Journal articles: 'Machining sound'

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Rafighi, Mohammad. "The cutting sound effect on the power consumption, surface roughness, and machining force in dry turning of Ti-6Al-4V titanium alloy." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 236, no. 6 (February 23, 2022): 3041–57. http://dx.doi.org/10.1177/09544062211072411.

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Titanium alloys are widely used in various industries such as aerospace, petrochemical, marine, and biomedical due to their high corrosion resistance, high strength, good heat resistance, and lightweight. However, the low thermal conductivity of titanium alloys makes their machinability poor compared to steel alloys. Therefore, it is of great importance to evaluate the machinability of titanium alloys. This experimental study presents the effects of machining parameters on the machinability factors such as surface roughness, power consumption, cutting sound, and machining force in dry turning of Ti-6Al-4V titanium alloy using CBN inserts. Sound emission is a substantial factor for the operator’s safety during the turning process. High cutting sound is generated due to removing a large amount of material from the workpiece using different cutting tools. Since there are not many studies related to the cutting sound in machining processes, the attempt was made to investigate the effect of cutting sound on the machinability factors. The variance analysis results presented the significant effect of cutting speed and cutting depth on power consumption. However, according to the normal plot of the standardized effect, all machining parameters have a high impact on the cutting sound. The highest level of machining parameters, especially cutting depth results in higher cutting sound due to the creation of vibration in the lathe and cutting tool. Besides, the feed rate was found to be the most influential parameter on the surface roughness with a 58.13% contribution. The machining force was affected by both cutting depth and feed rate. The findings revealed that increasing the cutting sound increases the machining force and surface roughness, while the power consumption drops. Based on the desirability function, 0.04 (mm/rev) feed rate, 0.05 (mm) cutting depth, and 60 (m/min) cutting speed were the optimum machining parameters for turning of Ti-6Al-4V titanium alloy.

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AKKUŞ, HARUN. "MULTIPLE OPTIMIZATION ANALYSIS OF MRR, SURFACE ROUGHNESS, SOUND İNTENSITY, ENERGY CONSUMPTION, AND VIBRATION VALUES IN MACHINABILITY OF TC4 TITANIUM ALLOY." Surface Review and Letters 28, no. 09 (April 30, 2021): 2150072. http://dx.doi.org/10.1142/s0218625x21500724.

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Research on machining continues increasingly today. The effects of independent variables (cutting speed, feed rate, cutting depth) on dependent variables (material removal rate (MRR), average surface roughness (Ra), sound intensity, energy consumption, and vibration) are among the most researched topics in machining. It is also important to achieve optimum results with low cost and time savings in machining. In this study, titanium alloy TC4 material was turned on CNC lathe. Taguchi L[Formula: see text] mixed level design was used in experimental design. MRR, Ra, sound intensity, energy consumption, and vibration values were measured for the determined cutting parameters. The measured values were researched experimentally and statistically. Effective parameters were determined. It was concluded that the cutting parameter that has the greatest effect on MRR, Ra, energy consumption, and vibration is the feed rate. In addition, the depth of cut was the parameter that most affected the sound intensity. Control experiments were carried out after determining the optimum machining parameters. With multiple optimization, the predictions were made with approximately 89% accuracy (92.75% for MRR, 92.49% for Ra, 89.45% for sound intensity, 92.70% for energy consumption, 96.16% for vibration).

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Dong, Quan Cheng, Chang Sheng Ai, and Na Wang. "The Study of Tool Wear and Breakage Based on the Characteristic Analysis of Acoustic Spectrum." Materials Science Forum 532-533 (December 2006): 197–200. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.197.

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Tool monitoring is an important factor to restrict the improvement of production efficiency, machining quality and automation level. The monitoring of the tool wear and breakage conditions on YCM-V116B machining center was studied, and the acquired milling sound signals were analyzed in detail. By means of the classical time-frequency analysis, it was discovered that the wear sound had its own characteristic frequency band, and the frequency component within the frequency band would change according to the change of wear conditions. So that the frequency component within the frequency band will be a good indicator to monitor the tool wear conditions excellently. On the other hand, the tool breakage sound is a random signal that a transient change in amplitude is produced probably when tool breaks. The tool breakage conditions can be detected exactly by the advantages of wavelet decomposition techniques. The analysis implies that the sound generated during the machining process can be used to monitor tool conditions, which provides a new approach to the sound applications in tool monitoring domain.

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Yang, Xuefeng, Xulin Cai, Wenan Yang, and Youpeng You. "Novel Tool Path Generation Method for Pocket Machining Using Sound Field Synthesis Theory." Machines 11, no. 2 (January 18, 2023): 131. http://dx.doi.org/10.3390/machines11020131.

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Contour parallel tool paths have been proved to be a preferred machining strategy for their advantage of less tool retractions and less sharp turns. The traditional geometrical algorithm-based tool path generation method often makes it hard to simply and simultaneously solve the problems of self-intersection, no residual, and smoothness at the same time due to their contradictions. To address this issue, a contoured parallel tool path generation method for pocket machining is developed in this study. It is based on sound field synthesis theory inspired by the phenomenon of sound wave propagation. Firstly, the simplified medial axis (SMA) tree of the pocket is extracted and the propagation direction of each SMA segment is calculated on account of the geometric characteristics of the pocket boundary. Secondly, the final tool path is obtained through the synthesis of the sound field. Finally, the novel method is verified on five different pockets to generate a contoured parallel milling tool path. After machining these pockets and measuring the machining time, roughness, and cutting force, the experimental results demonstrate that the tool path obtained by the novel method has advantages in improving machining quality and efficiency.

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Sun, Meng Zi, Fei Huang, and Hua Jing Li. "The Influence of Structural Parameters on the Sound Absorption Performance of Micro Perforated Absorber." Applied Mechanics and Materials 701-702 (December 2014): 424–27. http://dx.doi.org/10.4028/www.scientific.net/amm.701-702.424.

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The sound absorption performance of MPA (micro perforated absorber) mainly depends on its structural parameters. Reasonable parameter combination will get a high absorption coefficient. In this paper numerical simulation was used to study sound absorption performance. By this means, the influence of the different parameters on the sound absorption performance are discovered. To verify the result of numerical simulation, MPA samples are fabricated using optimized parameters by laser machining method. The sound absorption performances of these samples are tested and the experimental result is consistent with that of numerical simulation.

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Zajac, Jozef, Zuzana Hutyrová, and Imrich Orlovský. "Investigation of Surface Roughness after Turning of One Kind of the Bio-Material with Thermoplastic Matrix and Natural Fibers." Advanced Materials Research 941-944 (June 2014): 275–79. http://dx.doi.org/10.4028/www.scientific.net/amr.941-944.275.

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Study provides information about one type of bio-based composite – plastic with wood reinforcement in volume more than 50 % (advantage: renewable, inexpensive, can be used to isolate a sound and have got a low density) and about machining of this unique material. During the machining (turning process was use to produce a surfaces by removing material from a rotating workpiece) were changed two parameters – rotation speed and feed rate (depth of cut was constant). There were observed changes of parameter to surface roughness with change of conditions of machining process.

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Bhandari, Binayak. "Comparative Study of Popular Deep Learning Models for Machining Roughness Classification Using Sound and Force Signals." Micromachines 12, no. 12 (November 29, 2021): 1484. http://dx.doi.org/10.3390/mi12121484.

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This study compared popular Deep Learning (DL) architectures to classify machining surface roughness using sound and force data. The DL architectures considered in this study include Multi-Layer Perceptron (MLP), Convolution Neural Network (CNN), Long Short-Term Memory (LSTM), and transformer. The classification was performed on the sound and force data generated during machining aluminum sheets for different levels of spindle speed, feed rate, depth of cut, and end-mill diameter, and it was trained on 30 s machining data (10–40 s) of the machining experiments. Since a raw audio waveform is seldom used in DL models, Mel-Spectrogram and Mel Frequency Cepstral Coefficients (MFCCs) audio feature extraction techniques were used in the DL models. The results of DL models were compared for the training–validation accuracy, training epochs, and training parameters of each model. Although the roughness classification by all the DL models was satisfactory (except for CNN with Mel-Spectrogram), the transformer-based modes had the highest training (>96%) and validation accuracies (≈90%). The CNN model with Mel-Spectrogram exhibited the worst training and inference accuracy, which is influenced by limited training data. Confusion matrices were plotted to observe the classification accuracy visually. The confusion matrices showed that the transformer model trained on Mel-Spectrogram and the transformer model trained on MFCCs correctly predicted 366 (or 91.5%) and 371 (or 92.7%) out of 400 test samples. This study also highlights the suitability and superiority of the transformer model for time series sound and force data and over other DL models.

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Hao, Wangs Shen, Xun Sheng Zhu, Biao Jun Tian, and M. R. Chi. "Autoregressive Spectrum Analysis of Vibration and Condition Monitoring of Self-Propelled Rotary Tool." Key Engineering Materials 329 (January 2007): 743–48. http://dx.doi.org/10.4028/www.scientific.net/kem.329.743.

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Self-propelled rotary tools are being rediscovered for their applications in machining of ‘difficult-to-machine’ materials or for general improvement in the productivity of machining operations. The vibration characteristic and the occurrence of chatter during high speed cutting will induce the deterioration of precision and machining surface, tool wear and tool life. This paper deals with the identification of the vibration in SPRT cutting system with AR time series model. The experiment and deduction method provide a sound foundation for improving the structure with high antivibration strength, which could reduce the relative vibration between tool and workpiece in the alloweable scope.

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Miyazaki, T., Y. Tanaka, T. Tokunaga, and N. Taniguchi. "Controlling of Q-Switched YAG Laser Beam Machining by Generated Sound." CIRP Annals 42, no. 1 (1993): 243–46. http://dx.doi.org/10.1016/s0007-8506(07)62435-4.

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Casal-Guisande, Manuel, Alberto Comesaña-Campos, Alejandro Pereira, José-Benito Bouza-Rodríguez, and Jorge Cerqueiro-Pequeño. "A Decision-Making Methodology Based on Expert Systems Applied to Machining Tools Condition Monitoring." Mathematics 10, no. 3 (February 6, 2022): 520. http://dx.doi.org/10.3390/math10030520.

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The workers operating and supervising machining tools are often in charge of monitoring a high number of parameters of the machining process, and they usually make use of, among others, cutting sound signals, for following-up and assessing that process. The interpretation of those signals is closely related to the operational conditions of the machine and to the work environment itself, because such signals are sensitive to changes in the process’ input parameters. Additionally, they could be considered as a valid indicator for detecting working conditions that either negatively affect the tools’ lifespan, or might even put the machine operators themselves at risk. In light of those circumstances, this work deals with the proposal and conceptual development of a new methodology for monitoring the work conditions of machining tools, based on expert systems that incorporate a reinforcement strategy into their knowledge base. By means of the combination of sound-processing techniques, together with the use of fuzzy-logic inference engines and hierarchization methods based on vague fuzzy numbers, it will be possible to determine existing undesirable behaviors in the machining tools, thus reducing errors, accidents and harmful failures, with consequent savings in time and costs. Aiming to show the potential for the use of this methodology, a concept test has been developed, implemented in the form of a short case study. The results obtained, even if they require more extensive validation, suggest that the methodology would allow for improving the performance and operation of machining tools, as well as the ergonomic conditions of the workplace.

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Liu, Zhan Feng, and Ya Zhou Feng. "Design and Research of Amplitude Transformer in Ultrasonic Vibration Drilling System." Advanced Materials Research 139-141 (October 2010): 852–56. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.852.

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The ultrasonic vibration drilling presents superior technology effect than common methods in small-diameter deep hole machining areas, and can improve the machining quality and efficiency remarkably. The amplitude transformer usually is designed by users according to the requirement of production. Thus the design and manufacturing of amplitude transformer and the realization of the resonance of device are key problems in ultrasonic vibration drilling system. In this paper, we firstly analyzed the structure of amplitude transformer in the axial ultrasonic vibration drilling, and then designed and manufactured the composite amplitude transformer for small-diameter deep holes in the ultrasonic vibration drilling. After we carried out the test in the sound vibration system, the result indicated that the resonance of the sound system could be satisfied and the demand of small-diameter deep hole drilling could be met.

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Barylski, Adam, and Piotr Sender. "The Proposition of an Automated Honing Cell with Advanced Monitoring." Machines 8, no. 4 (October 28, 2020): 70. http://dx.doi.org/10.3390/machines8040070.

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Honing of holes allows for small shape deviation and a low value of a roughness profile parameter, e.g., Ra parameter. The honing process heats the workpiece and raises its temperature. The increase in temperature causes thermal deformations of the honed holes. The article proposes the construction of a honing cell, containing in addition to CNC honing machine: thermographic camera, sound intensity meter, and software for collecting and analyzing data received during machining. It was proposed that the level of sound intensity obtained during honing could be monitored continuously and that the images from a thermographic camera could be analyzed on-line. These analyses would be aimed at supervising honing along with the on-line correction of machining parameters. In addition to the oil cooler, the machining cell may have an automatic selection of the grain trajectory shape, with specified value of the radii of curvature of the abrasive grain trajectories, according to the wall thickness of the honed workpiece, which will result in reducing the temperature generated during honing. Automated honing cell can mostly increase honing process efficiency. Simulations in FlexSim showed the possibility of increasing the efficiency of the honing process more than 20 times.

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Сорокоумова, Дина, Dina Sorokoumova, Сергей Григорьев, Sergey Griroriev, Ксения Лаптева, Ksenia Lapteva, Дарья Шабалина, et al. "COMPARATIVE ASSESSMENT OF EFFICIENCY ULTRASONIC AND SOUND METHODS OF ACTIVATION IRRIGATIONAL SOLUTION IN ROOT CHANNELS WITH SIMPLE AND DIFFICULT ANATOMY (PILOT STUDY)." Actual problems in dentistry 15, no. 1 (May 6, 2019): 57–62. http://dx.doi.org/10.18481/2077-7566-2019-15-1-57-62.

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Background. The problem of increase in efficiency of endodontic treatment is relevant nowadays. Treat the decisive factors affecting quality of endodontic treatment: machining, irrigation and sealing of root channels. Machining of root channels does not allow to remove the greased layer. So an integral part of endodontic treatment is the irrigation of the root channel. Objectives ― to choose an optimum way of activation of irrigational solutions for removal of the greased layer in root channels with difficult anatomy. Methodology. The research of 30 intact painters removed on medical indications is conducted. Activation of irrigational solution was carried out by a sound the device EndoActivator and the ultrasonic IRRI K file on the device VDW.ULTRA. in root channels with simple and difficult anatomy. An object of a research was the internal wall of the root channel with the greased layer on the surface of dentine of the root. The research of samples was conducted by means of the scanning electronic microscope of JSM-6390LV. Results. When machining on an internal wall of root channels on the surface of dentine the greased layer is formed. Studying of samples with simple anatomy of root channels and activation of irrigational solutions revealed that the greased layer is removed throughout. When studying samples of teeth with difficult anatomy of root channels, it is determined, partially open dentinny a tubule at activation of solutions ultrasonic or sound by methods, and completely open dentin a tubule at activation of irrigational solution by the combined method. Conclusions. Carrying out activation of solutions in root channels with simple anatomy at a stage of a finishing irrigation is identical effectively as by ultrasonic, and sound methods. Application at a stage of a finishing irrigation of a sound method of activation in teeth with difficult anatomy of root channels allows to delete more than the greased layer, than ultrasonic activation. For the purpose of increase in efficiency of clarification of the root channel in teeth with difficult anatomy expediently combined use of sound and ultrasonic methods.

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Pinheiro, Cleverson, Manoel Cléber de Sampaio Alves, and Simone Simões Amaral. "Moisture Content and its Influence on the Roughness and Noise Emission during Wood Machining." Advanced Materials Research 1088 (February 2015): 680–85. http://dx.doi.org/10.4028/www.scientific.net/amr.1088.680.

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Numerous factors influencing the surface quality of wood after machining, among them we highlight the machining parameters and the properties of the wood. In the analysis of the influence of these factors on machining and in determining the quality measurement systems are used to obtain surface characteristics, these systems are divided into methods of contact and non-contact. The method for mechanical contact performed with the aid of the surface roughness tester is the most valued in the measurement of roughness of wood, however, aiming at a greater agility in these measurements, there is a need to seek alternatives for evaluation of surface quality, and one of these options is to use the forms of indirect measurements of this quality, as for example, the use of noise emission during the machining process. With this, the aim was to analyze the influence of the moisture content of the wood, at different levels, on surface quality of the species Pinus elliottii, determined by the method of mechanical probing move and relate this roughness with the sound emission issued for each class of humidity, during machining. The planning of experiments and statistical analyses were performed with the help of Taguchi method. The specimens were conditioned in greenhouses climatizadoras automatics for obtaining three classes of humidity. Machining tests of wooden pieces were performed on a machining center specific for this type of material. The roughness values were measured by a roughness verifier and the noise emission values were measured by for a measurer sound pressure level. Statistically significant differences were observed, the significance level of 10 %, on roughness and noise emission between the three levels of moisture. It was observed that with the increase in the moisture content occurred an increase of roughness and a reduction in noise emission. Monitoring of surface quality through noise level is an interesting alternative to the method of mechanical contact.

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Zhan, Jian Ming, Zhi Qiang Cao, Ming Ming Wu, and Jian Bo Zhang. "Compliant Control at Micro-Displacement in Hydrodynamic Suspension Ultra-Smooth Machining." Advanced Materials Research 53-54 (July 2008): 33–38. http://dx.doi.org/10.4028/www.scientific.net/amr.53-54.33.

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Hard-brittle materials can be polished by hydrodynamic suspension, which is based on the theory of sound eradiating. Owing to the high-speed rotating of the polishing tool, the polishing slurry would form dynamic pressure in the clearance between the work-piece and the tool. The dynamic pressure supplies abrasive particles the energy needed to impact on the work-piece surface, so the dynamic pressure will directly affect the machining effect. In order to obtain the steady and consistent machining quality, it’s necessary to implement the compliant control in the machining process, and adjust the dynamic pressure when needed. This paper utilizes piezoelectric ceramic micro-displacement actuating to investigate the technique that can achieve the control of micro-displacement between the polishing tool and the work-piece. It provides an effective mean for hydrodynamic slurry pressure in the hydrodynamic suspension ultra-smooth machining.

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Nahornyi, Volodymyr, Anton Panda, Jan Valíček, Marta Harničárová, Milena Kušnerová, Iveta Pandová, Stanislaw Legutko, Zuzana Palková, and Ondrej Lukáč. "Method of Using the Correlation between the Surface Roughness of Metallic Materials and the Sound Generated during the Controlled Machining Process." Materials 15, no. 3 (January 21, 2022): 823. http://dx.doi.org/10.3390/ma15030823.

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The article aims to use the generated sound as operational information needed for adaptive control of the metalworking process and early monitoring and diagnosis of the condition of the machined materials using a newly introduced surface roughness quality index due to the sound-controlled machining process. The object of the measurement was correlation between the sound intensity generated during cutting and the material parameters of the machined surface, i.e., the roughness of the machined surface and the degree of wear of the cutting tool. The roughness was measured during longitudinal turning of a steel billet with a P25 insert made of 12X18H10T steel and a T15K6 cutting insert made of a titanium, cobalt, and tungsten group alloy. The correlation between the sound and roughness of the machined surface was 0.93, whereas between the sound and wear of the cutting tool was 0.93. The correlation between sound and tool wear in the experiment with P25 and T15K6 cutting inserts and the correlation between sound and roughness is positive.

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Lee, Jun-Seok, and Dongjoon Kong. "Optimizing Alarm Location and Effects of Hearing Protection for Machining Industries." Proceedings of the Human Factors and Ergonomics Society Annual Meeting 49, no. 17 (September 2005): 1610–14. http://dx.doi.org/10.1177/154193120504901724.

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Emergency alarm systems are extremely important in our daily life since these can provide adequate and timely warning to people in event of threatened disaster. These systems cause a traumatic hearing loss due to their extremely high sound level. Hearing protection devices are the most popular and convenient solution for avoiding a traumatic hearing loss. However, the study of alarm location problems with hearing protection has not been much paid attention. The purposes of this study were; (1) to determine the number of alarm devices, their optimum locations and minimum sound power levels and; (2) to find the effectiveness of hearing protection devices. The selected working environment was a machining facility that usually generates extremely high noise level. An analytical model was provided and the effects of hearing protection devices were discussed with two examples. The results showed that hearing protection was highly required at or above 85dBA noisy environment.

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Svrzic, Srdjan, Marija Djurkovic, Gradimir Danon, Mladen Furtula, and Damjan Stanojevic. "On acoustic emission analysis in circular saw cutting beech wood with respect to power consumption and surface roughness." BioResources 16, no. 4 (October 25, 2021): 8239–57. http://dx.doi.org/10.15376/biores.16.4.8239-8257.

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A sound or a noise that accompanies wood machining processes is introduced by the tool rotation itself, by the friction of moving machine parts, or by wood-tool interaction. The sounds generated during machining with a circular saw could be analysed in order to monitor and possibly control the cutting process. Applying altered cutting parameters while cutting beech wood (Fagus sylvatica L.), which is the most common wood species in the Republic of Serbia, caused acoustic emissions that could be analysed throughout corresponding spectra. As shown in previous studies, altering the cutting parameters, e.g., the feed speed and tool override, resulted in variations in power consumption, surface roughness, and acoustic emission (or acoustic pressure). The aim of this paper was to provide a possible correlation between the applied cutting parameters and the acoustic emission spectra with respect to consumed power and the state of the machined surface. Along with acoustic emissions, the power consumption and surface roughness data were also acquired in order to make a possible relationship. By associating the idle circular saw acoustic spectra with background noise and comparing them with those obtained during machining, it was possible to indicate spectrum areas of particular interest for further analysis.

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Takahashi, Haruka, Katsuhiko Sakai, and Hiroo Shizuka. "Development of an In Situ Tool Wear Monitoring System Using the Cutting Sound." Advanced Materials Research 1117 (July 2015): 277–80. http://dx.doi.org/10.4028/www.scientific.net/amr.1117.277.

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This paper discusses the development of an in-situ, real-time tool wear monitoring system using the cutting sound that occurs during machining. In this study, the turning of carbon steel was implemented to examine the relationship between tool wear and the waveform of the cutting sound. Characteristic waveforms were extracted by fast Fourier transform (FFT) analysis of the cutting sound. The results indicated that the sound pressure of a specific frequency range increased during the progress of cutting-tool wear. In addition, it was possible to monitor the progress of tool wear by measuring the spectrum of a specific frequency range, even if the shape of the tool rest and the shapes of the work material were different, under certain cutting conditions.

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Jia, Jian Li, Jin He Liu, and Sha Sha Meng. "Design on ECM Device of Engine Connecting Rod Hot-Forging Die." Advanced Materials Research 411 (November 2011): 307–10. http://dx.doi.org/10.4028/www.scientific.net/amr.411.307.

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Electrochemical machining (ECM) molding was adopted to realize hot-forging die with high hardness, complex shape, high requirement for surface quality and sound demand effect. With the object of engine connecting rod hot-forging die, ECM cathode and device of hot-forging die main cavity and flash cavity were designed. The results indicate that ECM shaping can achieve hot-forging die machining with high efficiency, lowcost, no cutting stress and cavity primary shaping, and the machined hot-forging piece coincides well with the blueprint and obtains notable economic benefit.

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Huang, X. Z., Zhong Ning Guo, Zhi Gang Huang, Q. H. Li, Z. Q. Yu, T. M. Yue, and Wing Bun Lee. "Study of Ultrasonic Field in Polishing Based on Coupling Vibrations of Liquid." Key Engineering Materials 364-366 (December 2007): 967–72. http://dx.doi.org/10.4028/www.scientific.net/kem.364-366.967.

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The influences of ultrasonic field to polishing performance of Polishing Based on Coupling Vibration of Liquid (PCVL) are analyzed here. The simulation results shows that sound field in the original polishing device is rather uneven due to the existence of standing wave. To obtain better polishing performance, the experimental equipment was modified. Uniformity of the sound field was improved by preventing standing wave, thus a better surface quality could be achieved. Furthermore, a higher machining efficiency could be also obtained because sound intensity was strengthened at the same time. From the results serials of experiments, the improvements made by modified equipment are clearly shown.

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Ai, Chang Sheng, Y. J. Sun, and G. W. He. "Tool Wear Monitoring Based on Milling Acoustic Spectrum LPCC." Key Engineering Materials 499 (January 2012): 353–58. http://dx.doi.org/10.4028/www.scientific.net/kem.499.353.

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Cutting sound signal are acquisited in the vertical machining center using electret microphone, and would be applied to monitor tool wear. Linear Predictive Cepstrum Coefficient (LPCC) of milling sound signal within audibility threshold would be extracted as acoustic spectrum characteristic parameters, and the relativity between LPCC each order component and tools radial wear was analyzed. The experiments and analysis results conclude that there are characteristic components associated with tool wear in characteristic parameters LPCC of milling sound signal; the characteristic components associated with tool wear are mainly concentrated in the 6th, 7th and 8th order components LPCC; the method by characteristic parameters LPCC monitoring tool wear is feasible.

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AHN, Jung Hwan, Han Seog LIM, Shozo TAKATA, and Toshio SATA. "Machining Process/Tool Wear Monitoring System Based on Real-time Sound Recognition." Journal of the Japan Society for Precision Engineering 60, no. 8 (1994): 1144–48. http://dx.doi.org/10.2493/jjspe.60.1144.

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Gok, Arif, Cevdet Gologlu, Ibrahim H. Demirci, and Mustafa Kurt. "Determination of Surface Qualities on Inclined Surface Machining with Acoustic Sound Pressure." Strojniški vestnik – Journal of Mechanical Engineering 58, no. 10 (October 15, 2012): 587–97. http://dx.doi.org/10.5545/sv-jme.2012.352.

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Takata, S., J. H. Ahn, M. Miki, Y. Miyao, and T. Sata. "A Sound Monitoring System for Fault Detection of Machine and Machining States." CIRP Annals 35, no. 1 (1986): 289–92. http://dx.doi.org/10.1016/s0007-8506(07)61890-3.

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Nishibori, K., and Z. Ishikawa. "Development of Equipment for Detection of Unusual Sound Generated in Machining Center." Proceedings of JSME annual Conference on Robotics and Mechatronics (Robomec) 2003 (2003): 65. http://dx.doi.org/10.1299/jsmermd.2003.65_4.

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Liu, Xiaolong, Hongbing Li, Ning Li, and Kaizhuo Lei. "Effect of the Sound Source Position Error on Distribution Characteristics of Underwater Shock Wave Bunching Sound Field." Mathematical Problems in Engineering 2021 (July 14, 2021): 1–8. http://dx.doi.org/10.1155/2021/1050680.

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Curved reflection bunching technique of underwater plasma sound source (UPSS) uses the geometric characteristics of the curved reflector to reflect and bunching intense sound shock wave, so the center position error of the sound source is one of the important factors affecting the bunching performance of the shock wave. In this paper, the cause of the sound source position error is analyzed in detail, and nonlinear finite element software ANSYS/LS-DYNA (dynamic analysis software developed by LSTC) is used to establish the model of the shock wave bunching sound field. Through numerical simulations, the shock wave bunching sound field distribution characteristics under the influence of different position errors are comprehensively simulated, and the bunching performance of the shock wave and its influence law are deeply analyzed according to the simulation results. It provides guidance for reasonably controlling the machining error and installation error of the reflector and discharge electrode, estimating the effective discharge times of the discharge electrode, and formulating the design process.

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Sánchez, Jose Antonio, Luis Norberto López de Lacalle, and Aitzol Lamikiz. "Design of Optimum Planetary Electro Discharge Machining Strategies." Materials Science Forum 526 (October 2006): 67–72. http://dx.doi.org/10.4028/www.scientific.net/msf.526.67.

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The use of Electrical Discharge Machining (EDM) for the manufacturing of moulds and dies is generally accomplished by using different cutting regimens, from roughing to finishing, until the specified surface finish and dimensional tolerances are met. Multistage planetary EDM can be used to simplify the production process. Benefits such as the reduction of machining time, the need for less electrodes, electrode wear minimization and the improvement of the final surface finish of the component can be obtained. Design of multistage planetary EDM strategies requires a sound knowledge of the optimum radius for each orbit that assures surface roughness and dimensional accuracy together with a minimum machining time. Therefore, it is necessary to know the “exact” value of the gap at each stage. In this paper the influence of different process variables on the design of multistage planetary EDM strategies is analyzed.

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Rosentel, William. "Machining and Fabrication Equipment in Workplaces." INTER-NOISE and NOISE-CON Congress and Conference Proceedings 263, no. 1 (August 1, 2021): 5433–42. http://dx.doi.org/10.3397/in-2021-3102.

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Increasingly well-developed workplace acoustic standards have resulted in more consistent outcomes across projects and normalized occupant expectations of acoustic quality, enhancing productivity and satisfaction. Yet these standards are often not developed for or applied to R&D and manufacturing spaces that include traditional workplace room types and uses; design criteria is limited to OSHA-assessment for noise-at-work violations. Hybrid office buildings incorporating prototyping and maker spaces are common today and often contain high-noise equipment traditionally found in dedicated machine shops. As these facilities are incorporated alongside traditional offices, noise and vibration levels generated by fabrication equipment should be accurately quantified to avoid compromised workplace acoustics. While sound data is available for most large construction equipment, available data for smaller fabrication machines typically found in machine shops is often non-standardized and difficult to obtain. Field measurement of existing equipment installations can ground an acoustical analysis with real-world data and be highly valuable in evaluating potential noise and vibration impacts and applying cost-effective mitigation during design. This case study will present measurements obtained during a noise and vibration assessment of an existing machine shop located within an office building. The discussion will include limitations of the data and an assessment of potential for disruptions.

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Wu, Q., E. Liu, Y. H. He, and X. Tang. "Application Research on Extreme Learning Machine in Rapid Detection of Tool Wear in Machine Tools." Journal of Physics: Conference Series 2025, no. 1 (September 1, 2021): 012091. http://dx.doi.org/10.1088/1742-6596/2025/1/012091.

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Abstract In order to put an end to the product quality accidents caused by cutting tool breakage or severe wear in machining process, the paper explored an ELM model detection method based on voice recognition. In this paper, firstly it analysed the features of cutting sound signal in time-frequency domain, then discussed the extraction method of tool working state sensitive spectral energy statistical feature based on wavelet packet decomposition, and finally constructed an ELM fast detection model based on sound feature recognition. The experimental results demonstrated that the ELM detection model could achieve higher detection accuracy and faster response time. The simulation results show that the ELM model is effective and applicable in detecting tool wear with the help of sound recognition.

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Patwari, Md Anayet Ullah, Md Shariful Islam Chowdhury, Mohammad Ahsan Habib, Afzal Hossain Neelav, Md Sharfat Latif, and T. M. Moniruzzaman Sunny. "Tool Life Improvement by Externally Applied Ultrasonic Waves in Cutting Process of Dry Turning Operation of Mild Steel." Applied Mechanics and Materials 860 (December 2016): 58–63. http://dx.doi.org/10.4028/www.scientific.net/amm.860.58.

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Tool wear is an inevitable impediment in machining processes. It is the gradual failure of cutting tools due to regular use. Tool wear affects productivity, dimensional accuracy thereby indirectly representing a significant portion of the machining costs. In this paper, a novel technique has been proposed and adopted with an aim to reduce tool wear. External ultrasonic sound waves were applied in the turning process of mild steel in an attempt to reduce the cutting tool vibration thereby leading to improvements in tool life. In this unique technique ultrasonic sound has been applied from the both sides of the tool holder in the cutting process as waves to reduce tool vibrations and improvement of chip behavior at a certain optimized frequency. Experiments were carried out at 60 KHz ultrasonic frequency to determine the tool wear to the best degree possible. To investigate the cause of ultrasonic effects on tool wear, cutting tool vibration and chip morphology were also studied. The experimental results showed significant improvements in tool wear, vibration and chip behavior.

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Alatorre, David, Amir Rabani, Dragos Axinte, and David T. Branson. "Closed loop force control of in-situ machining robots using audible sound features." Mechanical Systems and Signal Processing 136 (February 2020): 106517. http://dx.doi.org/10.1016/j.ymssp.2019.106517.

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Frigieri, Edielson P., Carlos A. Ynoguti, and Anderson P. Paiva. "Correlation analysis among audible sound emissions and machining parameters in hardened steel turning." Journal of Intelligent Manufacturing 30, no. 4 (August 17, 2017): 1753–64. http://dx.doi.org/10.1007/s10845-017-1356-9.

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SADAMOTO, Akira, Takashi YAMAGUCHI, Shigeru NAGASAWA, Yasushi FUKUZAWA, Daishiro YAMAGUCHI, and Isamu KATAYAMA. "Sensing for Machining Using Pressure Level of Sound Radiated by Paperboard Die Cutting." Journal of the Japan Society for Precision Engineering 68, no. 12 (2002): 1554–58. http://dx.doi.org/10.2493/jjspe.68.1554.

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Wang, Z. W., G. Q. Pan, and Dong Hui Wen. "Applications of Ultrasonic Radiation Forces." Advanced Materials Research 215 (March 2011): 259–62. http://dx.doi.org/10.4028/www.scientific.net/amr.215.259.

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This keynote paper aims at introducing applications of ultrasonic radiation force in industry. The chosen focus is to understand how to use it. Since the phenomenon of acoustic levitation can reflect the exciting of ultrasonic radiation force directly. The paper starts with an analysis on the tungsten ball floating on a sound field and ultrasonic micro-manipulation study in micro Electronic Mechanical System (MEMS). And ultrasound has been successfully used to degrade wastewater as its cavitation. At the same time, different kinds of micro-ultrasonic machining were used to show how exciting machining and ultrasonic radiation combined. A view from the authors and the final Conclusions show future applications of ultrasonic radiation force.

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Huang, Pao-Ming, and Ching-Hung Lee. "Estimation of Tool Wear and Surface Roughness Development Using Deep Learning and Sensors Fusion." Sensors 21, no. 16 (August 7, 2021): 5338. http://dx.doi.org/10.3390/s21165338.

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This paper proposes an estimation approach for tool wear and surface roughness using deep learning and sensor fusion. The one-dimensional convolutional neural network (1D-CNN) is utilized as the estimation model with X- and Y-coordinate vibration signals and sound signal fusion using sensor influence analysis. First, machining experiments with computer numerical control (CNC) parameters are designed using a uniform experimental design (UED) method to guarantee the variety of collected data. The vibration, sound, and spindle current signals are collected and labeled according to the machining parameters. To speed up the degree of tool wear, an accelerated experiment is designed, and the corresponding tool wear and surface roughness are measured. An influential sensor selection analysis is proposed to preserve the estimation accuracy and to minimize the number of sensors. After sensor selection analysis, the sensor signals with better estimation capability are selected and combined using the sensor fusion method. The proposed estimation system combined with sensor selection analysis performs well in terms of accuracy and computational effort. Finally, the proposed approach is applied for on-line monitoring of tool wear with an alarm, which demonstrates the effectiveness of our approach.

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Chakraborty, Shankar, Partha Protim Das, and Vidyapati Kumar. "Application of grey-fuzzy logic technique for parametric optimization of non-traditional machining processes." Grey Systems: Theory and Application 8, no. 1 (February 5, 2018): 46–68. http://dx.doi.org/10.1108/gs-08-2017-0028.

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Purpose The purpose of this paper is to exploit the fullest potential and capability of different non-traditional machining (NTM) processes, it is often recommended to operate them at their optimal parametric combinations. There are several mathematical tools and techniques that have been effectively deployed for identifying the optimal parametric mixes for the NTM processes. Amongst them, grey relational analysis (GRA) has become quite popular due to its sound mathematical basis, ease to implement and apprehensiveness for multi-objective optimization of NTM processes. Design/methodology/approach In this paper, GRA is integrated with fuzzy logic to present an efficient technique for multi-objective optimization of three NTM processes (i.e. abrasive water-jet machining, electrochemical machining and ultrasonic machining) while identifying their best parametric settings for enhanced machining performance. Findings The derived results are validated with respect to technique for order preference by similarity to ideal solution (TOPSIS), and analysis of variance is also performed so as to identify the most significant control parameters in the considered NTM processes. Practical implications This grey-fuzzy logic approach provides better parametric combinations for all the three NTM processes with respect to the predicted grey-fuzzy relational grades (GFRG). The developed surface plots help the process engineers to investigate the effects of various NTM process parameters on the predicted GFRG values. Originality/value The adopted approach can be applied to various machining (both conventional and non-conventional) processes for their parametric optimization for achieving better response values.

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Núñez López, Pedro Jose, Eustaquio García Plaza, Angel Ramon Martín, and A. Egido. "An Integrated Methodology for the Teaching of Computer Aided Tools for Automated Machining." Materials Science Forum 692 (July 2011): 8–15. http://dx.doi.org/10.4028/www.scientific.net/msf.692.8.

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To date a wide variety of computer aided tools are available for computer numerical controlled (CNC) automated machine-tools. Solid modelling software and 3D computer-aided design (CAD) are know firmly established in the early design stage whereas computer aided machining (CAM) and computer numerical control (CNC) simulator software is employed during the manufacturing stage. Training in the use of these systems is often undertaken in separate technical disciplines and training courses (e.g., graphic representation, mechanical design, computer numerical control programming, computer-aided machining, manufacturing technology, etc.), but students often lack a sound global understanding of these tools and fail to comprehend the full potential of integrating these applications. Thus, the aim is to propose a global methodology for the teaching of computer aided automated machining systems by integrating an array of computer aided tools (3D solid modelling, CAD/CAM software, CNC simulators, DNC communication, etc.) in order to enhance knowledge and develop skills of the entire manufacturing process i.e., to provide practical hands-on tasks from the early design stages to the final stages of the computer aided automated machining of a product.

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Zhang, Qin He, Ru Du, Jian Hua Zhang, J. Y. Yang, and Sheng Feng Ren. "The Mechanism of Ultrasonic Vibration Improving MRR in UEDM in Gas." Materials Science Forum 471-472 (December 2004): 741–45. http://dx.doi.org/10.4028/www.scientific.net/msf.471-472.741.

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A new machining method, ultrasonic vibration aided electrical discharge machining (UEDM) in gas, is proposed in this paper. It is shown that electrical discharge machining with ultrasonic vibration aid can be achieved well in gas medium. In the process of UEDM in gas, the tool electrode is formed to be thin-walled pipe, high pressure gas medium is supplied from inside, and ultrasonic vibration is applied to workpiece. The property of ultrasonic is introduced. The same to other sound waves, ultrasonic have the characteristics of reflecting, refracting, intervening and resonance. The mechanism of elastic pole keeping in resonance with ultrasonic transferring from one end to the other end is explained with characteristics of ultrasonic. During the process of UEDM in gas, ultrasonic vibration of workpiece can improve the machining process. The theories of ultrasonic vibration increasing materials removal rate (MRR) are introduced. One theory is that the adhere strength between the metallic liquid drops and workpiece is not enough for the accelerative vibration, so metallic liquid drops will be ejected off easily. Another theory is that ultrasonic vibration increases the number of the effective discharge.

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MIYAZAKI, Toshiyuki, and Yoshihiro TANAKA. "Frequency of generated sound and material removal characteristics in Q-switched YAG laser machining." Journal of the Japan Society for Precision Engineering 55, no. 8 (1989): 1421–25. http://dx.doi.org/10.2493/jjspe.55.1421.

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Prakash, M., and PVS Dileep Aditya Dhar. "Investigation on the effect of drilling parameters on the tool wear and delamination of glass fibre-reinforced polymer composite using vibration signal analysis." Journal of Composite Materials 52, no. 12 (August 29, 2017): 1641–48. http://dx.doi.org/10.1177/0021998317728109.

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Glass fibre-reinforced polymer composite materials are widely used in industrial, aerospace and automotive sector. It has excellent properties such as high strength to weight ratio, higher fatigue limit, high stiffness to weight ratio, corrosion resistance and design flexibility. The strength of the composite highly depends upon orientation of the fibre material. Drilling is one of the major machining operations that are carried out on Glass fibre-reinforced polymer composite materials to the need for components assembly. There are many problems encountered while drilling glass fibre-reinforced polymer composites. The major problems are excessive tool wear and delamination of the composite during drilling, which reduce the strength of the composite during application. In the present study, the experimental investigations are carried out to analyse the effect of various machining parameters, i.e. cutting speed and feed rate on the tool wear and delamination. The time and frequency domain analysis of vibration signals measured using sound sensor is also used to predict the effect of machining parameters on delamination as well as to develop the tool replacement strategy.

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42

Kovacevic, R., M. Hashish, R. Mohan, M. Ramulu, T. J. Kim, and E. S. Geskin. "State of the Art of Research and Development in Abrasive Waterjet Machining." Journal of Manufacturing Science and Engineering 119, no. 4B (November 1, 1997): 776–85. http://dx.doi.org/10.1115/1.2836824.

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Thermodynamic analysis of material removal mechanisms indicates that an ideal tool for shaping of materials is a high energy beam, having infinitely small cross-section, precisely controlled depth, and direction of penetration, and does not cause any detrimental effects on the generated surface. The production of the beam should be relatively inexpensive and environmentally sound while the material removal rate should be reasonably high for the process to be viable. A narrow stream of high energy water mixed with abrasive particles comes close to meeting these requirements because abrasive waterjet machining has become one of the leading manufacturing technologies in a relatively short period of time. This paper gives an overview of the basic research and development activities in the area of abrasive waterjet machining in the 1990s in the United States.

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Chouchaoui, Ben, Joe Joe Gutierrez, Vince Mungioli, and Kassem Ghanem. "Machining Versus Molding Tolerances in Manufacturing Automotive Sealing Systems." Scientific Review, no. 510 (October 25, 2019): 179–84. http://dx.doi.org/10.32861/sr.510.179.184.

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The automotive industry has been at the forefront of converting traditional metal parts to plastics. The latter surely offer greater design freedom, opportunity for consolidation, fewer assembly operations, reduced secondary finishing, weight reduction, lower total system costs, a range of properties tailored to specific applications, the ability to withstand temperatures, immunity to most chemicals and corrosive environments. They offer processing in many colors, electrical non-conductivity (insulation from electrical shocks), good thermal breaks (“warmth-to-the-touch”), and low sound transmission (tendency to muffle noise). Nonetheless, plastics have only tapped an estimated 15% of their tremendous potential to replace metals. This is particularly to increase with newer high-performance plastics, increasing sophistication in alloying and blending technologies, and use of computer-aided design and engineering (CAD/CAE) systems. The latter enable engineers to visualize complex parts and molding tools more effectively and faster than ever before. This article identifies fundamental steps and requirements to conduct an efficient and successful conversion of metallic parts to plastics, reviewing the replacement design process from concept to production; an under-the-hood rear retainer for Ford Motor Company is detailed as a case study.

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Mishra, Dileep Kumar, ▪. Rahul, Saurav Datta, Manoj Masanta, and Siba Sankar Mahapatra. "Through hole making by electro-discharge machining on Inconel 625 super alloy using hollow copper tool electrode." Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 233, no. 2 (June 27, 2018): 348–70. http://dx.doi.org/10.1177/0954408918784701.

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A case experimental research on through hole making process on Inconel 625 super alloy by using hollow (tubular) copper tool electrode in electro-discharge machining has been delineated herein. Based on three controllable process variables namely peak discharge current, pulse-on duration, and gap voltage, experiments on through hole making have been carried out following the electro-discharge machining route (die-sinking electro-discharge machining without flushing). In addition to surface morphology, topographical features of the electro-discharge machined work surface have been examined for both internal cylindrical surface of the hole produced and also the external peripheral surface of the removed cylindrical part. The influence of the process parameters have been analyzed on various process performance features like material removal rate, surface roughness, surface crack density, white layer thickness, circularity, radial overcut, and hole taper. An optimal parameter setting has been identified for sound hole making and thereby to improve electro-discharge machining performance. Additionally, energy-dispersive X-ray spectroscopic analysis has been carried out to investigate the extent of carbon enrichment onto the electro-discharge machined work surface of Inconel 625 as affected by the pyrolysis of the dielectric fluid whilst executing electro-discharge machining operation. X-ray diffraction tests have been carried out to compare metallurgy of the electro-discharge machined work surface (various phases/precipitates present in bulk of the matrix material, extent of grain refinement, crystallite size, strain, and dislocation density) with respect to that of “as received” Inconel 625. Results, thus obtained, have also been compared to that of the micro-hardness test data.

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Fiala, Zdenek, Miroslav Piska, and Ales Jaros. "ON THE ANALYSIS OF THE SOUND SPECTRUM AT MACHINING OF THE GLASS-POLYESTER COMPOSITE MATERIAL." MM Science Journal 2014, no. 01 (March 11, 2014): 459–62. http://dx.doi.org/10.17973/mmsj.2014_03_201403.

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Lee, Cheng-Hsiung, Jung-Sing Jwo, Han-Yi Hsieh, and Ching-Sheng Lin. "An Intelligent System for Grinding Wheel Condition Monitoring Based on Machining Sound and Deep Learning." IEEE Access 8 (2020): 58279–89. http://dx.doi.org/10.1109/access.2020.2982800.

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Yang, Xiaocui, Liang Chen, Xinmin Shen, Panfeng Bai, Sandy To, Xiaonan Zhang, and Zhizhong Li. "Optimization of geometric parameters of the standardized multilayer microperforated panel with finite dimension." Noise Control Engineering Journal 67, no. 3 (May 1, 2019): 197–209. http://dx.doi.org/10.3397/1/376718.

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Standardized multilayer microperforated panel fabricated by laser beam machining of the spring steel was proposed for noise reduction in this study. Geometric parameters of the standardized multilayer microperforated panel, which include diameter of the hole, thickness of the panel, distance between the neighbor holes, and length of the cavity, were optimized for the better sound absorption performance. Sound absorption coefficient of the standardized multilayer microperforated panel was theoretically modeled based on the Maa's theory. The optimization of geometric parameters of the standardized multilayer microperforated panel was obtained by the Cuckoo search algorithm, and the finite dimension of 30 mm was treated as the additional constraint condition. Preliminary verification of the obtained optimal parameters was conducted through the constructed finite element simulation model. Actual sound absorption coefficients of the standardized multilayer microperforated panels with layer number of 1 to 4 were measured by standing wave method, which were consistent with theoretical data and simulation data, and the corresponding average values in the frequency range of 100â–“6000 Hz were 57.45%, 70.85%, 71.99%, and 72.28%, respectively. By theoretical modeling, parameter optimization, simulation, and experimental validation, an effective method was proposed to develop practical sound absorbers, which would promote their applications in noise reduction.

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Mohamedosman Elyass, Waddah, Vishal Sharma, Ganesh Kantak, and Mohd Mukhtar Alam. "Performance Investigation of Wire EDM Process Parameters." IOP Conference Series: Materials Science and Engineering 1224, no. 1 (January 1, 2022): 012001. http://dx.doi.org/10.1088/1757-899x/1224/1/012001.

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Abstract It is exceptionally difficult to create confusing geometry in such a material using traditional machining measurement. At present, companies use a non-regular machining strategy which uses energies like electricity, chemical, sound, light, etc. which are useful for machining hard materials. WEDM machines are used to cut complex and simple patterns and have the potential to achieve the maximum production capacity since the last few decades. This study was carried out in two parts. The first segment was consolidated with analyses of the Taguchi method depending on the signal-to-noise ratio (S / N) and regression modelling for the S / N ratio. In the second segment, the model condition was created using the RSM methodology. L16 orthogonal array was used with four levels of parameters namely, pulse on time, pulse off time, wire feed rate and peak current to find the effects on optimal response variables namely, cutting time, cutting rate, overcut and dimensional deviations. The results of the regression analysis showed that there was significant effect of pulse on/off and peak current on the cutting time and for cutting rate there was also significant effect of wire feed rated. Therefore, it can be concluded that all the four process parameters can affect the response variables.

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Dobrotvorskiy, Sergey, Yevheniia Basova, Oleksandr Kharchenko, Valerii Letiuk, Ihor Yakovenko, Alexey Kotliar, and Samra Youssef Mounif Abou. "DETERMINATION OF THE FEATURES OF THE SHAPE AND VIBRATION FREQUENCY OF TURBINE BLADES ON DIGITAL MODELS." Bulletin of the National technical university "Kharkiv Polytechnic Institute" Series: Techniques in a machine industry, no. 2 (September 27, 2022): 117–23. http://dx.doi.org/10.20998/2079-004x.2022.2(6).16.

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A digital solid model of a turbine blade with a mounting shelf has been developed in SolidWorks. The description of complex surfaces is made using spline functions. The method of computer simulation using SolidWorks Simulation was used to study the distribution of natural oscillations of the blade depending on the method of its fixing during machining. The spectra of natural oscillations of the blade in the sound range have been obtained and analyzed. The form of natural vibrations of complex surfaces is also analyzed. For the correct choice of processing parameters during machining, it is necessary to take into account both the conditions for fixing the part in the fixture and the natural frequency of the part. It is noted that an equally important parameter is the form of oscillations of a thin surface at the studied frequencies. It is noted that in the future it is possible to solve these problems through computer simulation.

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Li, Min, Lanrong Cai, and Junling Zhao. "Research on discharge characteristics of working mediums of electric discharge machining." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 235, no. 1-2 (August 20, 2020): 34–40. http://dx.doi.org/10.1177/0954405420951093.

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Successful surface modification can be obtained by Electrical Discharge Machining (EDM). In this work the discharge characteristics in misted deionized water and near-dry powder-mixed medium was studied systematically, as well as the microstructure and properties of electrical discharge strengthened layers on TC4 alloy. It indicates that the breakdown voltage of EDM in misted deionized water medium has been reduced to about 1/3 than in air medium. In near-dry powder-mixed medium, it is reduced to about 1/9, because the discharge gap is much larger than that of other mediums. In other words, a stable discharge can be obtained by larger discharge gaps and lower pulse energy than traditional EDM surface strengthening method, which leads to more stable discharge process. Experimental researches show that dense and sound combination with matrix like, multiphase hybrid intensification and chrysanthemum petal-like microstructure of strengthened layers can be observed in the near-dry powder-mixed medium. Meanwhile, it is found that the microhardness of the strengthened layer is up to about 1200 HV, which is four times higher than the base material.

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Journal articles on the topic 'Machining sound'

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