scholarly journals Metal Machining—Recent Advances, Applications, and Challenges

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 580
Author(s):  
Francisco J. G. Silva
Keyword(s):  
Surface Finish ◽  
Manufacturing Process ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
High Dimensional ◽  
Manufacturing Processes ◽  
Recent Advances ◽  
Metal Machining ◽  
Rapid Manufacture

Though new manufacturing processes that revolutionize the landscape regarding the rapid manufacture of parts have recently emerged, the machining process remains alive and up-to-date in this context, always presenting itself as a manufacturing process with several variants and allowing for high dimensional accuracy and high levels of surface finish [...]

scholarly journals Framework of models for selecting manufacturing processes and associated parameters for surface topographies

2019 ◽  
Vol 20 (3) ◽  
pp. 301
Author(s):  
Benoit Rosa ◽  
Maxence Bigerelle ◽  
Antoine Brient ◽  
Serge Samper
Keyword(s):  
Specific Surface ◽  
Surface Finish ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Manufacturing Processes ◽  
Operating Parameters ◽  
Electro Discharge Machining ◽  
Surface Topographies ◽  
Computer Aided ◽  
Aided Design

Choosing appropriate manufacturing processes to create functional surfaces is a challenging issue for some industrials. A specific surface finish can be obtained by different manufacturing processes, each of them having a different economic impact. Currently, no tool could guarantee the surface function through the choice of a manufacturing process and its associated operating parameters. This paper aims at discussing about a framework of models for selecting conventional or innovative manufacturing processes and their associated parameters with regards to surface topographies and textures. To achieve this, a concept of decomposition of database is introduced. Manufacturing processes such as, electro discharge machining, water jet machining (used for texturing surfaces), sandblasting and laser cladding are modelled. Finally, a concept that links such a database with computer aided design (CAD) software in order to integrate surfaces functionalities and manufacturing processes directly into the design step is discussed.

Dimensional Accuracy in PolyJet Printing: A Literature Review

2019 ◽  
Author(s):  
Ketan Thakare ◽  
Xingjian Wei ◽  
Zhijian Pei
Keyword(s):  
Additive Manufacturing ◽  
Layer Thickness ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
High Dimensional ◽  
Control Variables ◽  
Current Trends ◽  
Manufacturing Methods ◽  
Polyjet Printing ◽  
Part Orientation

Abstract PolyJet printing process is one of the additive manufacturing methods to print parts with high dimensional accuracy. To date, dimensional accuracies of such process have been investigated by a number of studies. This review will summarize those studies, and identify current trends. With respect to methods of measurements used in the reported studies, it is noted that no special preference is given to use of any method. In addition, the effects of four control variables of PolyJet process: part orientation, layer thickness, surface finish type and materials, on dimensional accuracy are noted based on the results of reported studies. There is consistency in results in studies considering control variables of layer thickness, surface finish type and materials. However, the results are inconsistent in studies considering part orientation.

Precision Control of Kerf in Metal Cutting Using Dry Micro WEDM: Issues and Challenges

2018 ◽  
Vol 775 ◽  
pp. 499-505 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Asfana Banu ◽  
Mohamed Abdul Rahman ◽  
Muataz Hazza Faizi Al Hazza ◽  
Erry Yulian Triblas Adesta
Keyword(s):  
Mathematical Models ◽  
Stable Process ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
High Dimensional ◽  
Dielectric Fluid ◽  
Wire Edm ◽  
Micro Wedm ◽  
Micro Tools ◽  
Edm Process

Micro dry wire EDM is a process where gas is used as the dielectric fluid instead of a liquid. In this process certain modifications of a wire EDM are needed during the machining operation to achieve stable machining. Optimizing kerf to get high dimensional accuracy is one of the critical issues in micro dry wire EDM. The fundamental modelling for optimum kerf using micro dry wire EDM has not been formulated yet. Due to the complex phenomenon, the prediction of optimum kerf in a micro dry wire EDM process is rather difficult. Hence, the main objectives of this research are to improve the micro dry wire EDM process and to develop mathematical models for optimum kerf using micro dry wire EDM. During the process improvement of micro dry wire EDM, various machining setup will be involve in order to achieve the most stable process. The most stable machining process will be used to prove the developed mathematical models. A mathematical relationship between kerf and process parameters is anticipated. The mathematical models in conjunction with experimental data will eventually produce the desired theory. The developed process and mathematical model of kerf is a breakthrough in fabricating products such as micro tools, molds etc. with optimum kerf and high dimensional accuracy. The successful completion of this research will contribute to the environmental friendly micromachining process.

Recent Research in Metal Machining

1945 ◽  
Vol 153 (1) ◽  
pp. 113-132
Author(s):  
D. F. Galloway
Keyword(s):  
Powder Metallurgy ◽  
Research And Development ◽  
Surface Finish ◽  
Manufacturing Processes ◽  
Industrial Efficiency ◽  
Metal Machining ◽  
Recent Developments ◽  
Machining Operations ◽  
First Time ◽  
Made In

Despite the introduction of comparatively new manufacturing processes such as powder metallurgy and plastics which are gradually assuming their true functions in industry, manipulation of metals by machining still occupies a place of major importance among methods of production and the efficiency with which machining operations are carried out continues to influence greatly the overall industrial efficiency of the country. Research provides a means of greatly accelerating progress toward the goal of efficient metal machining, and recent developments in other fields of science and industry now present opportunities of research and development in metal machining, incomparably greater than have hitherto been known. The progress recently made in the field of surface finish measurement which, for the first time, makes possible a rational investigation of finish machining operations, is just one example of newly acquired knowledge which can now be applied in solving the complex problems of metal machining.

Tool-Based Micro/Nano Machining: Development of Innovative Machine and Machining Processes

2020 ◽  
Author(s):  
Mustafizur Rahman ◽  
Keng Soon Woon ◽  
Wee Keong Neo
Keyword(s):  
Surface Finish ◽  
Continuous Production ◽  
Current Trend ◽  
Cutting Tools ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Successful Implementation ◽  
Micro Machining ◽  
Machining Processes ◽  
Ultra Precision

Abstract It is an unarguably fact is that the current trend in manufacturing is miniaturization of products with extreme surface finish. I addition, the surface finish and dimensional accuracy requirements of products as well components are getting remarkably stringent, especially in the areas of vision, information, biotech, environmental, measurement and medical industries. Moreover, these products need to accommodate increased number of functions. Production of such products and parts of micron level size with very high dimensional accuracy of nano meter level is getting more importance because of a steadily increasing demand for such industrial products. To satisfactorily meet these challenges micro/nanomachining technology must be developed. Such machining is usually performed either using techniques based on energy beams (beam-based micro-machining) or using solid cutting tools (tool-based micro/nanomachining). Some of the limitations of beam-based micro-machining are due to poor control of 3D structures, low aspect ratio of products and also low material removal rate. In addition, special facilities are required to perform these processes and the maximum achievable dimensions are relatively small. However, with the application of tool-based micro/nanomachining technology some of these limitations can be satisfactorily overcome using ultra precision machine tools and solid cutting tools to produce the micro-features with well-controlled shape, features and tolerances. In many cases, compound or hybrid or simultaneous machining process is required for effectively performing micromachining. To meet the challenges, multi-process machines are required and unfortunately such machines are not available. Consequently, the author will present the development of a first-of-its-kind multi-process machine tool and the innovative approaches to develop various compound, hybrid and simultaneous machining processes for the successful implementation of micromachining. Recently, nanomachining of difficult-to-machine materials is also getting more importance with the pervasive demand for fabrication of miniature, thinner and lighter products, intricate micro-shapes and structures on such materials. In addition, the products also require nano meter level surface finish. The author would like to present his contribution especially in the area ductile mode machining of brittle materials. This paper also presents the recent developments in the areas of deeper understanding of the mechanisms and machining technologies to generate nano-finish surface by machining processes. In this paper, the basic understanding of nanomachining mechanism, ‘extrusion-like’ chip formation metal cutting is briefly discussed. With the emergence of hybrid freeform surfaces to increase the optical performance and to provide new functions. To fulfill these objectives, the author and his team have carried out ultra-precision machining using fast tool servo (FTS) and slow slide servo (SSS) mechanisms. Some typical examples of the development of innovative nano machining processes and products have been presented in this paper. Finally, the development of a rotating tool for continuous production of radial Fresnel lenses has been presented.

Prediction and Investigation of Surface Quality in High Speed End-Milling of Silicon to Eliminate Conventional Finishing Operations

2011 ◽  
Vol 418-420 ◽  
pp. 1237-1241
Author(s):  
A.K.M. Nurul Amin ◽  
Mohd Dali M Ismail ◽  
Muhammad Iqbal Musa ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
High Speed ◽  
End Milling ◽  
High Surface ◽  
Small Diameter ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Machining Process ◽  
Dry Cutting

Surface finish and dimensional accuracy are two of the most important requirements in machining process. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In HSM determination of the optimum combination of cutting parameters for achieving the required level of quality, such as, minimum possible surface roughness and maximum tool life is a very important task. Silicon is conventionally finished using grinding followed by polishing and lapping to achieve required surface finish and surface integrity. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to ensure high surface roughness values through achievement of ductile mode machining of silicon. Investigations on the effect cutting parameters of high speed end milling on surface finish and integrity of silicon has been conducted to minimizing the amount of finishing requirement in machining of silicon, with the objective of reducing cost and increasing effectiveness of silicon manufacturing process. In this work statistical models were developed using the capabilities of Response Surface Methodology (RSM) to predict the surface roughness in high speed flat end milling of silicon under dry cutting conditions.

Study on Geometric Tolerances Information in Integrated Manufacturing Processes

2010 ◽  
Vol 37-38 ◽  
pp. 1292-1295
Author(s):  
Yan Chao ◽  
Hai Feng Zhang ◽  
Li Qun Wu
Keyword(s):  
Life Cycle ◽  
Data Model ◽  
Manufacturing Process ◽  
Product Life Cycle ◽  
Critical Role ◽  
Manufacturing Processes ◽  
Product Life ◽  
Internet Technologies ◽  
Geometric Tolerance ◽  
Geometric Tolerances

Tolerance information plays a critical role in many steps of the product life cycle. It is especially important due to the advances in Internet technologies and increasing integration requirements from industry. In this paper, geometric tolerances information in manufacturing process (IMP) is studied, and the layered conformance level of geometric tolerances is established according to ASME Y14.5-1994, STEP and DMIS. An EXPRESS-G data model of geometric tolerance information in IMP is established. The XML language is used to represent and program the geometric tolerances information in IMP.

A Goal-Oriented, Inverse Decision-Based Design Method to Achieve the Vertical and Horizontal Integration of Models in a Hot Rod Rolling Process Chain

2017 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Vignesh Rangaraj ◽  
B. P. Gautham ◽  
Amarendra Kumar Singh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Design Method ◽  
Manufacturing Processes ◽  
Process Chain ◽  
Structure Property ◽  
Horizontal Integration ◽  
Design Exploration ◽  
Unit Operations ◽  
Manufacturing Process Chain ◽  
Decision Based Design

Reducing the manufacturing and marketing time of products by means of integrated simulation-based design and development of the material, product, and the associated manufacturing processes is the need of the hour for industry. This requires the design of materials to targeted performance goals through bottom-up and top-down modeling and simulation practices that enables handshakes between modelers and designers along the entire product realization process. Manufacturing a product involves a host of unit operations and the final properties of the manufactured product depends on the processing steps carried out at each of these unit operations. In order to effectively couple the material processing-structure-property-performance spaces, there needs to be an interplay of the systems-based design of materials with enhancement of models of various unit operations through multiscale modeling methodologies and integration of these models at different length scales (vertical integration). This ensures the flow of information from one unit operation to another thereby establishing the integration of manufacturing processes (horizontal integration). Together these types of integration will support the decision-based design of the manufacturing process chain so as to realize the end product. In this paper, we present a goal-oriented, inverse decision-based design method to achieve the vertical and horizontal integration of models for the hot rolling and cooling stages of the steel manufacturing process chain for the production of a rod with defined properties. The primary mathematical construct used for the method presented is the compromise Decision Support Problem (cDSP) supported by the proposed Concept Exploration Framework (CEF) to generate satisficing solutions under uncertainty. The efficacy of the method is illustrated by exploring the design space for the microstructure after cooling that satisfies the requirements identified by the end mechanical properties of the product. The design decisions made are then communicated in an inverse manner to carry out the design exploration of the cooling stage to identify the design set points for cooling that satisfies the new target microstructure requirements identified. Specific requirements such as managing the banded microstructure to minimize distortion in forged gear blanks are considered in the problem. The proposed method is generic and we plan to extend the work by carrying out the integrated decision-based design exploration of rolling and reheating stages that precede to realize the end product.

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