This paper presents the micromanufacturing of aluminum (Al) alloy microrods using micro turning a... more This paper presents the micromanufacturing of aluminum (Al) alloy microrods using micro turning as a competing process to other nontraditional micromachining methods. In that regard, the challenges in such manufacturing have been identified and overcome. The strategies of step-by-step cutting have also been delineated. In addition, the influence of step size and step length on the cutting and thrust forces were investigated. The chip morphology for micromachining was examined using scanning electron microscopic imagery. The safe dimension of the microrod was calculated and, subsequently, used to fabricate microrod, conical tip rod, and grooved rod from 3 mm long and 1.5 mm diameter rod using an appropriately coded computer numerical control (CNC) micromachining center. Our results showed that the thrust force was responsible for part deflection, emphasizing the necessity for computing safe dimensions. At shallow step sizes, the thrust force was more dominant, causing plastic deformation associated with rubbing and burnishing. The chips produced were irregular and sliced in nature. Conversely, at high step sizes, the cutting force superseded the thrust force, resulting in chips that were spread more along the width as opposed to the depth. The chips also had a smoother interacting surface. Finally, micro turning was successfully implemented to manufacture milli-scale structures (i.e., 3 mm long) with micro features (150 to 230 µm diameter) on aluminum alloy materials.
The International Journal of Advanced Manufacturing Technology, 2018
In recent years, Inconel 718 is widely used in industries like aerospace, oil and gas, and automo... more In recent years, Inconel 718 is widely used in industries like aerospace, oil and gas, and automobile due to their unique combination of hardness, strength, temperature, and corrosion resistance properties. However, these materials pose challenges during conventional machining due to their high work hardening tendency, poor thermal conductivity, and chemical affinity towards the tool material. Consequently, rapid tool wear during the machining of Inconel 718 results in poor productivity. To overcome these issues, a non-contact hybrid electrical discharge and arc machining (HEDAM) process has been developed to machine such difficult-to-cut materials. Firstly, the design and development of the HEDAM circuit has been discussed. Subsequently, the working principle of the newly developed process has been studied followed by its performance comparison with the conventional EDM process. In addition, the material removal mechanism has also been discussed in detail. Finally, experimental results were reported, where holes were drilled using the developed HEDAM process. The HEDAM process has exhibited significant improvements in terms of material removal rate (MRR) which is around 12 times higher and electrode wear ratio (EWR) that is half when compared to conventional EDM. This high performance HEDAM process resulted in successful and efficient drilling of Inconel 718.
The International Journal of Advanced Manufacturing Technology, 2017
Inconel 718 is one of the most widely used super alloys in industries like oil and gas, aerospace... more Inconel 718 is one of the most widely used super alloys in industries like oil and gas, aerospace and automobile. However, properties like poor thermal conductivity and work hardening tendency make it difficult to machine, using a conventional machining approach. EDM is one of the effective and efficient ways of machining this exotic material. However, the material removal rate (MRR) is very low. In an attempt to enhance the performance of EDM, an arc machining module has been integrated into the existing EDM system and the compound process is named hybrid electrical discharge and arc machining (HEDAM). Due to the high thermal intensity of the sparks/arcs imparted by this process, the material removal rate is elevated.
This paper presents the micromanufacturing of aluminum (Al) alloy microrods using micro turning a... more This paper presents the micromanufacturing of aluminum (Al) alloy microrods using micro turning as a competing process to other nontraditional micromachining methods. In that regard, the challenges in such manufacturing have been identified and overcome. The strategies of step-by-step cutting have also been delineated. In addition, the influence of step size and step length on the cutting and thrust forces were investigated. The chip morphology for micromachining was examined using scanning electron microscopic imagery. The safe dimension of the microrod was calculated and, subsequently, used to fabricate microrod, conical tip rod, and grooved rod from 3 mm long and 1.5 mm diameter rod using an appropriately coded computer numerical control (CNC) micromachining center. Our results showed that the thrust force was responsible for part deflection, emphasizing the necessity for computing safe dimensions. At shallow step sizes, the thrust force was more dominant, causing plastic deformation associated with rubbing and burnishing. The chips produced were irregular and sliced in nature. Conversely, at high step sizes, the cutting force superseded the thrust force, resulting in chips that were spread more along the width as opposed to the depth. The chips also had a smoother interacting surface. Finally, micro turning was successfully implemented to manufacture milli-scale structures (i.e., 3 mm long) with micro features (150 to 230 µm diameter) on aluminum alloy materials.
The International Journal of Advanced Manufacturing Technology, 2018
In recent years, Inconel 718 is widely used in industries like aerospace, oil and gas, and automo... more In recent years, Inconel 718 is widely used in industries like aerospace, oil and gas, and automobile due to their unique combination of hardness, strength, temperature, and corrosion resistance properties. However, these materials pose challenges during conventional machining due to their high work hardening tendency, poor thermal conductivity, and chemical affinity towards the tool material. Consequently, rapid tool wear during the machining of Inconel 718 results in poor productivity. To overcome these issues, a non-contact hybrid electrical discharge and arc machining (HEDAM) process has been developed to machine such difficult-to-cut materials. Firstly, the design and development of the HEDAM circuit has been discussed. Subsequently, the working principle of the newly developed process has been studied followed by its performance comparison with the conventional EDM process. In addition, the material removal mechanism has also been discussed in detail. Finally, experimental results were reported, where holes were drilled using the developed HEDAM process. The HEDAM process has exhibited significant improvements in terms of material removal rate (MRR) which is around 12 times higher and electrode wear ratio (EWR) that is half when compared to conventional EDM. This high performance HEDAM process resulted in successful and efficient drilling of Inconel 718.
The International Journal of Advanced Manufacturing Technology, 2017
Inconel 718 is one of the most widely used super alloys in industries like oil and gas, aerospace... more Inconel 718 is one of the most widely used super alloys in industries like oil and gas, aerospace and automobile. However, properties like poor thermal conductivity and work hardening tendency make it difficult to machine, using a conventional machining approach. EDM is one of the effective and efficient ways of machining this exotic material. However, the material removal rate (MRR) is very low. In an attempt to enhance the performance of EDM, an arc machining module has been integrated into the existing EDM system and the compound process is named hybrid electrical discharge and arc machining (HEDAM). Due to the high thermal intensity of the sparks/arcs imparted by this process, the material removal rate is elevated.
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Papers by Ahmed Fardin