A multivariate quality loss function approach for parametric optimization of non-traditional machining processes

Due to various added advantages over the conventional material removal processes, non-traditional machining (NTM) processes have now been widely applied in different manufacturing industries. To achieve the desired response values, it is always recommended to operate these NTM processes at their optimal parametric settings. Various single response optimization techniques are already available to determine the optimal combinations of NTM process parameters for achieving maximum or minimum value of a single response. In this paper, a multivariate quality loss function approach is adopted for simultaneous optimization of responses for three NTM processes. It is observed that this approach outperforms the other multi-response optimization techniques, like desirability function, distance function and mean squared error methods with respect to the achieved re-sponse values. With modification of the corresponding objective function and constraints of the de-veloped non-linear programming problem, it can be effectively applied to any non-traditional as well as conventional machining process as a multi-objective optimization tool

Process developments in electrochemical arc machining.

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Applications of optimization techniques for parametric analysis of non-traditional machining processes: A Review

The constrained applications of conventional machining processes in generating complex shape ge-ometries with the desired degree of tolerance and surface finish in various advanced engineering materials are being gradually compensated by the non-traditional machining (NTM) processes. These NTM processes usually have higher procurement, maintenance, operating and tooling cost. Hence, in order to attain their maximum machining performance, they are usually operated at their optimal or near optimal parametric settings which can easily be determined by the application of dif-ferent optimization techniques. In this paper, 133 international research papers published during 2012-16 on parametric optimization of NTM processes are extensively reviewed to have an idea on the selected process parameters, observed responses, work materials machined and optimization techniques employed in those processes while generating varying part geometries for their industrial use. It is observed that electro discharge machining is the mostly employed NTM process, applied voltage is the identified process parameter with maximum importance, surface roughness and material removal rate are the two maximally preferred responses, different steel grades are the mostly machined work materials and grey relational analysis is the most popular tool utilized for para-metric optimization of NTM processes. These observations would help the process engineers to attain the machining performance of the NTM processes at their fullest extents for different work material and shape feature combinations

Transitory electrochemical masking for precision jet processing techniques

Electrochemical jet processing techniques provide an efficient method for large area surface structuring and micro-milling, where the metallurgy of the near-surface is assured and not adversely affected by thermal loading. Here, doped electrolytes are specifically developed for jet techniques to exploit the Gaussian energy distribution as found in energy beam processes. This allows up to 26% reduction in dissolution kerf and enhancements of the defined precision metric of up to 284% when compared to standard electrolytes. This is achieved through the filtering of low energy at discrete points within the energy distribution curve. Two fundamental mechanisms of current filtering and refresh rate are proposed and investigated in order to underpin the performance enhancements found using this methodology. This study aims to demonstrate that a step change in process fidelity and flexibility can be achieved through optimisation of the electrochemistry specific to jet processes

Development of a machine-tooling-process integrated approach for abrasive flow machining (AFM) of difficult-to-machine materials with application to oil and gas exploration componenets

This thesis was submitted for the degree of Doctor of Engineering and awarded by Brunel UniversityAbrasive flow machining (AFM) is a non-traditional manufacturing technology used to expose a substrate to pressurised multiphase slurry, comprised of superabrasive grit suspended in a viscous, typically polymeric carrier. Extended exposure to the slurry causes material removal, where the quantity of removal is subject to complex interactions within over 40 variables. Flow is contained within boundary walls, complex in form, causing physical phenomena to alter the behaviour of the media. In setting factors and levels prior to this research, engineers had two options; embark upon a wasteful, inefficient and poor-capability trial and error process or they could attempt to relate the findings they achieve in simple geometry to complex geometry through a series of transformations, providing information that could be applied over and over. By condensing process variables into appropriate study groups, it becomes possible to quantify output while manipulating only a handful of variables. Those that remain un-manipulated are integral to the factors identified. Through factorial and response surface methodology experiment designs, data is obtained and interrogated, before feeding into a simulated replica of a simple system. Correlation with physical phenomena is sought, to identify flow conditions that drive material removal location and magnitude. This correlation is then applied to complex geometry with relative success. It is found that prediction of viscosity through computational fluid dynamics can be used to estimate as much as 94% of the edge-rounding effect on final complex geometry. Surface finish prediction is lower (~75%), but provides significant relationship to warrant further investigation. Original contributions made in this doctoral thesis include; 1) A method of utilising computational fluid dynamics (CFD) to derive a suitable process model for the productive and reproducible control of the AFM process, including identification of core physical phenomena responsible for driving erosion, 2) Comprehensive understanding of effects of B4C-loaded polydimethylsiloxane variants used to process Ti6Al4V in the AFM process, including prediction equations containing numerically-verified second order interactions (factors for grit size, grain fraction and modifier concentration), 3) Equivalent understanding of machine factors providing energy input, studying velocity, temperature and quantity. Verified predictions are made from data collected in Ti6Al4V substrate material using response surface methodology, 4) Holistic method to translating process data in control-geometry to an arbitrary geometry for industrial gain, extending to a framework for collecting new data and integrating into current knowledge, and 5) Application of methodology using research-derived CFD, applied to complex geometry proven by measured process output. As a result of this project, four publications have been made to-date – two peer-reviewed journal papers and two peer-reviewed international conference papers. Further publications will be made from June 2014 onwards.Engineering and Physical Sciences Research Council (EPSRC) and the Technology Strategy Board (TSB

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

AbstractAmong the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiCp/Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiCp/Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiCp/Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiCp/Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiCp/Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications

Hybrid materials for meniscus replacement in the knee

The meniscus is cartilage that not only prevents the bones in knee joints to grind together but acts as a joint stabiliser. Many athletes and older people suffer from meniscus tears and degeneration. Meniscal tear treatments have been through meniscal suture or by partial meniscectomy (removal). These treatments may cause changes in loading or decreased contact area and increased contact stress. Consequently, the ultimate result is a total meniscectomy that potentially leads to osteoarthritis (OA). These current surgical strategies have lower success rates in younger patients. There are no successful artificial meniscus replacement devices for young patients, therefore, new materials for meniscus replacement are required. Here, the aim was to develop a novel biomimetic meniscus device made of a silica/polytetrahydrofuran (SiO2/polyTHF) inorganic/organic hybrid material. The device is biomimetic in terms of its structural design, mechanical properties, and integration with the host tissue. The device should delay onset of OA. The hybrid has unique properties in that is a bouncy material which has comparable mechanical properties to knee cartilage. Two pot hybrid synthesis was used to synthesise the SiO2/polyTHF hybrid and casting mould was developed based on the shrinkage factor of the hybrid. The hybrid synthesis modifications were conducted by controlling compositions and drying processes. Biological fixation of the hybrid meniscus was achieved by titanium anchors with gyroid porous architecture which can provide initial mechanical fixation and secondary biological fixation on the tibia. The architecture was designed using Solidworks and Rhinoceros software and printed by the Additive Manufacturing technique of selective laser melting (SLM). Mechanical testing of the device included compression, cyclic loading, shear strength and long-term 90 days in-vitro mechanical testing, tribology against living bovine 2 cartilage, and cell studies. The results suggest that combination of hybrid and Ti gyroid has potential to be meniscus implant due to comparable mechanical properties, low friction coefficient, and non-cytotoxicity.Open Acces

Experimental Studies on Machinability of Inconel Super Alloy during Electro-Discharge Machining: Emphasis on Surface Integrity and Metallurgical Characteristics of the EDMed Work Surface

Inconel alloys are Nickel-Chromium based high temperature super alloys widely applied in aerospace, marine, nuclear power generation; chemical, petrochemical and process industries. Execution of traditional machining operations on Inconel super alloy is quite difficult due to its very low thermal conductivity which increases thermal effects during machining operations. Inconel often exhibits strong work hardening behavior, high adhesion characteristics onto the tool face, and thereby alters cutting process parameters to a remarkable extent. Additionally, Inconel may contain hard abrasive particles and carbides that create excessive tool wear; and, hence, surface integrity of the end product appears disappointing. The extent of tool life is substantially reduced. Thus, Inconel super alloys are included in the category of ‘difficult-to-cut’ materials. In view of the difficulties faced during conventional machining, non-traditional machining routes like Electro-Discharge Machining (EDM), Wire Electro-Discharge Machining (WEDM), micro-machining (micro-electro-discharge drilling) etc. are being attempted for processing of Inconel in order to achieve desired contour and intricate geometry of the end product with reasonably good dimensional accuracy. However, low material removal rate and inferior surface integrity seem to be a challenge. In this context, the present dissertation has aimed at investigating machining and machinability aspects of Inconel super alloys (different grades) during electro-discharge machining. Effects of process control parameters (viz. peak discharge current, pulse-on time, gap voltage, duty factor, and flushing pressure) on influencing EDM performance in terms of Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (SR) of the EDMed Inconel specimens have been examined. Morphology along with topographical features of the EDMed Inconel work surface have been studied in view of severity of surface cracking and extent of white layer depth. Additionally, X-Ray Diffraction (XRD) analysis has been carried out to study metallurgical characteristics of the EDMed work surface of Inconel specimens (viz. phases present and precipitates, extent of grain refinement, crystallite size, and dislocation density etc.) in comparison with that of ‘as received’ parent material. Results, obtained thereof, have been interpreted with relevance to Energy Dispersive X-ray Spectroscopy (EDS) analysis, residual stress and micro-indentation hardness test data. Effort has been made to determine the most appropriate EDM parameters setting to optimize MRR, EWR, along with Ra (roughness average), relative Surface Crack Density (SCD), as well as relative White Layer Thickness (WLT) observed onto the EDMed work surface of Inconel specimens. Moreover, an attempt has been made to examine the ease of electro-discharge machining on Inconel work materials using Deep Cryogenically Treated (DCT) tool/workpiece. A unified attempt has also made to compare surface integrity and metallurgical characteristics of the EDMed Inconel work surface as compared to the EDMed A2 tool steel (SAE 304SS) as well as EDMed Titanium alloy (Ti-6Al-4V)

Heat Assisted Machining of Nickel Base Alloys: Experimental and Numerical Analysis

Nickel base alloys are frequently used in aerospace industries, marine, biomedical application and other demanding industries due to their high strength, high hardness, resistant to corrosion and ability to withstand at elevated temperature. But machining of these materials in conventional way impairs severely their machinability due to certain inherent properties like low thermal conductivity, high chemical affinity and presence of hard particles in the microstructure etc. Therefore, tool life is reduced, due to the abrasion wear from the hard particles and high temperature of the tool-chip interface due to diffusion wear during machining of nickel base alloys. In this work, hot machining is introduced for processing of nickel base alloys like Inconel 718, Inconel 625, and Monel 400. In this technique, heating on the workpiece is combined with conventional turning process was used to enhanced machinability of nickel base alloy without compromise quality and productive. The study revealed that the influence of the workpiece temperature on the workpiece surface enhanced machining performance in terms of better surface finish, MRR, and reduction of forces, wear compared to conventional turning process. The surface integrity has been studied in terms of surface roughness, and microhardness beneath the machined surface in hot machining operation. Finite element modeling was also employed to prediction of cutting force, temperature distribution, stress, in hot turning of Inconel 718. The finite element results were compared with the experimental value and close agreement was found. In any industries production of parts along with tool life, surface finish is the major concern. In order to optimize the machining of nickel base alloys, optimization technique was performed using desirability and principal component analysis. Finally, machinability comparison was made between three materials, in order to understand effect of machining parameters along with workpiece temperature. In the literature, no research studies were found on flame heat machining of nickel base alloys (Inconel 625, Inconel 718 and Monel 400). The research led to various contributions to finding in terms of experimental investigation, optimization and FEM modeling. The contribution of the thesis should be of interest who works in the areas of machining of hard materials