Forthcoming articles


International Journal of Mechatronics and Manufacturing Systems


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International Journal of Mechatronics and Manufacturing Systems (4 papers in press)


Regular Issues


  • Experimental Investigations into Rotary Magnetic Field and Tool assisted Electric Discharge Machining using Magneto Rheological Fluid as Dielectric   Order a copy of this article
    by Lokesh Upadhyay, M.L. Agarwal, Pulak M. Pandey 
    Abstract: The present study focuses on the development of an electric discharge machining method that used magneto rheological fluid as dielectric and rotary magnetic field assisted electric discharge tool. The work aims to improve performance of electric discharge machining by utilizing the combined effect of magneto rheological fluid with rotating electrode and magnetic field. This developed hybrid machining process has been designed to attain higher material removal rate for improving production rate. In this process, the surface roughness has been found higher as compared to when magnetic field and tool was kept stationary. M2 grade high speed steel workpiece was used for parametric study. The experimentation was performed to evaluate the effect of percentage contribution of alumina particles, discharge current, duty cycle, and pulse on time effect on material removal rate and surface roughness. The experimental findings demonstrated that EDM process with rotary magnetic field and tool with magneto rheological fluid as dielectric resulted in an increased material removal rate as compared to EDM with static magnetic field and tool. The following findings were found significant for a certain limit of carbonyl iron percentage in magneto rheological fluid.
    Keywords: Electric discharge machining; roughness; magneto rheological fluid; alumina.

  • Modeling and Analysis of Tool Deflections in Tailored Micro End Mills   Order a copy of this article
    by Samad Nadimi Bavil Oliaei, Yigit Karpat 
    Abstract: The deflection of micro end mills has a detrimental effect on surface quality of the machined micro components and adversely affects the achievable dimensional and geometrical tolerances. In this paper, the analysis and modeling of tool deflections of tailored micro end mills have been considered. The tool deflections are obtained using analytical models as well as finite element simulations, and verified using a dedicated measurement setup, which uses a capacitive sensor with a nanometer resolution for static tool deflection measurements. The optimization of the micro end mill geometry has been performed to determine optimum neck taper angle and transition radius of the single edge micro end mill to have minimum tool deflections. With the developed model, tool failure predictions for a given process parameter set can be performed and it can be used for better micro milling process planning.
    Keywords: Micromilling; Tailored Micro End Mill; Tool Deflection; Optimization; Tool Failure.

  • Performance of different abrasive tools in electrochemical honing of coated surfaces   Order a copy of this article
    by Harpreet Singh 
    Abstract: This paper highlights on the honing characteristics of various abrasive tool materials during the precision finishing of EN52 coated surface of the engine valve face using electrochemical honing (ECH) process. The investigation on various abrasive tool materials in ECH are first proposed, and it may help to enhance the process performance characteristics of ECH. It is a new technique, which in spite of being used in some industrial plants, in particular to smooth surfaces and is still not fully described due to the variety of the factors affecting the process. More information about the process is required, especially the honing related parameters, such as abrasive tool pressure, abrasive material, and abrasive size. Special shaped honing tools were designed and fabricated to study the present aspects. Two different types of abrasive tool material (Al2O3 and NiCr) for honing operation were used while ECH of EN52 work surface. The results of the experiments are finally furnished with the aim to generalize a useful guideline for the user to enable proper selection of conditions for obtaining good surface quality.
    Keywords: abrasive tool; ECH; EN52; engine valve face; HVOF; product recovery; surface finish.

  • Online correction of thermal errors based on a structure model   Order a copy of this article
    by Xaver Thiem, Bernd Kauschinger, Steffen Ihlenfeldt 
    Abstract: This article deals with the structure model based correction approach for thermal errors at machine tools. Structure models are physically based models of the thermo-elastic behaviour of machine tools. Input data of the model are technological loads captured in the machine control. The article focuses the experimental validation of the online correction on the example of a demonstrator machine (parallel kinematic). A finite element model with reduced model order is used as structure model. Besides the implementation of the correction approach the parameter adjustment of the model is described. The conducted experiments show that up to 87% of the maximal thermo-elastic error of the ball screw axes of the machine can be compensated with the proposed correction approach.
    Keywords: thermal error; machine tool; correction; compensation; structure model; online; control; parallel kinematics; accuracy; ball screw; FEM; finite element method; temperature; deformation.