Experimental investigation of tool wear and machining rate in rotary ultrasonic machining of nickel alloy

Popli, Dipesh; Gupta, Monika

doi:10.1080/10910344.2017.1365896

Cited by 21 publications

(7 citation statements)

References 26 publications

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“…A desirability function approach postulated by Harrington and later revitalized by Derringer and Suich was used to accomplish this objective [35,36]. This approach is commonly used to optimize the multiple output responses simultaneously [37][38][39][40][41]. In this approach, each of the response variable y i is normalized to a desirability value d i which lies in between 0 and 1.…”

Section: Multi-response Optimization Of Rt-musm Process With Wc Toolmentioning

confidence: 99%

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Kumar

Dvivedi

2019

J Braz. Soc. Mech. Sci. Eng.

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The tool wear affects the efficiency of micro-USM process and the quality of machined micro-features. In this research endeavor, wear mechanism of soft/ductile and hard/brittle tool materials is investigated comprehensively. Stainless steel-304 (SS-304) and tungsten carbide (WC) were selected as tool materials for rotary tool micro-USM (RT-MUSM) process. The effect of tool material properties on tool wear and performance of RT-MUSM process is also discussed. The effect of RT-MUSM process parameters, viz. rotation speed, feed rate, power rating and slurry concentration on material removal rate (MRR), depth of channel (DOC) and width over cut (WOC) are reported. The experimental results showed that SS-304 tool worn out rapidly due to plastic deformation followed by strain hardening. The superior properties of WC such as high wear resistance, compressive strength and good acoustic property led to reduction in tool wear and thereby significantly improved the performance of RT-MUSM. Additionally, multi-response optimization was applied to obtain maximum MRR, DOC and minimum WOC simultaneously.

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Section: Multi-response Optimization Of Rt-musm Process With Wc Toolmentioning

confidence: 99%

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Kumar

Dvivedi

2019

J Braz. Soc. Mech. Sci. Eng.

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“…The form error should be within the length of two helium light bands (0.58 μm) and the surface roughness should be at the nanometric scale to avoid surface/subsurface damages [ 9 , 10 , 11 ]. Overall, forming such a wavy face with extremely high manufacturing requirements using existing methods—for instance, lapping, polishing, general grinding, laser manufacturing, etc.—will inevitably encounter various inherent defects [ 12 , 13 , 14 , 15 , 16 , 17 ]. As a solution, a high accuracy line-contact envelope grinding method with a large diamond cup wheel based on a four-axis grinder was elaborated to fabricate such seals, and the detailed analyses of the forming principle were discussed in our previous paper [ 18 ].…”

Section: Introductionmentioning

confidence: 99%

“…Overall, forming such a wavy face with extremely high manufacturing requirements using existing methods-for instance, lapping, polishing, general grinding, laser manufacturing, etc.-will inevitably encounter various inherent defects [12][13][14][15][16][17]. As a solution, a high accuracy line-contact envelope grinding method with a large diamond cup wheel based on Micromachines 2021, 12, 388 2 of 14 a four-axis grinder was elaborated to fabricate such seals, and the detailed analyses of the forming principle were discussed in our previous paper [18].…”

Section: Introductionmentioning

confidence: 99%

Positioning Accuracy Determination of the Servo Axes for Grinding Wavy-Tilt-Dam Seals Using a Four-Axis Grinder

Gao

2021

Micromachines

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The wavy-tilt-dam (WTD) seal is considered to be one of the ideal sealing patterns used in nuclear reactor coolant pumps (RCPs). Grinding such seals with a four-axis grinder had been proposed and six grinding implementation strategies were described in our previous studies. However, another important issue is to determine the positioning accuracy of each servo axis so that the high-precision moving components can be selected properly. In the present paper, the positioning accuracy analysis is carried out to seek a balance between the manufacturing cost and the accuracy requirements. First, a geometric model is established for investigating the error sensitivity of each axis and setting reasonable accuracy allocation of the four axes. Subsequently, the combined influence of all four axes is assessed based on multi-body system (MBS) theory and homogeneous transformation matrix (HTM). According to the results calculated, positioning errors of the X-axis, Z-axis, B-axis, and C-axis within ±10 μm, ±0.1 μm, ±1 arcsec and ±60 arcsec are acceptable, respectively. Meanwhile, the form error calculated of the ground wavy face is no more than 109.74 nm. It is indicated that the accuracy level of the moving components is achievable by modern manufacturing techniques. The present paper is expected to serve as a theoretical basis for the design and development of the four-axis grinder.

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“…The super alloys were machined at different setting of input parameters to investigate their effects on conicity and circularity. In another research of the same group (Popli and Gupta, 2018b) (Popli and Gupta, 2017), the nickel-based super alloy was machined, and decision GS 10,2 approach of desirability-based optimization was used for the machining parameter settings, for machining rate and SR.…”

Section: Introductionmentioning

confidence: 99%

Parametric optimization of USM parameters by Taguchi and NSGA-II for the development of µ-channels on pure titanium

Gupta

Khanna

2020

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PurposeThis paper consolidates and presents the results of a work conducted to fabricate micro-channels on titanium grade-2 material by ultrasonic machining process (USM). In this research, the effects of important USM parameters, namely, kind of abrasives and its size, concentration of slurry, USM power rating and feed rate, have been probed on micro-channels quality for average surface roughness and process throughput in the form of material removal rate.Design/methodology/approachMultiple micro-channels on commercially pure titanium (i.e. Ti grade-2) have been fabricated in a single pass by employing micro-tool based USM process. Taguchi-based L18 (mixed level) OA has been selected for experimental design. Analysis of variance (ANOVA) study and regression modeling have also been done. Non-Dominated Sorting Genetic Algorithm (NSGA-II) has been used for process optimization to get optimum values of material removal rate (MRR) and surface roughness (SR).FindingsThe influence of important USM variables on SR and MRR have been investigated, and NSGA-II-based multi-response optimization has been done. The best surface roughness values obtained via NSGA-II solution for SiC and B4C are 0.354 µm and 1.303 µm, respectively. Scanned electron microscopic investigation proves the fabrication of micro-channels with smooth surfaces, and minimum burrs and other defects. The material removed from the surface was due to ductile fractures.Originality/valueMiniaturization is a modern trend these days to solve many precision, scientific and industrial problems. To manufacture precise micro-products, shapes and features, advanced and micro-machining processes can play a very prominent role. Micro-channels are typical micro-features required in micro-fluidic applications like micro heat exchangers and micro-pumps. Exhaustive review of existing research work indicated that precision micromachining of various materials can be effectively performed using USM, though not much work has been undertaken to explore the feasibility of multiple micro-channels in a single run using USM. The current work fulfills the gap, where multiple micro-channels on commercially pure titanium (i.e. Ti grade-2) have been fabricated in a single pass by employing micro-tool-based USM process.

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Experimental investigation of tool wear and machining rate in rotary ultrasonic machining of nickel alloy

Cited by 21 publications

References 26 publications

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Positioning Accuracy Determination of the Servo Axes for Grinding Wavy-Tilt-Dam Seals Using a Four-Axis Grinder

Parametric optimization of USM parameters by Taguchi and NSGA-II for the development of µ-channels on pure titanium

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