Stochastic Grinding Process Development For Metal Bonded Diamond Grinding Wheel

In order to accomplish this objective, weight assigned are W1= -0.1, W2=0.25 and W3=0.65. As in Table 5 and in Fig. 3, the optimal machining parameters predicted using SA are work speed (Vw= 51.15 m/min), feed rate (f = 16.30 mm/min) and depth of cut (d = 0.01 mm) for a minimum surface roughness of 0.476µm. For these parameters the roundness is found to be 0.028mm with a material removal rate of 20.34mm3/min.

To avoid steps between the different levels, the edges will be rounded. Therefore a minimal resolution of five microns is valid for the cut mark measurements, although the software allows measurements till to decimals because of its logarithm to calculate the surface. In this dissertation, all measurements are fully specified. However, a less accuracy of values less than five microns must not be forgotten. Higher resolutions till one micrometre are also possible, but the number of scanned levels is restricted. Therefore it is possible to analyse fine cut marks in a higher resolution, but in this case, cuts were up to 1 mm deep and a smaller resolution is sufficient. Using this resolution, the ends of cuts, which are very flat, were excluded because their size is approximately under 15 microns and therefore inaccuracies in measurement increase, which might influence the

In the etching business there are three primary techniques that are commonly used, one of them is surface etching. This etching process is fairly obvious; it is named surface etching because only the surface is being etched. In addition etching is done in one stage of blasting, which means that the designs are only black and white. This method allows unetched components to be etched. Carlos Bautista manager of etching company believes that a surface etching is the easiest etching method. This technique is very easy to learn since it’s not complicated, unlike the carving and shading techniques that are very complex.

Lawal et al. [16] has done an evaluation on the performance of vegetable oil in turning process in comparison to mineral oil. The investigation found that the vegetable oil surpass conventional oil-in-water performance in turning process. Likewise, Babur et al. [17] have conclude that vegetable oil are effective in producing better surface quality and tool wear than synthetic cutting fluids during turning process. Nevertheless, improvement on the performance of vegetable oil can be done by utilising powder particles such as MoS2, graphite, boric acid, etc. Improvement can be seen from using powder particle aided lubricant in terms of surface finish, coefficient of friction, wear and cutting force [18]. This is because powder particle has lattice layered structure (Fig. 1), relatively high load carrying capacity and low steady state coefficient of friction [19]. Moreover, powder particle such as boric acid are environmentally friendly and do not pose threat to operational workers according to the Environmental Protection Agency, which is desirable in creating a greener lubrication in machining application

The literature reveals that there are many methods to perform machining simulations. For instance, methods based on a partition of the space by lines, by voxels or by planes, methods based on meshes … etc. However, simulations of the machined surfaces in CAM software are very limited, purely geometric and don’t include any characteristic of the actual process that may damage the surface quality during machining. Furthermore, these simulations do not provide the required accuracy within a

Glass fiber reinforced plastics (GFRP) have been widely used in aircraft, automobile and structural applications. The components need high quality machined surface, better dimensional accuracy and surface consistency. But machining mechanism of composite materials is not easy to understand, because of its inhomogeneous and anisotropic behavior. The machining leads to several damages such as fiber cracks, delamination, fiber pullout and burning. Hence, research in machining of GFRPs is few when compared with metals, the effect of tool nomenclature and materials [1, 2]. The investigators have studied the machining of chip formation mechanisms [3,4 and 5]. The researcher investigated on machinability integrity on different fiber directions with different tool helix angles [6]. The experimental studies are also based on machining characteristics related to orthogonal cutting of unidirectional fiber

Diamond has a Face centered cubic structure. This arrangement makes the diamond toughest, high thermal conductor & gives optical diversion properties. The substitution of carbon with boron in diamond lattice improves the electron m0obility in the structure. Nanodiamonds are smoother than microcrystalline diamond which ranges between 10-100nm. Nanodiamonds are often termed as ‘cauliflower’ or ‘ballas’ diamond. They contain large number of grain boundaries with impurities of graphite. Even ultra naocrystalline diamonds have a grain size of 2-1nm [4].

CNC machining it works particularly well for hard, relatively brittle materials like steels and other metal alloys to produce high accuracy parts with well-defined properties and normally be more homogeneous and predictable in quality.

Microelectromechanical Systems (MEMS) are systems that are designed on a micro metre scale and have become more popular as the demand for devices to get smaller has increased. The main uses of these systems are for sensors, such as accelerometers and gyroscopes and other such devices like microscopy and inkjet nozzles for example. There are many materials that can be used for MEMS as the cost of the material is almost eradicated due to the micro size of the systems being produced. This brings materials such as gold, platinum and diamond can be used, as these materials have some properties which are very desirable for a MEM systems. The most common material that is currently used in MEMS is silicon and silicon based compounds as they

experimental values. Finally it was concluded that the predicted values are close to the experimental values [21]. Sheik-Ahmad et al investigated the influence of spindle speed, feed rate and depth of cut for edge trimming of CFRP composites on machined surface quality used by diamond abrasive cutters. Here the cutting forces, surface roughness, specific cutting energy and work specimen temperature were evaluated and analyzed. Lastly, all of these factors are also influenced on machining responses [22]. Qin et al. focused on full factorial experimental design for milling of CFRP composites and all helical milling experiments were carried out with a customized cutter. Find the effects of input process parameters on damage factor at exit

The steps to achieve the project aim are first by looking generally at all methods and abrasive materials suitable for polishing the surfaces of complex parts created by SLM and identify what type of roughness each technique removes. Then identify which of those methods gives the best properties and which one is unsuitable or might be suitable. Finally test the most suitable method to make sure it works and design a prototype.

In the present study two types of methodologies have been effectively utilized to conduct the experiments in a scientific manner, one is Taguchi’s Design of Experiments (DOE) and other method of design of experiments were based on randomly selected combination of cutting process parameters is shown below figure.

Milling is metal removal process distinguished from drilling and other machining operation. It is used in most high productive manufacturing industries, where quality is essential for parts. In milling operation, Metal removal takes place due to the cutting action of a revolving milling cutter, when work piece is fed on it. But for producing quality side surface of parts, end milling operation carried out. Drill bit can cut in axial order only, while a milling bit can generally cut in all directions, although some cannot cut axially. End mills are used in milling applications such as plunging, side milling and profile milling.

WEDM is considered as a unique adoption of the conventional EDM process which comprises of a main worktable, wire drive mechanism, a CNC controller, working fluid tank and attachments. The work piece is placed on the fixture table and fixed securely by clamps and bolts. The table moves along X and Y-axis and it is driven by the DC servo motors. Wire electrode usually made of thin copper, brass, molybdenum or tungsten of diameter 0.05-0.30 mm, which transforms electrical energy to thermal energy, is used for cutting materials. The wire is stored and wound on a wire drum which can rotate at1500rpm. The wire is continuously fed from wire drum which moves though the work piece and is supported under tension between a pair of wire guides located at the opposite sides of the work piece. During the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and the wire, eliminating the mechanical stresses during machining. Also the work piece and the wire electrode (tool) are separated by a thin film of dielectric fluid that is continuously fed to the machining zone to flush away the eroded

Abstract: This paper reviews on the various analyzing techniques of chatter stability in high speed milling. Milling at high spindle speed is an effective technology for processing various materials. During milling, unstable self-excited vibrations known as regenerative chatter can occur, causing excessive tool wear or failure and a poor surface finish on the machined work piece. There are several analyzing techniques that are used to increase the stability of the machining process such as, fuzzy arithmetic techniques, stability lobe diagram(SLD),Structural dynamic modification. Based on these analyzing techniques how the operating variables are changed to obtain the different predicted results is studied.