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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

Article
Publication date: 11 July 2022

Meltem Altin Karataş

Inconel 718 (IN718) is a high-performance nickel-based superalloy with high oxidation-corrosion-temperature resistance, high strength (tensile, fatigue, creep and…

102

Abstract

Purpose

Inconel 718 (IN718) is a high-performance nickel-based superalloy with high oxidation-corrosion-temperature resistance, high strength (tensile, fatigue, creep and rupture), durability, toughness, hardness and dimensional stability, which is difficult to machine with traditional fabrication methods. To overcome these difficulties, wire electrical discharge machining (WEDM), one of the modern manufacturing methods, is used.

Design/methodology/approach

Main performance criteria in WEDM; material removal rate (MRR), cutting speed, surface roughness, cutting width (kerf) and wire wear rate. In this study, the effect of processing parameters on kerf and MRR because of processing IN718 in WEDM was investigated. Machining parameters, voltage, wire feed rate and dielectric fluid pressure were determined. Deionized water was used as a dielectric fluid and 0.3 mm brass wire was used as wire in the experiments. Gray Relational Analysis (GRA), which is one of the multi-criteria decision-making methods, has been applied for the optimization of the machining parameters in the cutting process with the WEDM. Analysis of variance (ANOVA) was used to determine the effect percentages of the cut-off parameters.

Findings

The parameter with the highest effect was determined as tension with a rate of 76.95% for kerf and 91.21% for MRR.

Originality/value

The novel approach uses Taguchi-based GRA optimization as a result of cutting IN718 with WEDM, reducing cost and time consumption.

Details

Multidiscipline Modeling in Materials and Structures, vol. 18 no. 4
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 12 April 2018

Ramesh S., M.P. Jenarthanan and Bhuvanesh Kanna A.S.

The purpose of this paper is to investigate the performance of powder-mixed electric discharge machining (PMEDM) using three different powders which are aluminium (Al)…

Abstract

Purpose

The purpose of this paper is to investigate the performance of powder-mixed electric discharge machining (PMEDM) using three different powders which are aluminium (Al), silicon carbide (SiC) and aluminium oxide (Al2O3). Besides that, the influence of different tool materials was also studied in this experimental investigation. Hence, the work material selected for this purpose was AISI P20 steel and tool materials were copper, brass and tungsten. The performance measures considered in this work were material removal rate (MRR), tool wear rate and radial over cut (ROC).

Design/methodology/approach

The process variables considered in this study were powder types, powder concentration, tool materials, peak current and pulse on time. The experimental design, based on Taguchi’s L27 orthogonal array, was adopted to conduct experiments. Significant parameters were identified by performing the analysis of variance on the experimental data.

Findings

Based on the analysis of results, it was observed that copper tool combined with Al powder produced maximum MRR (58.35 mm3/min). Similarly, the Al2O3 powder combined with tungsten tool has resulted least ROC (0.04865 mm). It was also observed that wear rate of tungsten tool was very low (0.0145 mm3/min).

Originality/value

The experimental investigation of PMEDM involving three different powders (Al, SiC and Al2O3) was not attempted before. Moreover, the study of influence of different tool materials (Cu, brass and W) together with the different powders on the electric discharge machining performance was very limited.

Details

Multidiscipline Modeling in Materials and Structures, vol. 14 no. 3
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 14 August 2019

Husandeep Sharma, Khushdeep Goyal and Sunil Kumar

Tool steel (AISI D3) is a preferred material for industrial usage. Some of the typical applications of D3 tool steel are blanking and forming dies, forming rolls, press…

Abstract

Purpose

Tool steel (AISI D3) is a preferred material for industrial usage. Some of the typical applications of D3 tool steel are blanking and forming dies, forming rolls, press tools and punches bushes. It is used under conditions where high resistance to wear or to abrasion is required and also for resistance to heavy pressure rather than to sudden shock is desirable. It is a high carbon and high chromium steel. Therefore, wire electric discharge machining (WEDM) is used to machine this tool steel. The paper aims to discuss these issues.

Design/methodology/approach

The present experimental investigation evaluates the influence of cryogenically treated wires on material removal rate (MRR) and surface roughness (SR) for machining of AISI D3 steel using the WEDM process. Two important process responses MRR and SR have been studied as a function of four different control parameters, namely pulse width, time between two pulses, wire mechanical tension and wire feed rate.

Findings

It was found that pulse width was the most significant parameter which affects the MRR and SR. Better surface finish was obtained with cryogenically treated zinc coated wire than brass wire.

Originality/value

The review of the literature indicates that there is limited published work on the effect of machining parameters in WEDM in cryogenic treated wires. Therefore, in this research work, it was decided to evaluate the effect of cryogenically treated wires on WEDM.

Details

Multidiscipline Modeling in Materials and Structures, vol. 15 no. 6
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 3 December 2018

Kanwal Jit Singh, Inderpreet Singh Ahuja and Jatinder Kapoor

This review paper reveals the literature on ultrasonic, chemical-assisted ultrasonic and rotary ultrasonic machining (USM) of glass material. The purpose of this review…

Abstract

Purpose

This review paper reveals the literature on ultrasonic, chemical-assisted ultrasonic and rotary ultrasonic machining (USM) of glass material. The purpose of this review paper is to understand and describe the working principle, mechanism of material removal, experimental investigation, applications and influence of input parameters on machining characteristics. The literature reveals that the ultrasonic machines have been generally preferred for the glass and brittle work materials. Some other non-traditional machining processes may thermally damage the work surface. Through these USM, neither thermal effects nor residual stresses have been generated on the machined surface.

Design/methodology/approach

Various input parameters have the significant role in machine performance characteristics. For the optimization of output response, several input parameters have been critically investigated by the various researcher.

Findings

Some advance types of glasses such as polycarbonate bulletproof glass, acrylic heat-resistant glass and glass-clad polycarbonate bulletproof glass still need some further investigation because these materials have vast applications in automobile, aerospace and space industries.

Originality/value

Review paper will be beneficial for industrial application and the various young researcher. Paper reveals the detail literature review on traditional ultrasonic, chemical assisted ultrasonic and rotary USM of glass and glass composite materials.

Details

World Journal of Engineering, vol. 15 no. 6
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 9 April 2018

Ramesh S. and Jenarthanan M.P.

This study aims to focus on experimenting the performance of aluminum (Al) powder mixed electric discharge machining (PMEDM) of two different materials viz plastic mould…

Abstract

Purpose

This study aims to focus on experimenting the performance of aluminum (Al) powder mixed electric discharge machining (PMEDM) of two different materials viz plastic mould die steel (AISI P20) and nickel-based super alloy (Nimonic 75). This experimental study also focuses on using three different tool materials such as copper, brass and tungsten to analyze their influence on the process output. These materials find many uses in industrial as well as aerospace applications. The performance measures considered in this work are material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR).

Design/methodology/approach

The experimental design used in this work is based on Taguchi’s L18 orthogonal array. Besides considering work and tool material as one of the process variables, other process variables are peak current (Ip), pulse on time (Ton) and concentration of powder (Cp). The analysis of variance (ANOVA) is performed on the experimental data to determine the significant variables that influence the output.

Findings

It is found that copper produced maximum MRR and brass tool exhibited higher TWR. However, the surface finish of the machined work piece was very much improved by using the brass tool. Though the performance of tungsten tool lies between the above two tool materials, it showed very little wear during EDM with or without the addition of Al powder.

Originality/value

The experimental investigation of PMEDM of nickel-based super alloy (Nimonic 75) has not been attempted before. Besides that, the study on the influence of tungsten tool on the performance of EDM is also very limited.

Details

World Journal of Engineering, vol. 15 no. 2
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 18 August 2022

Shailendra Chauhan, Rajeev Trehan and Ravi Pratap Singh

This work aims to describe the face milling analysis on Inconel X-750 superalloy using coated carbides. The formed chips and tool wear were further analyzed at different…

Abstract

Purpose

This work aims to describe the face milling analysis on Inconel X-750 superalloy using coated carbides. The formed chips and tool wear were further analyzed at different cutting parameters. The various impact of cutting parameters on chip morphology was also analyzed. Superalloys, often referred to as heat-resistant alloys, have exceptional tensile, ductile and creep strength at high operating temperatures and good fatigue strength, and often better corrosion and oxidation resistance at extreme heat. Because of these qualities, these alloys account for more than half of the weight of sophisticated aviation, biomedical and thermal power plants today. Inconel X-750 is a high-temperature nickel-based superalloy that is hard to machine because of its extensive properties. At last, the discussion regarding the tool wear mechanism was analyzed and discussed in this article.

Design/methodology/approach

The machining parameters for the study are cutting speed, feed rate and depth of cut. One factor at a time approach was implemented to investigate the effect of cutting parameters on the cutting forces, surface roughness and material removal rate. The scatter plot was plotted between cutting parameters and target functions (cutting forces, surface roughness and material removal rate). The six levels of cutting speed, feed rate and depth of cut were taken as cutting parameters.

Findings

The cutting forces are primarily affected by the cutting parameters, tool geometry, work material etc. The maximum forces Fx were encountered at 10 mm/min cutting speed, 0.15 mm/rev feed rate and 0.4 mm depth of cut, further maximum forces Fy were attained at 10 mm/min cutting speed, 0.25 mm/rev feed rate and 0.4 mm depth of cut and maximum forces Fz were attained at 50 mm/min cutting speed, 0.05 mm/rev feed rate and 0.4 mm depth of cut. The maximum surface roughness value was observed at 40 mm/min cutting speed, 0.15 mm/rev feed rate and 0.5 mm depth of cut.

Originality/value

The effect of machining parameters on cutting forces, surface roughness, chip morphology and tool wear for milling of Inconel X-750 high-temperature superalloy is being less researched in the present literature. Therefore, this research paper will give a direction for researchers for further studies to be carried out in the domain of high-temperature superalloys. Furthermore, the different tool wear mechanisms at separate experimental trials have been explored to evaluate and validate the process performance by conducting scanning electron microscopy analysis. Chip morphology has also been evaluated and analyzed under the variation of selected process inputs at different levels.

Details

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

Keywords

Article
Publication date: 27 March 2020

Mayank Choubey, K.P. Maity and Abhishek Sharma

This research explores the finite element modeling of the crater and material removal rate (MRR) in micro-electrical discharge machining (micro-EDM) with and without…

Abstract

Purpose

This research explores the finite element modeling of the crater and material removal rate (MRR) in micro-electrical discharge machining (micro-EDM) with and without vibration of the workpiece. The application of workpiece vibration in the micro-EDM process improved flushing efficiency and enhanced material removal rate (MRR).

Design/methodology/approach

In this work, the two-dimensional axisymmetric finite element method (FEM) has been developed to predict the shape of the crater with and without vibration. The temperature distribution on the workpiece surface with and without vibration has been obtained in the form of the contour plot.

Findings

The MRR obtained from the numerical model revealed that there was an enhancement in MRR in micro-EDM with vibration as compared to without vibration. The effect of process parameters on MRR in micro-EDM with and without is also presented in this work.

Originality/value

In this work, the two-dimensional axisymmetric FEM model has been developed to predict the shape of the crater with and without vibration.

Details

Grey Systems: Theory and Application, vol. 10 no. 3
Type: Research Article
ISSN: 2043-9377

Keywords

Article
Publication date: 18 September 2017

Kanwal Jeet Singh, Inderpreet Singh Ahuja and Jathinder Kapoor

The purpose of this paper, an original research paper, is to study the optimization of material removal rate (MRR) in ultrasonic machining of polycarbonate bulletproof…

249

Abstract

Purpose

The purpose of this paper, an original research paper, is to study the optimization of material removal rate (MRR) in ultrasonic machining of polycarbonate bulletproof glass and acrylic heat-resistant glass. The machining of these materials is a very tough job. There are so many constraints which need to be taken into account while machining, but without proper knowledge of material properties and machining parameters, machining is not possible. This paper gives basic knowledge about polycarbonate bulletproof and acrylic heat-resistant glass and provides ways as to how these types of materials are processed or machined.

Design/methodology/approach

The Taguchi method was utilized to optimize the ultrasonic machining parameters for drilling these advanced materials. The relationship between MRR and other controllable process parameters such as concentration of slurry, type of abrasive, abrasive grit size, power rating, concentration of HF acid and type of tool material has been analyzed by using the Taguchi approach.

Findings

Through the Taguchi analysis, it is concluded that types of abrasive and HF acid concentrations have a significant role to play in MRR for both materials; in which, type of abrasive have 72.91 and 72.96 percent contribution in MRR for polycarbonate bulletproof and acrylic heat-resistant glass, respectively. Similarly, HF acid concentration has 14.70 and 14.65 percent contribution in MRR for polycarbonate bulletproof and acrylic heat-resistant glass, respectively. The MRR was improved by 34.44 percent in polycarbonate bulletproof glass and 29.25 percent in acrylic heat-resistant glass.

Originality/value

After experimental investigation, the results of the Taguchi modal are validated.

Details

Multidiscipline Modeling in Materials and Structures, vol. 13 no. 4
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 20 March 2020

Harvinder Singh, Vinod Kumar and Jatinder Kapoor

This study aims to investigate the influence of process parameters of wire electrical discharge machining (WEDM) of Nimonic75. Nimonic75 is a Nickel-based alloy mostly…

Abstract

Purpose

This study aims to investigate the influence of process parameters of wire electrical discharge machining (WEDM) of Nimonic75. Nimonic75 is a Nickel-based alloy mostly used in the aerospace industry for its strength at high temperature.

Design/methodology/approach

One factor at a time (OFAT) approach has been used to perform the experiments. Pulse on time, pulse off time, peak current and servo voltage were chosen as input process parameters. Cutting speed, material removal rate and surface roughness (Ra) were selected as output performance characteristics.

Findings

Through experimental work, the effect of process parameters on the response characteristics has been found. Results identified the most important parameters to maximize the cutting speed and material removal rate and minimize Ra.

Originality/value

Very limited research work has been done on WEDM of Nickel-based alloy Nimonic75. Therefore, the aim of this paper to conduct preliminary experimentation for identifying the parameters, which influence the response characteristics such as material removal rate, cutting speed, Ra, etc. during WEDM of Nickel-based alloy (Nimonic75) using OFAT approach and found the machinability of Nimonic75 for further exhaustive experimentation work.

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