Browse Topic: Machining processes
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
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
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
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
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
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
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
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
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
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
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
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
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