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Saha, Sucharita
- Investigation on the Correlation between Surface Roughness and Acoustic Emission Characteristics in Turning Process
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Authors
Affiliations
1 Surface Engineering and Tribology Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
2 Material Processing and Microsystem Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
1 Surface Engineering and Tribology Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
2 Material Processing and Microsystem Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
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Manufacturing Technology Today, Vol 18, No 6 (2019), Pagination: 3-9Abstract
One of the most significant feature for monitoring in machining processes is tool wear. It has a direct influence on the quality of machined surfaces. In-order to maintain the product quality and to reduce material wastage, online tool wear monitoring has become a regular practice. With the progress in tool wear, surface roughness changes accordingly and this change can be used to assess the tool condition. However, it is difficult to measure the surface roughness online. It is well known that interaction of tool and workpiece results in high frequency stress waves known as Acoustic Emissions (AE), which can be used as an indirect online method to monitor the surface roughness and in-turn tool wear. The analysis of AE signals which received significant attention in structural and machine health monitoring opens wide opportunities to monitor the machining process. Hence, in the present work an attempt has been made to explore the correlation between the acoustic emission characteristics and workpiece surface roughness during the high speed turning operation using AISI 4340 alloy steel workpiece with the help of Zirconia Toughened Alumina (ZTA) tool on a lathe machine. Experiments has been designed as per Central Composite Design (CCD) of Response Surface Methodology (RSM) with varying 3 levels of 3 parameters such as cutting speed, feed rate and depth of cut. For each experiment, AE signals are acquired and surface roughness is measured using Surtronic 25 portable surface roughness meter. Analysis of variance (ANOVA) is used to study the effect of control parameters on output responses and a model is prepared using regression analysis. It is observed from the ANOVA analysis that feed rate and cutting speed have profound influence on surface roughness and RMS respectively. The optimum condition is found at Cutting speed of 300 m/min with feed rate of 0.12 mm/rev and depth of cut of 1.5 mm with 97.15% desirability for minimum surface roughness and nominal RMS value. From the parametric study, it is observed that AE characteristic (RMS) shows good correlation with surface roughness which can be used for further analysis in online monitoring of tool wear.Keywords
AE Characteristics, RMS, Surface Roughness, Tool Wear.
References
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- A Review on Short Pulse Generator Used for Micro Electric Discharge Machining
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Authors
Affiliations
1 CSIR- Central Mechanical Engineering Research Institute (CMERI), Durgapur, West Bengal, IN
2 Academy of Scientific and Innovative Research (AcSIR) Anusandhan Bhawan, New Delhi, IN
3 Central Manufacturing Technology Institute (CMTI), Bengaluru, Karnataka, IN
1 CSIR- Central Mechanical Engineering Research Institute (CMERI), Durgapur, West Bengal, IN
2 Academy of Scientific and Innovative Research (AcSIR) Anusandhan Bhawan, New Delhi, IN
3 Central Manufacturing Technology Institute (CMTI), Bengaluru, Karnataka, IN
Source
Manufacturing Technology Today, Vol 18, No 12 (2019), Pagination: 3-11Abstract
Micro-EDM is a promising noncontact micro machining process; where the precisely controlled electric spark occurred between the tiny electrodes and erodes the material from electrically conductive work piece. Application of this Micro EDM is rapidly growing in manufacturing of metal products irrespective of its hardness having geometric features in range of micrometer to nanometer scale. In order to ensure the material removal in the order of few cubic micrometers it is desirable to use a low energy, shorter pulsed discharges at very high frequency. In this study, the detailed literature review related to low energy and short pulsed power circuits to use in Micro-EDM process conditions has been carried out. The advantages and issues of obtaining such high frequency short pulsed low energy discharge have been critically studied to set the future directions for further investigation.Keywords
Micro EDM, Pulse Generator, RC Relaxation Circuit, Transistor Type Pulse Generator.References
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- Study on Material Removal Rate and Surface Roughness using Graphene as Dielectric Additives in Micro-Electric Discharge Machining
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Authors
Affiliations
1 CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal, IN
2 Central Manufacturing Technology Institute, Tumkur Road, Bangalore, Karnataka, IN
1 CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal, IN
2 Central Manufacturing Technology Institute, Tumkur Road, Bangalore, Karnataka, IN
Source
Manufacturing Technology Today, Vol 20, No 11-12 (2021), Pagination: 3-9Abstract
Micro-electric discharge machining is the most distinguished micro-manufacturing process for engineering micro-parts of different geometric features. The slow material removal rate owing to the low energy short-pulsed electric discharge is the major bottleneck of the process in batch scale production. This paper is an attempt to increase the material removal rate (MRR) and enhance the surface integrity in micro-EDM using graphene as an additive in dielectric liquid. Graphene sheets synthesized using Hummers method followed by reduction and subsequent heating was dispersed in hydrocarbon based dielectric liquid by ultrasonication at temperature near to the flash point. The INCONEL 718 workpiece electrode has been immersed in the graphene suspended dielectric medium where as tungsten carbide of diameter 200µm has been used as tool electrode. It has been found that the MRR increases by 47 % in terms of volume of material removed and the surface roughness reduces by 73 % for graphene additive based dielectric medium as compared with dielectric without additive.Keywords
Micro-EDM, MRR, Surface Roughness, Graphene, Dielectric Medium.References
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