International Journal of Machining and Machinability of Materials http://www.inderscience.com/browse/index.php?journalID=191&year=2012&vol=11&issue=1 Inderscience Publishers Ltd en-uk International Journal of Machining and Machinability of Materials 1748-5711 1748-572X © 2012 Inderscience Publishers Ltd editor@inderscience.com https://www.inderscience.com/images/files/coverImgs/ijmmm_scoverijmmm.jpg http://www.inderscience.com/browse/index.php?journalID=191&year=2012&vol=11&issue=1 http://www.inderscience.com/link.php?id=44919 Electro-discharge diamond grinding (EDDG), a hybrid machining process comprising diamond grinding and electro-discharge grinding, has been developed for machining of electrically conductive difficult-to-machine very hard materials. The process employs simultaneous synergetic interactive effect of abrasion action and electro-discharge action. In this paper, a hybrid methodology comprising of Taguchi methodology (TM) and response surface methodology (RSM) has been applied for the multi-objective optimisation of EDDFG process. The approach first uses the Taguchi quality loss function to find the optimum level of input machining parameters such as wheel speed, current, pulse on-time and duty factor. The optimum input parameter values are further used as the central values in the RSM to develop and optimise the second-order response model. The three quality characteristics are material removal rate (MRR), wheel wear rate (WWR) and average surface roughness (ASR), which are of different nature, have been selected for optimisation. The developed response surface model for MRR, WWR and ASR has been found adequate. The results of quality characteristics with hybrid approach have been compared with the results of a single approach. Robust parameter design and multi-objective optimisation of electro-discharge diamond face grinding of HSS
Gyanendra Kumar Singh; Vinod Yadava; Raghuvir Kumar
International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 1 - 19
Electro-discharge diamond grinding (EDDG), a hybrid machining process comprising diamond grinding and electro-discharge grinding, has been developed for machining of electrically conductive difficult-to-machine very hard materials. The process employs simultaneous synergetic interactive effect of abrasion action and electro-discharge action. In this paper, a hybrid methodology comprising of Taguchi methodology (TM) and response surface methodology (RSM) has been applied for the multi-objective optimisation of EDDFG process. The approach first uses the Taguchi quality loss function to find the optimum level of input machining parameters such as wheel speed, current, pulse on-time and duty factor. The optimum input parameter values are further used as the central values in the RSM to develop and optimise the second-order response model. The three quality characteristics are material removal rate (MRR), wheel wear rate (WWR) and average surface roughness (ASR), which are of different nature, have been selected for optimisation. The developed response surface model for MRR, WWR and ASR has been found adequate. The results of quality characteristics with hybrid approach have been compared with the results of a single approach.

]]> 10.1504/IJMMM.2012.044919 International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 1 - 19 Gyanendra Kumar Singh; Vinod Yadava; Raghuvir Kumar Mechanical Engineering Department, Motilal Nehru National Institute of Technology, Allahabad, 211004, India. ' Mechanical Engineering Department, Motilal Nehru National Institute of Technology, Allahabad, 211004, India. ' Mechanical Engineering Department, Motilal Nehru National Institute of Technology, Allahabad, 211004, India hybrid machining diamond grinding electro-discharge machining electrical discharge machining robust design Taguchi methods response surface methodology RSM analysis of variance ANOVA material removal rate MRR wheel wear rate WWR average surface roughness ASR parameter design multi-objective optimisation very hard materials. 2012-01-16T23:20:50-05:00 11 1 1 19 2012-01-16T23:20:50-05:00 http://www.inderscience.com/link.php?id=44920 This study explores two variants of the FEM simulation model of orthogonal cutting process of AISI 1045 carbon steel with uncoated and multilayer-coated carbide tools, i.e., standard and power law-temperature dependent (PL-TD) options. The primary reason for undertaking this problem was unsatisfactory accuracy of the predictions of the cutting temperature and other thermal characteristics especially for coated cutting tools. Multi-layer coating is substituted by homogeneous monolithic layer with equivalent thermal properties. In addition, these simulation algorithms use material constitutive law comparable to the Johnson-Cook constitutive law. Basically, the FEM package applied allows the temperature distribution and heat flux intensity to be predicted closer to appropriate measurements and analytical computations. Originality of this simulation approach can be seen in elaborating more accurate models with updated thermal properties. Particularly, it contributes to predicting some fundamental relationships between all physical phenomena involved into the overall tool-chip contact behaviour. Coupled thermo-mechanical FEM-based modelling of the tool-chip contact behaviour for coated cutting tools
W. Grzesik; P. Nieslony
International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 20 - 35
This study explores two variants of the FEM simulation model of orthogonal cutting process of AISI 1045 carbon steel with uncoated and multilayer-coated carbide tools, i.e., standard and power law-temperature dependent (PL-TD) options. The primary reason for undertaking this problem was unsatisfactory accuracy of the predictions of the cutting temperature and other thermal characteristics especially for coated cutting tools. Multi-layer coating is substituted by homogeneous monolithic layer with equivalent thermal properties. In addition, these simulation algorithms use material constitutive law comparable to the Johnson-Cook constitutive law. Basically, the FEM package applied allows the temperature distribution and heat flux intensity to be predicted closer to appropriate measurements and analytical computations. Originality of this simulation approach can be seen in elaborating more accurate models with updated thermal properties. Particularly, it contributes to predicting some fundamental relationships between all physical phenomena involved into the overall tool-chip contact behaviour.

]]> 10.1504/IJMMM.2012.044920 International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 20 - 35 W. Grzesik; P. Nieslony Department of Manufacturing Engineering and Production Automation, Opole University of Technology, P.O. Box 321, 45-271 Opole, Poland. ' Department of Manufacturing Engineering and Production Automation, Opole University of Technology, P.O. Box 321, 45-271 Opole, Poland orthogonal cutting thermal behaviour contact stress FEM finite element method simulation coated cutting tools thermomechanical modelling tool-chip contact carbon steel carbide tooling cutting temperature temperature distribution heat flux intensity. 2012-01-16T23:20:50-05:00 11 1 20 35 2012-01-16T23:20:50-05:00 http://www.inderscience.com/link.php?id=44921 Performance of electrode materials is one of the important factors that determine the quality of the machined component and the cost involved in the operation of electro discharge machining (EDM) process. Low electrode wear resistance in graphite and copper electrodes necessitated the development of sintered composite electrodes for EDM operation. In this paper, authors attempted to develop a new copper-based metal matrix composite (Cu-B<SUB align="right">4C) to get an optimum combination of wear resistance, electrical and thermal conductivity. Here the copper-boron carbide composite was developed through powder metallurgy route and EDM experiments were carried out using mild steel specimen. Copper composite with 40% boron carbide reinforcement exhibits better metal removal rate (MRR) and tool removal rate (TRR) compared to conventional copper electrode. SEM and XRD results show the surface modification and formation of boron, B<SUB align="right">4C reinforced layer on the surface of mild steel work piece when machined with composite electrode. Performance analysis of Cu-B4C metal matrix composite as an EDM electrode
V. Senthilkumar; M. Chandrasekar Reddy
International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 36 - 50
Performance of electrode materials is one of the important factors that determine the quality of the machined component and the cost involved in the operation of electro discharge machining (EDM) process. Low electrode wear resistance in graphite and copper electrodes necessitated the development of sintered composite electrodes for EDM operation. In this paper, authors attempted to develop a new copper-based metal matrix composite (Cu-B<SUB align="right">4C) to get an optimum combination of wear resistance, electrical and thermal conductivity. Here the copper-boron carbide composite was developed through powder metallurgy route and EDM experiments were carried out using mild steel specimen. Copper composite with 40% boron carbide reinforcement exhibits better metal removal rate (MRR) and tool removal rate (TRR) compared to conventional copper electrode. SEM and XRD results show the surface modification and formation of boron, B<SUB align="right">4C reinforced layer on the surface of mild steel work piece when machined with composite electrode.

]]> 10.1504/IJMMM.2012.044921 International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 36 - 50 V. Senthilkumar; M. Chandrasekar Reddy Department of Production Engineering, National Institute of Technology, Tiruchirappalli – 620 015, Tamil Nadu, India. ' Department of Production Engineering, National Institute of Technology, Tiruchirappalli – 620 015, Tamil Nadu, India EDM electrodes metal matrix composites MMC sintering metal removal rate MRR tool removal rate TRR electrode wear ratio EWR electro-discharge machining electrical discharge machining mild steel wear resistance, electrical conductivity thermal conductivity copper boron carbide composites powder metallurgy. 2012-01-16T23:20:50-05:00 11 1 36 50 2012-01-16T23:20:50-05:00 http://www.inderscience.com/link.php?id=44923 This work is consecrated to the minimising of machining errors based on a method for the compensation of the trajectory to be machined in hemispherical milling. This compensation is found to be necessary because of the tool deflection due to the cutting forces. In order to remedy to the machining errors, caused by this deflection, a compensation method has been proposed. The latter is inspired from the mirror method, since the compensated position is going to be determined as being the trajectory reflection, deviated onto the mirror. The advantage of this proposed method is that it takes into account the three deflections d<SUB align="right">x, d<SUB align="right">y and d<SUB align="right">z, respectively to the directions X, Y and Z. After that, two-parallel machinings, separated by a groove and achieved absolutely in the same conditions and with the same tool, are carried out, on the same complex part. The first machining is with compensation, but the second is without compensation. The coordinates of the two obtained surfaces are recorded by a 3D measuring machine. The comparison of the two-surfaces shows the presence of an important correction of the tool trajectory, and reveals a similarity between the part obtained by simulation and the one conceived in CAM. Compensation of a ball end tool trajectory in complex surface milling
M. Smaoui; Z. Bouaziz; A. Zghal; M. Baili; G. Dessein
International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 51 - 68
This work is consecrated to the minimising of machining errors based on a method for the compensation of the trajectory to be machined in hemispherical milling. This compensation is found to be necessary because of the tool deflection due to the cutting forces. In order to remedy to the machining errors, caused by this deflection, a compensation method has been proposed. The latter is inspired from the mirror method, since the compensated position is going to be determined as being the trajectory reflection, deviated onto the mirror. The advantage of this proposed method is that it takes into account the three deflections d<SUB align="right">x, d<SUB align="right">y and d<SUB align="right">z, respectively to the directions X, Y and Z. After that, two-parallel machinings, separated by a groove and achieved absolutely in the same conditions and with the same tool, are carried out, on the same complex part. The first machining is with compensation, but the second is without compensation. The coordinates of the two obtained surfaces are recorded by a 3D measuring machine. The comparison of the two-surfaces shows the presence of an important correction of the tool trajectory, and reveals a similarity between the part obtained by simulation and the one conceived in CAM.

]]> 10.1504/IJMMM.2012.044923 International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 51 - 68 M. Smaoui; Z. Bouaziz; A. Zghal; M. Baili; G. Dessein Unit of Mechanics, Solids, Structures and Technological Development, Ecole supérieure des sciences et techniques, BP 56 Beb Mnara, 1008 Tunis, Tunisia. ' Unit of Mechanics, Solids, Structures and Technological Development, Ecole supérieure des sciences et techniques, BP 56 Beb Mnara, 1008 Tunis, Tunisia. ' Unit of Mechanics, Solids, Structures and Technological Development, Ecole supérieure des sciences et techniques, BP 56 Beb Mnara, 1008 Tunis, Tunisia. ' Ecole Nationale d'Ingénieurs de Tarbes, Laboratoire Génie de Production, Université de Toulouse, INP/ENIT, LGP, 47 avenue d'Azereix, BP 1629, F-65013 Tarbes Cedex, France. ' Ecole Nationale d'Ingénieurs de Tarbes, Laboratoire Génie de Production, Université de Toulouse, INP/ENIT, LGP, 47 avenue d'Azereix, BP 1629, F-65013 Tarbes Cedex, France ball end milling cutting forces tool deflection cutting force ball end tool trajectory complex surfaces trajectory compensation simulation. 2012-01-16T23:20:50-05:00 11 1 51 68 2012-01-16T23:20:50-05:00 http://www.inderscience.com/link.php?id=44924 Chemical vapour deposition (CVD) diamond wafer, as the material for optical transmission windows and new-generation computer chips, is required to be fine polished. However, no individual method can polish CVD diamond wafer with high efficiency and fine polishing quality. This paper attempts to polish CVD diamond wafer by compound method to solve this problem. With the method, CVD diamond wafer is first processed by electro-discharge machining (EDM) to remove course asperities, and subsequently polished by chemical mechanical polishing (CMP) to achieve fine surface. According to the experimental results, the roughness of CVD diamond wafer processed by EDM was reduced to Ra 0.781 µm from Ra 13.3 µm, and further reduced to Ra 1.284 nm polished by CMP. The material removal during EDM process can be a chemo-mechanical process, including gasification, melting, sputtering, oxidation and graphitisation. The graphitisation of the surface of CVD diamond wafer ensures EDM to be continued. While in CMP process, diamond is removed under the mechanical and tribochemical interaction. Polishing CVD diamond wafer by compound methods
Zewei Yuan; Zhuji Jin; Quan Wen; Kun Wang
International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 69 - 83
Chemical vapour deposition (CVD) diamond wafer, as the material for optical transmission windows and new-generation computer chips, is required to be fine polished. However, no individual method can polish CVD diamond wafer with high efficiency and fine polishing quality. This paper attempts to polish CVD diamond wafer by compound method to solve this problem. With the method, CVD diamond wafer is first processed by electro-discharge machining (EDM) to remove course asperities, and subsequently polished by chemical mechanical polishing (CMP) to achieve fine surface. According to the experimental results, the roughness of CVD diamond wafer processed by EDM was reduced to Ra 0.781 µm from Ra 13.3 µm, and further reduced to Ra 1.284 nm polished by CMP. The material removal during EDM process can be a chemo-mechanical process, including gasification, melting, sputtering, oxidation and graphitisation. The graphitisation of the surface of CVD diamond wafer ensures EDM to be continued. While in CMP process, diamond is removed under the mechanical and tribochemical interaction.

]]> 10.1504/IJMMM.2012.044924 International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 69 - 83 Zewei Yuan; Zhuji Jin; Quan Wen; Kun Wang No. 2, Linggong Road, Ganjingzi District, Dalian City 116024, LiaoNing Province, China. ' No. 2, Linggong Road, Ganjingzi District, Dalian City 116024, LiaoNing Province, China. ' No. 2, Linggong Road, Ganjingzi District, Dalian City 116024, LiaoNing Province, China. ' No. 2, Linggong Road, Ganjingzi District, Dalian City 116024, LiaoNing Province, China CVD diamond wafers electroless nickel phosphorous electro-discharge machining electrical discharge machining EDM chemical mechanical polishing CMP chemical vapour deposition wafer polishing. 2012-01-16T23:20:50-05:00 11 1 69 83 2012-01-16T23:20:50-05:00 http://www.inderscience.com/link.php?id=44922 Titanium alloys have been widely used in many industries because of their high strength-to-weight ratio, resistance to corrosion and high temperature stability. However, inherent properties like low thermal conductivity and chemical reactivity at elevated temperatures pose a major problem in machining of these alloys. Electric discharge machining (EDM) is a non-traditional material removal process used for machining of high strength-high temperature resistant (HSTR) alloys, tough and fragile components of electrically conductive materials by using shaped tools in the presence of dielectric fluid. The present paper reviews the fundamental principles of EDM and work done with regard to effect of operating parameters on material removal rate (MRR), tool wear rate (TWR), surface roughness and surface improvements on titanium alloys work piece. Electric discharge machining of titanium and its alloys: a review
Sanjeev Kumar; Rupinder Singh; Ajay Batish; T.P. Singh
International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 84 - 111
Titanium alloys have been widely used in many industries because of their high strength-to-weight ratio, resistance to corrosion and high temperature stability. However, inherent properties like low thermal conductivity and chemical reactivity at elevated temperatures pose a major problem in machining of these alloys. Electric discharge machining (EDM) is a non-traditional material removal process used for machining of high strength-high temperature resistant (HSTR) alloys, tough and fragile components of electrically conductive materials by using shaped tools in the presence of dielectric fluid. The present paper reviews the fundamental principles of EDM and work done with regard to effect of operating parameters on material removal rate (MRR), tool wear rate (TWR), surface roughness and surface improvements on titanium alloys work piece.

]]> 10.1504/IJMMM.2012.044922 International Journal of Machining and Machinability of Materials, Vol. 11, No. 1 (2012) pp. 84 - 111 Sanjeev Kumar; Rupinder Singh; Ajay Batish; T.P. Singh Department of Mechanical Engineering, Thapar University, Patiala (Punjab) India ' Department of Production Engineering, Guru Nanak Dev Engineering College, Gill Road, Gill Park, Ludhiana-141006, Punjab, India. ' Department of Mechanical Engineering, Thapar University, Patiala-147004, Punjab, India. ' Symbiosis Institute of Technology, Symbiosis International University, Near Lupin Research Park, Gram: Lavale, Tal: Mulshi, Pune 411042, India titanium alloys electric discharge machining EDM material removal rate MRR tool wear rate TWR surface roughness surface improvements electro-discharge machining surface quality. 2012-01-16T23:20:50-05:00 11 1 84 111 2012-01-16T23:20:50-05:00