY ELECTROCHEMICAL HONING PROCESS: A STATE OF ART REVIEW." Journal of Advanced Manufacturing Systems 10, no. 02 (2011): 309–27. http://dx.doi.org/10.1142/s0219686711002223.
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This paper presents a state-of-the-art review of high precision finishing of gears by electrochemical honing (ECH) process. It is an electrochemical (EC)-based hybrid machining process combining the faster material removal capability of electrochemical machining (ECM) process and controlled functional surface–generating capability of conventional honing in a single action. The precision finishing of gears by ECH is a productive, high-accuracy, long toollife gear finishing process. The present study contains a detailed description of the process principle, influencing parameters, process capabilities, equipment details, applications, advantages and limitations, and comprehensive literature review of past research work on the ECH of gears along with some guidelines for further research with an objective to revive the interest of the global research community to mature this process further.
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Li, Xiaokun, Yuankai Ren, Zhiyuan Wei, and Yong Liu. "Development of Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining Tool." Recent Patents on Mechanical Engineering 12, no. 4 (2019): 313–25. http://dx.doi.org/10.2174/2212797612666190808101736.
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Background: The fabrication of microstructures with high machining quality is always difficult when it is concerned with non-conductive hard and brittle materials such as glass and engineering ceramics. It is reported in related papers and patents that Electrochemical Discharge Machining (ECDM) process is a good choice for machining non-conductive, hard and brittle materials. However, the machining performance of ECDM process, especially in the aspect of geometric accuracy and surface quality, needs to be greatly improved. Objective: The purpose of this study was to improve the machining quality of conventional ECDM process by introducing ultrasonic vibration to ECDM process, develop an Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining (UAECDM) tool, and investigate the improvements of the machining performance by means of comparative experiments. Methods: Firstly, the machining principle of UAECDM was investigated, and the effects of ultrasonic vibration are discussed with the analysis of the micro process. Secondly, the hardware system, which consists of a machine tool body, XY and Z axes, an ultrasonic spindle system and motion control system, was established; and the software system was developed based on the analysis of the overall workflow of the machining process. Finally, comparative experiments, including ECDM drilling, UAECDM drilling, ECDM milling and UAECDM milling, were carried out to reveal the improvements of the machining quality. Results: In the UAECDM group, a micro-hole with the inlet diameter of 133.2µm as well as the 3 × 3 array of micro holes was fabricated on the glass workpiece with 300µm thickness, and a microgroove with the width of 119.2µm was successfully milled on the glass workpiece. It is shown in both microscopic photographs and optical measurements that the microstructures fabricated by UAECDM have better machining quality compared with similar microstructures fabricated by ECDM. Conclusion: Based on comparative experiments and discussions of the results, it has been proved that the machine tool can meet the requirement of the ultrasonic vibration-assisted micro electrochemical discharge machining and can improve the geometric accuracy and surface quality significantly.
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B.Saravanan, Raj L.Nirmal, P.Rajkumar, and Kumar K.Saravana. "Comparative Analysis of Coated and Non Coated HSS Tool with Zinc, Nickel, and Chromium." International Journal of Engineering and Management Research 9, no. 2 (2019): 183–85. https://doi.org/10.5281/zenodo.3356049.
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Machining is the heart of any manufacturing process so coating material have been used in the coating of tool steels. The tool used is high speed steel and are coated with Zinc, Nickel and Chromium separately. The various reasons to coat cutting tools are to increase tool life and improve the surface quality of the product, and to increase the production rate. The advantage of Zi, Ni, Cr coating include high hardness, good ductility, excellent lubricity, high chemical stability and tough resistance to wear, corrosion and temperature. In this paper, the principle, advantage and limitation of various Zn, Ni, Cr coating processes are summarized. This paper involves of machining hardened steel using Zi, Ni, Cr, coated HSS cutting tool is studied. This paper discussed about the wear and also hardness factor after coating compared with conventional cutting tool(high speed steel)
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Yan, Xiao Ling, Wang Long Wang, and Nan Xue. "Research and Simulation of an Efficient Circular Interpolation Algorithm." Advanced Materials Research 542-543 (June 2012): 1204–8. http://dx.doi.org/10.4028/www.scientific.net/amr.542-543.1204.
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During the process of conventional DDA circular interpolation, the synthesis feed rate fluctuations often, the machining errors are large also. A new efficient arc interpolation method is proposed in this paper, which uses the principle of DDA circular interpolation, it’s function is optimized and improved, Radius is used as the basis of interpolation feed, the left normalized data and pre-loaded are used also. The simulation result of VB program show that efficient circular interpolation method not only has high efficiency,but also has high accuracy.
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Yamamoto, Norimasa, Satarou Yamaguchi, and Tomohisa Kato. "Slicing of Rotating SiC Ingot by Electric Discharge Machining." Materials Science Forum 740-742 (January 2013): 843–46. http://dx.doi.org/10.4028/www.scientific.net/msf.740-742.843.
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A new method of electric discharge machining (EDM) is proposed for slicing a large silicon carbide (SiC) ingot in order to realize low kerf loss and fast cut. This principle is based on the rotating ingot, and it is called the rotating slicing method (RSM). It would be defecate the cutting chip effectively and one-point discharge. In this paper, we reported results of examinations of the RSM experimentally. Unstable discharge was not observed. Discharge damages on the wire surface were fewer than those of the conventional method. Net cutting speed was almost the same as the present method for the 2-inches ingot. The rotation axis of the ingot should be perpendicular to the feed direction of the wire, and it is important to fix the performance of the EDM such as the kerf loss. Roughness of the cutting surface was 3.4 µm of Ra
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Sano, Yasuhisa, Hiroaki Nishikawa, Yuu Okada, Kazuya Yamamura, Satoshi Matsuyama, and Kazuto Yamauchi. "Dicing of SiC Wafer by Atmospheric-Pressure Plasma Etching Process with Slit Mask for Plasma Confinement." Materials Science Forum 778-780 (February 2014): 759–62. http://dx.doi.org/10.4028/www.scientific.net/msf.778-780.759.
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Silicon carbide (SiC) is a promising semiconductor material for high-temperature, high-frequency, high-power, and energy-saving applications. However, because of the hardness and chemical stability of SiC, few conventional machining methods can handle this material efficiently. A plasma chemical vaporization machining (PCVM) technique is an atmospheric-pressure plasma etching process. We previously proposed a novel style of PCVM dicing using slit apertures for plasma confinement, which in principle can achieve both a high removal rate and small kerf loss, and demonstration experiments were performed using a silicon wafer as a sample. In this research, some basic experiments were performed using 4H-SiC wafer as a sample, and a maximum removal rate of approximately 10 μm/min and a narrowest groove width of 25 μm were achieved. We also found that argon can be used for plasma generation instead of expensive helium gas.
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Samardžiová, Michaela, Martin Kováč, and Martin Necpal. "Contact Measurement of Flatness of Parts with Low Rigidity." Key Engineering Materials 581 (October 2013): 437–42. http://dx.doi.org/10.4028/www.scientific.net/kem.581.437.
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An article deals with a measurement of flatness of thin-walled parts with low rigidity. The flatness is important for quality thin-walled parts made by milling. Measurement of the variation in the flatness of thin-walled components conventional 3-axis, high-speed 3-axis milling was done. In the first part is description of flatness and definition of thin-walled parts. Second part characterizes the measuring system, the principle of measurement and experimental setup. The last part of this work is evaluation of the experiment, which compares different factors to determinate flatness during machining of thin-walled parts.
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Wang, Bao Ming, Xue Song Mei, Zai Xin Wu, and Chi Bing Hu. "Tooth-Leap Shaping Method for Helical Gears." Applied Mechanics and Materials 217-219 (November 2012): 1769–73. http://dx.doi.org/10.4028/www.scientific.net/amm.217-219.1769.
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In order to reduce cyclic variation in rotational speed of generated gears or shaper cutter induced by additional rotation during shaping, tooth-leap shaping method for helical gears was proposed. Based on fundamentals of helical gears shaping kinematics, principle of tooth-leap shaping for helical gears was introduced. Furthermore, mathematic models of tooth-leap shaping motions for helical gears are established. Finally, several examples are calculated, results show that cyclic variation in rotational speed of generated helical gear can be reduced largely by tooth-leap shaping method comparing with conventional shaping method. Consequently this method will make shaping motions of helical gears more smooth and improve the machining accuracy of helical gears.
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Gong, Ya Dong, Guo Qiang Yin, Chao Wang, Xue Long Wen, and Jun Cheng. "Study on the Effect of Coarse Grinding Area Slope Angle on Surface Quality in Point Grinding." Advanced Materials Research 797 (September 2013): 118–22. http://dx.doi.org/10.4028/www.scientific.net/amr.797.118.
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There is a vitrified bond CBN point grinding wheel with coarse grinding area slope angle θ. This new grinding wheel has higher removing rate and better machining accuracy than conventional wheels. The design and manufacture principle of the new grinding wheels are studied in this paper. These wheels with different coarse grinding area slope angle θ are used to grind the stepped shaft of QT700 with a series of grinding parameters.VHX-1000E microscopic system and Micromeasure system are used to measure the surface quality of workpiece. In the same group of grinding parameters, compare the effect of these different wheels on surface roughness. The effect of deflection angle α on surface roughness is generalized.
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Zou, Yan Hua, and Takeo Shinmura. "Mechanism of a Magnetic Field Assisted Finishing Process Using a Magnet Tool and Magnetic Particles." Key Engineering Materials 339 (May 2007): 106–13. http://dx.doi.org/10.4028/www.scientific.net/kem.339.106.
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This paper describes a new efficient internal finishing process for a thick tubing (10~30mm in thickness), by the application of a magnetic field-assisted machining process using a magnet tool. Because a stronger magnetic force can be generated than conventional magnetic abrasives, it makes the internal finishing of thick non-ferromagnetic tubing possible. Moreover, in order to obtain a high-quality surface, this process method was developed using magnetic particles magnetically attracted on the magnet surface. This paper characterizes the processing principle and advantages of this process. Then, the mechanism of this finishing process was examined by a plane model experiment. It was clarified that the magnetism and shape of a magnetic particle influence realization possibility of this processing method, and it also influence the finishing characteristics.
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Li, Guo, Bo Wang, Jiadai Xue, Da Qu, and Peng Zhang. "Development of vibration-assisted micro-milling device and effect of vibration parameters on surface quality and exit-burr." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233, no. 6 (2018): 1723–29. http://dx.doi.org/10.1177/0954405418774592.
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Vibration-assisted cutting is an important technology with better performance in manufacturing micro-scaled components, compared with conventional cutting technology. This article first illustrates the development of vibration-assisted micro-milling device which is made based on piezoelectric plates and shows different vibration types with vibration principle of this device. It is then tested stable to output vibration with a frequency accuracy of 100 Hz and an amplitude accuracy of 100 nm. Two groups of experiments in micro-milling 6061 aluminum alloy are carried out. Compared with conventional micro-milling, using vibration assist is verified more effective in improving surface integrity and quality. Furthermore, with a proposed method of characterizing exit-burr size, the influences of vibration frequency and amplitude on surface roughness and exit-burr size are discussed. As a result, the mean surface roughness is found positive related to vibration frequency and negative related to vibration amplitude in most of the study range. To make guidance on optimizing vibration machining parameters, cubic polynomial fitting with 95% prediction interval is of enough accuracy.
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Juneja, Shahbaz, Jasgurpreet Singh Chohan, Raman Kumar, et al. "Impact of Process Variables of Acetone Vapor Jet Drilling on Surface Roughness and Circularity of 3D-Printed ABS Parts: Fabrication and Studies on Thermal, Morphological, and Chemical Characterizations." Polymers 14, no. 7 (2022): 1367. http://dx.doi.org/10.3390/polym14071367.
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Ever since the introduction of 3D printing, industries have seen an exponential growth in production and efficiency. Three-dimensional printing is the process of additive manufacturing (AM) in which the conventional method of material removal is challenged. Layer-on-layer deposition is the basic principle of the AM. Additive manufacturing technologies are used to create 3D-printed objects. An object is built in an additive technique by laying down successive layers of material until the object is complete. Each of these layers can be viewed as a cross-section of the item that has been lightly cut. When compared to traditional production methods, 3D printing allows the creation of complicated shapes with less material. In conventional methods, the materials go through several damages due to the tool–workpiece contact creating friction between them and the dissipated heat that damages the material. Overcoming the conventional method of machining with the help of 3D printing is a new advancement in the industries. The process involves using non-conventional methods for the machining of the parts. This research was oriented towards the chemical vapor jet drilling of the acrylonitrile–butadiene–styrene (ABS) materials. ABS materials are highly machinable and can be recycled for further usage. This paper focused on the usage of acetone as the chemical for drilling. The surface roughness and circularity of the drilled hole was taken into account for this research paper. We set up a manual experiment to run tests and get results. A vapor jet machine was designed with acetone as the core for the vapor. Various analyses were also formulated and conducted during experimentations. Surface roughness analysis provided the insight of roughness after the machining with the help of acetone vapor jet spray. SEM and micro-image parameters were also considered for more clear and advanced reports. In this research paper, DSC and FTIR analysis were performed to understand changes in the internal structure and the material properties of the ABS. Moreover, the research aimed to investigate the effect of various inputs processing parameters such as pressure, flow rate, and stand-off distance on the surface roughness and circularity of ABS workpiece material. The Taguchi L9 orthogonal array design was utilized to conduct tests by chemical vapor jet drilling using acetone and to evaluate the performance of the set-up while reducing the influence of interfering factors in order to provide reliable surface finish and circularity results. The results and conclusion of the research paper aimed to determine the most suitable parameters for the non-conventional acetone vapor jet drilling of the ABS material. The theoretical calculations predicted 1.64432 and 0.3289080 values of surface roughness and circularity, respectively. On the other hand, the experimental values were recorded as 1.598 for surface roughness and 0.322 for circularity. Therefore, a negligible error of 0.046 for surface roughness and 0.0031 for circularity, respectively, was noted which validate the statistical equations and the consistency of the combined vapor jet drilling process.
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Hirooka, Toshihiko, Tomokazu Kobayashi, Atsushi Hakotani, Ryuta Sato, and Keiichi Shirase. "Surface Roughness Control Based on Digital Copy Milling Concept to Achieve Autonomous Milling Operation." International Journal of Automation Technology 7, no. 4 (2013): 401–9. http://dx.doi.org/10.20965/ijat.2013.p0401.
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An autonomous and intelligent machine tool that performs machining operations by referring to CAD product data was developed in our previous study to solve fundamental issues with the conventional command method, which uses NC programs. A system, Digital Copy Milling (DCM), digitizing the principle of copymilling, was developed to generate tool paths during milling operations for dynamic tool motion control. In the DCM, the cutting tool is controlled dynamically to follow the surface of a CAD model corresponding to product shape, eliminating the need for the preparation of NC programs. Active tool motion controls were also realized to enhance the function of DCM. In this study, surface roughness control of the finished surface is realized as an additional enhanced function of DCM to achieve autonomous milling operations. This function allows the DCM to select cutting conditions and generates tool paths dynamically to produce the desired surface roughness: from rough, through semi-finished, to finished. The verification experiment is successfully carried out.
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Zhang, Canbin, Chi-Fai Cheung, Xiaoliang Liang, and Benjamin Bulla. "A Theoretical and Experimental Investigation of High-Frequency Ultrasonic Vibration-Assisted Sculpturing of Optical Microstructures." Applied Sciences 12, no. 21 (2022): 10937. http://dx.doi.org/10.3390/app122110937.
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Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials. It allows for a sub-micrometer form accuracy and surface roughness in the nanometer range. In this paper, high-frequency vibration-assisted sculpturing is used to efficiently fabricate quadrilateral microlens array with sharp edges, instead of using slow-slide-servo diamond turning with vibration. The machining principle of diamond sculpturing, the cutting dynamics of ultrasonic vibration, and the tool edge on the theoretical form error between the designed structure and the machined structure were investigated for this technique. Then, the quadrilateral microlens array was machined by means of conventional sculpturing (CS) and high-frequency ultrasonic vibration-assisted sculpturing (HFUVAS), respectively, followed by a study of the cutting performances including form accuracy, the surface morphology of the machined structure, and the tool wear. Results showed that conventional sculpturing fabricated microlens array with poor form accuracy and surface finish due to couple effect of material adhesion and tool wear, while the high-frequency ultrasonic vibration-assisted sculpturing achieved optical application level with sub-micrometer form accuracy and surface roughness of nanometer due to reduction of material adhesion and tool wear resulted from high-frequency intermittent cutting.
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Abou-El-Hossein, K. "Effect of Minimum Quantity Lubrication when Turning a Steel Grade." Applied Mechanics and Materials 541-542 (March 2014): 392–96. http://dx.doi.org/10.4028/www.scientific.net/amm.541-542.392.
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In turning operations a coolant is usually introduced to the cutting zone to reduce the friction developed at the tool-workpiece contact area and remove heat generated because of this rubbing action. Conventionally, a coolant is introduced into the cutting zone in excessive quantities. However, a lot of concern has been raised recently as a result of the uncontrolled using of coolants in the metal cutting industry. Therefore, the concept of minimum quantity lubricant (MQL) has been introduced recently. In this paper, the principle of MQL is utilised in machining of a steel grade. The performance of MQL in terms of surface finish is evaluated against both, the flood coolant and dry cutting modes. The results obtained show that MQL produces acceptable surface finish. Therefore, it is highly recommended to consider the application of MQL instead of flood cooling when turning steel grades.