Manufacturing Technology Today

P. Sivaprakasam ¹, P. Hariharen ¹, S. Gowri ¹

Affiliations
1 Dept of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai, IN

Abstract

This paper presents a systematic methodology for modeling and analysis of Material removal rate of micro wire EDM process using the Response Surface Methodology (RSM). The factors of micro WEDM process are voltage, capacitance and feed rate. The machining performance of material removal rate is response variable investigated. Experimental work carried out on metal matrix composite (LM 6- B₄C /9%) with zinc coated copper wire by a standard RSM design called a Central Composite Design (CCD). To analysis the proposed second order mathematical model for material removal rate using CCD for estimating the model coefficients of three factors and it has found that influences the MRR in micro WEDM process. Based on ANOVA, the voltage, feed rate and capacitance significant effect on the MRR.

Keywords

Micro EDM, Micro WEDM, ANOVA, Response Surface Methodology(RSM).

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G. Shanmugasundar ¹, S. Gowri ¹

Affiliations
1 Dept. of Manufacturing Engg., CEG, Anna University, Guindy, Chennai, IN

Abstract

Micro-machining is the most basic technology for the production of miniaturized parts with micron level dimensions. One type of tool based micromachining technology is micro turning. It is a conventional metal removal mechanism that has been miniaturized. Surface roughness plays an important role in product quality in producing of micron scale structures and components. In this paper, the effect and prediction of machining parameters on surface roughness in a micro turning operation on Aluminium was investigated by using the multiple Regression modeling concepts. In the micro-turning process, cutting conditions determine the time and cost of production which ultimately affect the quality of the final product. So reliable models and methods are required for the prediction of the output performance of the process.

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S. Gowri ¹, S. Somasundaram ¹, L. Jagan ¹

Affiliations
1 Dept. of Manufacturing Engg., CEG Campus, Anna University, Chennai, IN

Abstract

Super abrasive grinding is a development in the precision grinding technology for producing high surface finish on the surfaces. Cooling and lubrication are especially important to ensure workpiece quality because of high friction and intense heat generation involved in the process. Conventionally, liquid coolants in flood form are employed in grinding. The large contact area between the wheel and workpiece causes as tiff boundary layer around the periphery, which restricts the flow of fresh cutting fluids in the grinding zone. Hence, the usage of fluid coolant is in effective. Minimization and possibly the elimination of fluid coolants can be done by substituting their functions through the use of solid lubricants. In this work, the possibility of using Molybdenum-di-Sulphide as a lubricating medium to reduce the heat generated at the grinding zone is investigated by the use of an experimental setup in the surface grinding machine. The study of effect of wheel parameters and grinding parameters on surface roughness, surface damage, specific energy and grinding forces are analyzed and the results are compared with the results obtained in the dry grinding.

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M. Sreeramulu ¹, G. Arumaikkannu ¹, S. Gowri ¹

Affiliations
1 Department of Manufacturing Engineering, College of Engineering, Anna University, Chennai-25, IN

Abstract

The high degree of automation of layered manufacturing process and its ability to create geometrically complex parts to precise dimensions provide it with a unique potential for low volume production of rapid tooling and functional components. As the rapid prototyping going towards rapid manufacturing in recent days, strength becomes the main factor which affected by many process parameters. In this study, stress analysis has been done on FDM (Fused Deposition Modeling) parts mesostructure by finite element method. In this Finite Element Analysis (FEA) models were designed with different mesostructural process parameters like road width, air gap and slice thickness, on this a linear orthotropic analysis was done to know the effect of each parameter on stress distribution. FEA results were compared with experimental yield strength results and they have better agreement with experimental results in knowing the effect of each parameter on strength.

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G. Arumaikkannu ¹, S. Gowri ¹, S. Murali Krishna ¹

Affiliations
1 Department of Manufacturing Engineering, College of Engineering, Anna University, Chennai-600025, IN

Abstract

Rapid Prototyping (RP) is a class of emerging technologies in which three-dimensional parts are built directly from computer solid models without going through traditional manufacturing steps such as process planning, tool manufacturing etc. Fused Deposition Modeling (FDM), a type of Rapid Prototyping technique is a complex technology Involving many different process parameters. These parameters have great influence on the quality of parts. The porosity of a part has a great effect on the functionality of parts. In this paper a mathematical model has been developed using Response Surface Methodology (RSM) and regression analysis to predict the influence of various process parameters on the porosity of the parts produced by FDM technique. The effect of input parameters such as slice thickness, road width, and model temperature and air gap on porosity is investigated using this mathematical model. The experimental results are statistically analyzed to determine significant factors and their interactions. Conducting experiments using specific combination of the levels of the significant factors does validation. Experimental values and tests of hypothesis demonstrate that the model developed has a satisfactory goodness of fit.

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