Μm Depth Of Cut Research Articles

A novel method for air assisted nanosecond pulsed fiber laser beam transmission micro-channelling on thick PMMA material

The demand for scaling up polymeric materials for mass production or scaling down for microscale applications is at its peak in the modern era. Laser beam technology enables the formation of micro-channels on polymers, specifically polymethyl methacrylate (PMMA). This study examines the viability and cost-effectiveness of employing the diode pump fiber laser transmission technique to create micro-channels on thick, transparent PMMA under air-assisted circumstances for biomedical engineering and micro-fluidics applications. The analysis has included process variables such as pulse frequency, power, and cutting speed, as well as machining parameters including depth of cut, kerf width, and heat-affected zone (HAZ) width. The results of multi-objective optimization indicate that the following parameters—a pulse frequency of 51.30 kHz, a working power of 13 % of 50 W, and a cutting speed of 0.60 mm/s—contribute to the desired microfluidics response values: 12.54 µm depth of cut, 24.05 µm kerf width, and 5.98 µm HAZ width.

An application of artificial neural network and particle swarm optimisation technique for modelling and optimisation of centreless grinding process

Centreless grinding operation is widely used in manufacturing industry for its high level of accuracy and micro-finishing of shaft, pin material. This paper presents an application of artificial neural network and particle swarm optimisation techniques for modelling and optimisation of centreless grinding operation for machining of C40 steel crane-hook-pin. Full factorial design is used taking three factors at three levels each and a total 33 or 27 number of experiments are done in all possible combination of factors. The performance of this particular trained neural network has been tested with the experimental data and found satisfactory. Thus the proposed ANN model is efficiently used for predicting surface roughness in centreless grinding operation. Particle swarm optimisation technique combining with response surface modelling are used to find optimal parameter settings. The optimal parameter corresponds to 12 rpm regulating wheel speed, 1/3rd opening of coolant valve opening and 20.002 µm depth of cut.

Multiple-response modelling and optimisation of micro-turning machining parameters using response surface method

Response surface methodology (RSM) helps the engineers to raise a mathematical model to represent the behaviour of system as a convincing function of process parameters. This paper investigated the influence of three micro-turning process parameters, which were cutting speed (A), feed rate (B) and depth of cut (C). The response variables were average surface roughness ( R a ), tool wear ratio (TWR) and metal removal rate (MRR). Statistical models of these output responses were developed using three-level full factorial design of experiment. The developed models were used for multi-response optimisation by desirability function approach to obtain minimum R a , TWR and maximum MRR. Maximum desirability was found to be 86.63%. The optimised values of R a , TWR and MRR were 0.0295 µm, 0.0272, 0.098 mg/min respectively for 1101.94 rpm cutting speed, 10 µm/sec feed rate, 0.20 µm depth of cut. Optimised machining parameters were used in verification experiments, where the responses were found very close to the p...

A study on ultrasonic elliptical vibration cutting of tungsten carbide

Sintered tungsten carbide (WC) is a versatile metal matrix composite (MMC) material widely used in the tool manufacturing industries. Machining of this material with conventional cutting (CC) method is a real challenge compared to other difficult-to-cut materials. Ultrasonic elliptical vibration cutting (UEVC) method is a novel and non-conventional cutting technique which has been successfully applied to machine such intractable materials for the last decade. However, few studies have been conducted on cutting of WC using single point diamond tool (SPDT) applying the UEVC technique. This paper presents an experimental study on UEVC of sintered WC (∼15% Co) using polycrystalline diamond (PCD) tools. Firstly, experiments have been carried out to investigate the effect of cutting parameters in the UEVC method in terms of cutting force, flank wear, surface finish while cutting sintered WC. The tests have revealed that the PCD tools in cutting of WC by the UEVC method results in better cutting performance at 4 μm depth of cut (DOC) as compared to both a lower DOC (e.g. 2 μm) and a higher DOC (e.g. 6 or 8 μm). Moreover, the cutting performance improves with the decrease in both the feed rate and cutting speed in the UEVC method like conventional turning (CT) method. A minimum surface roughness, R a of 0.036 μm has been achieved on an area of about 1257 mm 2 with the UEVC performance. The CT method has also been employed to compare its cutting performance against the UEVC method. It has been observed that the UEVC method results in better cutting performances in all aspects compared to the CT method. Theoretical analysis on the UEVC method and analysis of the experimental results have been carried out to explain the reasons of better surface finish at 4 μm DOC and better cutting performance of the UEVC method.

Mechanistic Understanding of Material Detachment During Micro-Scale Polishing

A combined experimental and modeling approach has been devised to understand the material removal mechanism during abrasion of ductile copper discs. First, single grit scratch intersection experiments are conducted at the micro-scale (with 1-30 μm depth of cut). This is followed by FEM analysis. Then a simple analytical model is developed, and the model prediction is verified against experimental observations and results from numerical simulations. A characteristic material detachment length is correlated between experimental observations and model predictions. The insights gained from this exercise may be used to develop a mechanistic model of material removal in chemical mechanical polishing (CMP) of ductile materials.

Ultraprecision Diamond Turning of Glass with Ultrasonic Vibration

By applying ultrasonic vibration to a single-crystal diamond tool-tip, ductile machining of fused silica can be achieved even for 2 μm depth of cut. The increase in the critical depth of cut is significant and is a function of the ratio of vibration speed to cutting speed. Surface roughness Ra of 100 nm was obtained for up to 2 μm depth of cut.