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Article
Publication date: 3 October 2019

Dharmendra B.V., Shyam Prasad Kodali and Nageswara Rao Boggarapu

The purpose of this paper is to adopt the multi-objective optimization technique for identifying a set of optimum abrasive water jet machining (AWJM) parameters to achieve…

Abstract

Purpose

The purpose of this paper is to adopt the multi-objective optimization technique for identifying a set of optimum abrasive water jet machining (AWJM) parameters to achieve maximum material removal rate (MRR) and minimum surface roughness.

Design/methodology/approach

Data of a few experiments as per the Taguchi’s orthogonal array are considered for achieving maximum MRR and minimum surface roughness (Ra) of the Inconel718. Analysis of variance is performed to understand the statistical significance of AWJM input process parameters.

Findings

Empirical relations are developed for MRR and Ra in terms of the AWJM process parameters and demonstrated their adequacy through comparison of test results.

Research limitations/implications

The signal-to-noise ratio transformation should be applied to take in to account the scatter in the repetition of tests in each test run. But, many researchers have adopted this transformation on a single output response of each test run, which has no added advantage other than additional computational task. This paper explains the impact of insignificant process parameter in selection of optimal process parameters. This paper demands drawbacks and complexity in existing theories prior to use new algorithms.

Practical implications

Taguchi approach is quite simple and easy to handle optimization problems, which has no practical implications (if it handles properly). There is no necessity to hunt for new algorithms for obtaining solution for multi-objective optimization AWJM process.

Originality/value

This paper deals with a case study, which demonstrates the simplicity of the Taguchi approach in solving multi-objective optimization problems with a few number of experiments.

Details

Multidiscipline Modeling in Materials and Structures, vol. 16 no. 2
Type: Research Article
ISSN: 1573-6105

Keywords

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Article
Publication date: 20 November 2020

S. Madhu and M. Balasubramanian

The purpose of this study is for solving many issues in production that includes processing of complex-shaped profile, machining of high-strength materials, good surface…

Abstract

Purpose

The purpose of this study is for solving many issues in production that includes processing of complex-shaped profile, machining of high-strength materials, good surface finish with high-level precision and minimization of waste. Among the various advanced machining processes, abrasive jet machining (AJM) is one of the non-traditional machining techniques used for various applications such as polishing, deburring and hole making. Hence, an overview of the investigations done on carbon fiber-reinforced polymer (CFRP) and glass fiber-reinforced polymer (GRFP) composites becomes important.

Design/methodology/approach

Discussion on various approaches to AJM, the effect of process parameters on the glass fiber and carbon fiber polymeric composites are presented. Kerf characteristics, surface roughness and various nozzle design were also discussed.

Findings

It was observed that abrasive jet pressure, stand-off distance, traverse rate, abrasive size, nozzle diameter, angle of attack are the significant process parameters which affect the machining time, material removal rate, top kerf, bottom kerf and kerf angle. When the particle size is maximum, the increased kinetic energy of the particle improves the penetration depth on the CFRP surface. As the abrasive jet pressure is increased, the cutting process is enabled without severe jet deflection which in turn minimizes the waviness pattern, resulting in a decrease of the surface roughness.

Research limitations/implications

The review is limited to glass fiber and carbon fiber polymeric composites.

Practical implications

In many applications, the use of composite has gained wide acceptance. Hence, machining of the composite need for the study also has gained wide acceptance.

Social implications

The usage of composites reduces the usage of very costly materials of high density. The cost of the material also comes down.

Originality/value

This paper is a comprehensive review of machining composite with abrasive jet. The paper covers in detail about machining of only GFRP and CFRP composites with various nozzle designs, unlike many studies which has focused widely on general AJM of various materials.

Details

World Journal of Engineering, vol. 18 no. 2
Type: Research Article
ISSN: 1708-5284

Keywords

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Article
Publication date: 5 February 2018

Shankar Chakraborty, Partha Protim Das and Vidyapati Kumar

The purpose of this paper is to exploit the fullest potential and capability of different non-traditional machining (NTM) processes, it is often recommended to operate…

Abstract

Purpose

The purpose of this paper is to exploit the fullest potential and capability of different non-traditional machining (NTM) processes, it is often recommended to operate them at their optimal parametric combinations. There are several mathematical tools and techniques that have been effectively deployed for identifying the optimal parametric mixes for the NTM processes. Amongst them, grey relational analysis (GRA) has become quite popular due to its sound mathematical basis, ease to implement and apprehensiveness for multi-objective optimization of NTM processes.

Design/methodology/approach

In this paper, GRA is integrated with fuzzy logic to present an efficient technique for multi-objective optimization of three NTM processes (i.e. abrasive water-jet machining, electrochemical machining and ultrasonic machining) while identifying their best parametric settings for enhanced machining performance.

Findings

The derived results are validated with respect to technique for order preference by similarity to ideal solution (TOPSIS), and analysis of variance is also performed so as to identify the most significant control parameters in the considered NTM processes.

Practical implications

This grey-fuzzy logic approach provides better parametric combinations for all the three NTM processes with respect to the predicted grey-fuzzy relational grades (GFRG). The developed surface plots help the process engineers to investigate the effects of various NTM process parameters on the predicted GFRG values.

Originality/value

The adopted approach can be applied to various machining (both conventional and non-conventional) processes for their parametric optimization for achieving better response values.

Details

Grey Systems: Theory and Application, vol. 8 no. 1
Type: Research Article
ISSN: 2043-9377

Keywords

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Article
Publication date: 8 June 2021

M. Balasubramanian and S. Madhu

The purpose of the study is to machine the composites at lower machining time with higher accuracy without causing delamination.

Abstract

Purpose

The purpose of the study is to machine the composites at lower machining time with higher accuracy without causing delamination.

Design/methodology/approach

Abrasive jet machining is the technology appropriate for machining composite materials to obtain good dimensional accuracy without causing de-lamination. The central composite design was followed in deciding the number of experiments to be carried out.

Findings

The influence of abrasive jet machining process parameters on machining time, material removal rate (MRR) and kerf characteristics were investigated. The experimental results proved the newly designed internal threaded nozzle increased MRR, thereby reducing the machining time.

Originality/value

Machining of glass fibre reinforced polymer (GFRP) is one of the challenging tasks given its non-linear and in-homogeneous properties. In this investigation, newly developed threaded and unthreaded nozzles in machining were used for making holes on the GFRP composites.

Details

World Journal of Engineering, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1708-5284

Keywords

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Article
Publication date: 8 July 2021

M. Balasubramanian and S. Madhu

The purpose of this study is to bring out the machining characteristics of abrasive jet machining on carbon fibre reinforced thermoplastic composites utilized in aerospace…

Abstract

Purpose

The purpose of this study is to bring out the machining characteristics of abrasive jet machining on carbon fibre reinforced thermoplastic composites utilized in aerospace and biomedical applications. Biocompatibility materials such as carbon fibres and polyether thermoplastics, like polyether ether ketone (PEEK) are widely used in trauma and orthopaedic surgery. Due to the heterogeneity, layered construction of reinforcing phase bonds with a resin matrix and abrasiveness of the reinforcing fibre, traditional drilling of carbon fibre-reinforced composites (CFRPs) are always challenging task.

Design/methodology/approach

An investigation is carried out using abrasive jet machine for drilling PEEK filled with 30 Wt.% carbon fibre (CF 30) using threaded and unthreaded nozzle to study the effect of abrasive jet process variables on surface roughness (Ra) and delamination factor (DF). Pressure (P) and stand-off distance (SOD) as important technological abrasive jet factors were evaluated. It is found that higher abrasive jet pressure and minimum SOD maybe selected to achieve minimum delamination.

Findings

The study further reported that the threaded nozzle minimized the surface roughness by 43% and delamination factor up to 12%.

Originality/value

This study of experimenting and observing the machining characteristics of CF30 by using a threaded nozzle is being tried for the first time and the results are deliberated.

Details

World Journal of Engineering, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1708-5284

Keywords

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Article
Publication date: 4 June 2021

Sıtkı Akıncıoğlu

The purpose of this study was to optimize the surface roughness (Ra), delamination damage at the hole entrance (FdT) and at the hole exit (FdB) and kerf angle (K) in the…

Abstract

Purpose

The purpose of this study was to optimize the surface roughness (Ra), delamination damage at the hole entrance (FdT) and at the hole exit (FdB) and kerf angle (K) in the drilling of aramid fiber-reinforced polymer (AFRP) composite material using abrasive water jet (AWJ) machining.

Design/methodology/approach

The AFRP composite was produced by the vacuum infusion method. The drilling experiments were performed on an AWJ machine using a three-axis computerized numerical control system. Machine processing parameters were determined as water pressure (2,000, 3,000 and 4,000 bar), stand-off distance (2, 4 and 6 mm) and traverse feed rate (150, 250 and 350 mm/min). Optimization of processing parameters in the drilling experiments was carried out according to the Taguchi L27 (33) orthogonal array. In addition, gray relational analysis (GRA) was used to analyze the complex uncertainty affecting the results.

Findings

Results of the drilling operations demonstrated that water pressure (P) was the most effective parameter, with 65.3%, 65.2%, 49.8% and 52.1% contribution rates for Ra, FdT, FdB and K, respectively.

Practical implications

Reliable results have been obtained with Taguchi-based GRA while drilling AFRP composite material using AWJ. Significant results have been achieved to increase the hole quality in the drilling of AFRP composite material.

Originality/value

The new approach is to present more detailed analysis by using Taguchi method and multi-decision Taguchi-based gray relation analysis in AFRP composite material drilling using AWJ. Thus, time and experiment costs are saved.

Details

Aircraft Engineering and Aerospace Technology, vol. 93 no. 4
Type: Research Article
ISSN: 1748-8842

Keywords

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Article
Publication date: 1 October 2019

Meltem Altin Karatas, Hasan Gokkaya and Muammer Nalbant

The aim of this paper is to optimize the machining parameters to obtain the smallest average surface roughness values during drilling of the carbon fiber-reinforced…

Abstract

Purpose

The aim of this paper is to optimize the machining parameters to obtain the smallest average surface roughness values during drilling of the carbon fiber-reinforced polymer (CFRP) composite material with abrasive water jet (AWJ) and analyze the damage of the delamination.

Design/methodology/approach

CFRP composite material had been fabricated having fiber orientations frequently used in the aerospace industry (0°/45°/90°/−45°). Three different stand-off distances (1, 2 and 3 mm), three different water pressures (1,800, 2,800 and 3,800 bar) and three different hole diameters (4, 8 and 12 mm) were selected as processing parameters. The average surface roughness values were obtained, and delamination damage was then analyzed using Taguchi optimization. Drilling experiments were performed using the Taguchi L27 orthogonal array via Minitab 17 software. The signal/noise ratio was taken into account in the evaluation of the test results. Using the Taguchi method, the control factors giving the mean surface roughness values were determined. Analysis of variance was performed using the experimental results, and the effect levels of the control factors on the average surface roughness were found.

Findings

It was found that water pressure and hole diameter had a higher effect on average surface roughness, while water pressure and stand-off distance were effective on delamination.

Practical implications

Owing to their excellent thermal and mechanical properties, the CFRP composite materials show greater potential for their applications in aircraft and aerospace industry.

Originality/value

The novel approach is to reduce cost and spent time using Taguchi optimization as a result of AWJ drilling the material in this fiber orientation ([0°/45°/90°/−45°]s, which is often used in the aerospace industry).

Details

Aircraft Engineering and Aerospace Technology, vol. 92 no. 2
Type: Research Article
ISSN: 1748-8842

Keywords

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Article
Publication date: 18 January 2021

Anup Malik and Neel Sanghvi

The purpose of this paper is to optimize the laser-assisted jet electrochemical machining parameters, namely, supply voltage, inter-electrode gap, duty cycle and…

Abstract

Purpose

The purpose of this paper is to optimize the laser-assisted jet electrochemical machining parameters, namely, supply voltage, inter-electrode gap, duty cycle and electrolyte concentration during machining of WC-Co composite using grey relational analysis and fuzzy logic.

Design/methodology/approach

In this work, experiments were carried out as per the Taguchi methodology and an L16 orthogonal array was used to study the influence of various combinations of process parameters on material removal rate, hole taper angle and surface roughness height. As a dynamic approach, the multiple response optimization was carried out using grey relational analysis and fuzzy logic.

Findings

The process parameters were optimized using grey relational analysis and fuzzy logic for different machining conditions such as balanced manufacturing, high-speed manufacturing and high-quality manufacturing. The research documented in this paper can be scaled up for case studies regarding industrial applications to compare optimization methods for manufacturing processes that are already being carried out.

Originality/value

An attempt to optimize material removal rate, hole taper angle and surface roughness height together by a combined approach of grey relational analysis and fuzzy logic has not been previously done.

Details

World Journal of Engineering, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1708-5284

Keywords

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