Sharif Digital Repository

Electrical discharge machining is a non-traditional machining method broadly employed in industries for machining of parts that have typical profiles and require great accuracy. This paper investigates the effects of electrical parameters: pulse-on-time and current on three performance measures (material removal rate, microstructures and electrode wear rate), using distilled water and kerosene as dielectrics. A comparison between dielectrics for the machining of aluminum 6061 T6 alloy material in terms of performance measures was performed. Aluminum 6061 T6 alloy material was selected, because of its growing use in the automotive and aerospace industrial sectors. The experimental sequence... 

This paper outlines the effectiveness of the ultrasonic machining of alumina in terms of tool wear rate of the tool used and the material removal rate of work piece produced. The optimum combination of various input factors as type of abrasive slurry, their size and concentration, power and feed rate, in the machining of alumina has been determined by applying the Taguchi technique, also analysis is used to choose the best shape for horn. The study shows that among input parameters, power has the highest effect on MRR (material removal rate). Effects of grit size and feed rate on TWR (tool wear rate) also investigated  

Chatter is a limiting factor in machining systems with adverse effects for workpiece surface, tool and machine life and material removal rate. Proper modelling of this phenomenon requires that the dynamic characteristics of the machining system is known. It is common to obtain the dynamic of the system by modal tests in stationary condition. However, the vibration characteristics of a machine change between its operating and resting mode. The goal of this work is to study vibrations in boring using the vibrational characteristic in operational conditions using the operating deflection shape method. In this paper, vibration characteristics of the in the boring bar is obtained by both modal... 

The desired milling process with high material removal rate (MRR) and low surface roughness of the product can be achieved only if machining chatter is absent. Incorporating chatter into the optimal selection of the machining parameters leads to a complex problem. Therefore, the approach of selecting conservative intervals for the machining parameters is usually employed instead. In this paper, a practical approach is proposed to specify the optimal machining parameters (depth of cut and spindle speed) in order to maximize MRR and minimize forced vibrations by considering machining chatter. Firstly, the worst-case scenario-based optimization problem in terms of the surface quality is solved... 

In the machining processes, vibration suppression is crucial in order to achieve the high precision as well as high-quality surface and increase of the material removal rate. In this paper, an adaptive sliding mode control approach is presented to supress the chattering phenomenon in the boring process in the presence of model uncertainties and unmodeled dynamics. The boring bar is modeled as a cantilever Euler–Bernoulli beam, which is actuated by a piezo-actuator located at the bar's end. As a more realistic model, the cutting tool is modeled as an added mass at the bar's end. In order to derive the equations of motion, mode summation method with inclusion the first three modes of vibration... 

Chatter vibration is a major cause of limitations in increasing material removal rate in machining. Machining chatter is caused by the interaction between tool and work-piece. Various nonlinear phenomena in the machining process affect the occurrence of chatter. Finite element simulation of chip formation allows for incorporation of various factors in the chip formation process. It can therefore be used to simulate the occurrence of chatter in practical conditions and to predict the conditions that lead to stable cutting. In this paper, a one degree of freedom dynamic model of the cutting tool is used to simulate the interaction of machining dynamics with the thermo-mechanical chip formation... 

Peripheral milling is extensively used in manufacturing industry. To achieve more material removal rate, high precision and surface quality and increase tool life, chatter vibration must be suppressed. In this paper, an extended dynamic model of the peripheral milling process including both the structural nonlinearity and nonlinear cutting forces is presented. Using the multiple-scale approach, as a perturbation technique, internal resonance of the milling process is investigated. Transfer of the energy between the coupled x-y modes is studied. According to results obtained, it is possible to adjust the rate at which the x-mode (or y-mode) decays by implementation of the internal resonance... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, a single degree of freedom model of orthogonal turning process is used to set up the delay differential equation of motion with considering the tool wear effect as a contact force between the workpiece and tool flank surfaces. Sinusoidal spindle speed variations with different frequencies around the mean speed are modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. Results of the stability analysis and the... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, two control strategies are developed to suppress chatter vibration in the turning process including a worn tool. In the first stage, a sinusoidal spindle speed variation around the mean speed is modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. In the second stage, to improve the response of the system which is associated with small ripples under the steady state condition, an adaptive controller is designed. In... 

Chatter suppression is of great importance in machining processes for achieving more material removal rate, high precision and surface quality. In this paper, an H∞ control algorithm is proposed for chatter suppression in the presence of tool wear and parameter uncertainties. Orthogonal turning process is modelled as a single degree of freedom model that includes the effect of tool flank wear. Control input of the system is the force provided by a piezo-actuator.The turning process model includes the uncertainties in cutting velocity, tool wear and dynamic model parameters. Using the μ-synthesis technique, an H∞ optimal controller is designed based on a DK-iteration algorithm. The... 

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The... 

Laser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components. This research presents an experimental investigation on the effects of laser drilling process parameters on productivity (material removal rate), hole quality (hole taper) and drilling cost. Single-pulse drilling was employed to drill a thin-walled Inconel 718 superalloy plate of 1 mm thickness using pulsed Nd:YAG laser. The experiments were designed using Box-Behnken statistical approach to investigate the impacts of pulse energy, pulse duration, gas pressure and gas flow rate on the selected responses. Multi-objective optimisation was performed using response surface... 

In this paper, a tunable vibration absorber set (TVAs) is designed to suppress regenerative chatter in milling process (as a semi-active controller). An extended dynamic model of the peripheral milling with closed form expressions for the nonlinear cutting forces is presented. The extension part of the cutting tool is modeled as an Euler-Bernoulli beam with in plane lateral vibrations (x-y directions). Tunable vibration absorbers in x-y directions are composed of mass, spring and dashpot elements. In the presence of regenerative chatter, coupled dynamics of the system (including the beam and x-y absorbers) is described through nonlinear delay differential equations. Using an optimal... 

Dynamic vibration absorbers are used to reduce the undesirable vibrations in many applications such as electrical transmission lines, helicopters, gas turbines, engines, bridges, etc. Tuneable vibration absorbers (TVA) are also used as semi-active controllers. In this paper, the application of a TVA for suppression of chatter vibrations in the boring manufacturing process is presented. The boring bar is modeled as a cantilever Euler-Bernoulli beam and the TVA is composed of mass, spring and dashpot elements. In addition, the effect of spring mass is considered in this analysis. After formulation of the problem, the optimum specifications of the absorber such as spring stiffness, absorber...