This paper presents the application of a hybrid approach comprising of Neural Network (NN) and Ge... more This paper presents the application of a hybrid approach comprising of Neural Network (NN) and Ge netic Algorithm (GA) for modeling and optimization of Creep Feed Deep Surface Grinding (CFDSG) process. Finite Element Method (FEM) has been used to generate d ata set for NN model to predict the equivalent thermal stress within the contact zone of the work piece. Subsequently, NN model has been coupled with GA to find optimum input-output parameters of CFDSG. The proposed hybrid approach is well capable to predict thermal stresses in the workpiece quickly and also minimize it with reasonable accuracy during CFDSG process.
Electro-Discharge Diamond Face Grinding (EDDFG) is an advanced hybrid machining process for face ... more Electro-Discharge Diamond Face Grinding (EDDFG) is an advanced hybrid machining process for face grinding of wide variety of electrically conductive difficult-to-machine hard materials by suitable modification in Electro-Discharge Machining (EDM). In the present work, the EDDFG setup has been developed and tested for grinding difficult-to-machine materials and also attempted for fabrication of metal matrix composite of Aluminium (Al) reinforced by 10% Silicon Carbide (SiC p). To perform such hybrid machining process, the developed experimental setup was used for experimental study of EDDFG process on Al-SiC pMMCby considering the effect of gap current, pulse on time and wheel RPM on average surface roughness (R a) and material removal rate (MRR). The metal bonded diamond abrasive grinding wheel is mainly responsible for higher value of MRR. It was also observed that MRR is higher at moderate value of wheel RPM and wheel rotation improves the flushing action. The average surface roug...
The machining of thin and fragile material is very difficult for manufacturing industries and rap... more The machining of thin and fragile material is very difficult for manufacturing industries and rapid demand of requirement could not be achieved. Electrical discharge machining is more acceptable machine tool for machining hard and brittle electrically conductive materials but its productivity is very slow. In past decade, researchers are focus on electrical discharge grinding (EDG) for machining these material because there is no mechanical forces exerted on workpiece during machining and it gives better performances than EDM due to the rotating speed of wheel. The aim of this paper is to summarize a review on EDG process along with developments in same area and also focus on the future research scope in the same area.
Borosilicate glass has been set in the class of important engineering materials because of its ex... more Borosilicate glass has been set in the class of important engineering materials because of its excellent properties such as lower thermal expansion coefficient and lower density than soda lime glass, chemically inert, electrically non-conducting, optical clarity. Its applications are found in electronics industries, space exploration, chemical industries, optics, and implantable medical devices. The machining of borosilicate glass for creation of different types of features is difficult because of its brittle, nonconducting, and chemical inert nature. Electro-Chemical Discharge Machining is successfully utilized for machining of Borosilicate Glass. This paper discusses the comparison of machining performances of Electro-Chemical Discharge Machining process in two configurations, namely Drilling-ECDM and Sinking-ECDM, during machining of Borosilicate Glass. Machining performance is measured in terms of Material Removal Rate, Average Overcut and Hole Taper.
In ultrasonic machining (USM), higher amplitude is required for higher material removal rate (MRR... more In ultrasonic machining (USM), higher amplitude is required for higher material removal rate (MRR). The objective of this research is to develop a new horn design for high displacement amplitude for getting maximum MRR within a working condition. The profile of the horn has been optimized and designed. In this analysis, optimization procedure and finite-element method have been used for the design of horn of USM. In this, the variation of stress components along the length of the horn has been studied. In the middle, maximum stress is found due to a change in cross-section but it is within the endurance limit of the horn material. The cubic Bezier horn as compared with traditional horn is up to 19% more amplified. Finally, an optimized cubic Bezier profile for the horn has been designed, which has maximum displacement amplitude for higher MRR and safe working stresses for the horn material.
International Journal of Manufacturing, Materials, and Mechanical Engineering
In the present study, a novel technique, namely, evolutionary non-dominated sorting genetic algor... more In the present study, a novel technique, namely, evolutionary non-dominated sorting genetic algorithm-II (NSGA-II) was used in conjunction with developed artificial neural network (ANN) model to select optimal process parameters for achieving the better process performance in LBC. First, ANN with backpropagation algorithm was used to model the LBC of nickel based superalloy sheets. The input process parameters taken were oxygen pressure, pulse width, pulse frequency and cutting speed. The performance characteristics of interest in nickel based superalloy thin sheet cutting are average kerf taper and surface roughness. The ANN model was trained and tested using the experimental data obtained through experimentation on pulsed Nd-YAG laser beam machining system. The 4-10-11-2 backpropagation architecture was found more accurate and generalized for given problem with good prediction capability. The results show that the developed modelling and optimization tool is effective for process ...
Abstract In this paper, authors have endeavored to develop an experimental setup of Electrical Di... more Abstract In this paper, authors have endeavored to develop an experimental setup of Electrical Discharge Diamond Peripheral Surface Grinding which is a configuration of Electrical Discharge Diamond Grinding process. The machining performance characteristics were experimentally studied using the developed experimental setup during machining of a challenging material Al/SiCp/B4Cp hybrid metal matrix composite. Gap current, on-time, off-time, abrasive grit number, speed of wheel, and table speed were input process parameters considered. The influence of input process parameters were experimentally investigated on material removal rate and surface roughness using one parameter at a time approach. Scanning Electron Microscopy was used to study the surface texture and recast layers on machined surface. The surface finish is better achieved at a critical pulse off-time with appropriate declogging of diamond wheel. A specific abrasive grit size is suitable for better removal of thermal infested surface deteriorations with minimal marks of grinding traces. The presence of shallow craters and negligible thickness of recast layers on machined surface substantiate the potential capability and applicability of developed EDDPSG experimental system.
Abstract Cutting of sheet material is considered as an important process due to its relevance amo... more Abstract Cutting of sheet material is considered as an important process due to its relevance among products of everyday life such as aircrafts, ships, cars, furniture etc. Among various sheet cutting processes (ASCPs), laser beam cutting is one of the most capable ASCP to create complex geometries with stringent design requirements in difficult-to-cut sheet materials. Based on the recent research work in the area of sheet cutting, it is found that the Nd-YAG laser is used for cutting of sheet material in general and reflective sheet material in particular. This paper reviews the experimental analysis of Nd-YAG laser cutting process, carried out to study the influence of laser cutting parameters on the process performance index. The significance of experimental modeling and different optimization approaches employed by various researchers has also been discussed in this study.
Journal of Mechanical Science and Technology, 2017
Hybrid machining techniques are effective means for machining of difficult-to-cut, electrically c... more Hybrid machining techniques are effective means for machining of difficult-to-cut, electrically conductive hard and brittle materials. In the present work, performance characteristics of newly developed Electrical discharge diamond face surface grinding were experimentally studied during machining flat surfaces of a difficult-to-cut hybrid metal matrix composite, which is a new configuration of electrical discharge diamond grinding. Gap current, on and off time are the spark related parameters as well as grinding related parameters such as abrasive grit size, RPM of wheel, and table speed are considered as input process parameters. The role of input process parameters was investigated in machining performance such as MRR and Ra during electrical discharge diamond face surface grinding of Al/SiCp/B4Cp hybrid metal matrix composite. Scanning electron microscopy was also used to study the recast layers and surface texture of machined surface. Better surface finish with reduced recasts and higher MRR evince the potential applicability of the process.
ABSTRACT Studies on the applicability of various configurations of Electrical Discharge Diamond G... more ABSTRACT Studies on the applicability of various configurations of Electrical Discharge Diamond Grinding (EDDG) are facing many challenges during the machining of advance difficult-to-machine materials. In the present paper, description of a new configuration of EDDG, called the Electrical Discharge Diamond Face Surface Grinding (EDDFSG) system, has been discussed. Experimental investigations have been made using the one parameter at a time (OPAT) approach to study the effect of gap current, on-time, off-time, abrasive grit number, RPM of wheel and table speed on the material removal rate (MRR) and surface roughness (Ra) during EDDFSG of hybrid metal matrix composite (MMC). Surface texture and recast layers of the machined surface have also been studied using Scanning Electron Microscopy (SEM). Higher MRR with better surface finish and hardly seen recast layers on the machined surface demonstrate the potential applicability of the process for machining flat surfaces made of such challenging and complex materials.
Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture, Apr 17, 2015
Machining of metal matrix composites has always been challenges for manufacturing engineers due t... more Machining of metal matrix composites has always been challenges for manufacturing engineers due to the presence of hard and brittle reinforced particles. In this article, a new way of alternate application of electrical discharge grinding and abrasive grinding has been applied through the use of slotted grinding wheel. The developed machining process has been named as slotted electrical discharge abrasive grinding. The performances of slotted electrical discharge abrasive grinding process are tested on aluminum–silicon carbide–graphite (Al/SiC/Gr) metal matrix composite workpiece. The experiments were performed using one parameter at a time approach considering the effect of current, pulse on-time, pulse off-time, wheel speed and grit number on material removal rate and average surface roughness. It has been found that current ranges from 3 to 15 A and wheel speed ranges from 700 to 1300 r/min are more appropriate for machining of Al/SiC/Gr composite material within the ranges of selected parameters.
This article describes the experimental investigation related to creation of holes in aerospace t... more This article describes the experimental investigation related to creation of holes in aerospace titanium alloy workpiece using static electrode machining and electrical discharge drilling (EDD) process. Special attachment for holding and rotating the tool electrode was developed and installed on electrical discharge machining (EDM) machine by replacing the original conventional tool holder provided on die sinking EDM. The effect of input parameters such as gap current, pulse on-time, duty factor and RPM of tool electrode on output parameters for average hole circularity (Ca) and average surface roughness (Ra) have been studied. It is observed that the effect of rotating electrode machining has considerable influence on the output parameters over stationary electrode machining. The micro-graphs and photographs of few selected samples were taken by SEM and metallurgical microscope, which also commensurate with the findings of the study.
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2013
A thermal finite element model is proposed to simulate and predict hole taper ( Ta), heat-affecte... more A thermal finite element model is proposed to simulate and predict hole taper ( Ta), heat-affected zone and material removal rate during laser beam percussion drilling in two difficult-to-laser-drill materials having wide difference in their thermophysical and optical properties. The developed model incorporates temperature-dependent thermal properties, optical properties and phase change phenomena of the sheet materials to predict the hole profile through the isotherm generated along the depth of the hole due to repeated laser pulses. Hole characteristics and hole productivity parameters are compared for both the sheet materials. The predicted values of hole taper with respect to pulse width have been compared with the experimentally obtained values. It is observed that hole characteristics are mainly affected by pulse width in the Aluminium alloy sheet and pulse frequency in the Inconel sheet, whereas peak power has prominent effect on material removal rate for both the sheet mate...
Silicon wafers are being used extensively for making various micro-components in recent times. Th... more Silicon wafers are being used extensively for making various micro-components in recent times. The efficient machining with high levels of surface integrity is the major problem during finishing of silicon wafers. Various methodologies are being used, but no effective methodology has been found. In this paper, a new methodology called as micro-electro-discharge diamond grinding is reported as a feasible, effective method for silicon wafer finishing. The proposed setup with appropriate controller circuit has been discussed. The feasibility study of the proposed setup has been discussed in detail.
International Journal of Manufacturing Technology and Management, 2015
Advancement of new materials and machining technology has changed the domain and ranges both of a... more Advancement of new materials and machining technology has changed the domain and ranges both of aerospace vehicles, still a few problems of conventional as well as non-conventional machining processes is unresolved such as low material removal rate (MRR), frequent tool wear and poor surface finish, etc. In this experimental study, a new process in electrical discharge machining (EDM), termed as electrical discharge drilling (EDD is used to make the hole in titanium alloy (Ti-6Al-4V) and also used altogether a new approach of hybrid of methodologies for modelling as well as optimisation of the hole made for MRR, average surface roughness (Ra) and average circularity (Ca). The used methodology comprises of Taguchi methodology (TM) with response surface methodology (RSM) for modelling and RSM coupled with principal component analysis-based (PCA) grey relational analysis (GRA) for optimisation. The obtained results indicate that applied hybrid approaches in present study of EDD process are reasonable and substantiates with facts of improvement in MRR by 30.80%, Ra by 24.81% and Ca by 26.09%.
International Journal of Precision Engineering and Manufacturing, 2012
ABSTRACT This work presents the characteristics of advanced abrasion based hybrid machining proce... more ABSTRACT This work presents the characteristics of advanced abrasion based hybrid machining process consisting of electrochemical dissolution and magnetic abrasive machining process. The cylindrical electrochemical magnetic abrasive machining (C-EMAM) setup was developed and mounted as an attachment on lathe for high efficiency machining of cylindrical jobs. Experiments were conducted to explore the performance of the process on AISI-304 stainless steel tubes using unbonded magnetic abrasives. The effect of various process parameters viz. rotational speed of the workpiece, current to the electromagnet, electrolytic current and frequency of vibration on material removal and surface roughness were investigated. The electrochemical process has major contribution in material removal, whereas magnetic abrasive machining helps in reduction in surface roughness. This process has higher machining efficiency particularly at high value of electrolytic current and high rotational speed.
This paper presents the application of a hybrid approach comprising of Neural Network (NN) and Ge... more This paper presents the application of a hybrid approach comprising of Neural Network (NN) and Ge netic Algorithm (GA) for modeling and optimization of Creep Feed Deep Surface Grinding (CFDSG) process. Finite Element Method (FEM) has been used to generate d ata set for NN model to predict the equivalent thermal stress within the contact zone of the work piece. Subsequently, NN model has been coupled with GA to find optimum input-output parameters of CFDSG. The proposed hybrid approach is well capable to predict thermal stresses in the workpiece quickly and also minimize it with reasonable accuracy during CFDSG process.
Electro-Discharge Diamond Face Grinding (EDDFG) is an advanced hybrid machining process for face ... more Electro-Discharge Diamond Face Grinding (EDDFG) is an advanced hybrid machining process for face grinding of wide variety of electrically conductive difficult-to-machine hard materials by suitable modification in Electro-Discharge Machining (EDM). In the present work, the EDDFG setup has been developed and tested for grinding difficult-to-machine materials and also attempted for fabrication of metal matrix composite of Aluminium (Al) reinforced by 10% Silicon Carbide (SiC p). To perform such hybrid machining process, the developed experimental setup was used for experimental study of EDDFG process on Al-SiC pMMCby considering the effect of gap current, pulse on time and wheel RPM on average surface roughness (R a) and material removal rate (MRR). The metal bonded diamond abrasive grinding wheel is mainly responsible for higher value of MRR. It was also observed that MRR is higher at moderate value of wheel RPM and wheel rotation improves the flushing action. The average surface roug...
The machining of thin and fragile material is very difficult for manufacturing industries and rap... more The machining of thin and fragile material is very difficult for manufacturing industries and rapid demand of requirement could not be achieved. Electrical discharge machining is more acceptable machine tool for machining hard and brittle electrically conductive materials but its productivity is very slow. In past decade, researchers are focus on electrical discharge grinding (EDG) for machining these material because there is no mechanical forces exerted on workpiece during machining and it gives better performances than EDM due to the rotating speed of wheel. The aim of this paper is to summarize a review on EDG process along with developments in same area and also focus on the future research scope in the same area.
Borosilicate glass has been set in the class of important engineering materials because of its ex... more Borosilicate glass has been set in the class of important engineering materials because of its excellent properties such as lower thermal expansion coefficient and lower density than soda lime glass, chemically inert, electrically non-conducting, optical clarity. Its applications are found in electronics industries, space exploration, chemical industries, optics, and implantable medical devices. The machining of borosilicate glass for creation of different types of features is difficult because of its brittle, nonconducting, and chemical inert nature. Electro-Chemical Discharge Machining is successfully utilized for machining of Borosilicate Glass. This paper discusses the comparison of machining performances of Electro-Chemical Discharge Machining process in two configurations, namely Drilling-ECDM and Sinking-ECDM, during machining of Borosilicate Glass. Machining performance is measured in terms of Material Removal Rate, Average Overcut and Hole Taper.
In ultrasonic machining (USM), higher amplitude is required for higher material removal rate (MRR... more In ultrasonic machining (USM), higher amplitude is required for higher material removal rate (MRR). The objective of this research is to develop a new horn design for high displacement amplitude for getting maximum MRR within a working condition. The profile of the horn has been optimized and designed. In this analysis, optimization procedure and finite-element method have been used for the design of horn of USM. In this, the variation of stress components along the length of the horn has been studied. In the middle, maximum stress is found due to a change in cross-section but it is within the endurance limit of the horn material. The cubic Bezier horn as compared with traditional horn is up to 19% more amplified. Finally, an optimized cubic Bezier profile for the horn has been designed, which has maximum displacement amplitude for higher MRR and safe working stresses for the horn material.
International Journal of Manufacturing, Materials, and Mechanical Engineering
In the present study, a novel technique, namely, evolutionary non-dominated sorting genetic algor... more In the present study, a novel technique, namely, evolutionary non-dominated sorting genetic algorithm-II (NSGA-II) was used in conjunction with developed artificial neural network (ANN) model to select optimal process parameters for achieving the better process performance in LBC. First, ANN with backpropagation algorithm was used to model the LBC of nickel based superalloy sheets. The input process parameters taken were oxygen pressure, pulse width, pulse frequency and cutting speed. The performance characteristics of interest in nickel based superalloy thin sheet cutting are average kerf taper and surface roughness. The ANN model was trained and tested using the experimental data obtained through experimentation on pulsed Nd-YAG laser beam machining system. The 4-10-11-2 backpropagation architecture was found more accurate and generalized for given problem with good prediction capability. The results show that the developed modelling and optimization tool is effective for process ...
Abstract In this paper, authors have endeavored to develop an experimental setup of Electrical Di... more Abstract In this paper, authors have endeavored to develop an experimental setup of Electrical Discharge Diamond Peripheral Surface Grinding which is a configuration of Electrical Discharge Diamond Grinding process. The machining performance characteristics were experimentally studied using the developed experimental setup during machining of a challenging material Al/SiCp/B4Cp hybrid metal matrix composite. Gap current, on-time, off-time, abrasive grit number, speed of wheel, and table speed were input process parameters considered. The influence of input process parameters were experimentally investigated on material removal rate and surface roughness using one parameter at a time approach. Scanning Electron Microscopy was used to study the surface texture and recast layers on machined surface. The surface finish is better achieved at a critical pulse off-time with appropriate declogging of diamond wheel. A specific abrasive grit size is suitable for better removal of thermal infested surface deteriorations with minimal marks of grinding traces. The presence of shallow craters and negligible thickness of recast layers on machined surface substantiate the potential capability and applicability of developed EDDPSG experimental system.
Abstract Cutting of sheet material is considered as an important process due to its relevance amo... more Abstract Cutting of sheet material is considered as an important process due to its relevance among products of everyday life such as aircrafts, ships, cars, furniture etc. Among various sheet cutting processes (ASCPs), laser beam cutting is one of the most capable ASCP to create complex geometries with stringent design requirements in difficult-to-cut sheet materials. Based on the recent research work in the area of sheet cutting, it is found that the Nd-YAG laser is used for cutting of sheet material in general and reflective sheet material in particular. This paper reviews the experimental analysis of Nd-YAG laser cutting process, carried out to study the influence of laser cutting parameters on the process performance index. The significance of experimental modeling and different optimization approaches employed by various researchers has also been discussed in this study.
Journal of Mechanical Science and Technology, 2017
Hybrid machining techniques are effective means for machining of difficult-to-cut, electrically c... more Hybrid machining techniques are effective means for machining of difficult-to-cut, electrically conductive hard and brittle materials. In the present work, performance characteristics of newly developed Electrical discharge diamond face surface grinding were experimentally studied during machining flat surfaces of a difficult-to-cut hybrid metal matrix composite, which is a new configuration of electrical discharge diamond grinding. Gap current, on and off time are the spark related parameters as well as grinding related parameters such as abrasive grit size, RPM of wheel, and table speed are considered as input process parameters. The role of input process parameters was investigated in machining performance such as MRR and Ra during electrical discharge diamond face surface grinding of Al/SiCp/B4Cp hybrid metal matrix composite. Scanning electron microscopy was also used to study the recast layers and surface texture of machined surface. Better surface finish with reduced recasts and higher MRR evince the potential applicability of the process.
ABSTRACT Studies on the applicability of various configurations of Electrical Discharge Diamond G... more ABSTRACT Studies on the applicability of various configurations of Electrical Discharge Diamond Grinding (EDDG) are facing many challenges during the machining of advance difficult-to-machine materials. In the present paper, description of a new configuration of EDDG, called the Electrical Discharge Diamond Face Surface Grinding (EDDFSG) system, has been discussed. Experimental investigations have been made using the one parameter at a time (OPAT) approach to study the effect of gap current, on-time, off-time, abrasive grit number, RPM of wheel and table speed on the material removal rate (MRR) and surface roughness (Ra) during EDDFSG of hybrid metal matrix composite (MMC). Surface texture and recast layers of the machined surface have also been studied using Scanning Electron Microscopy (SEM). Higher MRR with better surface finish and hardly seen recast layers on the machined surface demonstrate the potential applicability of the process for machining flat surfaces made of such challenging and complex materials.
Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture, Apr 17, 2015
Machining of metal matrix composites has always been challenges for manufacturing engineers due t... more Machining of metal matrix composites has always been challenges for manufacturing engineers due to the presence of hard and brittle reinforced particles. In this article, a new way of alternate application of electrical discharge grinding and abrasive grinding has been applied through the use of slotted grinding wheel. The developed machining process has been named as slotted electrical discharge abrasive grinding. The performances of slotted electrical discharge abrasive grinding process are tested on aluminum–silicon carbide–graphite (Al/SiC/Gr) metal matrix composite workpiece. The experiments were performed using one parameter at a time approach considering the effect of current, pulse on-time, pulse off-time, wheel speed and grit number on material removal rate and average surface roughness. It has been found that current ranges from 3 to 15 A and wheel speed ranges from 700 to 1300 r/min are more appropriate for machining of Al/SiC/Gr composite material within the ranges of selected parameters.
This article describes the experimental investigation related to creation of holes in aerospace t... more This article describes the experimental investigation related to creation of holes in aerospace titanium alloy workpiece using static electrode machining and electrical discharge drilling (EDD) process. Special attachment for holding and rotating the tool electrode was developed and installed on electrical discharge machining (EDM) machine by replacing the original conventional tool holder provided on die sinking EDM. The effect of input parameters such as gap current, pulse on-time, duty factor and RPM of tool electrode on output parameters for average hole circularity (Ca) and average surface roughness (Ra) have been studied. It is observed that the effect of rotating electrode machining has considerable influence on the output parameters over stationary electrode machining. The micro-graphs and photographs of few selected samples were taken by SEM and metallurgical microscope, which also commensurate with the findings of the study.
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2013
A thermal finite element model is proposed to simulate and predict hole taper ( Ta), heat-affecte... more A thermal finite element model is proposed to simulate and predict hole taper ( Ta), heat-affected zone and material removal rate during laser beam percussion drilling in two difficult-to-laser-drill materials having wide difference in their thermophysical and optical properties. The developed model incorporates temperature-dependent thermal properties, optical properties and phase change phenomena of the sheet materials to predict the hole profile through the isotherm generated along the depth of the hole due to repeated laser pulses. Hole characteristics and hole productivity parameters are compared for both the sheet materials. The predicted values of hole taper with respect to pulse width have been compared with the experimentally obtained values. It is observed that hole characteristics are mainly affected by pulse width in the Aluminium alloy sheet and pulse frequency in the Inconel sheet, whereas peak power has prominent effect on material removal rate for both the sheet mate...
Silicon wafers are being used extensively for making various micro-components in recent times. Th... more Silicon wafers are being used extensively for making various micro-components in recent times. The efficient machining with high levels of surface integrity is the major problem during finishing of silicon wafers. Various methodologies are being used, but no effective methodology has been found. In this paper, a new methodology called as micro-electro-discharge diamond grinding is reported as a feasible, effective method for silicon wafer finishing. The proposed setup with appropriate controller circuit has been discussed. The feasibility study of the proposed setup has been discussed in detail.
International Journal of Manufacturing Technology and Management, 2015
Advancement of new materials and machining technology has changed the domain and ranges both of a... more Advancement of new materials and machining technology has changed the domain and ranges both of aerospace vehicles, still a few problems of conventional as well as non-conventional machining processes is unresolved such as low material removal rate (MRR), frequent tool wear and poor surface finish, etc. In this experimental study, a new process in electrical discharge machining (EDM), termed as electrical discharge drilling (EDD is used to make the hole in titanium alloy (Ti-6Al-4V) and also used altogether a new approach of hybrid of methodologies for modelling as well as optimisation of the hole made for MRR, average surface roughness (Ra) and average circularity (Ca). The used methodology comprises of Taguchi methodology (TM) with response surface methodology (RSM) for modelling and RSM coupled with principal component analysis-based (PCA) grey relational analysis (GRA) for optimisation. The obtained results indicate that applied hybrid approaches in present study of EDD process are reasonable and substantiates with facts of improvement in MRR by 30.80%, Ra by 24.81% and Ca by 26.09%.
International Journal of Precision Engineering and Manufacturing, 2012
ABSTRACT This work presents the characteristics of advanced abrasion based hybrid machining proce... more ABSTRACT This work presents the characteristics of advanced abrasion based hybrid machining process consisting of electrochemical dissolution and magnetic abrasive machining process. The cylindrical electrochemical magnetic abrasive machining (C-EMAM) setup was developed and mounted as an attachment on lathe for high efficiency machining of cylindrical jobs. Experiments were conducted to explore the performance of the process on AISI-304 stainless steel tubes using unbonded magnetic abrasives. The effect of various process parameters viz. rotational speed of the workpiece, current to the electromagnet, electrolytic current and frequency of vibration on material removal and surface roughness were investigated. The electrochemical process has major contribution in material removal, whereas magnetic abrasive machining helps in reduction in surface roughness. This process has higher machining efficiency particularly at high value of electrolytic current and high rotational speed.
Uploads
Papers by Vinod Yadava