Abstract: Development of artificial neural network (ANN) for
prediction of aluminum workpieces' surface roughness in ultrasonicvibration
assisted turning (UAT) has been the subject of the present
study. Tool wear as the main cause of surface roughness was also
investigated. ANN was trained through experimental data obtained
on the basis of full factorial design of experiments. Various
influential machining parameters were taken into consideration. It
was illustrated that a multilayer perceptron neural network could
efficiently model the surface roughness as the response of the
network, with an error less than ten percent. The performance of the
trained network was verified by further experiments. The results of
UAT were compared with the results of conventional turning
experiments carried out with similar machining parameters except for
the vibration amplitude whence considerable reduction was observed
in the built-up edge and the surface roughness.
Abstract: In the present work, a study has been made on the combination of the electrical discharge machining (EDM) with ultrasonic vibrations to improve the machining efficiency. In experiments the graphite used as tool electrode and material of workpiece was AISIH13 tool steel. The parameters such as discharge peak current and pulse duration were changed to explore their effect on the material removal rate (MRR), relative tool wear ratio (TWR) and surface roughness. From the experimental result it can be seen that ultrasonic vibration of the workpiece can significantly reduces the inactive pulses and improves the stability of process. It was found that ultrasonic assisted EDM (US-EDM) is effective in attaining a high material removal rate (MRR) in finishing regime.
Abstract: A mathematical model of the surface roughness
has been developed by using response surface methodology
(RSM) in grinding of AISI D2 cold work tool steels. Analysis
of variance (ANOVA) was used to check the validity of the
model. Low and high value for work speed and feed rate are
decided from design of experiment. The influences of all
machining parameters on surface roughness have been
analyzed based on the developed mathematical model. The
developed prediction equation shows that both the feed rate
and work speed are the most important factor that influences
the surface roughness. The surface roughness was found to be
the lowers with the used of low feed rate and low work speed.
Accuracy of the best model was proved with the testing data.
Abstract: The machining of Carbon Fiber Reinforced Plastics
has come to constitute a significant challenge for many fields of
industry. The resulting surface finish of machined parts is of primary
concern for several reasons, including contact quality and impact on
the assembly. Therefore, the characterization and prediction of
roughness based on machining parameters are crucial for costeffective
operations. In this study, a PCD tool comprised of two
straight flutes was used to trim 32-ply carbon fiber laminates in a bid
to analyze the effects of the feed rate and the cutting speed on the
surface roughness. The results show that while the speed has but a
slight impact on the surface finish, the feed rate for its part affects it
strongly. A detailed study was also conducted on the effect of fiber
orientation on surface roughness, for quasi-isotropic laminates used
in aerospace. The resulting roughness profiles for the four-ply
orientation lay-up were compared, and it was found that fiber angle is
a critical parameter relating to surface roughness. One of the four
orientations studied led to very poor surface finishes, and
characteristic roughness profiles were identified and found to only
relate to the ply orientations of multilayer carbon fiber laminates.
Abstract: A numerical simulation of micro Poiseuille flow has
performed for rarefied and compressible flow at slip flow regimes.
The wall roughness is simulated in two cases with triangular
microelements and random micro peaks distributed on wall surfaces
to study the effects of roughness shape and distribution on flow field.
Two values of Mach and Knudsen numbers have used to investigate
the effects of rarefaction as well as compressibility. The numerical
results have also checked with available theoretical and experimental
relations and good agreements has achieved. High influence of
roughness shape can be seen for both compressible and
incompressible rarefied flows. In addition it is found that rarefaction
has more significant effect on flow field in microchannels with
higher relative roughness. It is also found that compressibility has
more significant effects on Poiseuille number when relative
roughness increases.