Advances in Nonconventional Machining Processes

Advances in Nonconventional Machining Processes
اسم المؤلف
Suneev Anil Bansal
التاريخ
25 مارس 2022
المشاهدات
73
التقييم
(لا توجد تقييمات)
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Advances in Nonconventional Machining Processes
Edited by
Suneev Anil Bansal
Department of Mechanical Engineering
Maharaja Agrasen University
India
CONTENTS
PREFACE i
LIST OF CONTRIBUTORS ii
CHAPTER 1 ULTRASONIC MACHINING PROCESS – A REVIEW 1
INTRODUCTION 2
LITERATURE REVIEW 2
CONVENTIONAL MACHINING VERSUS NON-CONVENTIONAL MACHINING . 9
ULTRASONIC MACHINING VERSUS ROTARY ULTRASONIC MACHINING 9
CONCLUSIONS . 12
FUTURE ADVANCEMENTS . 13
CONSENT FOR PUBLICATION 13
CONFLICT OF INTEREST . 13
ACKNOWLEDGEMENTS . 13
REFERENCES . 13
CHAPTER 2 TOOL ELECTRODE MATERIAL AND TOOL FABRICATION TECHNIQUES
FOR ELECTRICAL DISCHARGE MACHINING PROCESS . 17
INTRODUCTION 17
PHYSICS OF EDM 18
Cold Emission of Electrons and Dielectric Breakdown . 19
Spark Formation, Melting and Evaporation 20
Collapse of Plasma Channel and Flushing 20
THEORIES OF METAL REMOVAL . 20
High Pressure Theory . 20
Static Field Theory 21
High Temperature Theory . 21
TOOL ELECTRODE MATERIALS . 21
FABRICATION OF ELECTRODES USING ALTERNATE APPROACHES . 29
CONCLUSIONS . 36
CONSENT FOR PUBLICATION 37
CONFLICT OF INTEREST . 37
ACKNOWLEDGEMENTS . 37
REFERENCES . 37
CHAPTER 3 THERMALLY ENHANCED NON-CONVENTIONAL MACHINING PROCESSA REVIEW . 42
INTRODUCTION 42
LASER BEAM MACHINING 43
Types of Lasers . 43
Difference Between Ordinary & Laser Light . 43
Principle of Laser Beam Machining . 44
Laser Drilling Overview . 44
Types of Laser Drilling . 45
LITERATURE REVIEW 46
Nd: YAG Laser Overview 52
CONCLUSIONS . 53
FUTURE SCOPE FOR LASER BEAM MACHINING RESEARCH 54
Janender Kumar, Amrinder Pal Singh, Anurag Thakur and Munish Mehta
Arminder Singh Walia, Vineet Srivastava, Vivek Jain and Amit Handa
Janender Kumar, Suneev Anil Bansal and Munish MehtaCONSENT FOR PUBLICATION 54
CONFLICT OF INTEREST . 54
ACKNOWLEDGEMENTS . 55
REFERENCES . 55
CHAPTER 4 AWJM PROCESS- A REVIEW . 58
INTRODUCTION 58
AWJM – LITERATURE 63
APPLICATIONS OF AWJ MACHINING 66
FUTURE SCOPE 67
CONCLUSIONS . 67
CONSENT FOR PUBLICATION 67
CONFLICT OF INTEREST . 67
ACKNOWLEDGEMENTS . 67
REFERENCES . 67
CHAPTER 5 INNOVATIONS IN ABRASIVE MACHINING 71
INTRODUCTION 71
LITERATURE REVIEW 72
Abrasive Air Jet Machining 72
Abrasive Water Jet Machining 73
Use of Cryogenic in AJM . 74
Thermally Enhanced AJM 75
Effect of Various Jet Conditions . 75
Intermittent Jet Conditions 75
Submerged Jet Conditions . 76
APPLICATIONS 76
Surface Texturing and Aspects for Tribology 77
MATERIAL REMOVAL MECHANISM 78
ELASTIC MODE MRM 78
EFFECT OF VARIOUS PROCESS PARAMETERS 79
Abrasive Size 79
Flow Rate 80
Nozzle Material and Geometry . 80
CONCLUSION . 83
CONSENT FOR PUBLICATION 83
CONFLICT OF INTEREST . 83
ACKNOWLEDGEMENTS . 84
REFERENCES . 84
CHAPTER 6 A REVIEW ON ELECTRICAL DISCHARGE MACHINING OF CERAMIC
BASED COMPOSITE MATERIAL . 88
INTRODUCTION 88
PRINCIPLE OF EDM . 89
ELECTRICAL DISCHARGE MACHINING OF CERAMICS 90
MECHANISM OF MATERIAL REMOVAL IN COMPOSITE CERAMICS . 91
MACHINING OF WC-CO COMPOSITE MATERIAL . 92
ELECTRICAL DISCHARGE MACHINING- LITERATURE SURVEY . 93
FUTURE PROSPECT 97
Mamta, Sachin Mohal, Saurabh Chaitanya and Ankitmani Tripathi
Anupam Thakur, Chander Prakash and Ramakant Rana
Mamta, Suneev Anil Bansal and Bhuvnesh KumarCONCLUSION . 98
CONSENT FOR PUBLICATION 98
CONFLICT OF INTEREST . 98
ACKNOWLEDGEMENTS . 98
REFERENCES . 98
CHAPTER 7 CURRENT DEVELOPMENTS IN MACHINING OF TITANIUM BASED
ALLOYS USING WIRE EDM . 103
INTRODUCTION 103
WIRE ELECTRIC DISCHARGE MACHINING (WEDM) . 105
WEDM Process Parameters 106
WIRE Electrode Properties . 107
Advancements in WEDM Process 108
Wire Electric Discharge Grinding 109
Micro Wire Elcetro Discharge Grinding . 109
Wire Electric Discharge Turning 109
Abrasive WEDM (AWEDM) . 109
DEVELOPMENTS IN WEDM OF TITANIUM BASED ALLOYS . 109
FUTURE PROSPECTS OF WEDM 115
CONCLUSION . 115
CONSENT FOR PUBLICATION 116
CONFLICT OF INTEREST . 116
ACKNOWLEDGEMENTS . 116
REFERENCES . 116
CHAPTER 8 RECENT DEVELOPMENTS IN EDM AND ITS TYPES 120
INTRODUCTION 120
CURRENT STATE OF EDM AND EFFECT OF PULSE NATURE ON EDM PROCESS 122
EFFECT OF WIRE POSITIONING 124
EFFECT OF WIRE TENSION . 125
EFFECT OF WIRE MATERIAL AND COMPOSITION . 126
Copper . 126
Brass 126
Coated Wires . 126
Diffusion Annealed Wires 127
EFFECT OF FLUSHING AND DIELECTRIC FLUID . 127
SMART WIRE EDM . 128
CONCLUDING REMARKS . 130
CONSENT FOR PUBLICATION 130
CONFLICT OF INTEREST . 130
ACKNOWLEDGEMENTS . 130
REFERENCES . 130
CHAPTER 9 ARTIFICIAL INTELLIGENCE AND ROBOTICS IN THE MANUFACTURING
INDUSTRY: OPPORTUNITIES AND CHALLENGES 133
INTRODUCTION 134
ARTIFICIAL INTELLIGENCE AND ROBOTICS IN MANUFACTURING 136
OPPORTUNITIES AND ADVANTAGES . 138
a). Direct Automation . 139
Kamaljit Singh and Virat Khanna
Anupam Thakur and Suneev Anil Bansal
Hitesh Pahuja, PK Khosla and Balwinder Singhb). 24/7 Production 139
c). Safety . 140
d). Lower Operational Costs . 140
e). Greater Efficiency 140
f). Quality Control . 141
g). Quick Decision Making . 141
CHALLENGES OF AI AND ROBOTICS IN MANUFACTURING 142
a). Data 142
b). Speed . 143
c). High Fidelity Requirement 143
d). Interpretability . 143
e). Employee Skillset and Training . 143
f). Safety Measures . 144
g). Budgeting for the Cost of the System 144
h). Managing Product Workflow 144
CONCLUSION . 145
CONSENT FOR PUBLICATION 145
CONFLICT OF INTEREST . 145
ACKNOWLEDGEMENTS . 145
REFERENCES . 145
SUBJECT INDEX
SUBJECT INDEX
A
Abrasive erosion process 63
Abrasive Air Jet Machining (AAJM) 72, 74
Abrasive Fluid Jet Polishing (AFJP) 83
Abrasive Grains 1
Abrasive Jet Machining 18, 45, 71, 73, 83
Abrasive Material 81, 82, 83, 59
Abrasive Size 79, 80, 81
Abrasive Water jet 18, 33, 36, 51, 58, 73, 74,
75, 97
Abrasive Water Jet Machining 18, 33, 36, 51,
58, 73, 74, 75, 97,
Abrasive Wire EDM 109
Alloy steel 29, 58, 113
Artificial intelligence 133, 134, 135, 138, 139,
145
Artificial Neural Network (ANN) 4, 5, 48, 53,
103, 112, 113
C
cemented carbides 95
Ceramic matrix 7
Chipping 6, 8
Chips 2, 49, 54, 72, 79
cobalt-bonded tungsten carbide 97
Complex Shape 29, 33, 35, 36, 42, 88
Composite Material 67, 76, 88, 92, 94, 95, 96
conductive materials 19, 90, 94
Conventional Machining 1, 2, 5, 9, 12, 21, 29,
44, 63, 77, 92, 103, 106
Coolant 12, 53
Crack Propagation 78, 110
Crater 20, 21, 33, 95, 96, 110
Cryogenic 72, 74, 83, 112
Cutting Forces 2, 3, 5, 6, 7, 8, 9, 12, 47, 50,
60, 61, 106
Cutting Tool 1, 10, 21, 23, 54, 92
Cutting Velocity(CV) 107, 123, 124
D
De-ionized water 106
Design of Experiment (DOE) 47, 53, 103
Dielectric Fluid 19, 20, 32, 104, 106, 127,
128, 129
Dielectric Pressure 27, 124
dimensional accuracy 33, 34, 35, 36, 104,
110, 115,
Ductile materials 62, 54
E
EDM Electrode 26, 28, 33
Elastic Erosion 71, 78
Electric pulses 122
Electrical Conductivity 17, 21, 22, 24, 25, 29,
90, 91, 92, 111
Electrical Discharge Machining (EDM) 17,
18, 45, 47, 88, 90, 93, 104
Electron Back Scatter Diffraction (EBSD)
103, 113
Elongation 108
Energy dispersive spectroscopy (EDS) 103,
110
F
Feed Rate 3, 6, 8, 62, 81, 111, 114, 115
Flow Rate 61, 66, 71, 72, 77, 80, 81, 82, 83,
96
Flow Velocity Distribution 74
Functionally Graded Materials(FGM) 80
H
Hard and Brittle Material 1, 2, 5, 9, 12, 13
Heat Energy 20, 42, 43, 88
High pressure liquid pump(HPLP) 59
High speed water jet 59
Hybrid composite material 94
Hybrid Machining 1, 3
Hybrid Machining 1, 3, 5, 6, 11, 42, 47, 53
Hybrid WEDM 108, 109
I
Intermittent Jet 75
K
Kerf 33, 36, 48, 62, 63, 64, 72, 81, 82, 96,
107, 112, 123,
L
Laser Beam Machining 3, 18, 42, 43, 44, 45,
46, 47, 48, 9, 50, 51, 52, 53, 54
M
Machine learning 134, 135, 137, 140, 141,
142
Machining Parameters 1, 91, 93, 94, 95, 98,
110, 113
Material Removal Mechanism 8, 9, 20, 74, 78,
91, 105
Material Removal Rate 1, 3, 4, 5, 6, 7, 12, 17,
18, 23, 24, 48, 49, 50, 60, 83, 107, 108,
109, 124
Micro AAJM 72
Micro AJM 65, 77
Micro EDM 3, 4, 49, 53, 94, 97, 109,
Micro investigation 97
Micro WEDG 108
micro-cutting 62
Micro-drilling 42, 47, 50, 53, 54
Micro-Drilling 42, 47, 50, 53, 54
micromachining 46, 49, 50, 51, 58
N
Nd: YAG 43, 44, 46, 47, 48, 49, 50, 51, 52,
53, 54
non-conductive materials 90
non-contact process 97, 103
Non-conventional Machining 1, 2, 9, 12, 42,
45, 48, 53, 58
non-conventional process 45, 48
Nozzle Weight Loss Rate (NWLR) 80
O
optimal condition 83, 124
optimal parameters 82
Optimal Size 81
Optimised 3, 4, 48
P
Peak Current 96, 107, 114, 123,
plastic deformation 26, 60, 61, 62, 63, 66,
76, 124, 130
Powder metallurgy 17, 24, 25, 26, 29, 30, 33,
34, 35, 36, 37, 95
powder metallurgy process 95
Powder Mix EDM 122
Pulse Generator 122, 123
Pulse Off Time 96, 103, 107, 110, 113, 114,
123, 124
Pulse on and off time 88, 95
pulse time 34, 53, 93, 97, 98
Pulses 47, 49, 53
R
Rapid prototyping 17, 32, 33, 35, 36
Redox 129
renewable energy 58
Robotics 133, 136, 139, 142,
Rotary Ultrasonic Machining (RUM) 1, 2, 3,
6, 7, 8, 9, 10, 11, 12, 13
S
Scanning Electron Microscopy (SEM) 48, 51,
97103, 110, 112, 113, 115,
Sensors 89, 128, 129, 130, 141
Smart Wire EDM 128
spark erosion process 20, 104
Standoff distance 62, 81, 83
stock removal rate 92, 93
Submerged Jet 76
Surface Finishing 123
T
Tensile Strength 21, 103, 107, 126
Thermal conductivity 17, 21, 22, 25, 60, 75150 Advances in Nonconventional Machining Suneev Anil Bansal
Thermally Enhanced AJM 75
Thermally Enhanced Machining 43, 46, 54,
59, 60
Titanium Alloy 5, 49, 58, 59, 64, 104, 105,
115,
Tool wear rate 3, 5, 8, 12, 24, 51, 93, 123,
124
Tooling 36, 47
Transmission Electron Microscopy (TEM)
60, 103, 113, 115
Tribology 71, 76, 77, 78
Tungsten carbide 24, 29, 92, 98, 122
U
Ultrasonic Machining (USM) 1, 2, 3, 4, 5, 6,
7, 8, 9, 12
V
Vibration frequency 110, 125
Vibrations 1, 4, 9, 10, 11, 125, 126
W
Water jet cutting 59, 65
water jet machining 18, 33, 36, 42, 51, 58,
59, 73, 74, 75, 97
Wire Composition 126
Wire Diameter 107, 108, 130
Wire EDM Grinding 108
Wire EDM Milling 108
Wire EDM Turning 109
Wire Electric Discharge Machining (WEDM)
103, 105, 107, 108, 111, 112, 113
Wire feed rate 107, 110, 113, 114, 123
Wire Tension 96

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