Article
Engineering, Mechanical
Yuying Yang, Min Yang, Changhe Li, Runze Li, Zafar Said, Hafiz Muhammad Ali, Shubham Sharma
Summary: Micro-grinding is an important step in most surgical operations, but technical challenges such as insufficient cooling capacity, poor visibility, and high grinding temperature have hindered its progress. To address these issues, a new micro-grinding process called ultrasonic vibration-assisted nanoparticle jet mist cooling (U-NJMC) is proposed, combining the advantages of ultrasonic vibration and nanoparticle jet mist cooling. The combined effect of U-NJMC on cooling has been investigated and compared to other grinding methods. Results show that U-NJMC significantly reduces grinding force, friction coefficient, specific grinding energy, and grinding temperature, making it a promising approach for clinical surgical micro-grinding of biological bone.
FRONTIERS OF MECHANICAL ENGINEERING
(2023)
Article
Automation & Control Systems
Mir Akmam Noor Rashid, Tanveer Saleh, Wazed Ibne Noor, Mohamed Sultan Mohamed Ali
Summary: The experimental investigation on the application of LBMM-mu EDM technique on stainless steel revealed the significant influence of laser input parameters, particularly scanning speed and power, on the performance of mu EDM. It was found that adjusting these laser parameters could either slow down or speed up the mu EDM processing time. The sequential machining technique was shown to reduce machining time, tool wear, and instability, while maintaining hole quality, compared to pure mu EDM process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Chemistry, Analytical
Weijing Kong, Ziyu Liu, Rudong Zhang, Yongbin Zeng
Summary: With the development of MEMS, there is an increasing demand for machining difficult-to-machine metal micro parts. Microelectric discharge machining is effective but causes recast layers. In this study, we propose wire electrochemical discharge micro-machining (WECDMM) with a new electrolyte system to remove recast layers. We optimize the electrolyte and analyze the effects of process parameters on machining quality.
Article
Materials Science, Multidisciplinary
Anshuman Kumar Sahu, Siba Sankar Mahapatra, Rahul Ravi, Srinivasa Rao Bakshi
Summary: The present experimental work focuses on fabricating a composite tool electrode using spark plasma sintering process and evaluating its performance in electro-discharge machining of titanium alloy. By considering various machining parameters and analyzing machining characteristics, it reveals the performance of the spark plasma sintered tool electrode.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Chemistry, Physical
Jing Li, Wanwan Chen, Yongwei Zhu
Summary: This study proposes a new mechanism for two-dimensional ultrasonic assisted grinding-electrolysis-discharge generating machining (2UG-E-DM). The influence of vibration directions on grinding characteristics and surface morphology was analyzed through motion simulation. Comparative experiments confirmed the effect of ultrasonic assistance on weakening of grinding force, widening of surface pits, and leveling of surface morphology. Simulation analysis of a single abrasive particle verified the experimental results. Machining tests showed that increasing workpiece and tool amplitude resulted in a faster reduction of normal force grinding force compared to tangential force grinding force. The effect of surface electrolysis discharge machining was significant, increasing the number of exposed particles while reducing both the residual height and surface roughness through vibration grinding. Increasing the two-dimensional amplitude to 5 μm expanded the grinding domain and significantly reduced surface roughness through the dragging and rolling of reinforced particles, resulting in good surface quality.
Article
Materials Science, Multidisciplinary
Fatih Hayati Cakir, Osman Nuri Celik
Summary: The study improved the machinability of Ti-6Al-4V alloy through cryogenic treatment, enhancing electrical conductivity and improving surface roughness of machined surfaces, providing an alternative approach for enhancing the machinability of the alloy.
METALS AND MATERIALS INTERNATIONAL
(2021)
Article
Engineering, Manufacturing
Rajesh Sahoo, Tapas Debnath, Promod Kumar Patowari
Summary: The current research analyzes the machining performance measures of titanium diamond using electro-discharge machining (EDM). The study identifies the optimal input parametric combination and examines the impact of current and pulse-on-time on material removal rate, tool wear rate, and average surface roughness. The analysis reveals that current has the most impact on material removal rate and surface roughness, while pulse-on-time has the most impact on tool wear rate.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Engineering, Manufacturing
Wang Sujuan, Yu Liangbao, Qin Chao, Sun Zhanwen
Summary: Titanium alloys are widely used in various industries due to their excellent mechanical properties. However, their poor thermal conductivity and low elastic modulus make them difficult to machine, especially in ultra-precision machining. This study investigates the use of micro-structured surfaces to improve the machinability of titanium alloys by reducing chip segmentation and cutting forces fluctuations. The results show that the micro-structured surface can effectively decrease cutting forces, reduce tool wear, and improve surface quality in ultra-precision machining of titanium alloy. This method also provides guidance for efficient and sustainable machining of titanium alloy parts with high surface quality.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)
Article
Engineering, Multidisciplinary
Manoj Kumar, P. S. Satsangi
Summary: This experimental study focused on machining tungsten alloy micro-tools using WEDG method on a hybrid micro-electro-discharge machine to achieve high productivity and finish. Parameters such as voltage, capacitance, and spindle speed were studied for their influence on material removal rate and surface roughness. The study identified challenges in machining tungsten material and proposed future directions for developing predominant fluted micro-tools.
SADHANA-ACADEMY PROCEEDINGS IN ENGINEERING SCIENCES
(2021)
Article
Materials Science, Ceramics
Ella Walter, Andrea Gommeringer, Frank Kern
Summary: Composites of yttria-neodymia co-stabilized zirconia with nanoscale tungsten carbide and alumina addition were manufactured and characterized. Alumina addition increased hardness and Young's modulus, and slightly increased bending strength. However, it reduced the transformability of the zirconia matrix and fracture toughness. In EDM, alumina reduced re-solidified layer thickness, surface defects, and improved surface smoothness, but had negligible effect on material removal rate.
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
(2023)
Article
Engineering, Manufacturing
Zhiqiang Liang, Yuchao Du, Yue Ma, Zhipeng Su, Rui Chen, Hao Yuan, Tianfeng Zhou, Xibin Wang
Summary: In this study, the mechanism of milling-grinding combined machining of cemented carbide was analyzed, and a new PCD micro end mill structure was designed. By establishing a mathematical model, the fabrication of a new micro mill with a certain helix flute width was realized. The experimental results showed that the new micro mill had improved surface quality and wear resistance, making it suitable for high-quality and high-efficiency machining.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Chemistry, Physical
Jacek Skiba, Mariusz Kulczyk, Sylwia Przybysz-Gloc, Monika Skorupska, Julita Smalc-Koziorowska, Mariusz Kobus, Kamil Nowak
Summary: This paper presents research on optimizing the unconventional plastic forming process of a copper alloy (CuCrZr) through hydrostatic extrusion (HE) and post-processing heat treatment. The study found that the post-processing treatment resulted in an improved microstructure, significantly increased hardness and strength, and maintained high electrical conductivity, thereby reducing electrode wear in the EDM process. The best results were obtained with a five-stage HE process combined with aging at 480 degrees C for 1 hour, reducing electrical discharge wear by over 50% compared to non-deformed copper electrodes.
Article
Automation & Control Systems
Yi Xu, Baoyang Jiang
Summary: Electrochemical discharge machining (ECDM) is a technology used for micromachining of non-conductive materials, but deep micro hole drilling encounters problems due to bubble accumulation at the entrance hole; recent research shows that improving electrolyte circulation through the magnetohydrodynamic effect can enhance machining efficiency.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Chemistry, Analytical
Timur Rizovich Ablyaz, Evgeny Sergeevich Shlykov, Karim Ravilevich Muratov, Sarabjeet Singh Sidhu
Summary: This study focuses on the wire-cut electro-discharge machining of polymer composite material (PCM) and demonstrates that by improving the workpiece conductivity and selecting appropriate process parameters, the cut-width accuracy can be significantly enhanced. Analysis of variance reveals that voltage and pulse duration play a crucial role in determining the cut-width, and the developed theoretical model proves to be effective within an acceptable range.
Article
Materials Science, Composites
Abual Hassan, Yan Li He, Mudassar Rehman, Kashif Ishfaq, Sadaf Zahoor, Mirza Zahid Hussain, Farah Siddique, De Chao Wang
Summary: This study focuses on investigating the machinability of carbon nanotubes/carbon fiber reinforced composites using electrical discharge machining, with a goal to improve machining stability and dimensional accuracy by adjusting pulse parameters. Experimental results indicate that peak current and gap voltage have significant impacts on radial over-cut, which are important factors affecting machining quality.
POLYMER COMPOSITES
(2022)
