Modeling of material removal in mechanical type advanced machining processes: a state-of-art review

Abstract

Performance of any machining process is evaluated in terms of machining rate and surface finish produced. Higher machining rate and better surface finish are desirable for better performance of any machining process. Comprehensive qualitative and quantitative analysis of the material removal mechanism and subsequently the development of analytical model(s) of material removal (MR) are necessary for a better understanding and to achieve the optimum process performance. Analytical MR models are also necessary for simulation, optimization and planning (i.e. operation and process planning) of the process, prediction of process performance indicators, verification and improvements of experimental results, selection of appropriate models for specific type of work material and machining conditions, etc. Since the inception of different unconventional machining processes, various investigators have proposed different analytical models of material removal as functions of controllable process variables. A continual need for a comprehensive and exhaustive review of various analytical material removal models for different advanced machining processes is being felt. This paper is intended to fulfil this need in the area of advanced machining. Various analytical and some semi-empirical/empirical material removal models (approximately 40) for different mechanical type advanced machining processes have been comprehensively and exhaustively reviewed, and have been presented in a format suitable for quick reference.