Journal articles: 'ECONOMICAL MACHINING'

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Hong, Shane Y. "Economical and Ecological Cryogenic Machining." Journal of Manufacturing Science and Engineering 123, no. 2 (September 1, 1999): 331–38. http://dx.doi.org/10.1115/1.1315297.

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To eliminate health and environmental problems caused by using conventional cutting fluid in the machining industry, a new economical and practical approach to cryogenic machining technology was developed. Using micro nozzle jetting to the cutting point locally, this approach minimizes the amount of liquid consumption to levels at which nitrogen costs less than conventional cutting fluid. It reduces tool wear and lengthens tool life up to five times, thereby allowing for high-speed cutting, improving productivity and reducing overall production cost. In addition, this approach reduces the frictional force, improves chip breaking, eliminates build-up edge, and improves surface quality. This paper discloses the new cryogenic machining approach, and assesses the econom- ics of the process in comparison with state-of-the-art conventional emulsion cooling.

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Zhou, Hong. "How to Guarantee the Machining Accuracy of the Improved Numerical Control Machine." Advanced Materials Research 655-657 (January 2013): 1242–45. http://dx.doi.org/10.4028/www.scientific.net/amr.655-657.1242.

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Advancing the machining accuracy of machine tool is one of aim of numerical control machine improving . There are many effecting machining accuracy factors of economical numerical control machine tool driven by a stepper motor . The way of improving machining accuracy and compensation method were put forward in this paper .

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SHARMA, RAJEEV, Binit Kumar Jha, and Vipin Pahuja. "ROLE OF SUSTAINABLE TECHNIQUES IN MANUFACTURING PROCESS: A REVIEW." International Journal of Engineering Technologies and Management Research 8, no. 2 (February 17, 2021): 41–45. http://dx.doi.org/10.29121/ijetmr.v8.i2.2021.869.

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Customary mineral based liquids are as a rule broadly utilized in cooling and greases in machining activities. Nonetheless, these cutting liquids are the suitable wellspring of numerous natural and organic issues. To kill the evil impacts related with cutting liquids, it is important to move towards practical machining methods. Such sustainable machining techniques utilize minimize the amount of cutting liquid, fluid nitrogen, vegetable oil or packed air as a cooling-oil medium. The liquids utilized in economical machining strategies are viewed as absolutely biodegradable and Eco-friendly. This paper is a careful survey of the relative multitude of current environmental friendly machining methods as of now rehearsed in the metal cutting cycle. It has been likewise discovered that these economical machining strategies more often than not give better outcomes as far as improved surface nature of the machined part, upgraded apparatus life, less cutting temperatures and slicing powers when contrasted with traditional wet machining techniques. The principle motivation behind this survey work is to recognize the diverse supportable strategies and empower the utilization of such procedures in metal machining, so that, the reducing interaction turns out to be more expense powerful and climate inviting.

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Liu, Zhan Qiang, Xing Ai, and Zhao Hui Wang. "A Comparison Study of Surface Hardening by Grinding Versus Machining." Key Engineering Materials 304-305 (February 2006): 156–60. http://dx.doi.org/10.4028/www.scientific.net/kem.304-305.156.

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This paper presents a comparison study of surface hardening by grinding versus machining. The technological, economical and ecological merits of machining hardening and grind-hardening process for steels are described. The mechanisms of machining hardening and grind-hardening of steels are investigated and compared. The phase transformation, plastic deformation and white layer generation are the principal factors contributing to the hardened surface layer by machining and grinding. The influences of the process parameters on the penetrated hardness are given for both grind-hardening and machining hardening operations. The future development trends of the grind-hardening and machining hardening are also presented.

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Kozak, J., K. P. Rajurkar, and S. Z. Wang. "Material Removal in WEDM of PCD Blanks." Journal of Engineering for Industry 116, no. 3 (August 1, 1994): 363–69. http://dx.doi.org/10.1115/1.2901953.

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Polycrystalline diamond (PCD) tools are now widely used in machining a large variety of advanced materials. However, the manufacture of PCD tool blanks is not an economical and efficient process. The shaping of PCD blanks with conventional machining methods (such as grinding), is a long, labor-intensive and costly process. Wire electric discharge machining (WEDM) promises to be an effective and economical technique for the production of tools from PCD blanks. However, a knowledge base for wire electrical discharge machining of PCD blanks needs comprehensive investigations into the proper parameter setting, metal removal mechanisms, and surface integrity of machined blanks. This paper presents the results of experimental and theoretical investigations of the influence of discharge frequency and discharge energy on the material removal rate of WEDM of PCD blanks. The mechanism of removing diamond grains from the matrix during electrical erosion is also discussed on the basis of thermal stresses between the diamond grain and cobalt phase.

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Silva, Francisco J. G., Vitor F. C. Sousa, Arnaldo G. Pinto, Luís P. Ferreira, and Teresa Pereira. "Build-Up an Economical Tool for Machining Operations Cost Estimation." Metals 12, no. 7 (July 15, 2022): 1205. http://dx.doi.org/10.3390/met12071205.

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Currently, there is a lack of affordable and simple tools for the estimation of these costs, especially for machining operations. This is particularly true for manufacturing SMEs, in which the cost estimation of machined parts is usually performed based only on required material for part production, or involves a time-consuming, non-standardized technical analysis. Therefore, a cost estimation tool was developed, based on the calculated machining times and amount of required material, based on the final drawing of the requested workpiece. The tool was developed primarily for milling machines, considering milling, drilling, and boring/threading operations. Regarding the considered materials, these were primarily aluminum alloys. However, some polymer materials were also considered. The tool first estimates the required time for total part production and then calculates the total cost. The total production time is estimated based on the required machining operations, as well as drawing, programming, and machine setup time. A part complexity level was also introduced, based on the number of details and operations required for each workpiece, which will inflate the estimated times. The estimation tool was tested in a company setting, comparing the estimated operation time values with the real ones, for a wide variety of parts of differing complexity. An average error of 14% for machining operation times was registered, which is quite satisfactory, as this time is the most impactful in terms of machining cost. However, there are still some problems regarding the accuracy in estimating finishing operation times.

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Liu, Y. H., Y. F. Guo, and J. C. Liu. "Electric discharge milling of polycrystalline diamond." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 211, no. 8 (August 1, 1997): 643–47. http://dx.doi.org/10.1243/0954405981516580.

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Polycrystalline diamond (PCD) has been used widely in modern industry. However, the manufacture of PCD blanks is not an economical and efficient process. The shaping of PCD blanks with conventional machining methods (such as grinding), is a long, labour-intensive and costly process. Electromachining processes promise to be effective and economical techniques for the production of tools and parts from PCD blanks. Wire electric discharge machining is able to effectively slice PCD. Electrical discharge machining (EDM) and electrical discharge grinding (EDG) shape PCD blanks at a lower cost. However, EDM and EDG of a large surface area on PCD show lower efficiency. This paper presents a new process of machining PCD using electrical discharge (ED) milling. ED milling employs a DC source instead of the pulse generator used in EDM, and uses a water-based emulsion as the machining fluid. This process is able to effectively machine a large surface area on PCD, and effectively machine other advanced conducting materials such as cubic born nitride (CBN), and ceramics. The effect of pulse on-time, peak current, and polarity on the process performance has been investigated.

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Klocke, Fritz, Markus Zeis, and Andreas Klink. "Technological and Economical Capabilities of Manufacturing Titanium- and Nickel-Based Alloys via Electrochemical Machining (ECM)." Key Engineering Materials 504-506 (February 2012): 1237–42. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.1237.

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In this paper technological and economical capabilities of manufacturing titanium- and nickel-based alloys via unpulsed Electrochemical Machining (ECM) are presented. A standardized test to receive typical workpiece material removal properties according to its electrochemical machinability is introduced. First of all the experimental setup of this test is described in detail. The test results for the materials Ti-6Al-4V and Inconel 718 are presented and discussed. Here the feed rate – current density- and surface roughness – current density curves are in focus. With help of these two functions as an example out of many possible applications the capability of blisk manufacturing by electrochemical machining is quantified. Therefore the theoretical machining times for both materials of substituted blisk geometry are calculated. Finally on this basis an economical comparison between ECM and milling as rough estimation is executed.

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Ingemansson, A. R. "TECHNICAL AND ECONOMICAL ANALYSIS OF EFFICIENCY CHANGES OF TECHNOLOGICAL PROCESSES OF MACHINING DUE TO IMPLEMENTATION OF DIGITAL PRODUCTION SYSTEMS." IZVESTIA VOLGOGRAD STATE TECHNICAL UNIVERSITY, no. 8(243) (August 28, 2020): 32–35. http://dx.doi.org/10.35211/1990-5297-2020-8-243-32-35.

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Kusa, Martina, and Frantisek Pechacek. "Design of Experiments and Definition of Criteria for the Evaluation and Analysis of the Process of Machining in a Robotic System." Applied Mechanics and Materials 474 (January 2014): 85–90. http://dx.doi.org/10.4028/www.scientific.net/amm.474.85.

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Machining of different materials brings increasing of productivity, economical effectivity and quality of work piece. Constant development of Robotics and information systems brings new views of using robots in a process of production. Instead of using robots for a purpose of manipulation with work pieces, it is possible to use a robot directly for machining. Robotics machining technology has its advantage in application, which represents an adequate alternative in machining of metals on tradition of machine systems. The aim of the suggested plan of the experiment is to identify the optimal approach and combinations of each parameter during milling.

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Jain, Pushpendra, S. Soni, and Prashant Baredar. "Review on Machining of Aluminium Metal Matrix Composites." Material Science Research India 11, no. 2 (November 3, 2014): 114–20. http://dx.doi.org/10.13005/msri/110204.

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Metal matrix composites have superior mechanical properties in comparison to metals over a wide range of operating conditions. This make them an attractive option in replacing metals for various engineering applications. This paper provides a literature review, on machining of Aluminium metal matrix composites (AMMC)especially the particle reinforced Aluminium metal matrix composites. This paper is an attempt to give brief account of recent work to predict cutting parameters &surface generated in AMMC.By suitably selecting the machining parameters, machining of AMMC can be made economical.

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Karim, Md Rezaul, Juairiya Binte Tariq, Shah Murtoza Morshed, Sabbir Hossain Shawon, Abir Hasan, Chander Prakash, Sunpreet Singh, Raman Kumar, Yadaiah Nirsanametla, and Catalin I. Pruncu. "Environmental, Economical and Technological Analysis of MQL-Assisted Machining of Al-Mg-Zr Alloy Using PCD Tool." Sustainability 13, no. 13 (June 30, 2021): 7321. http://dx.doi.org/10.3390/su13137321.

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Clean technological machining operations can improve traditional methods’ environmental, economic, and technical viability, resulting in sustainability, compatibility, and human-centered machining. This, this work focuses on sustainable machining of Al-Mg-Zr alloy with minimum quantity lubricant (MQL)-assisted machining using a polycrystalline diamond (PCD) tool. The effect of various process parameters on the surface roughness and cutting temperature were analyzed. The Taguchi L25 orthogonal array-based experimental design has been utilized. Experiments have been carried out in the MQL environment, and pressure was maintained at 8 bar. The multiple responses were optimized using desirability function analysis (DFA). Analysis of variance (ANOVA) shows that cutting speed and depth of cut are the most prominent factors for surface roughness and cutting temperature. Therefore, the DFA suggested that, to attain reasonable response values, a lower to moderate value of depth of cut, cutting speed and feed rate are appreciable. An artificial neural network (ANN) model with four different learning algorithms was used to predict the surface roughness and temperature. Apart from this, to address the sustainability aspect, life cycle assessment (LCA) of MQL-assisted and dry machining has been carried out. Energy consumption, CO2 emissions, and processing time have been determined for MQL-assisted and dry machining. The results showed that MQL-machining required a very nominal amount of cutting fluid, which produced a smaller carbon footprint. Moreover, very little energy consumption is required in MQL-machining to achieve high material removal and very low tool change.

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Prema, Satya, G. Y. Shreeshail, and T. M. Chandrashekharaiah. "Analysis of Machining Parameter and Surface Finish of Al-Si Alloys with Grain Refiners and/or Modifier." Materials Science Forum 830-831 (September 2015): 91–94. http://dx.doi.org/10.4028/www.scientific.net/msf.830-831.91.

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The Al-Si alloy is a structural material which generally consists of two or more particulates. However, Al-Si alloys are the most common alloys and commercially available ones due to their economical production. The utilization of Al-Si alloys has given the scope of study to improve in its properties using some grain refiner like Al-5Ti-1B, Al-3B and modifiers like Al-10Sr. The Al alloys were selected based on the economical uses and also, on the basis such that hypoeutectic (i.e., LM-25), eutectic (i.e., LM-6) and hypereutectic (i.e., LM-30). This project aimed to synthesize Al alloys (LM-6, LM-25 and LM-30) by melt stirring method with varying amount of grain refiners and / or modifier. The Prepared composites were characterized for machining properties. Alloys were evaluated for their machining properties which include surface roughness, lathe and drill tool dynamometer and comparing the machining properties with the minor addition of grain refienrs and/or modifier. The study concluded that, the addition of Al-3B to eutectic (i.e., LM-6) alloys has better surface finish.

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Chakule, Rahul R., Sharad S. Chaudhari, Kailas V. Chandratre, Pralhad B. Patole, and Poonam S. Talmale. "Nanofluids, micro-lubrications and machining process optimisations − a review." Manufacturing Review 10 (2023): 1. http://dx.doi.org/10.1051/mfreview/2022034.

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The lubrication is a prime requirement of metal cutting industries to assure high quality performance. The conventional technique of coolant flow is less economical and eco-friendly. Recently, nano fluids found better cutting fluid in machining due to potential thermal and heat transfer properties. The role of micro-lubrication techniques and process optimization are equally important for improving process performance. The literature review presents the findings of different researchers in the field of nano fluids and micro-lubrication techniques. The experimental studies were focused on better process performance using micro-lubrication techniques, especially nanofluid MQL with optimized process parameters. The thermal conductivity of water based TiO2 nano fluid shows improvement by 22% in base fluids. The case study discussed which is focused on preparation and characterization of nano fluid, experimental setup and optimization of process parameters by Jaya algorithm. Finally, application of nano fluid, and challenges during nano fluid preparation is identified. The scope of research work is recommended for further study to obtain an economical, eco-friendly manufacturing process.

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Satynarayana, Kosaraju, Kumkuma Rajkiran, and Kalemula Sai Kiran. "Experimental investigation in machining EN18 using coated tool under dry and MQL condition." E3S Web of Conferences 184 (2020): 01060. http://dx.doi.org/10.1051/e3sconf/202018401060.

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EN 18 is one of the versatile metal that exists its presences in all the industrial, transportation and building equipment’s. Machining of these material is done on large scale and consumes a whole lot of lubrication unit. Present paper discuss regarding the usage and substitutional to flood coolant systems by minimum quality lubrication ((MQL) systems for economical friendly green machining operation. Using three-factor parameters speed (50, 75, 100 m/min), feed (0.05, 0.1, 0.15 mm/rev) and depth of cut (0.4, 0.8, 1.2 mm) are varied and turned on the EN 18 steel. The experimental outcomes of surface roughness is discussed with comparison with dry machining and ST-CUT 54 MQL machining. It was observed that with MQL turning the roughness produce better compared to dry machining. The optimum condition was found to be cutting speed at 100m/min, feed at 0.05mm/rev and depth of cut at 0.4mm. The outcomes are useful for improved machining industrial practices.

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Wakabayashi, Toshiaki, Keisuke Yamada, Shota Koike, and Toshifumi Atsuta. "Turning of Titanium Alloy Using Near-Dry Methods with MQL, Coolant Mist and Hybrid Mist Supplies." Key Engineering Materials 749 (August 2017): 101–6. http://dx.doi.org/10.4028/www.scientific.net/kem.749.101.

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Because of effective machining operations with a very small amount of cutting fluids, near-dry machining attracts increasing attentions for environmental and economical benefits. MQL machining has so far been recognized as the most representative near-dry method and it is highly successful in machining of most ordinary steels. Recent concern for environmentally friendly manufacturing further encourages the attempts at applying near-dry operations to machining of difficult-to-cut materials. Since titanium alloys are typical difficult-to-cut materials, this paper investigates the cutting performance of various near-dry methods in turning of a titanium alloy from the view point of elongating the tool life. Those near-dry operations include supply methods of regular MQL mist, coolant mist and hybrid mists, where the coolant mist is atomized water-soluble cutting fluid and hybrid mists are the mixture of MQL and coolant mists. The regular MQL operation provided longer tool life than that of dry machining. In addition, compared with MQL machining, the hybrid mist operations could further extend tool life and, in particular, the single coolant mist operations demonstrated the possibility of making the tool life longer than that of ordinary wet machining with flood cutting fluid supply.

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Kim, Eun, and Choon Lee. "A Study on the Optimal Machining Parameters of the Induction Assisted Milling with Inconel 718." Materials 12, no. 2 (January 11, 2019): 233. http://dx.doi.org/10.3390/ma12020233.

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This paper focuses on an analysis of tool wear and optimum machining parameter in the induction assisted milling of Inconel 718 using high heat coated carbide and uncoated carbide tools. Thermally assisted machining is an effective machining method for difficult-to-cut materials such as nickel-based superalloy, titanium alloy, etc. Thermally assisted machining is a method of softening the workpiece by preheating using a heat source, such as a laser, plasma or induction heating. Induction assisted milling is a type of thermally assisted machining; induction preheating uses eddy-currents and magnetic force. Induction assisted milling has the advantages of being eco-friendly and economical. Additionally, the preheating temperature can be easily controlled. In this study, the Taguchi method is used to obtain the major parameters for the analysis of cutting force, surface roughness and tool wear of coated and uncoated tools under various machining conditions. Before machining experiments, a finite element analysis is performed to select the effective depth of the cut. The S/N ratio and ANOVA of the cutting force, surface roughness and tool wear are analyzed, and the response optimization method is used to suggest the optimal machining parameters.

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Sharma, Rajeev, Binit Kumar Jha, and Vipin Pahuja. "A COMPREHENSIVE REVIEW ON EVALUATION OF ENVIRONMENTAL FRIENDLY MACHINABILITY, CUTTING FLUIDS AND TECHNIQUES IN METAL CUTTING OPERATION." International Journal of Advanced Research 9, no. 04 (April 30, 2021): 223–35. http://dx.doi.org/10.21474/ijar01/12677.

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Todays, due to the environmental concerns, growing contamination and pollution regulations, the demand for renewable and biodegradable cutting fluids is increasing day by day. Environmental friendly machining is one of the latest approach which is economical and also eco-friendly that improve the machinability. Different types of environmental friendly machining techniques are available e.g. MQL machining, cryogenic machining, dry machining and high pressure cooling approach. In this article, an attempt is made regarding environmental friendly machining processing, including different types of cutting fluids and machining techniques. The Knowledge of cutting fluid and its processing conditions is of critically importance to maximize the efficiency of cutting fluids in any machining process. In general, the generation of heat in the cutting zone due to friction at the tool-chip interface and the friction between the safety surface of the tool and the work piece is always the deciding factor on the quality of the work piece surface. In any manufacturing industries or company two factors play important role in machinability and productivity e.g. surface quality and tool wear. The main objective of this review article that analysis the different environmental friendly machining techniques and encourages the cooling approach in metal cutting operation. So finally, after the literature survey found that environmental friendly machining approach is cost effective machining process and also eco-friendly machining process.

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Nahak, Binayaka, and Ankur Gupta. "A review on optimization of machining performances and recent developments in electro discharge machining." Manufacturing Review 6 (2019): 2. http://dx.doi.org/10.1051/mfreview/2018015.

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Electro discharge machining (EDM) is a popular unconventional machining process widely employed in die-making industries. Careful selection of process parameters such as pulse current, voltage, on and off time, etc. is essential for machining of hard and conductive materials using EDM. Previous researchers working in the area of EDM have extensively analyzed the machining performance through experimental study, modeling, and simulation and also by theoretical analysis. This article discusses the significant summary of the work performed by earlier researchers through a detailed literature survey. Relevant literature on EDM and impact of process parameters on performance measures such as surface quality, tool wear rate and material removal rate are reviewed. The challenge and limitation of EDM process are also highlighted in this article. It is observed that optimization of process parameters is essentially required for effective and economical machining. So, this article addresses the various issues related to EDM and also provides brief insight into some of the current generation applications of EDM process explored in various industries.

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Prakash, J., and S. Gopalakannan. "Experimental Investigation and Performance Characteristics Study of Electrolyte in Micro Electrochemical Machining." Applied Mechanics and Materials 787 (August 2015): 416–20. http://dx.doi.org/10.4028/www.scientific.net/amm.787.416.

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Many advanced machining processes have higher initial investment, maintenance and tooling costs. In these circumstances micro electrochemical machining [µECM] processes meet the requirements with better efficiency and economy. The micro electrochemical machining process parameter such as electrolyte concentration, machine voltage, and pulse on time and duty factor are optimized with considerations of the multiple performance characteristics such as material removal rate (MRR) and overcut. Increase in electrolyte concentration considerably improves MRR but yields a poorer over cut. Increased machine voltage serves to increase both MRR and over cut significantly. Increased pulse on time and duty factor did not have notable impact on MRR and overcut. Less concentration of sodium chloride [NaCl] is sufficient for machining compared with sodium nitrate [NaNO3]. Higher MRR and better over cut are achieved with sodium chloride and moreover it is more economical than sodium nitrate.

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Hong, S. Y., and M. Broomer. "Economical and ecological cryogenic machining of AISI 304 austenitic stainless steel." Clean Products and Processes 2, no. 3 (November 23, 2000): 0157–66. http://dx.doi.org/10.1007/s100980000073.

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Qiao, Yang, Xing Ai, and Zhan Qiang Liu. "Research on Cutting Performance of High-Speed Steel Drills during Drilling the Powder Metallurgy Nickel-Based Superalloy." Key Engineering Materials 464 (January 2011): 556–59. http://dx.doi.org/10.4028/www.scientific.net/kem.464.556.

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The present paper is an experimental investigation on the machinability of powder metallurgy (PM) nickel-based superalloy during drilling using high-speed steel (M42) drills. The effect of machining parameters on the cutting force, cutting temperature and tool wear were investigated during the experimentation. The effect of machining parameters on the tool wear was examined through SEM micrographs. The research work findings will also provide useful economic machining solution by utilizing economical high-speed steel drills during drilling processing of powder metallurgy nickel-based superalloy, which is otherwise usually machined by costly coated carbide tools or CBN tools. The present approach and results will be helpful for understanding the machinability of powder metallurgy nickel-based superalloy during drilling for the manufacturing engineers.

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Znojkiewicz, Natalia, Dariusz Korzeniewski, and Martyna Wiciak. "Wear Analysis of Cemented Carbide during Turning of Cast Iron Considering Economical Machining Speed." Archives of Mechanical Technology and Materials 37, no. 1 (January 26, 2017): 27–34. http://dx.doi.org/10.1515/amtm-2017-0004.

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Abstract The purpose of this paper is to find economical machining speed during turning of grooves for piston rings with various feeds. In the first part of the paper, literature analysis concerning durability of cutting tools is presented. Next, the wear of cemented carbide cutting tools during turning of cast iron is researched. The research has been done for seven cutting tools. During conducted turning trials, angular speed has been altered from n=530rev/min to n=710rev/min and feeds from f=0.007mm/rev to f=0.105mm/rev. On the basis of Taylor’s equation, which relates cutting speed to tool life, the economical cutting speed is established with the application of two various methods.

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Bedada, Boki Dugo, Guteta Kabeta Woyesssa, Moera Gutu Jiru, Besufekad Negash Fetene, and Tekle Gemechu. "Experimental Investigation on the Advantages of Dry Machining over Wet Machining during Turning of AISI 1020 Steel." Journal of Modern Mechanical Engineering and Technology 8 (November 30, 2021): 12–25. http://dx.doi.org/10.31875/2409-9848.2021.08.2.

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In this study, the experiment was conducted to investigate the advantage of dry machining over wet machining during turning of AISI 1020 steel using cemented carbide tool on a CNC lathe machine. Surface roughness and cutting temperature were measured by VOGEL surface roughness tester and infrared thermometer respectively. The experiments were conducted based on Taguchi L9 orthogonal array design. Surface roughness, cutting temperature, tool life, and machining cost were analyzed graphically. The average surface roughness and cutting temperature achieved with wet machining was 2.01 μm and 26.540C, which was 17.41% and 44.86% respectively, lower than dry machining. The high cutting temperature in dry turning result in short tool life, which was 41.15% shorter than wet turning. The machining cost of wet turning was about 56% greater than the cost of dry turning. The cost of coolant in wet turning is 42.88% greater than that of the cutting tools. The highest cost was shared by tool cost, which was 81.33% of the total cost for dry turning, while 70.00% of the total cost was shared by coolant cost for wet turning. Results revealed that dry turning is more economical than wet turning.

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Baig, Rahmath Ulla, Syed Javed, Mohammed Khaisar, Mwafak Shakoor, and Purushothaman Raja. "Development of an ANN model for prediction of tool wear in turning EN9 and EN24 steel alloy." Advances in Mechanical Engineering 13, no. 6 (June 2021): 168781402110267. http://dx.doi.org/10.1177/16878140211026720.

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An imperative requirement of a modern machining system is to detect tool wear while machining to maintain the surface quality of the product. Vibration signatures emanating during machining with a single point cutting tool have proven to be good indicators for the tool’s health. The current research undertaken utilizes vibration signatures while turning EN9 and EN24 steel alloy to predict tool life using Artificial Neural Network (ANN). During initial meager experimentation, tool acceleration during machining was recorded, and the width of the flank wear at the end of each run was measured using Tool Makers Microscope. The recorded experimental data is utilized to develop the neural network with the variation of operating parameters and corresponding tool vibration with measured tool flank wear. The endeavor undertaken for the development of ANN flank wear prediction model was effective with a regression coefficient of 0.9964. The proposed methodology of indirect measurement of tool wear is efficient, economical for the machining industry to predict tool life, which in turn avoids catastrophic tool failure.

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Mandal, Nirmal Kumar, and Tanmoy Roy. "Modelling and Optimization of Tool Chip Interface Temperature and Surface Roughness in CNC Dry Turning of EN 24 Steel." Advanced Engineering Forum 16 (April 2016): 7–15. http://dx.doi.org/10.4028/www.scientific.net/aef.16.7.

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Abstract. Kinetic energy of a machining process is converted into heat energy. The generated heat at cutting tool and work piece interface has substantial impact on cutting tool life and quality of the work piece. On the other hand, development of advanced cutting tool materials, coatings and designs, along with a variety of strategies for lubrication, cooling and chip removal, make it possible to achieve the same or better surface quality with dry or Minimum Quantity Lubrication (MQL) machining than traditional wet machining. In addition, dry and MQL machining is more economical and environment friendly. In this work, 20 no. of experiments were carried out under dry machining conditions with different combinations of cutting speed, feed rate and depth of cut and corresponding cutting temperature and surface roughness are measured. The no. of experiments is determined through Design of Experiments (DOE). Nonlinear regression methodology is used to model the process using Response Surface Methodology (RSM). Multi-objective optimization is carried using Genetic Algorithm which ensures high productivity with good product quality.

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López de Lacalle, Luis Norberto, Adrián Rodríguez, Aitzol Lamikiz, and Ainhoa Celaya. "Combining Multiaxis Machining and Burnishing in Complex Parts." Advanced Materials Research 188 (March 2011): 43–48. http://dx.doi.org/10.4028/www.scientific.net/amr.188.43.

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In this paper the ball burnishing as a finishing process for sculptured surfaces is studied. This technique is a quick, easy and economical process for a significant improvement of high-end parts. Aiming at the burnishing of complex parts, different strategies are possible. In this case two strategies are presented: continuous burnishing (CB) using 5-axis interpolation and patch burnishing (PB) using 3+2 axis interpolation. Two parts have been previously machined in five-axis and then finished using ball burnishing techniques. The first one is an AISI 1045 hemisphere and the second one is a DIN 1.2379 part (64 HRC). Surface quality has been evaluated for both strategies obtaining a significant improvement of surface roughness and hardness.

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Budiman, Arie Yudha, and Amrifan Saladin Mohruni. "A REVIEW ON THIN WALLED CRYOGENIC MACHINING ON INCONEL OR AEROSPACE MATERIALS." Journal of Mechanical Science and Engineering 7, no. 1 (October 7, 2020): 001–5. http://dx.doi.org/10.36706/jmse.v7i1.34.

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Cutting fluids are widely used in machining processes throughout the world. However, this cutting liquid is the source of many environmental pollution problems. In order to reduce or eliminate the effect produced by cutting fluids, it is necessary to switch to a continuous machining technique such as using small amounts of cutting fluid, liquid nitrogen, vegetable oil or compressed air as a cooling lubrication medium. Cryogenic coolant is found to be more efficient, economical, cost-effective and environmentally friendly when compared to the conventional coolant, especially in mass production. In machining difficult-to-cut materials such as thin walled materials for the aerospace industry, cooling applications are needed. Ni-based super alloy, Inconel is a material for aerospace applications because of its high durability to wear and material that is resistant to oxidation and corrosion at high temperatures. This paper presents a review and explanation of thin wall machining using cryogenic cooling systems on Inconel or aerospace materials.

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Fan, Jing Ming, Cheng Yong Wang, Jun Wang, and Guo Sheng Luo. "Effect of Nozzle Type and Abrasive on Machinablity in Micro Abrasive Air Jet Machining of Glass." Key Engineering Materials 359-360 (November 2007): 404–8. http://dx.doi.org/10.4028/www.scientific.net/kem.359-360.404.

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Micro abrasive jet machining (MAJM) is a high effective economical technology for three dimensional micro structure fabrications of brittle materials. It is widely used in the fabrication of semiconductors, electronic devices, micro electro-mechanical systems (MEMS), optical-electronic and optical devices, and medical instruments. In this paper, based on the experimental study of MAJM for glass, the influences of the nozzle type/size and abrasive type on the material erosion rate and structure profile are analyzed. The results show that the rectangular nozzle can yield a more accurate and efficient machining performance due to reduced flux effect. By contrast, with round nozzle all the cross section profiles of the machined patterns show rounded V-type shape. The rectangular nozzle is able to produce geometry with flat shape. The machining area is almost independent of the abrasive hardness, and the erosion rate increases with the increase in the hardness of the abrasive grits. The nozzle geometry is of great importance for machining accuracy and the efficiency.

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Tirelli, Stefano, Elio Chiappini, Matteo Strano, Michele Monno, and Quirico Semeraro. "Economical Comparison of Cryogenic vs. Traditional Turning of Ti-6Al-4V: A Case Study." Key Engineering Materials 651-653 (July 2015): 1204–10. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.1204.

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Due to their poor machinability, titanium alloys need to be worked at low cutting speeds to prevent a fast tool failure caused by the very high temperatures that are reached at the tool-chip interface. As demonstrated by previous works by the authors, an improvement of productivity for Titanium alloys can be obtained by adopting cryogenic cooling during the machining operations.The present work shows the features of a toolholder specifically designed for cryogenic adduction in turning operations, following Hong’s design guidelines. The paper compares tool life results between traditional and cryogenic rough turning by adopting Grade 5 titanium as the working material. Rough turning is economically more relevant to the machining industry, especially in the aerospace field where generally a large quantity of rough material has to be removed due to the very high buy-to-fly ratio of aerospace components. A full factorial experimental plan was performed basing on typical rough turning parameters. Machining outputs such as forces, roughness, temperatures, friction coefficients were calculated in order to define statistical differences between cryogenic cooling method using the special toolholder and traditional oil water emulsion cooling system.Furthermore, thanks to tool life results the Taylor’s law for cryogenic and traditional cases was calculated and an hypothetical production scenario for Ti6Al4V parts was analysed. An analytical model to calculate production costs and time was built for both cooling methods. A 4-turrets turning centre was considered and cooling methods and costs per hour of machine tool were taken into account in a cost model. The results show that the benefits in terms of tool life offered by liquid nitrogen cooling allows to improve productivity by adopting higher optimal cutting parameters. This improvement, coupled to an increase of tool life, is very significant and allows not only to reduce time of production but also to cover the major costs of liquid nitrogen and have a slight reduction of machining total costs.

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Adesta, Erry Yulian Triblas, and Muataz H. F. Al Hazza. "Machining Time Simulation in High Speed Hard Turning." Advanced Materials Research 264-265 (June 2011): 1102–6. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1102.

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High speed hard turning is an advanced manufacturing technology that reduces the machining time because of two reasons; reducing the manufacturing steps and increasing the cutting speed. This new approach needs an economical justification; one of the main economical factors is the machining time. The machining time was breaking down into three main parts; productive time, non productive time, and preparation time. By using matlab Simulink, a new program was developed for machining time allowing the manufacturer to find rapidly the values of cutting time parameters and gives the management the opportunity to modify the processing parameters to achieve the optimum time by using the optimum cutting parameters. Table 1: Nomenclature d Depth of cut M T total machining time pmv t Total movement time D Work piece diameter h t handling time pch t Total Tool changing time f Feed rate tc t tool changing time pre t Total preparing time z e Engagement distance on Z-axis ch t Tool changing time per piece, prg t Programming time x e Degagement distance on X-axis am t Machine allowance time su t Set up time k Number of passes ao t Operator allowance time sum t Machine set up L Tool life a t Allowance time sut t Tool set up l Work piece length o t Tool movement at the rapid speed suw t Work piece set up N Spindle speed oA t From zero point to cutting point TH Tool hardness tool n No. of tool posts in the turret p t Total productive time o X tidy of the O t point o1 p Initial position of the turret. o Z = abciss of the O t point w Work piece weigh o2 p Position of the used tool c V Cutting speed c w Width of cutting speed r Rotation speed of the turret f V Feeding speed tool n no. of tool in the turret c t Cutting time o V Rapid speed speed r : Turret rotation speed

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Han, Jian, Li Ping Wang, Lian Qing Yu, and Hai Tong Wang. "Thermal Error Modeling and Compensation of a CNC Machining Center." Advanced Materials Research 490-495 (March 2012): 1516–20. http://dx.doi.org/10.4028/www.scientific.net/amr.490-495.1516.

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Error modeling and compensation is the most effective way to reduce thermal errors. In this paper, a novel approach to predict the thermal error of machine tool based on M-RAN is presented, clustering analysis is used to select the temperature variables, and then an easy and economical measurement system is applied to measure the temperature variables and thermal shift of CNC machining center. The thermally induced errors are estimated in real-time using the trained M-RAN network. The proposed approach is verified through error compensation test.

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Singh, Jeewan, Harvinder Singh, and Aneesh Goyal. "Influence of minimal quantity lubrication (MQL) technique in achining evolution: A review and applications." International Journal of Advance Research and Innovation 3, no. 4 (2015): 107–12. http://dx.doi.org/10.51976/ijari.341519.

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Metal working fluids (MWFs) are one of the types of lubricants, which are extensively used in machining operations. Most of the MWFs are mineral oil based fluids. Due to their advantages, the consumption of MWFs is increasing in machining industry. Mineral, synthetic and semi-synthetic MWFs involve in the ecological cycle with air, soil and water and their toxicity effects damages the ecosystem. Vegetable oil lubricants are potential substitutes for mineral oil not only because they are renewable raw materials but also because they are biodegradable and non-toxic. Currently, there is a wide-scale evaluation of the use of metal working fluids (MWFs) in machining. Industries are looking for ways to reduce the amount of lubricants in metal removing operations due to the ecological and economical aspects. By implementing near-dry machining or a minimal quantity of lubrication (MQL), MWFs consumption can be reduced. The MQL technique involves the application of a small quantity of lubricant dispensed to the tool–work piece interface by compressed air flow. This paper gives a review on the mechanical performance of minimum quantity lubrication compared to completely dry and flood lubrication for various machining operations.

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Panda, Asutosh, Sudhansu Ranjan Das, and Debabrata Dhupal. "Machinability Investigation of HSLA Steel in Hard Turning with Coated Ceramic Tool: Assessment, Modeling, Optimization and Economic Aspects." Journal of Advanced Manufacturing Systems 18, no. 04 (November 19, 2019): 625–55. http://dx.doi.org/10.1142/s0219686719500331.

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The present study addresses the machinability investigation in finish dry hard turning of high strength low alloy steel with coated ceramic tool by considering cutting speed, feed and depth of cut as machining parameters. The technological parameters like surface roughness, flank wear, chip morphology and economical feasibility have been considered to investigate the machinability performances. Twenty seven set of trials according to full factorial design of experiments are performed and analysis of variance, multiple regression method, Taguchi method, desirability function approach and finally Gilbert’s approach are subsequently applied for parametric influence study, mathematical modeling, multi-response optimization, tool life estimation and economic analysis. Results indicated that feed and cutting speed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness and tool flank wear is considered. Abrasions, adhesion followed by plastic deformation have been observed to be the principal wear mechanism for tool life estimation and observed tool life for coated ceramic insert is 47[Formula: see text]min under optimum cutting conditions. The total machining cost per part is ensued to be lower ($0.29 only) as a consequence of higher tool life, reduction in downtime and enhancement in savings, which finds economical benefits in hard turning. The current work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process considering techno-economical and ecological aspects.

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Vinay, Sachin, Sachin Bhanwal, and Sahil Yadav. "ABRASIVE JET MACHINING AND OPTIMIZATION OF PROCESS PARAMETERS." International Journal of Advanced Research 9, no. 5 (May 31, 2021): 607–16. http://dx.doi.org/10.21474/ijar01/12883.

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Abrasive Jet Machining also known as micro-abrasive blasting or pencil blasting is one of the mechanical energy based economical non-traditional machining process for cutting, deburring, polishing, drilling, etching and cleaning of alloys, brittle metals and non-metallic materials due to its high degree of flexibility and low stress forces with less heat generation.In AJM process, fine abrasive grits (silicon carbides, Aluminium oxides, Sodium bicarbonate, Boron Carbides, Crushed glass and Dolomite etc.) of typically ~0.025 mm are accelerated in a high velocity (150-300 m/s) jet of gas stream or air which is generated by converting pressure energy of carrier gas or air to its Kinetic energy and hence high velocity jet and nozzle directs abrasive jet in a controlled manner towards the work surface. Small fractures are created after impacting abrasive particles on the work surface.

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Seghedin, Neculai Eugen, and Dragoş Florin Chitariu. "The Tightening Accuracy of Workpieces in the Multiple Clamping Devices." Applied Mechanics and Materials 657 (October 2014): 524–28. http://dx.doi.org/10.4028/www.scientific.net/amm.657.524.

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Fixtures are used for orientation-positioning-tightening of workpieces during machining on machine tools. Multiple clamping fixtures are intended to clamp several workpieces for simultaneous or successive machining. Multiple clamping is characterized by a series of economical advantages, due to the reduction of total machining time. These advantages are more important once the number of workpieces is higher or if the machining is made with compound tools. Due to the complexity, overall size and the high number of components, the multiple clamping fixtures have diminished accuracy than simple fixture due to elastic and contact deformations of fixtures housing, of supports etc. Also, multiple clamping fixtures present diminished rigidity and dynamic stability. From the analysis of the specialized literature results that there are a few paper on the subject of multiple clamping. In the paper there are presented the causes that can lead to the diminish of the accuracy of multiple fixture. The modalities for the determination of fixtures precision are presented, also, for the parallel and serial multiple clamping fixtures.

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Kale, Ishaan R., Mayur A. Pachpande, Swapnil P. Naikwadi, and Mayur N. Narkhede. "Optimization of advanced manufacturing processes using socio inspired cohort intelligence algorithm." International Journal for Simulation and Multidisciplinary Design Optimization 13 (2022): 6. http://dx.doi.org/10.1051/smdo/2021033.

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The demand of Advanced Machining Processes (AMP) is continuously increasing owing to the technological advancement. The problems based on AMP are complex in nature as it consisted of parameters which are interdependent. These problems also consisted of linear and nonlinear constraints. This makes the problem complex which may not be solved using traditional optimization techniques. The optimization of process parameters is indispensable to use AMP's at its aptness and to make it economical to use. This paper states the optimization of process parameters of Ultrasonic machining (USM) and Abrasive water jet machining (AWJM) processes to maximize the Material Removal Rate (MRR) using a socio inspired Cohort Intelligent (CI) algorithm. The constraints involved with these problems are handled using static penalty function approach. The solutions are compared with other contemporary techniques such as Particle Swarm Optimization (PSO), Artificial Bee Colony (ABC), Modified Harmony Search (HS_M) and Genetic Algorithm (GA).

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38

Haldar, Barun, Hillol Joardar, Borhen Louhichi, Naser Abdulrahman Alsaleh, and Adel Alfozan. "A Comparative Machinability Study of SS 304 in Turning under Dry, New Micro-Jet, and Flood Cooling Lubrication Conditions." Lubricants 10, no. 12 (December 12, 2022): 359. http://dx.doi.org/10.3390/lubricants10120359.

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The main objective of this experimental investigation is to examine favourable machining conditions by utilising fewer resources of machining industries for the techno-economical and ecological benefits. The machining operations are performed in turning SS 304 using coated carbide tool inserts under dry, water-soluble cutting fluid solution in the form of flood cooling and small-quantity lubrication (SQL) conditions by employing a newly formed micro-jet for a comparative classical chips study and analysis. The machining experiments are conducted in turning by a 25 kW precision CNC lathe with a special arrangement of micro-jets into the machining zone. Machining speeds and feed rates are varied under dry, micro-jet, and flood cooling conditions and their effects are studied on the type of chips and their morphology, chip reduction coefficient (ξ), and chip shear plane distance (d). The effect of machining environments on tool health conditions (such as BUEs, tool-edge chipping, and edge breaking) is examined for the inferences. In the range of low-speed machining (less than 600 m/min), metal cutting seems easier in flood cooling conditions, but it imposes more unfavourable effects (such as edge chipping and edge breaking) on the ceramic cutting tool’s health. On the other hand, the dry machining condition shows a favourable performance for a ceramic cutting tool. The optimum machining condition is found in the micro-jet SQL by the analysis of experimental data and observation results for the tool and work combination. The analysis of the results is carried out by the response surface methodology (RSM) and artificial neural network (ANN). The ANN model is found to be more accurate than RSM. The aspects of effective green machining are emphasised.

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Beaucamp, Anthony T. H., and Yoshimi Takeuchi. "Reverse Engineering Algorithm for Cutting of Ruled Geometries by Wire." International Journal of Automation Technology 16, no. 3 (May 5, 2022): 349–55. http://dx.doi.org/10.20965/ijat.2022.p0349.

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Abrasive wire cutting (AWC) and wire electric discharge machining (WEDM) are efficient and economical processes for the fabrication of precision parts from bulk material. Operating costs and manufacturing lead times are low compared to more general methods such as 5-axis CNC milling, turning, or electro-discharge machining. In this paper, an algorithm based on differential geometry in Euclidean space is proposed for reverse engineering of ruled geometries. The algorithm can determine whether a given geometry is producible by wire cutting, and can also derive the associated wire trajectories. Implementation is demonstrated by producing complex turbine blade geometries on 4-axis wire cutting machines with an overall shape accuracy of 20–40 μm peak-to-valley.

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Abdur-Rasheed, Alao. "A Fundamental Study of Vibration Assisted Machining." Advanced Materials Research 264-265 (June 2011): 1702–7. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1702.

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Conventional diamond cutting of ferrous materials is rarely economical due to the rapid tool wears which result from diffusion and graphitization of the tools. Conventional machining of hard-brittle materials like silicon and germanium results in surface and subsurface damage due to their brittle fracture. Although ductile mode machining (DMM) concept can be used to have a flawless machining on these materials but the mirror surfaces can only be realized on expensive ultraprecision machine tools because the critical depth of cut must be on the order of 1μm or less. Furthermore, there is a need to eliminate or reduce the use of cutting fluids during machining due to their attendant ecological hazards. However, grinding is one of the most difficult processes with regard to eliminating cutting fluids. Vibration assisted machining (VAM) can be used to minimize the problems enumerated above. VAM combines precision machining with small-amplitude tool vibration to improve the fabrication process. It has been applied to a number of processes ranging from turning, drilling to grinding. Therefore, this paper discusses DMM, the general overview of VAM, the basic kinematics of one-dimensional VAM; the advantages derived from using VAM and the ability of VAM to machine brittle materials in the ductile regime at increased depth of cut are described. Finally, the research directions in VAM are outlined.

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Kimmelmann, Martin, and Thomas Stehle. "Simulating the Bearing Load due to Unbalance in Wood Machining Tools." Advanced Materials Research 1140 (August 2016): 337–44. http://dx.doi.org/10.4028/www.scientific.net/amr.1140.337.

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To realise the high cutting speeds required in wood machining for a productive cutting process, high-speed spindles are used especially in CNC machining centres. The high rotational speed during operation, however, results in great centrifugal forces at the tool. Particularly unbalance here leads to a great loading of the spindle bearing as well as to reduced occupational safety. Unlike metal removal, the machining of wood and engineered wood products is subject to other requirements regarding the process parameters, such as e.g. higher cutting speeds or material removal rates. For that reason, economical sensible balance qualities for tools in wood machining are analysed within the IGF project 18381 N „Establishing the necessary balance quality of tools in wood machining“, which is carried out in cooperation with a working group from industry and funded by the Federal Ministry for Economic Affairs and Energy (BMWi). In order to analyse how unbalances in tools influences the loads of the spindle bearing, a simulation model of a spindle will be developed and constructed for wood machining. Serving as a basis of the model, the frequency responses of the static spindle will be established by experiment. Based on this, the natural vibration behaviour of the spindle will be simulated in a finite element model. Finally, it will be presented how test tools with different balance conditions influence the bearing load of the spindle.

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Wakabayashi, Toshiaki, Junji Kuhara, Toshifumi Atsuta, Akira Tsukuda, Norio Sembongi, Junichi Shibata, and Satoshi Suda. "Near-Dry Machining of Titanium Alloy with MQL and Hybrid Mist Supply." Key Engineering Materials 656-657 (July 2015): 341–46. http://dx.doi.org/10.4028/www.scientific.net/kem.656-657.341.

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Near-dry machining attracts increasing attentions for environmental and economical benefits, and MQL machining has been recognized as the most representative near-dry method. It is highly successful in machining of most ordinary steels, and synthetic biodegradable polyol esters play a significant role as an effective cutting fluid with a very small amount. Recent concern for environmentally friendly manufacturing further encourages the attempts at applying near-dry operations to machining of difficult-to-cut materials. Since titanium alloys are typical difficult-to-cut materials, this paper investigates the cutting performance of various near-dry methods in turning of a titanium alloy from the view point of elongating the tool life. Those near-dry methods include regular MQL and hybrid mist supply operations, where the hybrid mist is a mixture of MQL mist and coolant mist which is atomized water-soluble cutting fluid. The regular MQL operation provided considerably long tool life compared with that of dry machining and the hybrid mist operation showed the possibility of making the tool life longer. The cutting performance was largely influenced by the type of MQL lubricants. In particular, a synthetic polyol ester lubricant having low viscosity indicated the successful cutting performance when it was combined with the coolant mist supply in the hybrid mist application.

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Amrita, M., Kamesh B, Srikant R R, Bharati MSS, Chandu B, and Venugopal Rao Soma. "Sustainability Evaluation of Machining Ti6Al4V with Graphene Inclusion." International Journal of Automotive and Mechanical Engineering 19, no. 2 (June 28, 2022): 9647–59. http://dx.doi.org/10.15282/ijame.19.2.2022.02.0744.

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Ti6Al4V has wide applications but is generally considered to belong to the “difficult to machine” category. The present work aims at evaluating sustainability while machining Ti6Al4V with inclusion of graphene. Graphene is included using two methods in this work. In method one, graphene is included as a dispersant in cutting fluid and applied as minimum quantity lubrication (MQL). In the other method, graphene is filled in microholes on tools to form self-lubricating tools. Experiments are performed, and results are used to evaluate carbon footprint of the operation on the environment. Economic analysis is also performed—application of graphene as dispersant as well as in solid form enhanced machining capability of Ti6Al4V. Application of 0.3 wt.% graphene dispersed cutting fluid is found to be the most economic. The use of graphene in both forms could improve the machinability of Ti6Al4V and is also found to be economical but has enhanced carbon emission to the environment.

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44

Guo, Lei, Xinrong Zhang, Shibin Chen, and Jizhuang Hui. "An Experimental Study on the Precision Abrasive Machining Process of Hard and Brittle Materials with Ultraviolet-Resin Bond Diamond Abrasive Tools." Materials 12, no. 1 (January 2, 2019): 125. http://dx.doi.org/10.3390/ma12010125.

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Ultraviolet-curable resin was introduced as a bonding agent into the fabrication process of precision abrasive machining tools in this study, aiming to deliver a rapid, flexible, economical, and environment-friendly additive manufacturing process to replace the hot press and sintering process with thermal-curable resin. A laboratory manufacturing process was established to develop an ultraviolet-curable resin bond diamond lapping plate, the machining performance of which on the ceramic workpiece was examined through a series of comparative experiments with slurry-based iron plate lapping. The machined surface roughness and weight loss of the workpieces were periodically recorded to evaluate the surface finish quality and the material removal rate. The promising results in terms of a 12% improvement in surface roughness and 25% reduction in material removal rate were obtained from the ultraviolet-curable resin plate-involved lapping process. A summarized hypothesis was drawn to describe the dynamically-balanced state of the hybrid precision abrasive machining process integrated both the two-body and three-body abrasion mode.

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Okamura, Katsumi, Saturo Kukino, and Tomohiro Fukaya. "New Pcbn for Heavy Interrupted Cutting of Hardened Steel." Materials Science Forum 534-536 (January 2007): 1117–20. http://dx.doi.org/10.4028/www.scientific.net/msf.534-536.1117.

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PCBN tools are used worldwide for machining of hardened steel parts in automotive industries. Because cutting by PCBN tools has many advantages, which are high-precision, highefficiency, high-flexibility and low total machining cost, compared with conventional grinding methods. But in heavy interrupted cutting of hardened steel, the tool life is not so stable by sudden breakage of the cutting edge, and total cost of cutting by PCBN is not so economical compared to the grinding. So the conventional grinding is still main process in such applications. Recently, demand for decreasing machining cost has grown in heavy interrupted cutting and much tougher PCBN material is required. To solve this problem, new PCBN has been developed. New PCBN has very fine and homogeneous microstructure to increase the toughness of sintered body that it provides a reliable tool life for heavy interrupted cutting. The features and cutting performances of new PCBN are described in this report.

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Bai, Y. J., Lian Hong Zhang, and Cheng Zu Ren. "Experimental Investigation on Honing of Small Holes." Key Engineering Materials 329 (January 2007): 303–8. http://dx.doi.org/10.4028/www.scientific.net/kem.329.303.

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As a special kind of grinding, honing is a typical low speed precision machining process, which is of low grinding speed, little grinding heat and little thermal-residual deformation of workpiece, suitable for precision machining of holes in the precision couples of internal-combustion engine. Experimental investigation on effects of process parameters on honing efficiency of small holes was put forward in this paper to obtain economical machining efficiency. Circumferential speed, reciprocate speed and working pressure of honing stone are the key factors which affect the machining efficiency and quality of honing. Taking it as a case study the honing of the small middle hole of the valve seat of balancing valve couples of internal combustion engines, honing experiments were carried out in this paper to investigate the relationships of material removing rate in rough honing versus circumferential speed, reciprocate speed and working pressure in honing of small holes. The results show that in honing of small holes the material removal rate in rough honing increases with circumferential speed, reciprocate speed and reticulate cross-angle increasing but decreases when the two speeds exceed certain critical values, and the surface quality in finishing honing is improved by increasing circumferential speed.

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Rahman, M. M., Md Ashikur Rahman Khan, K. Kadirgama, M. M. Noor, and Rosli A. Bakar. "Optimization of Machining Parameters on Tool Wear Rate of Ti-6Al-4V through EDM Using Copper Tungsten Electrode: A Statistical Approach." Advanced Materials Research 152-153 (October 2010): 1595–602. http://dx.doi.org/10.4028/www.scientific.net/amr.152-153.1595.

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Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of peak ampere, pulse on time and pulse off time on tool wear rate (TWR) of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. A mathematical model for electrode wear rate is developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest TWR. Long pulse off time provides minimum TWR and the impact of pulse interval on TWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters.

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Uhlmann, E., S. Reinkober, and P. Käpernick. "Trochoidale Fräsbearbeitung mit Industrierobotern/Trochoidal milling with industrial robots – steel manufacturing with a robot arm." wt Werkstattstechnik online 109, no. 07-08 (2019): 589–93. http://dx.doi.org/10.37544/1436-4980-2019-07-08-79.

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Industrieroboter leisten heute einen entscheidenden Beitrag zur Umsetzung flexibler Produktionssysteme. Früher hauptsächlich für Handhabungsaufgaben eingesetzt, erweitert sich das heutige Anwendungsfeld auch auf Bearbeitungsaufgaben. Besonders die spanende Bearbeitung mit Industrierobotern hat in den letzten Jahren an Bedeutung gewonnen. Die erzielbare Genauigkeit ist dabei von den Prozesskräften abhängig. Trochoidales Fräsen bietet hier einen innovativen Ansatz zur wirtschaftlichen und genauen Bearbeitung mit Industrierobotern.   Today, industrial robots make a decisive contribution to the implementation of flexible production systems. Previously mainly used for handling tasks, the current field of application extends to machining tasks. In particular, the milling with industrial robots has gained in importance in recent years. The achievable accuracy depends on the process forces. Trochoidal milling offers an innovative approach to economical and accurate machining with industrial robots.

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Weng, Feng Tsai, Chen Siang Hsu, and Wen Feng Lin. "Fabrication of Micro Components to Silicon Wafer Using EDM Process." Materials Science Forum 505-507 (January 2006): 217–22. http://dx.doi.org/10.4028/www.scientific.net/msf.505-507.217.

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In this paper, the machining possibilities of silicon wafers by the EDM process are described. Micro components of silicon wafer were processed by EDM process. A fine tungsten carbide rod was machined as tool electrode for EDM process. Performance was investigated utilizing serious experiments. Micro hole was process with the fine electrode using EDM drilling. Micro slots were also processed on the surface of a silicon plate by a copper section electrode. The surface roughness of the silicon wafers in the EDM process was investigated. Array-micro-hole was machined by a tungsten carbide multi-electrode. Array micro holes on the coaxial circle were processed by a graphite-copper electrode of Dia.0.45mm. Batch production technology for economical EDM machining of micro holes were proposed.

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BAŁON, Paweł, Edward REJMAN, Robert SMUSZ, Janusz SZOSTAK, and Bartłomiej KIEŁBASA. "HIGH SPEED MILLING IN THIN-WALLED AIRCRAFT STRUCTURES." Applied Computer Science 14, no. 2 (June 30, 2018): 82–95. http://dx.doi.org/10.35784/acs-2018-15.

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Aircraft structures are designed to mainly consist of integral elements which have been produced by welding or riveting of component parts in technologies utilized earlier in the production process. Parts such as ribs, longitudinals, girders, frames, coverages of fuselage and wings can all be categorized as integral elements. These parts are assembled into larger assemblies after milling. The main aim of the utilized treatments, besides ensuring the functional criterion, is obtaining the best ratio of strength to construction weight. Using high milling speeds enables economical manufacturing of integral components by reducing machining time, but it also improves the quality of the machined surface. It is caused by the fact that cutting forces are significantly lower for high cutting speeds than for standard machining techniques.

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Journal articles on the topic 'ECONOMICAL MACHINING'

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