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Multi-objective parametric optimization of wire electric discharge machining for Die Hard Steels using supervised machine learning techniques
Published in Rajeev Agrawal, J. Paulo Davim, Maria L. R. Varela, Monica Sharma, Industry 4.0 and Climate Change, 2023
Pratyush Bhatt, Pranav Taneja, Navriti Gupta
The output variables obtained in WEDM are: Surface Roughness (Ra): It is a measure of irregularities on machined surfaces or the measure of vertical aberrations along a flat surface. It is measured in μm using a surface roughness comparator or profilometer.Material Removal Rate (MRR): It refers to the material removed per unit time. It is measured in mm3/min [6]. MRR=Kerfwidth(k)×Thicknessofworkpiece(t)×Cuttingvelocity(Vc)
Micro EDM Drilling
Published in Ajay M. Sidpara, Ganesh Malayath, Micro Electro Discharge Machining, 2019
Ajay M. Sidpara, Ganesh Malayath
As the diameter of the electrode increases, the machining area increases. As a result, the parasitic capacitance or stray capacitance between the tool and the workpiece increases. This has a direct impact on the discharge energy. With the increase in stray capacitance, the discharge energy also increases. Moreover, the bigger electrodes make debris removal more difficult, which leads to an elevated percentage of abnormal discharges. Due to this “area effect,” material removal rate (MRR) and tool wear will increase (Liu et al., 2016b). The taper angle of the hole increases with an increase in the machining area. This area effect also has a significant influence on the material migration phenomena during micro EDM milling (Wang et al., 2018).
General-Purpose Metal-Cutting Machine Tools
Published in Helmi Youssef, Hassan El-Hofy, Traditional Machining Technology, 2020
Milling is the removal of metal by feeding the work past a rotating multitoothed cutter. In this operation, the material removal rate (MRR) is enhanced, as the cutter rotates at a high cutting speed. The surface quality is also improved due to the multi-cutting edges of the milling cutter. The action of the milling cutter is totally different from that of a drill or a turning tool. In turning and drilling, the tools are kept continuously in contact with the material to be cut, whereas milling is an intermittent process, as each tooth produces a chip of variable thickness. Milling operations may be classified as peripheral (plain) milling or face (end) milling (Figure 3.38).
Intelligent machining: a review of trends, achievements and current progress
Published in International Journal of Computer Integrated Manufacturing, 2021
M. Imad, C. Hopkins, A. Hosseini, N.Z. Yussefian, H.A. Kishawy
Dohner et al. (2004) published a work demonstrating the effectiveness of active structural control in milling to minimize instabilities caused by chatter. Strain gauges mounted to the base of the tool interact with sets of electro-restrictive actuators to counteract any chatter being detected. By doing so, the material removal rate (MRR) for a certain operation can be increased, without the surface finish becoming unacceptable. Previous works have described the theory of active structural control using sensor-actuator couples, but this is the first paper found to validate the concept with experimental work. By increasing the range of cutting parameters that result in a stable cutting operation, this application of smart machine tools can be used to improve productivity by allowing for material to be removed in a shorter time, without sacrificing the quality of the produced surface.
Experimental investigation on machinability of DMLS Ti6Al4V under dry drilling process
Published in Materials and Manufacturing Processes, 2019
Jiaqiang Dang, Gongyu Liu, Yaofeng Chen, Qinglong An, Weiwei Ming, Ming Chen
Also, it can be concluded that with the increment of feed rate from 0.06 mm/rev to 0.12 mm/rev, cutting temperature shows an increase by 31°C, 25°C, 46°C, and 33°C under n = 500 rev/min to 1500 rev/min, respectively. However, when the feed rate reaches up to 0.15 mm/rev, there indicates a dropping trend of temperature rise as the spindle speed increases, especially the marginal increment of 10°C under n =1500 rev/min. The increasing feed rate could improve the Material Removal Rate (MRR), which means more energy will be consumed and transformed to heat, thus leading to the increment of cutting temperature. Nevertheless, as the feed rate increases over 0.12 mm/rev, the dissipation of heat in the cutting zone becomes stronger due to the larger chip removal. That would cause a slight decrease of cutting temperature. Hence, it is reasonable to select a larger f of 0.15 mm/rev at the high spindle of 1500 rev/min for the improvement of production efficiency when drilling DMLS Ti6Al4V.
A novel energy efficiency grade evaluation approach for machining systems based on inherent energy efficiency
Published in International Journal of Production Research, 2021
Feng Ma, Hua Zhang, Qingshan Gong, K. K. B. Hon
Cutting energy consumption is a function of cutting power and cutting time, and cutting power can be expressed as a function of material removal rate (MRR) (Gutowski 2009; Hu et al. 2015). MRR can be obtained according to the design and manufacturing features of the work-piece. Usually, the running time can be calculated automatically according to the machining path, and the feed speed after the NC code is compiled. At this time, the real cutting time can be calculated approximately by the ratio of cutting volume to MRR. As shown in following equation: