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Journal articles on the topic 'Unconventional machining processes'

Author: Grafiati
Published: 4 June 2021
Last updated: 17 February 2022

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1

Pandey, Shrihar, and Pankaj K. Shrivastava. "Vibration-assisted electrical arc machining of 10% B4C/Al metal matrix composite." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 234, no. 6 (December 1, 2019): 1156–70. http://dx.doi.org/10.1177/0954406219890375.

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To shape advanced engineering materials, many unconventional machining processes have been developed. Electrical discharge machining is such an unconventional machining process which is very popular nowadays but it is limited by poor material removal efficiency. Electrical arc machining is another unconventional machining process which is quite similar to electrical discharge machining and is now gaining attention from research fraternity due to its high material removal efficiency. In the present research, an innovative unconventional machining process known as vibration-assisted electrical arc machining has been developed. The performance of vibration-assisted electrical arc machining has been evaluated during machining of Al–B4C metal matrix composite by considering peak current, flushing velocity of dielectric and tool vibrations as input control factors. The quality characteristics considered were material removal rate, tool wear rate, relative electrode wear rate and surface roughness. It has been observed that vibration-assisted electrical arc machining results in approximately 3000% more material removal rate as compared to conventional electrical discharge machining during machining of Al–B4C metal matrix composite. The effects of various input control factors on output parameters have also been discussed. Further modelling and optimization of the process parameters has also been done by artificial intelligence approach.
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2

Gamage, J. R., and A. K. M. DeSilva. "Assessment of Research Needs for Sustainability of Unconventional Machining Processes." Procedia CIRP 26 (2015): 385–90. http://dx.doi.org/10.1016/j.procir.2014.07.096.

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3

Kovac, Pavel, Zdenko Krajny, Ljubomir Soos, and Borislav Savkovic. "OVERVIEW OF MATERIAL PROCESSING MECHANISMS IN UNCONVENTIONAL MACHINING METHOD." Journal of Production Engineering 24, no. 1 (June 30, 2021): 1–9. http://dx.doi.org/10.24867/jpe-2021-01-001.

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From the point of view of the concept itself, technology is a set of processes, rules and habits used in the production of various objects in the most diverse spheres of production, or human activity itself. Therefore, there are several designations and naming of production technologies in the professional literature. Historically, probably the oldest systematic designation and division of production technologies and processes is given as early as 1963 in the German standard: Begriffe der Fertigungsverfahren DIN 8580. The standard defines production processes for the production of geometrically certain solids. In the paper is shown explanations of mechanisms of machining when is used unconventional machining technologies.
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Ruszaj, Adam. "Unconventional processes of ceramic and composite materials shaping." Mechanik 90, no. 3 (March 6, 2017): 188–94. http://dx.doi.org/10.17814/mechanik.2017.3.39.

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In order to reach the high quality parts of machines or tools very often ceramic or composite materials on metalic or ceramic base are being applied. Efficient shaping above mentioned materials using cutting or classical grinding is difficult because of their high mechanical properties. Rational solution is application of unconventional machining methods as: electrochemical, electrodischarge or electrochemical – electrodischarge (ECDM) in case when machined materials are at least partly conductive of electrical current. In case of shaping ceramic materials unconductive for electrical current the rational solution can be application of Spark Assisted Chemical Engraving (SACE) process – the special kind of ECDM process.
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Cieloszyk, Janusz. "Face rotary turning tools (FRTT) in high productivity process." Mechanik 92, no. 11 (November 12, 2019): 736–38. http://dx.doi.org/10.17814/mechanik.2019.11.100.

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The article presents an unconventional method of machining rolling surfaces. This method is called face rotary turning tools (FRTT) or spinning tools technology. Advantages and limitations of the method were discussed and its effectiveness in modern machining processes was shown, based on the proposed simple models.
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Grzesik, Wit. "Hybrid machining processes. Definitions, generation rules and real industrial importance." Mechanik 91, no. 5-6 (May 28, 2018): 338–42. http://dx.doi.org/10.17814/mechanik.2018.5-6.50.

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Some important trends in the development of advanced machining processes with potential applications in Production/Manufacturing 4.0 are presented. In general, both conventional and unconventional machining processes are characterized in terms of potential technological possibilities related to their hybridization allowing the performance of more productive and effective machining processes. This is due to the fact that hybrid processes considerably enhance the advantages of individual processes and minimize potential disadvantages in individual processes. Possible classification systems of hybrid processes including the CIRP terminology are overviewed and some representative examples are provided. In particular, the hybrid machining processes based on the simultaneous and controlled interaction of process mechanisms and/or energy sources leading to the synergic effect (1 + 1 = 3) on the process performance are taken into account. Some conclusions and future trends in the implementation of hybrid processes are outlined.
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7

JAIN, NEELESH K., and VIJAY K. JAIN. "PROCESS SELECTION METHODOLOGY FOR ADVANCED MACHINING PROCESSES." Journal of Advanced Manufacturing Systems 02, no. 01 (June 2003): 5–45. http://dx.doi.org/10.1142/s0219686703000204.

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Manufacture of a product in a desired shape and size with the desired characteristics and properties depends not only on the design of the product but also on the selection of an appropriate manufacturing process(es), which requires knowledge about the various alternatives available. This paper describes the process selection methodology for unconventional or advanced machining processes (AMPs), along with a preliminary selection strategy for basic type of manufacturing process. These two tasks along with parametric optimization form the core of an integrated and automated process planning system for an advanced machining environment. The process selection methodology for the AMPs is based on elimination and ranking strategy. To facilitate the process selection, AMPs have been reclassified or regrouped according to their material application capabilities, shape or manufacturing feature generating capabilities, operational capabilities, economic aspects, and environmental aspects. The described process selection methodologies for basic manufacturing process and AMPs, have been implemented in a software named as APSPOAMPS (Automated Process Selection and Parametric Optimization of AMPs). This paper also describes the proposed reclassifications of AMPs, implementation details of the developed software along with the two test examples.
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8

Shrivastava, Pankaj Kumar, Shrihar Pandey, and Shivam Dangi. "Electrical arc machining: Process capabilities and current research trends." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 15 (May 1, 2019): 5190–200. http://dx.doi.org/10.1177/0954406219846151.

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Electrical arc machining is the thermal energy-based unconventional machining process, which utilizes energy of arc to melt and vaporize workpiece material. Electrical arc machining has the capability to machine advanced materials such as metal matrix composites, superalloys, and conductive ceramics effectively. The process is considered to be efficient than most of the other unconventional machining processes in terms of the material removal rate. But it has got limitations because it results in a very poor surface finish. Tool wear rate, recast layer formation, surface and subsurface cracks, and geometrical inaccuracy are other limitations up to a certain extent. In this paper, the comprehensive review of research carried out so for in the area of electrical arc machining has been presented. The paper discusses the detailed experimental and theoretical studies done on electrical arc machining to elucidate the effects of various input control factors on different quality characteristics. The paper also contains modeling and optimization studies done so far in electrical arc machining and finally discusses the future research possibilities in the area.
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9

Dhande, S. G., K. P. Karunakaran, and B. K. Misra. "Geometric Modeling of Manufacturing Processes Using Symbolic and Computational Conjugate Geometry." Journal of Engineering for Industry 117, no. 3 (August 1, 1995): 288–96. http://dx.doi.org/10.1115/1.2804333.

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The present paper describes a unified symbolic model of conjugate geometry. This model can be used to study the geometry of a cutting tool and the surface generated by it on a blank along with the kinematic relationships between the tool and the blank. A symbolic algorithm for modeling a variety of shape generating processes has been developed. It has been shown that using this algorithm one can develop geometric models for conventional machining processes such as milling, turning, etc. as well as unconventional or advanced machining techniques such as Electric Discharge Machining (EDM), Laser Beam Machining (LBM) etc. The proposed symbolic algorithm has been implemented using the symbolic manipulation software, MACSYMA. The algorithm is based on the concepts of envelope theory and conjugate geometry of a pair of mutually enveloping surfaces. A case study on the manufacture of a helicoidal surface and an illustrative example are given at the end of the paper.
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10

Pritima, D., J. Vairamuthu, P. Gopi Krishnan, S. Marichamy, B. Stalin, and S. Sheeba Rani. "Response analysis on synthesized aluminium-scandium metal matrix composite using unconventional machining processes." Materials Today: Proceedings 33 (2020): 4431–35. http://dx.doi.org/10.1016/j.matpr.2020.07.672.

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11

Kumar, K. Saran, and S. Karthick. "Control of Stand-off-Distance in Abrasive Jet Machining - A Fuzzy Approach." Applied Mechanics and Materials 592-594 (July 2014): 106–11. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.106.

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In general Unconventional Machining Processes (UCMs) or Non Traditional Machining Processes (NTMs) are used only when no other Traditional Machining Processes can meet the necessary requirements, both efficiently and economically. This is because using of most of NTMs incurs relatively higher installation, maintenance, operating and tooling costs. Now-a-days, complicated and intricate shaped structures and drilling of square and micro holes are done using the NTMs. Among the several NTMs available, Abrasive Jet Machining (AJM) is one widely used technique. There are several Process Parameters involved in this process and also have a greater impact on the overall machining performances (i.e.) Material removal Rate (MRR). In this paper a novel approach is made to control the Stand-off-Distance (SOD) at an optimal level to achieve higher MRR using Fuzzy Logic. The Fuzzy controller technique such as Type 1 Fuzzy Logic Controller and Interval Type 2 Fuzzy Logic Controller are compared which tends to control the servo mechanism that actuates the nozzle to maintain the altitude between nozzle tip and workpiece. This experimentation will serve the purpose of handling materials with non-uniform surfaces in them.
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12

MAITY, K. P., and M. CHOUBEY. "A REVIEW ON VIBRATION-ASSISTED EDM, MICRO-EDM AND WEDM." Surface Review and Letters 26, no. 05 (June 2019): 1830008. http://dx.doi.org/10.1142/s0218625x18300083.

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Electrical discharge machining (EDM) is an unconventional machining process used for machining of hard-to-cut materials. Both EDM and micro-EDM processes are extensively used for producing dies and molds, complex cavities, and 3D structures. In recent years, researchers have intensively focused on improving the performance of both micro-EDM and EDM processes. This paper reviews the research work carried out by the researchers on vibration-assisted EDM, micro-EDM, and wire EDM. The consolidated review of this research work enables better understanding of the vibration-assisted EDM process. This study also discusses the influence of vibration parameters such as vibration frequency and amplitude on the material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR). The important issues and research gaps in the respective area of research are also presented in this paper.
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13

Narayanan, G. Sankara, and Durairaj Vasudevan. "A Mathematical Model for Wire Cut Electrical Discharge Machine Parameters Using Artificial Neural Network." Advanced Materials Research 984-985 (July 2014): 9–14. http://dx.doi.org/10.4028/www.scientific.net/amr.984-985.9.

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Unconventional machining process finds heavy application in aerospace, automobile and in production industries where accuracy is most needed. This process is chosen over other traditional methods because of the advent of composite and high strength materials, multifaceted parts and also because of its elevated precision. Regularly in unconventional machines, trial and error method is used to fix the values of process parameters. An algorithm incorporating Artificial Neural Network (ANN) is proposed to create mathematical model functionally relating process parameters and operating parameters of a wire cut electric discharge machine (WEDM) and copper is the work piece. This is accomplished by training a learning algorithm of feed forward neural network with back propagation. The required data used for training and testing the ANN is obtained by conducting trial runs in wire cut electric discharge machine. Proposed algorithm paves reduction in time for fixing the values for the process parameters and thus reduces the production time along with reduction in cost of machining processes and thereby increases the production as well as the efficiency. The programs for training and testing the neural network are developed, using matlab 7.0.1 package.
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14

Tyagi, R. K. "A review of few unconventional machining processes based on the concept of velocity shear instability in plasma." Production & Manufacturing Research 2, no. 1 (January 2014): 216–27. http://dx.doi.org/10.1080/21693277.2014.899934.

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15

Thangamani, Geethapriyan, Muthuramalingam Thangaraj, Khaja Moiduddin, Syed Hammad Mian, Hisham Alkhalefah, and Usama Umer. "Performance Analysis of Electrochemical Micro Machining of Titanium (Ti-6Al-4V) Alloy under Different Electrolytes Concentrations." Metals 11, no. 2 (February 2, 2021): 247. http://dx.doi.org/10.3390/met11020247.

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Titanium alloy is widely used in modern automobile industries due to its higher strength with corrosion resistance. Such higher strength materials can be effectively machined using unconventional machining processes, especially the electro-chemical micro machining (ECMM) process. It is important to enhance the machining process by investigating the effects of electrolytes and process parameters in ECMM. The presented work describes the influence of three different combinations of Sodium Chloride-based electrolytes on machining Titanium (Ti-6Al-4V) alloy. Based on the ECMM process parameters such as applied voltage, electrolytic concentration, frequency and duty cycle on response, characteristics are determined by the Taguchi design of experiments. The highest material removal rate (MRR) was achieved by the Sodium Chloride and Sodium Nitrate electrolyte. The combination of Sodium Chloride and Citric Acid achieve highest Overcut and Circularity. The optimal overcut was observed from the Sodium Chloride and Glycerol electrolyte due to the presence of glycerol. The better conicity was obtained from Sodium Chloride and Citric Acid in comparison with other electrolytes. A Sodium Chloride and Glycerol combination could generate better machined surface owing to the chelating effect of Glycerol.
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16

Fatatit, Abubaker Y., and Ali Kalyon. "Determination of Multi-performance Characteristics in Electric Discharge Machining of DIN 1.2767 Steel Using Grey Relational Analysis." ARO-THE SCIENTIFIC JOURNAL OF KOYA UNIVERSITY 9, no. 1 (March 1, 2021): 1–7. http://dx.doi.org/10.14500/aro.10718.

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Electric discharge machining (EDM) is one of the most important unconventional machining processes, which can cut hard materials and complex shapes that are difficult to machine by conventional machining processes easily and with high accuracy. In this study, L18 orthogonal array combined with gray relational analysis (GRA) is implemented to investigate the multiple performances characteristics in EDM of DIN 1.2767 Tool Steel. Machining process parameters selected were discharge current (Ip), pulse-on time (Ton), pulse-off time (Toff), and electrode material (copper alloys [NSS and B2]). The investigated performances characteristics were tool wear rate (TWR) and material removal rate (MRR). Analysis of variance (ANOVA) and Taguchi’s signal-to-noise ratio with the help of Minitab-17 software were used to analysis the effect of the process parameters on TWR and MRR. The experimental results and data analysis reveal that TWR and MRR are more affected by Ip and Ton. The minimum TWR was obtained at parametric combination Ip (6A), Ton (800 μs), and Toff (800 μs) and the maximum MRR attained at Ip (25A), Ton (800 μs), Toff (200 μs), and NSS electrode. After applying GRA, the optimal parametric combination for MRR and TWR was determined as Ip (25A), Ton (800 μs), Toff (200 μs), and NSS electrode. The study also exhibited the occurrence of an interaction between the variables on the responses. In addition, scanning electron microscopy images showed that the metal surface was affected with the increase in Ton and Toff.
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17

Escaich, Cécile, Zhongde Shi, Luc Baron, and Marek Balazinski. "Machining of Titanium Metal Matrix Composites: Progress Overview." Materials 13, no. 21 (November 6, 2020): 5011. http://dx.doi.org/10.3390/ma13215011.

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The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).
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Alazemi, Fahad Kh A. O. H., Mohd Na’im Abdullah, Mohd Khairol Anuar Mohd Ariffin, Faizal Mustapha, and Eris Elianddy Supeni. "Optimization of Cutting Tool Geometry for Milling Operation using Composite Material – A Review." Journal of Advanced Research in Materials Science 76, no. 1 (January 18, 2021): 17–25. http://dx.doi.org/10.37934/arms.76.1.1725.

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Fibre reinforced composite materials having their own specific advantages are why they currently gain more and more attention. A vital procedure once preparations of materials are done is the machining process. Various secondary operations such as milling, drilling, turning and various unconventional processes are used for achieving near net shape and size of desired component. Compared to conventional materials, fibre reinforced composite materials are more practical to be use in machining process due to less amount of cutting forces are required to complete the exact shape and size of desired component. Therefore, a review on milling of fibre reinforced composite material will be helpful for numerous researchers and other manufacturing industries, which are currently working in this field. This review paper represents the classification of composite materials, Fiber Reinforced Plastic (FRP) Composites and Carbon Fibre Reinforced Plastic (CFRP) Composites. In addition, this review also defines the machinability of CFRP composites selection and tool design of end mill.
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19

Sánchez, Carlos J., Pedro M. Hernández, María D. Martínez, María D. Marrero, and Jorge Salguero. "Combined Manufacturing Process of Copper Electrodes for Micro Texturing Applications (AMSME)." Materials 14, no. 10 (May 12, 2021): 2497. http://dx.doi.org/10.3390/ma14102497.

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Surface texturing has brought significant improvements in the functional properties of parts and components. Sinker electro discharge machining (SEDM) is one of the processes which generates great texturing results at different scale. An electrode is needed to reproduce the geometry to be textured. Some geometries are difficult or impossible to achieve on an electrode using conventional and even unconventional machining methods. This work sets out the advances made in the manufacturing of copper electrodes for electro erosion by additive manufacturing, and their subsequent application to the functional texturing of Al-Cu UNS A92024-T3 alloy. A combined procedure of digital light processing (DLP) additive manufacturing, sputtering and micro-electroforming (AMSME), has been used to produce electrodes. Also, a specific laboratory equipment has been developed to reproduce details on a microscopic scale. Shells with outgoing spherical geometries pattern have been manufactured. AMSME process has shown ability to copper electrodes manufacturing. A highly detailed surface on a micrometric scale have been achieved. Copper shells with minimum thickness close to 300 µm have been tested in sinker electro discharge machining (SEDM) and have been shown very good performance in surface finishing operations. The method has shown great potential for use in surfaces texturing.
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20

Jampana, Venkata N. Raju, P. S. V. Ramana Rao, and A. Sampathkumar. "Experimental and Thermal Investigation on Powder Mixed EDM Using FEM and Artificial Neural Networks." Advances in Materials Science and Engineering 2021 (September 6, 2021): 1–12. http://dx.doi.org/10.1155/2021/8138294.

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Electric discharge machining (EDM) process is one of the earliest and most extensively used unconventional machining processes. It is a noncontact machining process that uses a series of electric discharges to remove material from an electrically conductive workpiece. This article is aimed to do a comprehensive experimental and thermal investigation of the EDM, which can predict the machining characteristic and then optimize the output parameters with a newly integrated neural network-based methodology for modelling and optimal selection of process variables involved in powder mixed EDM (PMEDM) process. To compare and investigate the effects caused by powder of differently thermo physical properties on the EDM process performance with each other as well as the pure case, a series of experiments were conducted on a specially designed experimental setup developed in the laboratory. Peak current, pulse period, and source voltage are selected as the independent input parameters to evaluate the process performance in terms of material removal rate (MRR) and surface roughness (Ra). In addition, finite element method (FEM) is utilized for thermal analysis on EDM of stainless-steel 630 (SS630) grade. Further, back propagated neural network (BPNN) with feed forward architecture with analysis of variance (ANOVA) is used to find the best fit and approximate solutions to optimization and search problems. Finally, confirmation test results of experimental MRR are compared using the values of MRR obtained using FEM and ANN. Similarly, the test results of experimental Ra also compared with obtained Ra using ANN.
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21

Al Hazza, Muataz Hazza Faizi, Amin M. F. Seder, Erry Y. T. Adesta, Mohammad Riza, and N. M. Shaffiar. "Multi Objective Optimisation for High Speed End Milling Using Simulated Annealing Algorithm." Advanced Materials Research 1115 (July 2015): 113–16. http://dx.doi.org/10.4028/www.scientific.net/amr.1115.113.

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Machining at high cutting speeds produces higher temperatures in the cutting zone. These temperatures affect the surface quality and flank wear progress. Therefore, determining the optimum cutting levels to achieve the minimum surface roughness and flank wear is an important for it is economical and mechanical issues. This paper presents the optimization of machining parameters in end milling processes by using the simulated annealing algorithm (SAA) as one of the unconventional methods in optimization. The minimum arithmetic mean roughness (Ra) and minimum flank wear length were the objectives. The mathematical models have been developed, in terms of cutting speed, feed rate, and axial depth of cut by using Response surface Methodology (RSM). This paper presents the optimum cutting parameters: cutting speed, feed rate and depth of cut to achieve the minimum values of surface roughness and minimum flank wear length. The results show that the cutting speed in the range of 200 m/min, feed rate of 0.05 mm/tooth and depth of cut of 0.1mm gave the minimum arithmetic mean roughness (Ra) for 164 and minimum flank wear for 0.0379 in the boundary design of the experiment after 8000 iteration.
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22

Bîrdeanu, Aurel Valentin, Mihaela Bîrdeanu, Gabriel Gruionu, and Lucian Gheorghe Gruionu. "Processing Technologies Applied for Realizing New Medical Micro-Devices Components." Advanced Engineering Forum 27 (April 2018): 98–102. http://dx.doi.org/10.4028/www.scientific.net/aef.27.98.

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The paper presents the new methods of use of processing technologies for realizing proof-of-concept new medical micro-devices components. By using both classical mechanical machining and unconventional laser beam cutting and welding combined with soldering two proof-of-concept medical devices components were realized. The materials processed were stainless steel and super-elastic nitinol alloy. The selection of the processing technologies was done based on the specific requirements of the devices components as well as the characteristics of the applied materials. The selected technologies were fit for the requirements of the proof-of-concept medical micro-devices components, further RTD work being needed in order to comply with the bio-compatibility and in-exploitation requirements. The specific outcomes of using classical mechanical machining and laser beam processing are presented.
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Przesmycki, Aleksander, Tadeusz Sałaciński, Maciej Winiarski, Rafał Świercz, and Tomasz Chmielewski. "Evaluation of surface roughness, dimensional and shape accuracy of Al₂O₃ ceramics in hardened state after milling." Mechanik 92, no. 12 (December 9, 2019): 790–94. http://dx.doi.org/10.17814/mechanik.2019.12.109.

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The effect of technological parameters of machining on surface roughness, dimensional and shape accuracy in the process of milling Al2O3 ceramics in hardened state was evaluated. The unique properties of ceramic materials cause more and more interest in them in various branches of industry. Ceramics in the hardened state can be processed using unconventional methods and conventional methods while maintaining the appropriate technological parameters. Ceramics cutting tests were carried out in a hardened state (face and shape milling) on a CNC milling machine using PCD tools. Geometric surface structure study and measurements of geometric dimensions were made.
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Herghelegiu, Eugen, Crina Radu, Carol Schnakovszky, and Ion Cristea. "High Pressure Water Jet Cutting of the Al 6061 T651 Aluminum Alloy." Applied Mechanics and Materials 371 (August 2013): 245–49. http://dx.doi.org/10.4028/www.scientific.net/amm.371.245.

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Water jet cutting is an unconventional technology used for materials processing. It is known to be one of the most versatile and rapid cutting methods that can be applied to process a greater variety of materials such: metallic materials, non-metallic materials, stone, glass etc. By comparing with the classical technologies, the water jet cutting presents the following advantages: very low side forces during the machining; it is rapid; it is silent; no thermal distortion, high flexibility and has a good cutting accuracy and minimal burrs. In this paper the influence of the high pressures on the surface quality of the workpieces processed by water jet abrasive cutting is presented. The studied parameters were as follows: width of the processed surface at the jet inlet (Li), width of the processed surface at the jet outlet (Lo), deviation from perpendicularity (u), inclination angle (α) and roughness (Ra).
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Monka, Peter. "The Comparison of Surface Roughness Characteristics Achieved by the Machining with Conventional and Unconventional Geometry of Tools." Advanced Materials Research 622-623 (December 2012): 352–56. http://dx.doi.org/10.4028/www.scientific.net/amr.622-623.352.

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The paper deals with the experiments realized by means of cutting tool with linear cutting edge not parallel with the axis of the workpiece in order to be observed the suitable values of surface roughness characteristics in dependency on the feed and cutting speed. During experiments were machined three types of steels. Acquired data were statistical processed by regression analysis. The results of the measurements show that the investigated cutting tool enables to secure the same values of surface profile characteristics of steels as a classical cutting tool at finishing with the significant increase of the feed per revolution. It directly influences length of the technological operation time which is several times shortened and so the machining productivity can increase.
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Lipiec, Piotr, Dominik Wyszynski, and Sebastian Skoczypiec. "Primary Research on Jet ECM Processing of Difficult to Cut Materials." Key Engineering Materials 554-557 (June 2013): 1793–99. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1793.

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Unconventional production techniques became interesting and promising part of manufacturing methods. They provide complementary, to traditional loss methods, solutions enabling use of high - performance engineering materials for construction of machinery and industrial equipment. By using properly selected methods or their hybrids difficult to cut materials as steel, alloys, sintered materials and composites can be processed. Among the wide variety of unconventional methods of materials forming, particular attention should be given to electrochemical machining, which has been successfully used in various industries. This fact proves attractiveness and versatility of ECM. The method could be used on large scale and many variations was developed as each application requires an individual approach and has own requirements. One of the least known and described type of electrochemical machining is jet ECM where the electrolyte jet stream acts as a tool. In this kind of machining, the part is shaped only in the area where the electrolyte jet strikes the surface. This is due to the fact that the current density distribution is located just below the stream. In the area around the jet hitting the work piece thin electrolyte layer is formed. Thickness of that layer is growing rapidly. Since the electrolyte jet machining is an electrochemical process, the machined surface has all the benefits of ECM. There is no burrs and low temperature of the process prevents appearance of cracks and there is no heat-affected zone. Electrolyte jet machining can be used as well as in macro and micro drilling, turning, texturing, and electroplating. The process can be controlled by proper selection of such parameters as time, the current density and the diameter of the jet. Jet ECM can be used not only for material removal, but also for coloration (passivation) by means of anodic dissolution. 3D shaping of elements is also possible by controlling the current and the velocity of the electrolyte stream. In addition, by changing the polarity of the applied voltage it is possible to use this method in broadly considered electroplating. The paper presents results of the initial research on jet electrochemical machining (jet ECM) of acid proof steel and tungsten carbide. The material processing was carried in two ways – drilling holes and shaping grooves. Shaping was realized in milling and face turning regime. The influence of the two basic process parameters voltage and pressure was examined. In order to get rough information about the jet ECM process experiment planning method was applied. Obtained results enable planning of the further extended research.
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Herghelegiu, Eugen, Crina Radu, Carol Schnakovszky, and Ion Cristea. "Influence of the Distance between the Cutting Head and Working Sample on the Geometric Precision in Water Jet Abrasive Cutting Process." Applied Mechanics and Materials 371 (August 2013): 240–44. http://dx.doi.org/10.4028/www.scientific.net/amm.371.240.

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Water jet cutting is an unconventional technology used for materials processing. Abrasive water jet cutting has become a highly developed industry technology. Its development has been favored by the fact that abrasive water jet cutting can be used in practically all areas in which solids are processed stone, glass, plastics, composite materials and metals. It is known to be one of the most versatile and rapid cutting methods that can be applied to process a greater variety of materials such: metallic materials, non-metallic materials. By comparing with the classical technologies, the water jet cutting presents the following advantages: very low side forces during the machining; it is rapid; it is silent; no thermal distortion, high flexibility and has a good cutting accuracy and minimal burrs. The aim of the present paper is to present the results of the study regarding the influence of the distance between the cutting head and working sample processed by abrasive water jet cutting on the surface roughness and dimensional accuracy of the processed part.
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28

"A STUDY ON MODERN UNCONVENTIONAL MACHINING PROCESSES AND ITS MACHINING PARAMETERS CHARACTERISTICS." International Journal of Advance Engineering and Research Development 4, no. 01 (January 30, 2017). http://dx.doi.org/10.21090/ijaerd.43211.

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29

Prabhakaran, M., C. Sivakandhan, Chevvuri Venkata Sai Ram Gopal, Sai Nikhilesh Pilla, Ram Subbiah, and S. Marichamy. "Machinability investigations on cupronickel MMC through unconventional machining processes." Materials Today: Proceedings, November 2020. http://dx.doi.org/10.1016/j.matpr.2020.10.117.

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30

Pritima, D., P. Gopi Krishnan, P. Padmanabhan, and B. Stalin. "Performance of electrical energy based unconventional machining processes – Review." Materials Today: Proceedings, February 2021. http://dx.doi.org/10.1016/j.matpr.2020.12.749.

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31

"Optimization of Process Parameters of Electrical Discharge Machining Process for Performance Improvement." International Journal of Innovative Technology and Exploring Engineering 8, no. 11 (September 10, 2019): 3830–36. http://dx.doi.org/10.35940/ijitee.k2262.0981119.

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Unconventional machining methods are used where conventional techniques are unachievable, inacceptable or cost ineffective. Number of unconventional techniques has been developed to achieve special machining conditions. When these methods are engaged properly, they provide several benefits over conventional methods. High strength alloys can be machined easily, complicated contours and difficult geometries with close tolerances and better surface topograph can be developed using unconventional processes. One of the most popular unconventional machining methods is electrical discharge machining. In this paper, the detailed investigation has carried out to give an insight into the progression of research in the domain of spark machining and optimizing important process variables of this type of machining. It has been found from the available literature that optimization of process parameters of electrical discharge machining can improve machining performance pertaining to material removal and surface finish. Identifying the research gaps and are presented under the heading analysis and discussion. Conclusions drawn from this work will be useful in carrying out research in the sphere of unconventional EDM.
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CHOUBEY, MAYANK, and K. P. MAITY. "EXPERIMENTAL INVESTIGATION OF MICRO-EDM OPERATION IN INCONEL 718." Surface Review and Letters, August 14, 2021, 2150102. http://dx.doi.org/10.1142/s0218625x2150102x.

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The increasing trends towards miniaturized and lightweight components for various engineering and aerospace applications by unconventional machining the demand for micro-electrical discharge machining (EDM) have become increasingly wide. Micro-EDM is one of the most promising unconventional machining processes as compared to other unconventional machining due to its lower cost, ease of operation, and accuracy. This research explores the experimental investigation of micro-EDM operation on hard and difficult to machine material Inconel 718. The micro-holes were fabricated on an Inconel 718 workpiece with a copper electrode. The influence of input process parameters on material removal rate (MRR), machining time, and quality of the fabricated micro-holes were studied. Overcut and taperness of the fabricated micro-sized through holes were measured to address the accuracy of the fabricated micro-holes in micro-EDM operation. Experimental results reveal that the increase in current and voltage increases the MRR, and reduced machining time but at the cost of dimensional accuracy of the fabricated holes. The high value of current and voltage resulted in poor surface quality. The optimum machining condition that gives higher MRR with higher machining precision was obtained by experimenting while machining Inconel 718.
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33

Jayappa, Pradeep, Santhosh Srinivasan, K. Vetrivel Murugan, C. Thangavel, M. Bala Theja, G. Phanindra Raja Varma, S. Marichamy, and Ram Subbiah. "An overview on role of unconventional machining processes on different materials." Materials Today: Proceedings, September 2021. http://dx.doi.org/10.1016/j.matpr.2021.08.253.

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34

Rajasuthan, K., M. Palpandi, Veernapati Gitanjali, Panati Nithya, Ram Subbiah, and S. Marichamy. "Evaluation of material removal rate of stellite alloy using unconventional machining processes." Materials Today: Proceedings, November 2020. http://dx.doi.org/10.1016/j.matpr.2020.10.260.

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35

Boopathi, Sampath. "An extensive review on sustainable developments of dry and near-dry electrical discharge machining processes." Journal of Manufacturing Science and Engineering, September 23, 2021, 1–37. http://dx.doi.org/10.1115/1.4052527.

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Abstract Electrical discharge machining (EDM) is very essential unconventional electro-thermal machining process to machine the contour profile of hard materials in modern production industries. The liquid dielectric fluid has been replaced by the gas and minimum quantity of liquid mixed with gas (gas-mist) to encourage the green machining processes. The various gases and gas-mist have been used as the working fluid in dry and near-dry EDM respectively. The research-contextual, various dielectric fluids, sustainable and innovative developments, process parameters, machining characteristics, and optimization techniques applied in various dry and near-dry EDM have been illustrated through an extensive literature survey. Future research opportunities in both dry and near-dry EDM have been summarized to promote eco-friendly EDM research activities.
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36

"Hybridization of Electrical Discharge Machining Process." International Journal of Engineering and Advanced Technology 9, no. 1 (October 30, 2019): 1059–65. http://dx.doi.org/10.35940/ijeat.a9477.109119.

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: This paper discusses the recent developments in the field of Electrical Discharge Machining (EDM) hybrid process. Spark machining is a universally recognised unconventional process, excluding the restriction of having low machining efficiency. To overcome this, various investigations have been made on designing of electrode, types of dielectric medium, variations in input parameters etc. Although material expulsion rate have been found to improve, nonetheless it cannot encounter the requirements of modern industries and the quality of surface is inferior. To increase further the utility of EDM, its hybridization with other process have to be carried out. A hybrid process can reduce the machining time while maintaining better surface and material expulsion rate. In hybrid process, the mechanism of two processes is applied concurrently or consecutively. Although, the performance of combined process is better as compared to the individual processes but hybridization increases the process complexity.
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37

Che, Demeng, Ishan Saxena, Peidong Han, Ping Guo, and Kornel F. Ehmann. "Machining of Carbon Fiber Reinforced Plastics/Polymers: A Literature Review." Journal of Manufacturing Science and Engineering 136, no. 3 (March 26, 2014). http://dx.doi.org/10.1115/1.4026526.

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Carbon fiber reinforced plastics/polymers (CFRPs) offer excellent mechanical properties that lead to enhanced functional performance and, in turn, wide applications in numerous industrial fields. Post machining of CFRPs is an essential procedure that assures that the manufactured components meet their dimensional tolerances, surface quality and other functional requirements, which is currently considered an extremely difficult process due to the highly nonlinear, inhomogeneous, and abrasive nature of CFRPs. In this paper, a comprehensive literature review on machining of CFRPs is given with a focus on five main issues including conventional and unconventional hybrid processes for CFRP machining, cutting theories and thermal/mechanical response studies, numerical simulations, tool performance and tooling techniques, and economic impacts of CFRP machining. Given the similarities in the experimental and theoretical studies related to the machining of glass fiber reinforced polymers (GFRPs) and other FRPs parallel insights are drawn to CFRP machining to offer additional understanding of on-going and promising attempts in CFRP machining.
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"Design and Optimization of EDM using Metal Matrix Composite by Genetic algorithm and Jaya Algorithm." International Journal of Innovative Technology and Exploring Engineering 9, no. 4 (February 10, 2020): 3216–21. http://dx.doi.org/10.35940/ijitee.d1109.029420.

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Aluminum Boron carbide (Al-B4C) is a form of metal matrix composite (MMC) belongs to advanced category of material which is gaining popularity now-a-days because of its excellent mechanical and physical properties. Unconventional machining processes (UMPs) are now day’s best options to machine such kinds of modern materials. Electro discharge machining (EDM) process now days the best UMP whichever utilizes thermic energy power of spark for material removal. In present research the EDM has been carried out in Al-B4C MMC by varying different EDM parameters to evaluate material removal rate (MRR) and tool wear rate (TWR). The response surface model (RSM) has been developed for both the MRR and TWR. The developed RSM has been utilized during optimization. Optimizations of responses the MRR and or TWR have been done by using genetic algorithm and jaya algorithm. Finally both the algorithms have been compared with respect to current manufacturing paradigm.
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Yadav, Sunil Kumar, Manoj Kumar Singh, and Bharat Raj Singh. "Effect of Unconventional Machining on Surface Roughness of Metal: Aluminum and Brass- A Case Study of Abrasive Flow." SAMRIDDHI : A Journal of Physical Sciences, Engineering and Technology 2, no. 1 (June 11, 2015). http://dx.doi.org/10.18090/samriddhi.v2i1.1598.

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Abrasive finishing techniques are developed to overcome the problems such as high direct labor cost and to produce finished precision parts with specific features for finishing inaccessible areas. Abrasive finishing is carried out with a large number of cutting edges, which have indefinite orientation and geometry. Abrasive fine finishing processes are commonly employed because of their inherent capabilities of finishing various geometries of form, (i.e., flat surface, round surface, etc), and various geometries of surface relation (i.e. parallelism, squareness, straightness, angularity, etc.), with the desired dimensional accuracy and surface finish. In AFM, the medium gently and uniformly scrape the surfaces and/or edges, whereas it is not so in the case of grinding. In grinding, abrasives are held rigidly by hard (solid) bond material, whereas in AFM abrasives are held by semisolid bond (or medium). In all these abrasive finishing processes, the grain-workpiece interaction involves one or more of the basic modes of material deformation, i.e., cutting, ploughing and rubbing. Basically cutting is a material removal process, ploughing is a material displacement process and rubbing / sliding is a surface modification process. The key components of AFM process are the machine, tooling and abrasive medium. Process input parameters such as extrusion pressure, number of cycles, grit composition and type, tooling and fixture designs have impact on AFM output responses (such as surface finish and material removal). AFM is capable to produce surface finish (Ra) as good as 0.05 ?m, deburr holes as small as 0.2 mm and radius edges from 0.025 mm to 1.5mm. AFM has wide range of applications in industries such as aerospace, medical, electronics, automotive, precision dies and moulds as a part of their manufacturing activities.
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40

"Machine Ability Characteristics of PWEDM Process." International Journal of Innovative Technology and Exploring Engineering 9, no. 1 (November 10, 2019): 3580–83. http://dx.doi.org/10.35940/ijitee.a3962.119119.

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The traditional machining consists of a specific contact between the tool and work piece. As a result of this contact the tool may wear out after a few operations. In addition to that, the MRR (Material Removal Rate), Surface Finish, etc. is also lowered. As a result of these drawbacks, traditional or conventional machining processes cannot be used to machine ceramic based alloys and thus we opt for unconventional machining process. The Electrical Discharge Machine contains of two spaces one is Electrode and other is Work piece. In this concept the among the tool wear rate is moderate and the surface roughness is to be poor. The tool cost is so high. Hence continuously tool modification is not possible. So in the work main objective of the problem is reduced the tool wear rate and increase the MRR. (Material removal rate). So in the case we are consider in the surface roughness. The surface roughness is to be high is the taken in industrial application. So we have focus with surface roughness. These are the considering with in our problems. In our aim is reducing the toll wear and improve the Material Remove rate. In order to addition of graphite in Electrolyte. When added the electrolyte in Graphite the Toll wear rate decrease and increase a material Removal Rate. Finally we have disc the DOE process
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