Micromachining of difficult-to-machine materials is of prime focus nowadays. One such material is Titanium, which has numerous applications in aerospace, chemical, and biomedical industries. The micromachining of Titanium has become the need of the day because of its exhilarating properties. This investigation employs a tailor-made electrolyte sonicated micro-electrochemical discharge machining (ES-µ-ECDM) system to generate microholes in a commercially pure titanium plate with a thickness of 1000 µm. The machining chamber is the ultrasonication unit (36 kHz) with process parameters voltage (V), concentration (wt%), and duty factor (DF) chosen at three levels. The FCC-RSM-based DOE is selected for experimentation to study the machining characteristics like material removal rate, overcut, and circularity. Through holes were achieved at parameters of 80 V, 25 wt%, and 60% DF and 80 V, 30 wt%, and 50% DF. The incorporation of ultrasonication into the system enhanced electrolyte replenishment and evacuation of the debris at the machining vicinity. The assistance technique improved the gas film stabilization around the tool enabling uniform machining. The multi-response optimization is performed using the MOJAYA algorithm to obtain Pareto optimal solutions, and the MADM (R-method) is employed to obtain the optimal parameter. The optimal parameter was found to be 69 V, 30 wt%, and 50% DF, at which the machined microhole was found to have a circularity of 0.9615 with minimal surface defects.
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http://dx.doi.org/10.1038/s41598-022-20001-4 | DOI Listing |
Biofabrication
January 2025
Mechanical Engineering, National Institute of Technology Meghalaya, Shillong, Shillong, Meghalaya, 793003, INDIA.
The process of micromachining has garnered attention for its ability to create three-dimensional tiny features, particularly in ultra-hard and exotic materials. The present work investigates the effect of different parameters of the µ-ED milling, such as pulse on time (Ton), pulse off time (Toff), voltage (V), and tool rotation (TR) on the dimensional deviation (DD), material removal rate (MRR), surface roughness (Ra), and machined surface characteristics (analysed by EDS and FESEM). The sesame oil as dielectric and tungsten-copper as tool electrodes were used to maintain the accuracy and improve the machinability of bio-grade Nitinol SMA.
View Article and Find Full Text PDFMaterials (Basel)
January 2025
Department of Machine Design and Manufacturing Engineering, Kielce University of Technology, al. Tysiaclecia Panstwa Polskiego 7, 25-314 Kielce, Poland.
The minimum cutting thickness is a key value in machining processes, as below this value the material will only undergo elastic and plastic deformation without chip removal. Existing measurement methods require time-consuming preparation and complicated procedures. This work focuses on the development of a new, simplified method for determining the minimum cutting thickness (h) using a contact profilometer that can be used in industry.
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December 2024
Department of Manufacturing Techniques and Automation, Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, Wincentego Pola 2, 35-959 Rzeszów, Poland.
The paper presents the results of an analysis of the effect of brushing on the edge condition of workpieces with complex geometric shapes, formed during milling, on a five-axis DMU 100 monoBLOCK machining center. A set of EN-AW 7075 aluminum alloy specimens with curvilinear edges requiring multi-axis machining was prepared. The change of edge condition after the milling process was realized using Xebec tools with flexible ceramic fibers.
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December 2024
Laser Fusion Research Center, China Academy of Engineering Physics, Mianyang 621900, China.
The ultraprecision machining of diamond presents certain difficulties due to its extreme hardness. However, the graphitization modification can enhance its machinability. This work presents an investigation into the characteristics of the graphitization modification in polycrystalline diamond induced by a nanosecond pulsed laser.
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December 2024
Department of Lifting and Transport Machines and Engineering of Port Technological Equipment, Odessa National Maritime University, 34, Mechnikova St., 65029 Odesa, Ukraine.
Evaluating the current technical condition and residual life of structures that may have reached or exceeded the end of their design life is a challenging issue in many industrial sectors. This paper focuses on the assessment of the structural integrity of structural elements of a seaport portal crane after operation for about 33 years. Test specimens were extracted from two crane elements, a jib (element A) as the most seriously loaded unit and, for comparison, a boom (element B) as the less loaded one, and machined in two different orientations, longitudinal and transversal.
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