Non-traditional Machining Research Articles

A comprehensive study of electrochemical machining of monel-400 alloy with different electrolytes: Research challenges

Electrochemical machining plays an important role in production and manufacturing industries like aircraft, atomic and healthcare. Even with difficult –to- machine materials, ECM is generally preferred to machine- nickel- based alloys like Monel 400 or Monel super alloy which consists of about 67 % Nickel and 23 % Copper. It is highly unaffected to corrosion and various acids such as sulphuric acid (H2SO4), hydrochloric acid (HCl) etc. due to which it is highly used in aerospace, oil production and refining, marine applications, industrial heat exchangers. Nowadays nickel hydroxides are major concerns which are toxic to environment present in sludge while machining nickel based alloys like Monel alloys and other super alloys need to be filtered before discharged into environment. This paper reviews the Electrochemical machining of Monel 400 alloy by various influencing parameters like applied voltage, current density, concentration of electrolyte, electrolyte pressure and type of electrolyte on material removal rate (MRR) tool wear rate (TWR) and surface roughness (SR). The study also suggests that the varying process parameters of ECM machining influence the various machining performances such as material removal rate (MRR) tool wear rate (TWR) and Surface finish (Ra) for Monel 400 alloy. In a recent study which utilized meta-heuristic algorithms (MFO and GWO) helped in increasing MRR by 0.242 g/min and Nickel presence by 57.72 PPM while machining Monel 400 and hence a better machining performance is obtained. The paper also aims at addressing the latest developments in machining Monel alloy as compared with conventional methods of machining and its various research challenges for further developments in non-traditional machining processes.

EFFECT OF ZINC COATED BRASS AND LN2 COOLED ZINC COATED BRASS ELECTRODES IN WEDM PERFORMANCE ON INCOLOY

Due to their superior mechanical qualities, such as corrosion resistance and carburization resistance, particularly at high temperatures, nickel-based superalloys are being used more often in the aviation, marine, and nuclear industries. Because of their great strength, low heat conductivity, and strain hardening properties, nickel-based superalloys are particularly difficult to process conventionally. Wire electric discharge machining, one of the non-traditional machining techniques, is utilised in this study to cut Inconel 800. (Incoloy). Wire cut EDM uses electrodes made of zinc-coated brass wire that have been cryogenically chilled. The RSM approach is used to arrange trials using Servo voltage and Wire feed as constant variables and Wire tension, Pulse on time, and Wire feed as changeable factors. In order to maximizes responses, lower is better and higher is better criteria are used to assess material removal and surface roughness for zinc-treated brass and cryogenically chilled (LN2) zinc-treated brass.

Optimization and Prediction of Process Parameters during Abrasive Water Jet Machining of Hybrid Rice Straw and Furcraea foetida Fiber Reinforced Polymer Composite

In the last few decades, natural composite materials have been considered one of the highly sustainable ecological alternatives for reducing the consumption of synthetic materials. Today, research on natural fiber composites is the main thrust for their use in various industrial applications. Further, continuous research works are being carried out to utilize natural composites as an alternative to synthetic materials. However, the inhomogeneity of composites, delamination, fiber pullout, higher surface roughness (SR) and dimensional inaccuracy under traditional machining have led the attention towards non-traditional machining, such as abrasive water jet machining, to achieve high-quality components. Hence, in this study, an experimental analysis based on the design of experiments is conducted on the machinability of a hybrid rice straw/Furcraea foetida composite under abrasive water jet machining (AWJM). Further, the concentration of the rice straw and the AWJ process parameters are varied, and their effects on the quality of machining is evaluated. The experimental trials are designed based on the Taguchi L27 orthogonal array, followed by an analysis of variance (ANOVA). From extensive experimentations, the concentration of rice straw is observed to be the most contributing (93.5%) factor to the SR. The traverse speed (TS) shows the highest percentage contributions of 93.13%, 55.50 and 55.70% to the material removal rate (MRR) and the top (TKW) and bottom kerf widths (BKW), respectively. However, the interaction between the fiber concentration and traverse speed gives the maximum contribution (35.04%) to the kerf taper (KT). A second-order response surface model is generated to study the effects of the process parameters on the SR, MRR, TKW, BKW and KT in any experimental domain. Finally, the microstructural characteristics of the machined surfaces, such as micro-cracks, debonding, and fiber pullout, are discussed.

Optimization of wire-EDM process parameters for Ni–Ti-Hf shape memory alloy through particle swarm optimization and CNN-based SEM-image classification

Shape memory alloys (SMAs) have the unique ability to regain their shape under specified conditions, making them extremely useful for a wide range of applications. However, non-traditional machining techniques could be more effective for high-temperature SMAs as they provide better shape recovery properties than conventional methods, necessitating this study's unconventional wire electric discharge machining procedure. The surface morphology of Ni–Ti-Hf-based alloys was examined using scanning electron microscopy. A convolutional neural network model was used to categorize SEM images based on the material removal rate, utilizing the pixel intensity histogram of the processed images. The study discovered that the material remelted as the discharge energy increased, leaving lumps and globules on the surface. The size of debris lumps, pores, and globules increased with increasing Ra values. Moreover, widening the inter-electrode gap by expanding the servo-voltage facilitated efficiently removing debris from the machined site. The TOPSIS method for particle swarm optimization was employed to find the optimal solutions, yielding TON = (124.239, 116.228), TOFF = (54.532, 40.781), Servo voltage = (36.216, 43.766), and Wire-Feed = (2.157, 8). These results were validated through experimentation, with minimal error percentages of 2.01%, 2.046% (MRR), and 3.86%, 1.611% (Ra) for both sets of input parameters, respectively.

Front Matter

Message from the General Chair Ladies and Gentlemen,Good morning!Welcome to Xi’an to participate in the 2023 International Conference on Non-Traditional Machining and Intelligent Manufacturing. On behalf of the 24,110 teachers and students of Xi’an Technological University, I would like to extend a warm welcome to the researchers and scholars from all over the world and congratulations on the successful conference.It is a great pleasure to see so many scholars attending this conference; I sincerely welcome all scholars to attend the annual academic conference. NTMIM is a high-level international forum for engineers and scientists to state their innovative ideas and research results. It is also a multi-track international forum for academics, practitioners and research students to exchange their ideas, techniques, methods, and applications for the latest technology.This is the fourth session and it has been a series conference every one or two years. For this conference, it solicits high-quality papers in the following disciplines: Non-Traditional Machining Technology, Intelligent Manufacturing, Mechatronics and Control Engineering, Special Processing Technology. The conference had received nearly 200 manuscripts; the quality of the papers received at this time was significantly higher than the last and accepted 48 papers after two rounds of double-blind reviews. The acceptance rate is about 24%.The conference is mainly organized by Xi’an Technological University and State and Provincial Joint Engineering Research Center of Precision and Ultra-Precision Machining and Measurement, Located in Xi’an, China, supported by the College of Engineering, Design and Physical Sciences, Brunel University London, UK, University of California, Merced (UCM), USA, Missouri Western State University, USA, James Cook University, Australia, University of Huddersfield UK, and many other world-class universities. Without the support of these universities, the conference would not have been held successfully. On behalf of the conference general Chair, I would like to say thank you.Xi’an is an ancient capital with a history of 3,000 years. It is a place where scholars exchange technologies and travel is full of beauty. I believe that our meeting will convey friendship, exchange academic views and communicate the future. Just like the theme of the conference, Cooperation! Exchange! Communication! Welcome to Xi’an.Ph.D. Zhao XiangmoProf. and President of Xi'an Technological University, ChinaDirector of 111 Project on Information of Vehicle-Infrastructure Sensing and ITS, China.List of Sponsors name list and individual logos, Message from the Program Chair, Organizing Committee, Optional Additional Front Matters are available in this pdf.

Optimization of process parameters in wire electrical discharge machining using teaching learning based optimization

The Un-Conventional or Non-Traditional machining process is aimed to produce products at right quality. WEDM (Wire electrode discharge machining) is unconventional advanced machining technique for better accuracy. In WEDM a thin wire is used to remove the material from the work piece through electrical spark. Parameters optimization plays a major role in machining process to achieve better quality. In this paper, a technique TLBO (teacher and learner based optimization) was used to parameters optimization in WEDM process of high speed steel (HSS) plates. Experimental values were taken from Sivanaga Malleswara Rao et al. (2017) article..

Optimization of process parameters on wire cut electrical discharge machining and surface integrity studies of AA6070/MgO composites

There are a variety of uses for metal matrix composites (MMC), including the aerospace and automotive industries. Because of their benefits including light weight and inexpensive cost, they are popular. Wire cut electric discharge machining (WEDM) stands out as a great option for creating complex or complicated shapes out of composite materials, especially when compared to other common non-traditional machining processes. An AA6070 metal matrix composite containing 5% and 10% MgO weight fraction (wt) was made using the stir casting method in this work. Various process factors, such as wire tension (WT), dielectric pressure (Pd), gap voltage (Vg) and peak current (IP) are taken into account when the AMMC specimen is machined utilising WEDM. Slot machining rate (MR) and surface roughness (Ra) can be measured and assessed using L18 mixed Orthogonal Array (OA) investigations. Experiments are examined using TOPSIS and ANOVA methodologies for order preference based on similarity to the ideal results (ANOVA). Analysis has shown that the best mixture of processing factors for improved MR and Ra: wt = 5%, vg = 50 V, WT = 13 g, Ip = 9 A, and Pd = 15 bar. Machining Rate and Ra have ideal process parameters of 1.5 mm/min and 3.648 m. ANOVA shows that MR and Ra are significantly influenced by peak current.

Investigation of mechanical properties and microstructure characteristics on ultrasonic metal welding of aluminum alloy 8011 sheets

The non-traditional machining processes are widely used to manufacture geometrically complex and precision parts for the aerospace, electronics, and automotive industries. In which, the ultrasonic welding technique can be used for welding various materials ranging from metals to non-metals and composites with minimum processing time and cost. The present work is to understand the workings of the ultrasonic metal welding process as well as to determine the best welding parameters, such as weld pressure and time for three different thicknesses aluminum sheets using the design of experiment approach. Based on the experimental design, a series of experiments are conducted using L27 orthogonal array and a data collection system tensile testing equipment was used to compute the weld strength for each specimen. The highest weld strength of thickness 0.1, 0.2, and 0.3 mm are 98.2 MPa, 98.38 MPa, and 90.23 MPa respectively. Also, the relation between weld strength and grain area is observed using microstructural analysis. Grain area often decreases as weld strength increases. The coefficient of multiple determination is used to validate the findings of experimental work, and it shows that the results are good.

The m-polar fuzzy set ELECTRE-I with revised Simos’ and AHP weight calculation methods for selection of non-traditional machining processes

Using improvements to the recently published m-polar fuzzy set (mFS) elimination and choice translating reality-I (ELECTRE-I) approach for calculating criteria weights, the selection of a Non-Traditional Machining (NTM) process problem from the industry is solved in this research. The criteria weights for the m-polar fuzzy ELECTRE-I method are evaluated using the Analytical Hierarchy Process (AHP) approach and the Revised Simos' method. For the ELECTRE family's criteria weight calculations, the Simos’ approach has been revised. Many researchers calculated the weight of the criteria in the selection of the NTM process using the AHP approach. Problems with both physical and intangible properties can be solved using the m-polar fuzzy ELECTRE-I approach. Additionally, it has the ability to solve MCDM issues with more variables. The improved Simos' technique is used in this work because it incorporates user choices for the criteria, or user voting for the criterion. Using expert assistance, the AHP technique prioritizes the criterion based on pair-by-pair comparisons of the criteria. The AHP approach makes compromises between the criteria. The ultimate selection of the process based on the needed aim is affected by both tangible and intangible features in the NTM selection dilemma. The impact of criteria weight techniques on the choice of the NTM process is examined using a single dimensional sensitivity analysis. AHP approach is proven to be less stable for criteria weight variation than the improved Simos' weight calculation method. The updated Simos' method, which takes into account user preferences, performs better for the m-polar fuzzy ELECTRE-I algorithm than the AHP weight calculation method.

Process Parameter Optimization of Abrasive Jet, Ultrasonic, Laser Beam, Electrochemical, and Plasma Arc Machining Processes Using Optimization Techniques: A Review

<div>A comprehensive literature review of the optimization techniques used for the process parameter optimization of Abrasive Jet Machining (AJM), Ultrasonic Machining (USM), Laser Beam Machining (LBM), Electrochemical Machining (ECM), and Plasma Arc Machining (PAM) are presented in this review article. This review article is an extension of the review work carried out by previous researchers for the process parameter optimization of non-traditional machining processes using various advanced optimization algorithms. The review period considered for the same is from 2012 to 2022. The prime motive of this review article is to find out the sanguine effects of various optimization techniques used for the optimization of various considered objectives of selected non-traditional machining processes in addition to deemed materials and foremost process parameters. It is found that most of the researchers have more inclination towards the minimization of Surface Roughness (SR) compared to the maximization of the Material Removal Rate (MRR) as their objective function for AJM and PAM. Similarly, for USM and ECM, researchers are more inclined towards the maximization of MRR compared to the minimization of SR. Minimization of the Heat-Affected Zone (HAZ) and SR are the two most considered response parameters for the LBM and its allied processes. This study provides ready-to-use details on the use of various advanced optimization techniques for AJM, USM, LBM, ECM, and PAM, with the considered workpiece material, process parameters, and imposed limitations. This review work is carried out on such a large scale that it will help future researchers and industrialists to decide their research direction.</div>

Simultaneous optimization of wire electric discharge drilling responses

Trepan drilling with wire electrical discharge machine is performed to make macro size hole in tool steel. Electrical discharge drilling is thermal energy based non-traditional machining process. In this process metal removes from the work is due to melting phenomena. In present study L9 orthogonal array approach is used for the drilling experimentation. Pulse on time, pulse off time, wire feed and current are elected as machining parameters. After experimentation surface quality and material removal rate are considered as responses of drilled hole. Grey relational technique is used to determine the optimum level of machining parameters for drilled hole quality responses. Wire feed is found significant factor followed by pulse off time, pulse on time and current for the combined responses.

Investigation study of electrical discharge machining parameters on material removal rate for AISI M2 material

EDM (Electrical Discharge Machining) is a common non-traditional machining technique for manufacture geometry parts made of intricate or extremely rigid metals that are challenging to manufacture using conventional manufacturing techniques. Electrical discharge machining by utilizing electrical discharge erosion, classify the meaning of material removal (MR). This paper's main objective is to discuss the ideal EDM parameters in order to use high-speed steel as workpiece AISI M2 and with using brass & copper as electrodes. Pulse on-time are (100, 150, and 200 µs), Current (10, 24 and 42 A) and Pulse off-time (4, 12 and 25 µs) are the input parameters effect on the material removal rate (MRR) used in the experimental work. The present study's findings shown that the highest MRR with using copper & brass as electrodes with pulse on-time 200 µs, pulse off-time 12 µs and current 42 A, at (0.31284 g/min and 0.18769) respectively, and the lowest average value of the removed material was when evaluating current 10 A, Ton is 100 µs, Toff is 4 µs, at (0.05451g/min and 0.01898 g/min) respectively.

Performance of magnetized tool in electrochemical micromachining on scrapped alloy wheel matrix composite

Hybrid machining processes play an important role in traditional and non-traditional machining processes. Addingthe magnetic field effect in electrochemical micromachining (ECMM) improves the machining efficiency and accuracy of the micro-hole machined. The process parameters, namely, voltage,duty cycle and electrolyte concentration,wereused as input parameters, while machining rate (MR) and overcut (OC) are performance measures considered in this research. The workpiecewasa scrapped alloy wheel matrix fabricated with a stir-casting process reinforced with alumina (Al2O3). The EDAX and SEM image study was performed to understand the composition and surface quality of the machined workpiece, respectively. The micro-hole without magnetic field effect was also conducted to under­standthe possible advantageof magnetic field appliedin ECMM.

The m-polar fuzzy ELECTRE-I integrated AHP approach for selection of non-traditional machining processes

In the literature, there are a number of decision-making strategies that can be used to choose the best NTM processes. Chen (Citation2014) introduced a novel method to handle fuzzy data that includes multipolar uncertainty, referred to as the m-polar fuzzy set (mFS) approach. The mFS method, along with other multi-criteria decision-making (MCDM) techniques, is a good way to choose between options. An illustration of such a combination is the mFS elimination and choice translating reality-I (ELECTRE-I) . A criteria weight approach is also needed to increase the accuracy of the mFS ELECTRE-I method. The mFS ELECTRE-I method and the analytical hierarchy process (AHP) criteria weight calculation method are combined in the current work. The unique thing about this method is that it can be used to solve both MCDM and MCGDM problems by combining the mFS ELECTRE-I with the AHP criteria weight method. A single-dimensional weight sensitivity analysis is performed to confirm the technique’s stability for different criterion weights for the AHP method on alternative rank performance. The results of the NTM process selection are validated by previous research findings. EDM turned out to be the best way to create machine precise holes on duralumin alloy, and ECM turned out to be the best alternative to generate the surface of revolution in stainless steel. A C++-based soft solution that uses the mFS ELECTRE-I technique to analyze various MCDM and MCGDM problems has been developed. With the soft solution, you can fix problems with selecting the FMS, the robot, and so on.

A review of electrical discharge machining (EDM) and its optimization techniques

Non-traditional machining processes replace outdated manufacturing processes for machining hard metal matrix composite materials. Electrical Discharge Machining (EDM) is a non-conventional process that carries out machining depending on the materials’ thermal conductivity, melting point and electric resistivity. Stainless steel is used to produce nearly half of the world’s production units, and this process ensures the machining of stainless steel effectively. Various EDM processes are used to carry out various machining processes, which otherwise would not have been possible by any other machining operation. This paper provides an insightful review of existing literature, focusing on the techniques and associated parameters. In particular, input parameters, such as peak current, pulse on time, and pulse off time, are studied, along with the effect of dielectrics against the output parameters, such as metal removal rate and surface rudeness. Researchers in the past intensely focus on tool wear ratio. From this review, it is evident that researchers emphasized the material removal rate, surface finish and marching efficiency of the process under consideration.Besides, it is concluded that researchers did not seem to emphasize on study of different optimization techniques in this regard.

A Short Review on AWJM of Natural Fibre Reinforced Composite Materials

A composite is a solid material created by combining two or more different substances, each with its own set of qualities, to create a new substance with properties that outperform the original components for a specific use. Currently composite materials are widely applied across various fields due to its superior properties. The fibre reinforced composites being light in weight, and high strength are replacing metals in many applications. Nowadays, more focus is paid in developing sustainable and environment friendly materials without compromise in the quality. This reason led to the development of Natural Fibre Reinforced Composite (NFRC) materials, which is gaining more attention towards them. Though many NFRCs were developed, machining is a very big challenge. Compared to the traditional machining processes, the non-traditional machining process is proved to be recommendable for machining NFRC materials. In this article, the numerous research endeavors carried out in machining of NFRCs using Abrasive Water Jet Machining (AWJM) process is reviewed. This article describes the different parameters considered in AWJM process and their influence over the machining characteristics of NFRCs. Based on the different research carried out, the use of nanofillers in the right composition is expected to increase the performance of the AWJM process over NFRCs.

State of the Art in Power Supply of Electrical Discharge Machining, Electrochemical Machining and their Variants

Power supply is the indispensable component for stable non-traditional machining based on electric power, such as electrical discharge machining (EDM), electrochemical machining (ECM), EDM-ECM combined machining, and EDM-ECM hybrid machining. The properties of power supply have significant effects on the machining performance, including efficiency, accuracy, and surface quality. This paper reviews the research progress and technical application in power supply of EDM, ECM, EDM-ECM combined machining, and EDM-ECM hybrid machining. The circuit principle, performance index, process effect of power supply are systematically analyzed. Moreover, the applications are summarized, and the future development are prospected.

Modeling of laser-assisted micro-milling

The difficulties in the mechanical micro-machining process regarding the tool deflection, size effect and tool wear are much more pronounced than those in mechanical macro-machining. However, the role of mechanical micro-machining cannot be overestimated as an alternative against the non-traditional machining methods in manufacturing complex micro-parts with high dimensional and geometrical accuracies. Laser-Assisted Machining (LAM) can be used as a promising method by reducing the cutting forces and providing the possibility of increasing the Material Removal Rate (MRR) to enhance the productivity of mechanical micro-machining of difficult-to-cut material. Unlike common LAM, the parts are structured before machining using the ultra-short pulsed laser, followed by removing some parts of the material and consequently changing uncut chip thicknesses at the machining process. A model has been developed to understand how the structuring of the parts before micro-milling affects the uncut chip thicknesses at the micro-milling process. The model includes a variety of input parameters in terms of structure, tool, and process parameters to investigate this novel LAM comprehensively. Based on model results, the uncut chip thicknesses are reduced through the structuring of the part. The structure density was found as the most crucial parameter in uncut chip thickness reduction. The influence of structure density on cutting force reduction was also studied in the experiment. Workpieces made of titanium alloy (Ti6Al4V) were structured using a pico-second laser at different structure densities. The structured parts were machined at two feeds of 10 and 50 µm/tooth with a 35 m/min constant cutting speed. Structure density's role in reducing cutting force was also considerable. In addition, the contribution of different factors affecting cutting force reduction in this novel LAM process is discussed.

Micromachining of predesigned perpendicular copper micropillar array by scanning electrochemical microscopy

Because the electrochemical reactions can occur gently at normal temperature and pressure, electrochemical micromachining (ECMM) is an important nontraditional precision machining technique free of tool wear, heating effect, residual stress, surface and subsurface damage, comparing with the ultra-precision milling, electrical discharging machining, laser beam machining, etc. Although scanning electrochemical microscopy (SECM) has been proven powerful in ECMM, it is difficult to fabricate the predesigned perpendicular microstructures because of the inhomogenous potential distribution, the complex electrode reaction kinetics and the interfacial mass transfer processes. Here we succeeded in fabricating the copper micropillar arrays by combining the SECM direct-writing mode and the ultrashort voltage pulse (USVP) modulations. The machining accuracy and efficiency are affected by multiple technical parameters, including the amplitude, the period and the duty cycle of the USVP modulations, the components and concentration of the electrolyte solution, the tip-substrate distance, the motion mode of the tool electrode, etc. By employing multiple parameters central composite experimental designs, we succeed in optimizing the technical parameters and avoiding the complexities of electrode processes. The results demonstrate the powerful capability of SECM in the controllable micromachining of the perpendicular metallic microstructures.

Review of Research Progress in Nontraditional Machining of Ultrahigh-Temperature Ceramic Matrix Composites

Ultrahigh-temperature ceramic matrix composites are currently among the most promising high-temperature-resistant materials, owing to their high-temperature strength, high-toughness and excellent corrosion resistance; they are widely used in national defense and aerospace fields. However, it is a difficult material to machine, and high precision is difficult to achieve using traditional machining methods. Nontraditional machining methods are not constrained by material physical and mechanical properties, and good surface quality is easily obtained, which is an important direction in the field of ultrahigh-temperature ceramic matrix composites. This paper summarizes the recent nontraditional machining methods utilized in the fabrication of ultrahigh-temperature ceramic matrix composites. Firstly, various nontraditional machining methods for ultrahigh-temperature ceramic matrix composites based on borides, carbides and nitrides are reviewed, and the machining performances under different machining conditions are compared. Subsequently, the problems and challenges of ultrahigh-temperature ceramic matrix composite nontraditional machining are summarized and discussed. Lastly, the future development path of nontraditional machining methods for ultrahigh-temperature ceramic matrix composites is summarized and predicted.