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Article
Publication date: 2 May 2019

Shankar Chakraborty, Prasenjit Chatterjee and Partha Protim Das

To meet the requirements of high-dimensional accuracy and surface finish of various advanced engineering materials for generating intricate part geometries, non-traditional

Abstract

Purpose

To meet the requirements of high-dimensional accuracy and surface finish of various advanced engineering materials for generating intricate part geometries, non-traditional machining (NTM) processes have now become quite popular in manufacturing industries. To explore the fullest machining capability of these NTM processes, it is often required to operate them while setting their different controllable parameters at optimal levels. This paper aims to present a novel approach for selection of the optimal parametric mixes for different NTM processes in order to assist the concerned process engineers.

Design/methodology/approach

In this paper, design of experiments (DoE) and technique for order preference by similarity to ideal solution (TOPSIS) are combined to develop the corresponding meta-models for identifying the optimal parametric combinations of two NTM processes, i.e. electrical discharge machining (EDM) and wire electrical discharge machining (WEDM) processes with respect to the computed TOPSIS scores.

Findings

For EDM operation on Inconel 718 alloy, lower settings of open circuit voltage and pulse-on time and higher settings of peak current, duty factor and flushing pressure will simultaneously optimize all the six responses. On the other hand, for the WEDM process, the best machining performance can be expected to occur at a parametric combination of zinc-coated wire, lower settings of pulse-on time, wire feed rate and sensitivity and intermediate setting of pulse-off time.

Practical implications

As the development of these meta-models is based on the analysis of the experimental data, they are expected to be more practical, being immune to the introduction of additional parameters in the analysis. It is also observed that the derived optimal parametric settings would provide better values of the considered responses as compared to those already determined by past researchers.

Originality/value

This DoE–TOPSIS method-based approach can be applied to varieties of NTM as well as conventional machining processes to determine the optimal parametric combinations for having their improved machining performance.

Details

Journal of Modelling in Management, vol. 14 no. 2
Type: Research Article
ISSN: 1746-5664

Keywords

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

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: 4 July 2016

K. Jayakrishna, R. Jeya Girubha and S. Vinodh

The purpose of this paper is to present the comparison of sustainability characteristics of conventional and computer numerical control (CNC) turning process. The…

Abstract

Purpose

The purpose of this paper is to present the comparison of sustainability characteristics of conventional and computer numerical control (CNC) turning process. The sustainability performance measures of both the processes were also being evaluated.

Design/methodology/approach

The study discusses the achievement of sustainability characteristics at the manufacturing process level of widely used industrial process, mechanical machining. Sustainable development includes improvements in material, product design and manufacturing process orientations. The present study narrates the sustainability characteristics at the process level.

Findings

The results confirm that the overall sustainability characteristics of CNC machining are potentially high considering the economic and environmental aspects of the machining parameters. A detailed life cycle analysis for both conventional and CNC turning was performed to evaluate the environmental impact and benefits.

Research limitations/implications

The study contributed in the paper is limited to process dimension of sustainability. The economic and environmental aspects of machining were also being discussed.

Practical implications

The conduct of the study enabled the comparison of sustainability characteristics of conventional and CNC-turning processes. The approach could also be expanded for the comparison of sustainability characteristics of other manufacturing processes also.

Originality/value

The study is an attempt to explore the process sustainability by the comparison of environmental impact of making processes. Hence, the contributions are original.

Details

Journal of Engineering, Design and Technology, vol. 14 no. 3
Type: Research Article
ISSN: 1726-0531

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: 7 October 2020

Yizhi Shao, Oluwamayokun Bamidele Adetoro and Kai Cheng

This study aims to optimize the manufacturing process to improve the manufacturing quality, costs and delivering time with the help of multiscale multiphysics modelling…

Abstract

Purpose

This study aims to optimize the manufacturing process to improve the manufacturing quality, costs and delivering time with the help of multiscale multiphysics modelling and simulation. Multiscale multiphysics-based modelling and simulations are receiving more and more interest by research community and the industry particularly in the context of increasing demands for manufacturing high precision complex products and understanding the intrinsic complexity in associated manufacturing processes.

Design/methodology/approach

In this paper, some modelling and analysis techniques using multiscale multiphysics modelling are presented and discussed.

Findings

Furthermore, the possibility of adopting the multiscale multiphysics modelling and simulation to develop the virtual machining system is evaluated, and further supported with an industrial case study on abrasive flow machining (AFM) of integrally bladed rotors using the techniques and system developed.

Originality/value

With the development of multiscale multiphysics-based modelling and simulation, it will enable effective and efficient optimisation of manufacturing processes and further improvement of manufacturing quality, costs, delivery time and the overall competitiveness.

Article
Publication date: 9 August 2013

M. Santhi, R. Ravikumar and R. Jeyapaul

The purpose of this paper is to present a new method to optimize the electro chemical machining process parameters for titanium alloy (Ti6Al4V).

475

Abstract

Purpose

The purpose of this paper is to present a new method to optimize the electro chemical machining process parameters for titanium alloy (Ti6Al4V).

Design/methodology/approach

The desirability function analysis (DFA), fuzzy set theory with trapezoidal membership function and Technique for Order Preference by Similarity to an Ideal Solution (TOPSIS) method are used to optimize the electro chemical machining process parameters for titanium alloy (Ti6Al4V). In recent years, the utilization of titanium and its alloys, especially of Ti6Al4V materials, in many different engineering fields has undergone a tremendous increase. The ECM process has a potential in the machining of Ti6Al4V. The machining parameters such as electrolyte concentration, current, applied voltage and feed rate with multiple responses such as material removal rate (MRR) and surface roughness (SR) are considered. Experimental work is carried out on Ti6Al4V using second order central composite rotatable design. The two responses are converted into global knit quality index using DFA. Fuzzy set theory with trapezoidal membership function is used to convert all machining parameters and responses into fuzzy values. Then a TOPSIS approach which determines the optimal machining parameters in terms of higher closeness coefficient is proposed to optimize the machining parameters of ECM for titanium alloy. Finally, ANOVA is performed to investigate the significance of each machining parameter and to identify the most influencing factor which affects the process responses.

Findings

The optimal machining parameters for ECM process are determined using desirability function analysis, fuzzy set theory and TOPSIS.

Originality/value

A new method is proposed to optimize the electro chemical machining process parameters for titanium alloy.

Details

Multidiscipline Modeling in Materials and Structures, vol. 9 no. 2
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 18 April 2019

S. Rajendra Prasad, K. Ravindranath K. Ravindranath and M.L.S. Devakumar M.L.S. Devakumar

The choice of best machining parameters is an extremely basic factor in handling of any machined parts. The purpose of this paper is to exhibit a multi-objective…

Abstract

Purpose

The choice of best machining parameters is an extremely basic factor in handling of any machined parts. The purpose of this paper is to exhibit a multi-objective optimization technique; in view of weighted aggregate sum product assessment (WASPAS) technique toward upgrade the machining parameters in modified air abrasive jet machining (MAAJM) process: injecting pressure, stand-off distance (SOD), and abrasive mesh size measure with 100 rpm rotatable worktable on Nickel 233 alloy material. Three conflicting destinations, material removal rate (MRR), surface roughness (SR) and taper angles (Ta), respectively, are considered at the same time. The proposed procedure uses WASPAS, which is the examination of parametric optimization of the abrasive jet machining (AJM) process. The results was used any scopes of reactions in MAAJM process is the ideal setting of parameters are resolved through investigations represented. There is wide utilization of Nickel 233 in aviation enterprises; machining information on producing a hole utilizing MAAJM for the first time is given in this work, which will be helpful different industries.

Design/methodology/approach

This paper exhibits a multi-objective optimization technique; in view of WASPAS technique toward upgrade the machining parameters in MAAJM process: injecting pressure, SOD, and abrasive mesh size measure with 100 rpm rotatable worktable on Nickel 233 alloy material.

Findings

As an outcome of using the tool in any ranges of responses in the AJM process, the optimal setting of parameters is determined through experiments illustrated. The machining data of generating a hole using AJM are studied for the first time in this work, which will be useful for aerospace industries, where Nickel 233 is used broadly.

Originality/value

A new material in unconventional machining process and also a multi-objective optimization technique are adopted.

Details

Multidiscipline Modeling in Materials and Structures, vol. 15 no. 3
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 4 July 2016

Uday Hameed Farhan, Majid Tolouei-Rad and Adam Osseiran

The purpose of this paper is to develop a model of analytic hierarchy process (AHP), a multiple criteria decision-making method, to assist selecting suitable machine

440

Abstract

Purpose

The purpose of this paper is to develop a model of analytic hierarchy process (AHP), a multiple criteria decision-making method, to assist selecting suitable machine configurations for special purpose machines (SPMs) from available alternatives.

Design/methodology/approach

The necessary criteria and sub-criteria were identified and used in the developed model. The assessment process was carried out by constructing the hierarchy of four levels. Then, pairwise comparison matrices were created for each level to compute the weights for the alternatives. The model was programmed and implemented by software for practical use.

Findings

Different scenarios were obtained from the assessment process of the developed AHP model showing the influence of changing the relevant importance of the elements in the hierarchy on the selection of SPMs configurations. Selection of the suitable scenario was also affected by some factors of manufacturing preferences and industry recommendations such as cost and production rate.

Originality/value

This is a new application of AHP method which assists decision makers to select suitable configurations for SPMs, and reduce the time required for designing SPMs.

Details

Journal of Manufacturing Technology Management, vol. 27 no. 6
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 27 February 2020

Wei Liu, Zicheng Zhu and Songhe Ye

The decision-making for additive manufacturing (AM) process selection is typically applied in the end of the product design stages based upon an already finished design…

Abstract

Purpose

The decision-making for additive manufacturing (AM) process selection is typically applied in the end of the product design stages based upon an already finished design. However, due to unique characteristics of AM processes, the part needs to be designed for the specific AM process. This requires potentially feasible AM techniques to be identified in early design stages. This paper aims to develop such a decision-making methodology that can seamlessly be integrated in the product design stages to facilitate AM process selection and assist product/part design.

Design/methodology/approach

The decision-making methodology consists of four elements, namely, initial screening, technical evaluation and selection of feasible AM processes, re-evaluation of the feasible process and production machine selection. Prior to the design phase, the methodology determines whether AM production is suitable based on the given design requirements. As the design progresses, a more accurate process selection in terms of technical and economic viability is performed using the analytic hierarchy process technique. Features that would cause potential manufacturability issues and increased production costs will be identified and modified. Finally, a production machine that is best suited for the finished product design is identified.

Findings

The methodology was found to be able to facilitate the design process by enabling designers to identify appropriate AM technique and production machine, which was demonstrated in the case study.

Originality/value

This study addresses the gap between the isolated product design and process selection stages by developing the decision-making methodology that can be integrated in product design stages.

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