Surface Finish Research Articles

Experimental Analysis of Spiral Finishing Process on EDM Drilled Hole in Titanium

It is quite evident that some of the experimental research works have been carried out by researchers in the area of spiral polishing using abrasive for surface finishing improvement but most of the experiment has been employed on Steel or Alloy Steel as a material. Very few number of research works have been performed by researchers across the globe on the Spiral Polishing Method of Titanium holes made by Electrical Discharge Machining (EDM). Therefore, experimental investigations were carried out in the area of Spiral Polishing and Finishing of EDM-drilled holes of various materials to meet the desired goal of demands on the surface quality. This experimentation aims to develop a novel method with spiral polishing using abrasive flow finishing. To explore the search investigation and find out the better surface finishing for through holes made on EDM, the process parameters have been designed using the Taguchi L16 orthogonal array with input parameters such as Current (I), Pulse on time (Ton), and Pulse off time (Toff). The addition of Boron Carbide Powder with Handwash, Glycerine, Shampoo, and Liquid Soap is used to decrease the Surface Roughness (Ra) with a ratio of 5 : 1. The Taguchi technique is used to assess the P/M process parameter setting for a given signal to noise (S/N) ratio.

Surface finish enhancement in fused deposition modeling of PLA using chloroform: a comprehensive characterization study

Surface finish enhancement in fused deposition modeling of PLA using chloroform: a comprehensive characterization study

PERFORMANCE EVALUATION AND ECONOMIC ASSESSMENT IN ELECTRICAL DISCHARGE MACHINING OF SS316 USING GRAPHITE POWDER DISPERSED IN BIODEGRADABLE PALM OIL DIELECTRIC

In today’s rapidly evolving manufacturing industry, researchers and engineers are constantly seeking innovative methods to improve machining processes. One such area of interest is the use of electrical discharge machining (EDM) for difficult-to-machine metals like SS316. This research compares the performance and economic aspects of traditional EDM and powder-mixed EDM when machining SS316 using copper electrode. Graphite powder dispersed in biodegradable palm oil is investigated as a dielectric media with the aim of enhancing EDM performance. According to the findings, the analysis of the cutting performance of different machinability aspects revealed that using graphite powder mixed with palm oil as a dielectric in EDM outperformed conventional EDM relating to material removal, surface finish, surface hardness, electrode wear rate and hole overcut. The flushing condition and unique properties of graphite powder and palm oil, such as cooling, and thermal conductivity, contributed to the improved performance observed in EDM processes. These findings highlight the potential of graphite powder mixed with palm oil as a promising alternative dielectric in EDM, offering enhanced machining capabilities and improved surface quality. The total machining expenditure per part under PMEDM (INR 505.50) is lowered by 9.2% than expenditure under conventional EDM (INR 525). The surface microhardness of the machined component attained using graphite powder-mixed EDM is enhanced in comparison to that achieved using standard EDM due to the creation of a carbon-rich re-solidified layer.

Long‐time high‐pressure processing of a patatin‐rich potato proteins isolate: impact on aggregation and surface properties

SummaryIn this study, a 4% (w/w) dispersion of a commercial patatin‐rich potato protein isolate (Po‐PI) was pressurised at 400 MPa up to 48 h at 20 °C. Protein aggregation induced by high‐pressure processing (HHP) was followed by dynamic light scattering, intrinsic fluorescence (in‐situ or ex‐situ) or SAXS analysis. Surface properties (surface hydrophobicity and interfacial properties) of the HHP‐induced aggregates were also investigated. A gradual dimer dissociation/protein unfolding was observed under pressure. Po‐PI exhibited a slow relaxation time under pressure. Long‐time HHP (>4 h) induced significant modification of the Po‐PI protein structure with partial non‐reversible unfolding. After 48 h of pressurisation at 400 MPa, large aggregates (160 nm) were obtained and a monomodal distribution in intensity and in number frequency was observed indicating a controlled aggregation. Up to 24 h of pressurisation at 400 MPa, intermediate states were obtained after high‐pressure release. SDS‐PAGE profiles showed that HHP‐induced aggregation of Po‐PI was driven by non‐covalent interactions. All high‐pressure processed dispersions displayed a higher surface hydrophobicity as compared to non‐treated Po‐PI. Po‐PI dispersion treated for 8 h at 400 MPa presented the lowest adsorption rate, the highest final surface tension and formed the most rigid interfacial film. Po‐PI showed resistance to moderate pressure levels (400 MPa) and long pressure application times were required to induce significant protein denaturation/aggregation (≥24 h) and to optimally modify its interfacial properties (8 h).

Five-Axis Finish Milling Machining for an Inconel 718 Alloy Monolithic Blisk

Blisks subjected to rough machining for channel creation must undergo finishing processes, and such processes must achieve the required tolerance limits. A high-quality surface finish and predictable long tool life are critical for the finish milling of blisks. Accordingly, the aim of this study was to optimize parameters for the finish machining of an Inconel 718 alloy monolithic blisk. Ball-cone mills were used to machine the blade surface at a constant depth. A sensory tool holder was used to collect cutting force signals during machining, and a digital microscope was used to examine tool wear. The surface texture measuring instrument was used to measure blisk blade surface roughness to evaluate processing quality. This study manipulated two cutting parameters, namely cutting speed and feed per tooth, and investigated their effects. The relationship between cutting conditions and machining efficiency was analyzed. According to the experimental results, we identified a set of optimal parameters at effective cutting speeds of 46.53 m/min, feed per tooth of 0.1 mm/tooth, and depth of cut of 0.05 mm for marginal tool wear and fast cutting speeds. Then the corresponding tool life was estimated by using the derived parameters.

Enhancing surface integrity and performance of EDM with sustainable dielectrics and electrode modifications

A common non-traditional method for precise machining of hard materials is electro-discharge machining (EDM). The efficiency and surface quality in the EDM process are decided by the design and type of the electrodes. Because of its lightweight, cost-effectiveness and easy machinability, aluminium is employed in a wide range of applications. In this work, AlSi10Mg electrodes are manufactured by different processing routes such as 3D printing, casting, and extrusion. Different characterization techniques are carried out to determine the mechanical, electrical, and thermal properties of all differently processed aluminium alloy electrodes. The processing route influence during the EDM of Ti-6Al-4V is evaluated with different levels of operating parameters using conventional EDM oil and lemon peel biodiesel as dielectrics. The experiments are performed with 3 different levels of current (Ip) and pulse on time (Ton) with a constant voltage. The output responses viz. material removal rate (MRR), Tool wear rate (TWR), average surface roughness (Ra) and white layer thickness (WLT) are considered to compare the EDM performance exhibited by differently processed aluminium alloy electrodes. The 3D printed aluminium alloy electrode produces about 23% less TWR and 18% improved surface quality than the conventional (extruded) electrode. The performance exhibited by the cast aluminium alloy electrode is sub-optimal when compared to electrodes processed by the other two routes. The microscopic examination revealed that WLT could be reduced to the extent of about 29% and 39% with 3D printed AlSi10Mg electrodes when compared with extruded and cast electrodes. The present study concluded that a 3D printed electrode with lemon peel dielectric is the most preferable combination for high surface finish operation.

Experimental Investigation and Optimization of Coaxiality Error Analysis with CNC Turning Process on Delrin for Assembly Fit

This paper mainly deals with the machining operation like turning operation, Material Removal Rate and Surface Roughness are the important parameter which is to be considered for quality product. The material selected for the experiment is DELRIN 500. Turning is one of the important processes that is widely used to create cylindrical components and it is also used for surface finish the product to make it smooth. Nowadays, plastic materials are widely used for making variety of components. To make a component with high dimensional accuracy, turning operation is used. The main concerns of turning are tooling cost and the effect of process on machinability characteristics. It can be seen that the output responses value has a minimum roughness average and a high degree of geometrical quality precision. High degree surface finish is induced by medium speed, feed rate, and small nose radius. The coaxial error was minimized by using medium speed, feed and larger nose radius. Experimentally found that third specimen (RPM -750) (FEED -0.08 mm/Rev) and (NOSE RADIUS 0.8) obtained minimum geometrical error along with minimum Surface roughness. Delrin is a crystalline plastic that offers an excellent balance of properties that bridge the gap between metals and plastics. Delrin possesses high tensile strength, creep resistance and toughness. It also exhibits low moisture absorption

OPTIMIZATION OF CUTTING PARAMETERS TO ENHANCE SURFACE FINISH

The Objective of this project work is to Productivity and Surface finish improvement in CNC Die and Punch machining through optimization in cutting parameters. This technical paper studies the different machining parameters i.e. DOC, cutting feed and cutting speed by using different material cutters like cemented carbide cutters, HSS cutters, Insert types cutters. In this thesis an attempt to make use of Japanese optimization technique to optimize cutting parameters during high-speed milling of aluminum alloy using cemented carbide cutting tool.

Effects of surface finishes, heat treatments and printing orientations on stress corrosion cracking behavior of laser powder bed fusion 316L stainless steel in high-temperature water

Stress corrosion cracking (SCC) of laser powder bed fusion 316 L stainless steel in oxygenated high-temperature water environments with chloride addition at 288 °C was studied. The influences of surface finishes (as-built, mechanically polished, Hirtisation® and shot peened), heat treatments (solution annealing at 1066 and 1150 °C and hot isostatic pressing) and the printing orientations on SCC were evaluated. Hirtisation resulted in a lower SCC susceptibility than as-built or polished surface while shot peening showed the lowest apparent SCC resistance. A high annealing temperature decreases SCC resistance. The effect of printing orientation is material and environment dependent.

Effect of metallic substrate and rubber elastic materials over passive constrained layer damping on tool vibration during boring process

Tool vibration is a key factor that affects surface finish, generates noise, and reduces the tool life during conventional boring because of the excessive overhanging length of the tool holder. The interaction between the dynamics of the machine tool and the boring process led to progressive vibration. The creation of appropriate mechanisms in reducing tool vibration will help manufacturing industries to become more productive. In this research, in order to control vibration in the overhanging boring bar, a passive vibration control method was employed. Constrained layer dampers consist of boring bar, substrate, and elastic materials and it is used to minimize tool vibration produced during boring operation. The investigation utilized computational analysis through the ANSYS Workbench platform, employing key parameters such as the overhanging length of the tool holder (100, 150, and 200 mm), substrate material (aluminum, brass, and copper), and elastic material (Nitrile rubber, Natural rubber, and polyurethane). A comprehensive series of 27-run boring experiments were conducted to assess the impact of the constrained layer damper on tool vibration and cutting properties. The results of the study revealed remarkable improvements in various performance metrics. The constrained layer damper demonstrated an impressive 98% reduction in tool vibration, signifying its efficacy in dampening vibrational forces during the boring operation. Furthermore, a substantial 83% decrease in surface roughness was observed, indicating enhanced machining precision and surface finish. The constrained layer damper also exhibited a noteworthy 97.5% reduction in tool wear, highlighting its ability to significantly prolong tool life under challenging machining conditions.

Comparison of STP and TP Modes of Wire and Arc Additive Manufacturing of Aluminum–Magnesium Alloys: Forming, Microstructures and Mechanical Properties

Aluminum–magnesium (Al–Mg) alloys, known for their lightweight properties, are extensively utilized and crucial in the advancement of wire and arc additive manufacturing (WAAM) for direct high-quality printing—a focal point in additive manufacturing research. This study employed 1.2 mm ER5356 welding wire as the raw material to fabricate two sets of 30-layer thin-walled structures. These sets were manufactured using two distinct welding modes, speed-twin pulse (STP) and twin pulse (TP). Comparative evaluations of the surface quality, microstructures, and mechanical properties of the two sets of samples indicated that both the STP and TP modes were suitable for the WAAM of Al–Mg alloys. Analyses of grain growth in the melt pools of both sample sets revealed a non-preferential grain orientation, with a mixed arrangement of equiaxed and columnar grains. The STP mode notably achieved a refined surface finish, a reduced grain size, and a slight increase in tensile strength compared to the TP mode. From the comparison of the tensile data at the bottom, middle, and top of the two groups of samples, the additive manufacturing process in the STP mode was more stable.

Design and Fabrication of Recycling Non Bio Degradable Materials Into Products

This project focuses on recycling non-biodegradable materials to help the environment from global waste and pollution. It investigates methods to transform non- biodegradable materials into new products, aiming to reduce environmental damage caused by solid waste. It will select specific solvents that match the type of plastic to make recycling more effective. The combination of mechanical and chemical operation is used for achieving the objective of the project. The shredder machine is used for mechanical operation and the acetone solvent is used for chemical operation. The process starts with collecting plastic materials and sorting them manually based on their properties. The sorted materials undergo various stages. The waste materials are cleaned with water and crushed using a shredder machine. Chemical treatment (acetone) is used to dissolve the crushed pellets. The acetone takes 2-3 hours to react with the plastic. After this period, the waste materials transition into a semi-solid stage. In this stage, some adhesive materials are mixed with the dissolved plastic to improve the bonding strength and surface finishing of the final product. The semi-solid plastic is then fed into a die for the development of new products such as table bushes and door handles. The solvent added to the plastic is evaporated after 30 minutes of drying in sunlight. After the evaporation of acetone from the die, the final product is obtained. The final specimens undergo mechanical testing such as hardness test, tensile test and compression test. By utilizing a shredder machine and acetone, this project demonstrates how non-biodegradable materials can be turned into useful products, helping to reduce waste and protect the environment

Evaluation Approach for Residual Stress in Drilling of Aluminum Alloy

Residual stress is one of the critical evaluation factors as well as machining accuracy and surface finish in cutting. From the perspective of the fastening strength of parts, residual stress in drilling has an influence on the product or part life. Especially in the aircraft manufacturing, the tensile residual stress is crucial as it can cause major accidents. However, few studies have focused on residual stress in drilling so far. Most of them investigated the characteristics of residual stress based on the experimental data. This paper discusses residual stress in drilling in terms of its mechanical effect. The residual stresses in the inner surfaces of holes were measured in the depth direction from the top of the plate. The change in the residual stress has good correlation with the chip flow direction and the load applied to the inner surface, which acts as a counter force to the cutting force near the outermost ends of the lips. The cutting force is determined using an analytical model based on the minimum cutting energy. The correlation between the residual stress and the direction of the load applied to the inner surface depends on the margin width and back taper on the peripheral sides of a drill. The effect of the margin contact on the residual stress is characterized by linear regression analysis. Finally, an analysis-neural network hybrid system was developed to estimate the residual stresses in drilling. In the system, the mechanical effects of the drilling process, which are the magnitude and direction of the load applied to the inner surface, are obtained through analytical simulation. Meanwhile, the margin effects are expressed as the coefficients in the linear functions, which are associated with the margin width and back taper angle by a neural network. Then, another neural network, working as a post process, estimates the residual stresses using the information of mechanical and margin effects. The developed system is validated by presenting a comparison between the estimated and the actual residual stresses.

Design and Development of Pneumatic Sheet Metal Cutting Machine

It is important to note that in today's industrial era, sheet metal is cut and bent into a variety of shapes to obtain better surface finish and flexibility in manufacturing processes. The use of modern techniques, such as pneumatic sheet cutting machines, has greatly improved the efficiency of sheet metal cutting and bending processes. This review focuses on the reliability, performance, and design simplification of pneumatic sheet cutting machines. Additionally, it examines the energy lost in the pneumatic cylinder while it imparts force on the cutting blade. The energy efficiency of pneumatic and compressed air systems is a critical aspect in the development of sustainable production. The objective of this cross-discipline review is to provide production and life cycle engineering researchers with an update on the state of the art in energy efficiency for pneumatic production and associated compressed air infrastructure.

Comparative analysis of modern technologies of additive production

In today's conditions, 3D printing is used to create unique models, prototypes, and equipment necessary for conducting experiments and studying various phenomena and processes, for the rapid prototyping of various parts and devices in scientific and engineering research. 3D printing technologies are actively used to create individual medical implants, prostheses, and organ models for training and planning operations, which significantly improves the quality of medical care. In the aerospace and automotive industries, additive manufacturing is used to create lightweight and durable parts helping to reduce weight and improve vehicle efficiency. The use of additive manufacturing methods, technologies, and tools allows you to check and test designs and concepts before mass production. In this work, a detailed analysis of various existing 3D printers is carried out depending on the tasks, and modern technologies of additive manufacturing are investigated depending on the set goals and scientific and applied tasks. Such technologies include Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, and Digital Light Processing. In the work, a comparative analysis of these technologies was carried out according to various criteria, such as principle of operation, materials, resolution, surface finish, accuracy, speed, strength, application, cost, complexity of parts, and post-processing. For each technology, the advantages and disadvantages of its use are determined depending on the goals and objectives. It should be noted that some materials may not be suitable for printing complex parts or require additional support during the printing process. This can lead to complexity in the processing of products and increase the time and costs of printing. Improper selection of materials for 3D printing can be harmful to the environment or human health when used incorrectly. For example, some plastic materials may emit toxic elements or have low biodegradability. Also, using excess expensive material unnecessarily can increase the cost of the project. Keywords: additive manufacturing, 3D printing, additive manufacturing technologies, Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, Digital Light Processing.

The effect of surface roughness on the performance of 3D printed surface plasmon resonance sensors for refractive index measurements

AbstractIn this study, a polymer-based surface plasmon resonance (SPR) sensor for refractive index measurements was designed and manufactured via inkjet 3D printing; then, it was optically characterized. Next, it was investigated how the surface finish of the 3D printed optical waveguide affects the sensor performance, i.e., its sensitivity. More in detail, it was studied how the surface roughness changes with the placement of the 3D printed items on the building platform. To achieve this purpose, a Phase I distribution-free quality monitoring analysis of the selected manufacturing process was implemented for a small pilot production run. The aim was to check the stability of surface roughness versus the placement of the 3D printed parts on the building platform. The 3D printed sensor’s surface roughness was assessed through a profilometry study. In particular, the surface roughness was determined for the core of the optical waveguide used to excite the SPR phenomena. Furthermore, the SPR sensors were optically characterized to find the existing relationship between their sensitivity and the considered quality of surface finish. In particular, by varying the surface roughness of the used waveguide, the light scattering in the waveguide changes, and the SPR sensitivity changes too, similarly to the light-diffusing fibers covered by gold nanofilms where the guided light is scattered through a plurality of voids distributed in the core. The procedure followed to investigate the sensor roughness, and establishing their performance enabled the optimal operative range for their application in practice to be identified. Finally, a better knowledge of the 3D printing manufacturing process has been achieved to improve quality of surface finish.

Optimizing the boron-loaded pH/temperature dual responsive polymer for controlled release of boron from wood

ABSTRACT Disodium octoborate tetrahydrate (DOT) is a well-received and eco-friendly preservative. However, it is prone to leaching from wood in humid conditions or rainy seasons, causing problems such as decreased efficiency in resisting fungi and poor surface performance in surface finishing. To obtain enhanced leaching resistance and simultaneously achieve controlled release of DOT, a pH and temperature dual responsive poly (2-hydroxyethyl methacrylate/2-(Dimethylamino) ethyl methacrylate) (PDH) was prepared and optimized for in situ construction of DOT-loaded PDH (PDHD) in wood. Results showed that PDH displayed obvious pH and temperature-responsive swelling, and when loaded with DOT, the PDHD consequently released DOT in a pH and temperature-responsive way. Fourier transform infrared spectroscopy, Solid-13C NMR analysis and Dynamic mechanical analysis confirmed the copolymerization of 2-Hydroxyethyl methacrylate (HEMA) and 2-(Dimethylamino) ethyl methacrylate (DMAEMA), as well as the presence of crosslinked structure formed from hydrogen bond between the hydroxyl group of HEMA and the N,N-dimethylamino groups of DMAEMA. After that, the PDHD was in situ constructed in wood for controlled release of boron. During the water leaching test, the modified wood exhibited a boron fixation rate of 49.05% compared with 0.72% of the neat DOT-treated wood. Besides, it presented controlled release activity in response to pH and temperature. This work provides new approaches to the fixation of boron preservatives and notably realizes responsive releasing of boron compounds for long-term wood preservation.

Optimization of process parameters and predicting surface finish of PLA in additive manufacturing—a neural network approach

Optimization of process parameters and predicting surface finish of PLA in additive manufacturing—a neural network approach

Development of a Genetic Algorithm – Artificial Neural Network model to optimize the Dimensional Accuracy of parts printed by FFF

Purpose Fused Filament Fabrication (FFF) is one of the growing technologies in additive manufacturing, that can be used in a number of applications. In this method, process parameters can be customized and their simultaneous variation has conflicting impacts on various properties of printed parts such as dimensional accuracy (DA) and surface finish. These properties could be improved by optimizing the values of these parameters. Design/methodology/approach In this paper, four process parameters, namely, print speed, build orientation, raster width, and layer height which are referred to as “input variables” were investigated. The conflicting influence of their simultaneous variations on the DA of printed parts was investigated and predicated. To achieve this goal, a hybrid Genetic Algorithm – Artificial Neural Network (GA-ANN) model, was developed in C#.net, and three geometries, namely, U-shape, cube and cylinder were selected. To investigate the DA of printed parts, samples were printed with a central through hole. Design of Experiments (DoE), specifically the Rotational Central Composite Design method was adopted to establish the number of parts to be printed (30 for each selected geometry) and also the value of each input process parameter. The dimensions of printed parts were accurately measured by a shadowgraph and were used as an input data set for the training phase of the developed ANN to predict the behavior of process parameters. Then the predicted values were used as input to the Desirability Function tool which resulted in a mathematical model that optimizes the input process variables for selected geometries. The mean square error of 0.0528 was achieved, which is indicative of the accuracy of the developed model. Findings The results showed that print speed is the most dominant input variable compared to others, and by increasing its value, considerable variations resulted in DA. The inaccuracy increased, especially with parts of circular cross section. In addition, if there is no need to print parts in vertical position, the build orientation should be set at 0° to achieve the highest DA. Finally, optimized values of raster width and layer height improved the DA especially when the print speed was set at a high value. Originality/value By using ANN, it is possible to investigate the impact of simultaneous variations of FFF machines’ input process parameters on the DA of printed parts. By their optimization, parts of highly accurate dimensions could be printed. These findings will be of significant value to those industries that need to produce parts of high DA on FFF machines.

Surface roughness evaluation when brushing heat-resistant alloy components

AbstractNowadays, the combination of additive manufacturing technologies, together with the use of materials such as Inconel 718, opens new opportunities in the manufacture of aeronautical turbines. However, parts obtained directly through additive manufacturing are far from being considered suitable in their initial state, as they exhibit a poor surface finish that compromises their mechanical characteristics. Common among the defects found in such components are ridges stemming from thermal deformations during the powder fusion process. Therefore, abrasive brushing emerges as the prevalent method to rectify these surface imperfections. However, conventional roughness indicators prove insufficient in accurately characterizing such local defects during surface analysis. Consequently, this study investigates surface conditions of Inconel 718 parts produced through additive manufacturing, particularly focusing on defects caused by peak alignments along the powder fusion direction. Thus, a series of frontal brushing operations were conducted under varying conditions, with the aim of increasing the feed rate to address these defects. Subsequently, the effectiveness of the brushing process was assessed through the calculation of peak areas. The analysis of this indicator revealed that the maximum feed rate enabling complete removal of the peak marks was 500 mm/min.