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Engineering Problem Optimized Using Cuckoo Search Algorithm
Published in Kaushik Kumar, Divya Zindani, J. Paulo Davim, Optimizing Engineering Problems through Heuristic Techniques, 2020
Kaushik Kumar, Divya Zindani, J. Paulo Davim
Machining is part of the manufacturing of all the metal parts. Modern machining and conventional machining are the two types of machining processes. On the one hand, conventional machining process removes the workpiece material in the form of chips such as milling, drilling and turning. Abrasive water jet machining, chemical machining, photochemical machining, ultrasonic machining are the examples of modern machining processes. One of the recent modern machining methods is abrasive water jet machining process (Yusup et al., 2014) that has been employed for machining of hard materials such as intricate profiles. Some of the advantages of the abrasive water jet machining process are: higher flexibility, high versatility and minimized thermal distortion. Furthermore, small cutting force is another probable advantage of this process. Action of high speed water jet mixed with abrasive particles results in the material removal mechanism in case of abrasive water jet machining process. Because of the umpteen advantages, the abrasive jet machining process has been used widely by numerous manufacturing industries.
The Role of Manufacturing Process Design in Technology Commercialization
Published in Harriet B. Nembhard, Elizabeth A. Cudney, Katherine M. Coperich, Emerging Frontiers in Industrial and Systems Engineering, 2019
Brian K. Paul, Patrick McNeff, Sam Brannon, Michael O’Halloran
Within any given manufacturing process step, there may be several ways that step can be implemented. For example, steps 2 and 4 in Figure 14.4 are both blanking steps for sheet metal in which the raw material sheet is cut to the size of the lamina that is needed. Blanking can be implemented using photochemical machining (PCM) or with a punch and die. Which process you choose should reflect the process requirements. For example, during early stages of product development, the device will need to be prototyped to confirm that the product concept meets functional requirements. The criteria used to select process steps for prototyping, with a production volume of one, are different than the criteria used to select process steps for manufacturing thousands or millions. Criteria for prototyping include the speed with which the job can be turned around as well as the cost of the touch tooling for making the part. The cost and lead time to make the punch and die set are prohibitive during prototyping. Consequently, PCM would be a better choice for blanking during prototyping while the punch and die would be a better choice assuming that the process requirements include a sizeable market to offset the costs of the die set during production.
Advances and Applications of Nontraditional Machining Practices for Metals and Composite Materials
Published in T. S. Srivatsan, T. S. Sudarshan, K. Manigandan, Manufacturing Techniques for Materials, 2018
Ramanathan Arunachalam, Rajasekaran Thanigaivelan, Sivasrinivasu Devadula
Chemical machining is one of the oldest nontraditional machining practices and is more suitable for producing shallow intricate cavities in materials independent of the strength or hardness. The process uses a simple principle of controlled dissolution of the workpiece material when it comes in contact with an etchant. Chemical milling and photochemical machining are two main variations of the chemical machining process. The main application of chemical machining is in the aerospace industry (for light-weighting of airframe structures produced by other manufacturing processes). However, the main concern with this process is the safety and environmental issues, especially because of the toxicity of both etchant and masking materials. In recent years, with environmental issues becoming very serious, advancements in chemical machining have been made in relation to this. Many initiatives have been taken in the “greening” of the photochemical machining process (Allen 2005). Aqueous cleaning solutions are being used to replace solvents used in metal cleaning. Similarly, a liquid photoresist is coated from aqueous solution rather than organic solvents. On-site etchant regeneration has been applied to solve the issue of waste etchant disposal. Photographic processing has been eliminated by using laser direct imaging of photoresists and high-resolution inkjet printing of resists. With the developments in sensors and automation systems, the efficiency of the process has improved.
Optimization of photochemical machining process for fabrication of microchannels with obstacles
Published in Materials and Manufacturing Processes, 2021
Sandeep Sitaram Wangikar, Promod Kumar Patowari, Rahul Dev Misra, Ranjitsinha R. Gidde, Shrikrushna B. Bhosale, Avinash K. Parkhe
PCM can be one of the utmost commendable processes for micro features fabrication of various shapes and thus fabrication of master mold for soft lithography, but a very limited research has been observed in this area. For analyzing the influence of control parameters on the response measures viz. rate of etch, surface finish (roughness), undercut, etc., photochemical machining was carried out on various materials viz. brass, copper, stainless steel, nickel, aluminum, silicon, germen silver, Inconel, Monel, etc. In the fabrication of microchannels with obstacles, the edge deviation (ED) is an important parameter to be assessed. Further, the comparative study on PCM using different metals for fabrication and characterization of micro features is not observed in the literature.