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.
Review
Materials Science, Multidisciplinary
Xuyang Zhu, Guangxian Li, John Mo, Songlin Ding
Summary: This paper reviewed the state-of-the-art technologies applied in machining semiconductors, summarized the advantages and disadvantages of each method, introduced the latest research outcomes, and discussed the future development trend.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Review
Automation & Control Systems
Shengsheng Zhang, Jianping Zhou, Guoyu Hu, Lizhong Wang, Yan Xu
Summary: This paper introduces the development history, machining mechanism, application features, process parameters and their impact on process performance of electrochemical discharge machining (ECDM), and discusses the future direction of ECDM.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
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
Engineering, Manufacturing
Shatarupa Biswas, Amrit Raj Paul, Ananda Rabi Dhar, Yogesh Singh, Manidipto Mukherjee
Summary: This study aims to develop genetic algorithm (GA) and particle swarm optimization (PSO) integrated multi-objective multi-layer neural network (MOMLNN) models for multi-material optimization in wire electrical discharge machining (WEDM). The models are used to identify optimum parameters for simultaneous WEDM of specific Ni-based superalloys. The GA integrated model shows slightly higher accuracy compared to the PSO integrated model. The results provide insights into the effects of process variables and compositional elements on material removal rate, kerf width, surface roughness, and recast layer thickness.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2023)
Article
Chemistry, Analytical
Yanyan Chen, Xudong Guo, Guojun Zhang, Yang Cao, Dili Shen, Xiaoke Li, Shengfei Zhang, Wuyi Ming
Summary: This paper proposes a hybrid intelligent process model, combining two-temperature model (TTM) and molecular dynamics simulation (MDS) for predicting the removed depth and material removal rate in micro-electrical discharge machining (micro-EDM). The relationship between input process parameters and process responses is established using Gaussian process regression (GPR), which is trained and optimized with numerical simulation data. The results show that the proposed model accurately predicts the performance of micro-EDM process.
Review
Materials Science, Multidisciplinary
Sergey N. Grigoriev, Khaled Hamdy, Marina A. Volosova, Anna A. Okunkova, Sergey V. Fedorov
Summary: Ceramics are widely used in engineering applications due to their unique properties, but their high hardness and brittleness make traditional machining difficult. Electrical discharge machining is considered a method for machining non-conductive ceramics. However, current results of ceramic machining using electrical discharge still fall short of expectations.
MATERIALS & DESIGN
(2021)
Review
Materials Science, Multidisciplinary
Ya Lu, Peiyan Sun, Xiaohong Yang, Xudong Guo, Xiaoke Li, Wuyi Ming
Summary: Ultrahigh-temperature ceramic matrix composites have excellent properties and are widely used in national defense and aerospace fields. Traditional machining methods face challenges in achieving high precision. Nontraditional machining methods provide solutions and are the future direction for ultrahigh-temperature ceramic matrix composites. This paper summarizes recent nontraditional machining methods, compares their performances, discusses challenges, and predicts the future development of nontraditional machining methods for these composites.
Review
Automation & Control Systems
Milla Caroline Gomes, Aline Goncalves dos Santos, Deborah de Oliveira, Gabriel Viana Figueiredo, Kandice Suane Barros Ribeiro, German Alberto Barragan De los Rios, Marcio Bacci da Silva, Reginaldo Teixeira Coelho, Wayne N. P. Hung
Summary: Metal additive manufacturing is used to produce near-net-shape engineering components, but requires suitable subtractive techniques to control defects and improve surface quality. Traditional micro-machining as a post-processing operation for MAM has potential for future development in areas such as micro-tool assessment and prevention of built-up edge.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Oliver Voigt, Urs Alexander Peuker
Summary: This study investigates the waste products of die-sink electro discharge machining (die-sink EDM) and explores their suitability as recycled materials in additive manufacturing (AM). The study finds that the waste particles fulfill the main requirements for AM usage in terms of size and shape, but chemical purity and the removal of undesired elements need improvement.
Article
Automation & Control Systems
Qi Jing, Yongbin Zhang, Lingbao Kong, Min Xu, Fang Ji
Summary: The study investigated the effects of increased power and frequency on the machining characteristics of very high-frequency micro-electrical discharge machining (VHF micro-EDM), revealing that higher power leads to higher material removal rate (MRR) at the same frequency. Furthermore, at the same power, both MRR and the size of discharge craters increase and then decrease with frequency, peaking at 65 MHz. Additionally, experimental results showed that the optimal processing surface was achieved at 110 MHz frequency and 8.0 W total power for a copper workpiece.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Chemistry, Physical
Shuliang Dong, Hongchao Ji, Jian Zhou, Xianzhun Li, Lan Ding, Zhenlong Wang
Summary: Micro-liquid floated gyroscopes are widely used in military applications. However, the machining of micro-ball sockets in beryllium copper alloy is challenging due to its excellent properties. In this study, we developed a method for milling micro-ball sockets in C17200 beryllium copper alloy using micro-electrical discharge machining, achieving high precision by optimizing the machining parameters. This method provides a new way to fabricate micro-ball sockets in C17200 with high efficiency for micro-liquid floated gyroscopes.
Article
Engineering, Manufacturing
Abdul Wahab Hashmi, Harlal Singh Mali, Anoj Meena, Kuldeep K. Saxena, Ana Pilar Valerga Puerta, Dharam Buddhi
Summary: This paper examines the feasibility of using waste vegetable oils and waste coal ash as abrasive flow machining media to improve the surface quality of FDM parts. Through an optimized experimental design, it was found that the use of coal-ash-based media can achieve a maximum improvement of 83% in surface quality.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Review
Engineering, Mechanical
Smitkumar Savsani, Shamsher Singh, Harlal Singh Mali
Summary: This paper provides a comprehensive review of research on developing prostheses using additive manufacturing (AM), exploring the opportunities and challenges in this field. The findings show that using AM technologies in prosthetics can improve physical and cognitive ergonomics, reduce costs and delivery time, and provide patient-specific, lightweight solutions for complex designs to enhance comfort and clinical outcomes.
RAPID PROTOTYPING JOURNAL
(2023)
Review
Chemistry, Physical
Akshat Srivastava Kulshrestha, Abhimanyu Singh Mertiya, Deepak Rajendra Unune, Ashok Kumar Dargar
Summary: This paper presents a comprehensive review of the research on electrical discharge grinding (EDG) and electrical discharge diamond grinding (EDDG). It discusses the advantages and limitations of these hybrid machining processes, highlighting the improvement in material removal through the rotating motion of the grinding wheel. The paper also explores the current research status and future research perspective in the area of EDG and EDDG processes.
SURFACE REVIEW AND LETTERS
(2023)
Article
Engineering, Manufacturing
Abdul Wahab Hashmi, Harlal Singh Mali, Anoj Meena, Kuldeep K. Saxena, Ana Pilar Valerga Puerta, U. Sathish Rao, Dharam Buddhi, Kahtan A. Mohammed
Summary: The design and manufacture of medical implants is an important area of research, and this paper presents an experimental investigation on the post-processing of FDM printed knee implant replicas using AFM. The rheology of the AFM media is optimized to achieve maximum material removal rate, and the effects of the newly prepared AFM media on the FDM printed pattern are studied.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Manufacturing
Naresh Kaushik, Anoj Meena, Harlal Singh Mali
Summary: High-entropy alloys are emerging materials that are being widely studied for synthesis and characterization. However, the research on their machinability and product realization is still at an early stage. This study examined the effect of element composition and machining parameters on cutting forces, chip morphology, machined surface topography, surface micro-hardness, and tool wear mechanism. The results showed that the composition of the high-entropy alloy and the machining parameters had significant influence on the machining results. The equiatomic CrMnFeCoNi HEA demonstrated higher microhardness compared to the non-equiatomic HEA sample.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Materials Science, Multidisciplinary
Pragati Priyanka, Pawan Sharma, Harlal Singh Mali, Prince Sharma
Summary: The development and characterization of carbon-kevlar interyarn hybrid textile composites (CKI-HTCs) allows their utilization under high strain rate compression. The addition of kevlar enhances the stiffness and toughness of the composites. The effects of strain rate variation and fabric weaving pattern on the dynamic mechanical behavior and failure mechanisms of the composites are investigated.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Orthopedics
Shamsher Singh, Harlal Singh Mali, Anil Kumar Jain
Summary: This study aims to identify the contemporary apprehensions, concerns, and challenges of parents seeking CTEV treatment for their child through the Ponseti Method in India. A descriptive cross-sectional study of 200 parents of the children undergoing treatment at a multispecialty hospital is carried out using a telephone interview. The findings show that male children present later, physical distance is associated with child discomfort and travel method affects follow-up.
JOURNAL OF ORTHOPAEDICS
(2023)
Article
Materials Science, Multidisciplinary
Arvind Kumar Singh, Anup Malik, Harlal Singh Mali, Mahendra Singh Shekhawat
Summary: In this study, electric discharge machining (EDM) with a centreless turning attachment was used to enlarge the diameter of axis-symmetric thin-walled cylindrical components. Response surface methodology (RSM) was employed to investigate the effects of impulse current (IP), pulse on time (Ton), and pulse off count (Toff count) on material removal rate (MRR), enlargement in diameter (EN), and circularity (Cir). The optimum process parameters were found to be impulse current (15 A), pulse on time (490 μs), and pulse off count (6), resulting in MRR of 366 mg/min, EN of 229 μm, and Cir of 0.014 μm. Additionally, the sample's topography changed as hardness and corrosion resistance increased.
ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES
(2023)
Review
Thermodynamics
Shashank Singh, Anup Malik, Harlal Singh Mali
Summary: This article critically examines the research on modifications in geometry of channels for thermo-hydraulic performance enhancement and aims to determine the best channel configuration with optimal parameters. It explores various designs and their influencing parameters, as well as presents conclusions and potential recommendations for future research.
APPLIED THERMAL ENGINEERING
(2023)
Article
Engineering, Mechanical
Pawan Sharma, Harlal Singh Mali, Anurag Dixit
Summary: In this research, a Mode-I interlaminar fracture modeling of a double cantilever beam (DCB) composite laminate was conducted using various fracture modeling techniques such as virtual crack closure technique (VCCT), cohesive zone modeling (CZM), and extended finite element method (XFEM). The comparison of the results with experimental data showed that the three-dimensional XFEM-CZM technique had excellent accuracy and moderate mesh dependency in predicting crack behavior.
JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING
(2023)
Article
Engineering, Mechanical
Nikhil Jain, Jinesh Kumar Jain, Pravin Pandit Harane, Deepak Rajendra Unune
Summary: This study proposes and investigates a water-in-oil (W/O) nano-emulsion, synthesized from refined jatropha oil, as an alternative dielectric for electric discharge machining (EDM). The results indicate that the W/O nano-emulsion can improve the material removal rate (MRR) and reduce the relative wear ratio (RWER) compared to conventional EDM oil.
JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING
(2023)
Article
Materials Science, Multidisciplinary
Akshat Srivastava Kulshrestha, Barun Haldar, Deepak Rajendra Unune, Ashok Kumar Dargar
Summary: This study assesses the performance of electrical discharge diamond face grinding (EDDFG) in processing super alloy Monel 400, and finds that EDDFG has better material removal rate and surface roughness compared to other machining methods. The study also evaluates the influence of diamond grit number and grinding wheel speed on the machining performance, and uses a multi-objective genetic algorithm to determine the optimal parametric settings.
MATERIALS RESEARCH EXPRESS
(2023)
Article
Engineering, Multidisciplinary
Akshat Srivastava Kulshrestha, Deepak Rajendra Unune, Ashok Kumar Dargar
Summary: This study investigates and optimizes the electro discharge face grinding (EDFG) process for processing Monel 400 alloy. The research utilizes the central composite design (CCD) and analysis of variance (ANOVA) to determine the significance of process parameters, with a focus on the grinding wheel speed (GWS). The optimal process parameters are obtained through the Desirability approach and Genetic algorithm (GA), and the GA approach is found to be more effective in optimizing the EDFG process.
SADHANA-ACADEMY PROCEEDINGS IN ENGINEERING SCIENCES
(2023)
Review
Engineering, Multidisciplinary
Abdul Wahab Hashmi, Harlal Singh Mali, Anoj Meena, Mohammad Farukh Hashmi, Neeraj Dhanraj Bokde
Summary: Computer vision offers economic, automated, quick, and reliable solutions for inspecting and evaluating surface quality, especially in industries requiring 100% inspection. This paper discusses the characterization of surface texture of traditional or non-traditional manufactured parts using computer/machine vision methods and the assessment of machine vision parameters such as surface roughness, waviness, flatness, and surface texture.
CMES-COMPUTER MODELING IN ENGINEERING & SCIENCES
(2023)
Review
Engineering, Mechanical
Abdul Wahab Hashmi, Harlal Singh Mali, Anoj Meena
Summary: This paper investigates the functionality of additively manufactured parts, focusing on dimensional accuracy and surface finish. It discusses various techniques for improving the surface quality of AM parts, categorizing them into chemical, thermal, mechanical, and hybrid-based methods.
RAPID PROTOTYPING JOURNAL
(2023)
