Browse Topic: Machining processes

Items (1,737)
This specification covers requirements for the superfinishing of High Velocity Oxygen/Fuel (HVOF) applied tungsten carbide thermal spray coatings
AMS B Finishes Processes and Fluids Committee
This specification covers a free-machining, low-alloy steel in the form of round bars 3.50 inches (88.9 mm) and under in nominal diameter produced by a die-drawing process
AMS E Carbon and Low Alloy Steels Committee
This study focuses on machining automobile parts such as drive shafts and axles made of low alloy steel AISI 4140. The influence of cutting inserts geometrical parameters, viz., relief angle (RIA), rake angle (RAA), and nose radius (NA) are studied by designing experiments using Taguchi’s methodology. Numerical simulation is conducted using DEFORM-2D; a suitable L9 orthogonal array (OA) is considered for this work for varying combinations of inputs, and the resultant cutting force, maximum principal stress, and tool life are determined. Adopting a signal-to-noise (S/N) ratio minimizes the outputs for better machining conditions and achieves high-quality components with precision, tolerance, and accuracy. The ideal conditions obtained from the S/N ratio are RAA of 6°, RIA of 3°, and NR of 0.6 mm. Analysis of variance presents that the NR influences the resultant cutting force, wear depth, and work piece damage 73.51%, RAA following by 23.99%, and RIA by 2.03% achieved with a R2 value of
Senthilkumar, N.
This study describes the Taguchi optimization process applied to optimize drilling parameters for glass fiber reinforced composite (GFRC) material. The machining process is analyzed in relation to process parameters using analysis of variance (ANOVA). The characteristics assessed for both the drilling and the specimen include speed, feed rate, drill size, and specimen thickness. The commercial software program MINITAB14 was used to collect and analyze the measured results. Cutting force and torque during drilling are examined in relation to these parameters using an orthogonal array and a signal-to-noise ratio. The primary goal is to identify the critical elements and combinations of elements that impact the machining process to achieve minimal cutting thrust and torque, based on the evaluation of the Taguchi technique
Raja, RosariJannet, SabithaKandavalli, Sumanth Ratna
Wire Electrical Discharge Machining (WEDM) is a highly accurate machining approach that is well-known for its capability to create intricate forms in materials with high levels of hardness and intricate geometries. Invar 36, a nickel-iron alloy, is extensively utilized in industries that demand exceptional dimensional stability across a wide temperature range. The objective of this exploration is for optimizing the WEDM parameters of Invar 36 material. Additionally, a predictive model called Adaptive Neuro-Fuzzy Inference System (ANFIS) will be developed to forecast the machining performance. The study involved conducting experimental trials to analyze the influence of crucial factors in WEDM. These parameters included pulse-on time (Ton), pulse-off time (Toff), and current. The objective was to examine their influence on key performance indicators such as material removal rate (MRR), surface roughness (Ra). The methodology of Design of Experiments (DOE) enabled a systematic
Natarajan, ManikandanPasupuleti, ThejasreeKiruthika, JothiKatta, Lakshmi NarasimhamuSilambarasan, R
The larger domain of surface texture geometry and other input variables related to engine operation, i.e., elevated temperature, has remained to be studied for finding suitable surface texture for real-time engine operations. In previous efforts to find suitable surface texture geometry and technique, the tribological performance of the piston material (Al4032) with dimples of varying diameters (90 to 240 μm) was evaluated under mixed and starved lubrication conditions in a pin-on-disk configuration. The disc was textured using a ball nose end mill cutter via conventional micromachining techniques. The area density and aspect ratio (depth to diameter) of the dimples were kept constant at 10% and 1/6, respectively. SAE 20W-40 oil was used as a lubricant with three separate drop volumes. The experiments were conducted in oscillating motion at temperatures of 50, 100 and 150°C. Conventional micromachining achieved improved dimensional precision and minimized thermal damage. Textured
Sahu, Vikas KumarShukla, Pravesh ChandraGangopadhyay, Soumya
Wire Electrical Discharge Machining (WEDM) is an advanced method of machining that provides distinct benefits in machining materials with high hardness and intricate geometries. Invar 36, a nickel-iron alloy with a lower coefficient of thermal expansion, is widely used in the aerospace, automotive, and electronic industries because of its excellent dimensional stability across a broad range of temperatures. The main objectives are to optimize the machining parameters and create regression models that can accurately predict the key performance indicators. Experimental trials were performed utilizing a WEDM setup to machine Invar 36 under various machining conditions, such as pulse-on time, pulse-off time, current setting percentage (%). The machining performance was evaluated by measuring the material removal rate (MRR), surface roughness (Ra). The design of experiment method (DOE) was utilized to systematically investigate the parameter space and determine the most effective machining
Natarajan, ManikandanPasupuleti, ThejasreeKiruthika, JothiKrishnamachary, PCSilambarasan, R
Wire Electrical Discharge Machining (WEDM) is a highly accurate machining method that is well-known for its capacity to create complex forms in conductive materials with exceptional precision. Cupronickel, a hard material consisting of copper, nickel, and additional components, is widely employed in marine, automotive, and electrical engineering fields because of its exceptional ability to resist corrosion and conduct heat. The intention of this study is to optimize the parameters of Wire Electrical Discharge Machining (WEDM) for Cupronickel material and create regression models to accurately forecast the performance of the machining process. An exploration was carried out to analyze the influence of important parameters in wire electrical discharge machining (WEDM), namely pulse-on time, pulse-off time, and applied current on key performance indicators such as material removal rate (MRR), surface roughness (Ra). The methodology of design of experiments (DOE) enabled a systematic
Natarajan, ManikandanD, PalanisamyPasupuleti, ThejasreeA, GnanarathinamUmapathi, DSilambarasan, R
This specification covers a corrosion-resistant nickel-copper alloy in the form of bars up to 3.00 inches (76.2 mm), inclusive, in thickness and forgings and forging stock of any size
AMS F Corrosion and Heat Resistant Alloys Committee
Wire Electrical Discharge Machining (WEDM) has attracted considerable attention in contemporary manufacturing because of its capacity to accurately form conductive materials. This study aims to optimize the parameters of Wire Electrical Discharge Machining (WEDM) for SAE 1010 material, which is a commonly used low-carbon steel. The Taguchi-based Grey Relational Approach (GRA) is employed for this purpose. The goal is to optimize machining efficiency and quality while minimizing production costs. The research methodology combines the Taguchi method for experimental design with the GRA for multi-response optimization. The Taguchi L27 orthogonal array is utilized to carry out experiments, taking into account three controllable factors: pulse-on time, pulse-off time, and discharge current. In addition, the performance characteristics to be optimized include surface roughness (Ra) and material removal rate (MRR). The experimental results are analyzed using the GRA (Grey Relational Analysis
Natarajan, ManikandanPasupuleti, ThejasreeKiruthika, JothiKrishnamachary, PCSilambarasan, R
Wire Electrical Discharge Machining (WEDM) is a widely used manufacturing method that is employed to shape complex geometries in conductive materials such as cupronickel, which is highly regarded for its resistance to corrosion and ability to conduct heat. The aspiration of this investigation is to improve the effectiveness and accuracy of Wire Electrical Discharge Machining (WEDM) for cupronickel material by utilizing the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) optimization method. The study analyzes the impact of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on important machining outcomes such as surface roughness, material removal rate. Experimental trials are performed to collect data on these parameters and their corresponding machining characteristics. The TOPSIS optimization method is utilized to determine the most favourable parameter settings by evaluating each parameter combination against the ideal and
Pasupuleti, ThejasreeNatarajan, ManikandanKiruthika, JothiC, NavyaSilambarasan, R
Wire Electrical Discharge Machining (WEDM) is a highly adaptable machining process that is extensively employed across various engineering industries to achieve precise machining of conductive materials. SAE 1010, a steel with low carbon content, is widely used in automotive, aerospace, and machinery components because it can be welded easily and shaped effectively. The aspiration of this study is to optimize the parameters of WEDM for SAE 1010 material by employing the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. An empirical study was carried out to examine the impact of crucial machining variables, such as pulse-on time, pulse-off time, applied current on performance metrics of machining, such as material removal rate (MRR), surface roughness (Ra) and Overcut. The utilization of the design of experiments (DOE) methodology enabled the methodical investigation of the parameter space. Taguchi based TOPSIS provides a comprehensive approach to parameter
Natarajan, ManikandanPasupuleti, ThejasreeKiruthika, JothiKatta, Lakshmi NarasimhamuSilambarasan, R
Wire Electrical Discharge Machining (WEDM) is a contemporary method that is extensively employed for intricate machining operations, especially in materials with high hardness and intricate shapes. Invar 36, a nickel-iron alloy known for its minimal change in size with temperature and consistent dimensions, poses distinct difficulties in the process of machining because of its specific properties. This study explores the process of optimizing WEDM parameters for Invar 36 material by adopting the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) approach. The study involved conducting experimental trials to analyze the influence of significant machining variables, such as pulse-on time, pulse-off time, applied current, on performance indicators such as material removal rate (MRR), surface roughness (Ra). The Taguchi based TOPSIS method was utilized to analyze the problem of multi-criteria decision-making and determine the most favorable parameter configurations
Pasupuleti, ThejasreeNatarajan, ManikandanKiruthika, JothiKrishnamachary, PCSilambarasan, R
Wire Electrical Discharge Machining (WEDM) is now a crucial technique for shaping complex shapes in conductive materials such as SAE 1010 steel. This study aims to enhance machining efficiency and accuracy by developing regression analysis to model and optimize WEDM parameters for SAE 1010 material. The study aims to examine the impact of various parameters in WEDM, such as pulse-on time, pulse-off time, and discharge current, on key machining responses, including surface roughness (Ra), material removal rate (MRR). Experimental investigations are being carried out to achieve this objective. A set of Wire Electrical Discharge Machining (WEDM) experiments are conducted using a factorial design, resulting in a dataset that can be used for regression modeling. Subsequently, regression models are constructed to forecast machining responses using input parameters. The models are improved through statistical analysis, to evaluate the importance of each parameter. The regression equations
Pasupuleti, ThejasreeNatarajan, ManikandanKiruthika, JothiKatta, Lakshmi NarasimhamuSilambarasan, R
Wire Electrical Discharge Machining (WEDM) is an important method engaged to make intricate shapes in conductive materials like Cupronickel, which is well-known for its ability to resist corrosion and conduct heat. The intention of this exploration is to enhance the effectiveness and accuracy of Wire Electrical Discharge Machining (WEDM) for Cupronickel material by utilizing a Taguchi-based Grey Relational Analysis (GRA). The study examines the impact of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on key machining outcomes such as surface roughness (Ra), material removal rate (MRR). A comprehensive dataset is generated for analysis through a systematic series of experiments designed using the Taguchi method. Grey relational grades are assessed to measure the connections between the input parameters and machining responses, making it easier to determine the best parameter settings. The Taguchi-based GRA approach provides a systematic approach for
Pasupuleti, ThejasreeNatarajan, ManikandanKiruthika, JothiRamesh Naik, MudeSilambarasan, R
Wire Electrical Discharge Machining (WEDM) is an essential manufacturing process used to shape complex geometries in conductive materials such as cupronickel, which is valued for its corrosion resistance and electrical conductivity. The aim of this explorative study is to enhance the efficiency and precision of machining by creating a specialized predictive model using an Adaptive Neuro-Fuzzy Inference System (ANFIS) for cupronickel material. The study examines the intricate correlation between process variables of the WEDM (Wire Electrical Discharge Machining) technique, such as pulse-on time (Ton), pulse-off time (Toff), and discharge current, and crucial machining responses, including surface roughness, material removal rate. Data is collected through systematic experimentation in order to train and validate the ANFIS predictive model. The ANFIS model utilizes the collective learning capabilities of neural networks and fuzzy logic systems to precisely forecast machining responses by
Pasupuleti, ThejasreeNatarajan, ManikandanKiruthika, JothiKatta, Lakshmi NarasimhamuSilambarasan, R.
ABSTRACT Ground vehicles are complex systems with many interrelated subsystems - finding the sweet-spot among competing objectives such as performance, unit cost, O&S costs, development risk, and growth potential is a non-trivial task. Whole Systems Trade Analysis (WSTA) is a systems analysis and decision support methodology and tool that integrates otherwise separate subsystem models into a holistic system view mapping critical design choices to consequences relevant to stakeholders. As a highly integrated and collaborative effort WSTA generates a holistic systems and Multiple Objective Decision Analysis (MODA) model. The decision support model and tool captures and synthesizes outputs from individual analyses into trade-space visualizations designed to facilitate rapid and complete understanding of the trade-space to stakeholders and provide drill down capability to supporting rationale. The approach has opened up trade space exploration significantly evaluating up to 1020+ potential
Edwards, ShatielCilli, MatthewPeterson, TroyZabat, MikeLawton, CraigShelton, Liliana
ABSTRACT The armor research and development community needs a more cost-effective, science-based approach to accelerate development of new alloys (and alloys never intended for ballistic protection) for armor applications, especially lightweight armor applications. Currently, the development and deployment of new armor alloys is based on an expert-based, trial-and-error process, which is both time-consuming and costly. This work demonstrates a systematic research approach to accelerate optimization of the thermomechanical processing (TMP) pathway, yielding optimal microstructure and maximum ballistic performance. Proof-of-principle is being performed on titanium alloy, Ti-10V-2Fe-3Al, and utilizes the Hydrawedge® unit of the Gleeble 3800 System (a servo-hydraulic thermomechanical testing device) to quickly evaluate mechanical properties and simulate rolling schedules on small samples. Resulting mechanical property and microstructure data are utilized in an artificial intelligence (AI
Lillo, ThomasChu, HenryAnderson, JeffreyWalleser, JasonBurguess, Victor
Related to traditional engineering materials, magnesium alloy-based composites have the potential for automobile applications and exhibit superior specific mechanical behavior. This study aims to synthesize the magnesium alloy (AZ61) composite configured with 0 wt%, 4 wt%, 8 wt%, and 12 wt% of silicon nitride micron particles, developed through a two-step stir-casting process under an argon environment. The synthesized cast AZ61 alloy matrix and its alloy embedded with 4 wt%, 8 wt%, and 12 wt% of Si3N4 are subjected to an abrasive water jet drilling/machining (AJWM) process under varied input sources such as the diameter of the drill (D), transverse speed rate (v), and composition of AZ61 composite sample. Influences of AJWM input sources on metal removal rate (MRR) and surface roughness (Ra) are calculated for identifying the optimum input source factors to attain the best output responses like maximum MRR and minimum Ra via analysis of variant (ANOVA) Taguchi route with L16 design
Venkatesh, R.
ABSTRACT FeMnAlC alloys exhibit lower density (6.5-7.2 g/cm3) than traditional military steels (7.9 g/cm3) while maintaining similar energy absorption capabilities. Material substitutions in legacy systems must meet existing form/fit/function requirements, limiting opportunities for lightweighting of existing designs. This study examines production and material properties of thick plate with a nominal chemistry of 30% Mn, 9%Al and 1%C, in the wrought condition. Due to the high aluminum and carbon content, there are unique challenges to large scale (45+ ton heat) production versus typical armor steel chemistries. Lab-scale wrought and production material are characterized, comparing microstructure, and mechanical properties. Processing practices including teeming flux and rolling temperature are discussed. The high manganese content of this alloy presents challenges for welding and machining practices, such as limited compatibility of weld wires and substantial work hardening during
Sebeck, KatherineToppler, IanRogers, MattLimmer, KristaCheeseman, BryanHowell, RyanHerman, William
ABSTRACT Today’s combat vehicle designs are largely constrained by traditional manufacturing processes, such as machining, welding, casting, and forging. Recent advancements in 3D-Printing technology offer tremendous potential to provide economical, optimized components by eliminating fundamental process limitations. The ability to re-design suitable components for 3D-printing has potential to significantly reduce cost, weight, and lead-time in a variety of Defense & Aerospace applications. 3D-printing will not completely replace traditional processes, but instead represents a new tool in our toolbox - from both a design and a manufacturing standpoint
Deters, Jason
Super Duplex Stainless Steels (SDSS) are attracting attentions of the manufacturing industries due to the excellent corrosion resistance to critical corrosion. But SDSS2507 is the hardest to machine with lowest machinability index among DSS family. Moreover, formation of built-up layer (BUL) and work hardening tendency makes it further difficult to machine. Researchers have the conflict in opinions on using wet machining or dry machining using tool coatings. In this investigation SDSS2507 machining is carried out using uncoated and PVD–TiAlSiN-coated tools. The wet and dry machining environment are compared for increase in cutting speed from 170 m/min to 230 m/min. Excellent properties of PVD–TiAlSiN coatings exhibited microhardness of 39 GPa and adhesion strength of 88 N, which outperformed the uncoated tools. Tool life exhibited by coated tools was four times higher than uncoated tools. Wet machining was found to be ineffective when PVD-coated tools are used, exhibiting the same
Sonawane, Gaurav DinkarBachhav, Radhey
Recent developments in manufacturing techniques and the development of Al7075 metal matrix composites (MMCs) with reinforcements derived from industrial waste have been steadily gaining popularity for aerospace and automobile applications due to their outstanding properties. However, there are still a lot of limitations with these composite materials. A great deal of research has been done to create new Al7075 MMC materials with the use of economic fly ash (FA) that possesses superior mechanical properties, corrosion resistance, density, and cycle cost. This review outlines different synthesis techniques used in the development of Al7075 MMCs using stir casting. Effects of FA along with other reinforcements on the mechanical, wear, machining, and microstructural properties of the composite are also discussed. Finally, a summary of the application of FA-based MMCs and a recap of the previous discoveries and challenges are reported. Future scope and potential areas of application are
Kumar, RandhirMondal, Sharifuddin
The primary objective of this article is to study the improvement of machining efficiency of EN-31 steel by optimizing turning parameters using newly developed cutting fluids with different proportions of aloe vera gel and coconut oil, utilizing the Taguchi technique. Furthermore, performance metrics including material removal rate (MRR), surface roughness, and tool wear rate (TWR) were assessed. Analysis of variance (ANOVA) suggested that as cutting speed and feed increase, the MRR is positively influenced, but likewise tool wear is intensified. The surface roughness exhibited a positive correlation with cutting speed, and a negative correlation with increasing both cutting speed and feed. It was found that the maximum MRR value was attained at a cutting speed of 275 m/min, a feed rate of 1.00 mm/rev, and a cutting fluid composition of 30% aloe vera and 70% coconut oil. For the best surface smoothness, it is advisable to adjust the cutting speed to 350 m/min and the feed rate to 0.075
Premkumar, R.Ramesh Babu, R.Saiyathibrahim, A.Murali Krishnan, R.Vivek, R.Jatti, Vijaykumar S.Rane, Vivek S.Balaji, K.
This specification provides processing and acceptance requirements for electrical discharge machining (EDM) when applied to the manufacturing of parts
AMS B Finishes Processes and Fluids Committee
The EN24 and EN42 materials were machined by the electric discharge machine (EDM). The study aimed to optimize the input variables for the multiple outputs, such as metal removal rate (MRR), tool wear rate (TWR), and surface roughness. The machining of the metal is essential to analyze the surface quality and the production rate. The MRR is a prediction of the production rate and surface roughness resembling the quality of the surface. The input variables were current (A), pulse on time (ton), and pulse duty factor (T). The three levels of current were 3A, 6A, and 9A. The ton time was selected as 30 μs, 50 μs, and 70 μs. The pulse duty factors were selected as 4, 5, and 6. The Taguchi optimization techniques are used to optimize process parameters. The L9 orthogonal array was selected for the process. ANOVA analysis was employed to check the rank of the input parameters relative to the output. The maximum MRR were at 9A, 70 μs, and 4 duty factor for the EN24. The best MRR were at 9A
Sahu, Kapil DevSingh, RajnishChauhan, Akhilesh Kumar
In this investigation, AA6351 alloy matrix composites with a larger volume proportion of SiC (20 wt%) were fabricated and tested for microstructure and mechanical behavior. Composites were hot extruded from mechanically milled matrix and reinforcements. Hot extrusion uniformly distributed reinforcements in the matrix and strengthened phase interaction. Mechanical ball milling causes AA6351 powder to become more homogeneous, reducing the mean particle size from 38.66 ± 2.31 μm to 23.57 ± 2.31 μm due to particle deformation. The micrograph shows that the SiC particles are equally dispersed in the AA6351 matrix, avoiding densification and reinforcing phase integration issues during hot extrusion. In hot extrusion, SiC particles are evenly distributed in the matrix, free of pores, and have strong metallurgical bonds, resulting in a homogenous composite microstructure. SiC powders and mechanical milling increase microhardness and compressive strength, giving MMC-A 54.9% greater than AA6351
Saiyathibrahim, A.Murali Krishnan, R.Jatti, Vinaykumar S.Jatti, Ashwini V.Jatti, Savita V.Praveenkumar, V.Balaji, K.
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