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Bijoy Bhattacharyya - One of the best experts on this subject based on the ideXlab platform.

  • Micro hole fabrication on quartz using ultrasonic micromachining process
    International Journal of Precision Technology, 2020
    Co-Authors: Sushil Kumar, B. Hansda, Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Ultrasonic micromachining (USMM) has immense potential for micro-machining on quartz which is used in different field of applications such as optics, metrology and micro electro mechanical system (MEMS) etc. In this paper the influences of process parameters such as power rating, abrasive slurry concentration and Tool Feed Rate on material removal Rate (MRR), overcut and taper angle of the micro hole on quartz by USMM have been investigated. Stainless steel of grade 304 has been selected as the micro-Tool material for ultrasonic micro drilling on quartz. The higher value of MRR of 0.4235 mm/min has been obtained at power rating of 400 W, abrasive slurry concentration of 40% and Tool Feed Rate of 1.2 mm/min. The lower value of overcut of 55 µm and taper angle of 0.600 of micro hole have been obtained at abrasive slurry concentration of 20%, power rating of 300 W and Tool Feed Rate of 1 mm/min.

  • Optimisation of ultrasonic machining of zirconia bio-ceramics using genetic algorithm
    International Journal of Manufacturing Technology and Management, 2020
    Co-Authors: Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Ultrasonic machining is one of the most extensively used non-traditional machining processes for the machining of non-conductive, brittle materials such as carbides, glasses and bio-ceramics. The present paper includes the investigation into surface roughness of machined of hexagonal holes and material removal Rate during ultrasonic machining of zirconia bio-ceramics. The response surface methodology was employed for developing empirical models. Abrasive grit size, abrasive slurry concentration, power rating and Tool Feed Rate have been considered as controlling parameters of ultrasonic machining process. Multi-objective optimisation has been carried out for minimising surface roughness of hole surface and maximising material removal Rate during hexagonal profile generation by USM. However, for searching out the best optimal solution, genetic algorithm (GA) is used. Unlike traditional optimisation techniques, GA is strong and performs well in multi objective optimisation problems. Using genetic algorithm, maximum MRR of 0.2365 g/min and minimum surface roughness of 0.58 μm were obtained at the optimal parametric combination such as abrasive grit size of 57 μm, abrasive slurry concentration of 42 g/l, power rating of 492 W and Tool Feed Rate of 0.88 mm/min.

  • Chapter 7 – Influencing Factors of EMM
    Electrochemical Micromachining for Nanofabrication MEMS and Nanotechnology, 2020
    Co-Authors: Bijoy Bhattacharyya
    Abstract:

    Various important influencing factors of electrochemical micromachining (EMM) have been elaboRated. EMM power supply with various configurations has been described. Electrolyte for EMM for different applications indicating suitability for a wide range of metal machining during EMM has also been discussed. Report on the possibility of utilizing nontoxic eco-friendly electrolyte is included. The influence of inter-electrode gap, temperature, concentration, electrolyte flow, and Tool Feed Rate has also been described with the help of a large number of practical results.

  • Rotary Ultrasonic Machining–New StRategy of Cutting and Finishing
    Materials Forming Machining and Tribology, 2020
    Co-Authors: Sushil Kumar, Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Rotary ultrasonic machining (RUM) is an abrasive based advanced machining technique for cutting and finishing of various hard and fragile materials like ceramic, ceramics composite, glass, titanium and its alloy etc. RUM is the development over stationary ultrasonic machining for enhancement of MRR, geometrical accuracy and surface roughness. The basic mechanism of RUM is the combination of ultrasonic machining and conventional diamond grinding. In this chapter development, principle, mechanism, setup details of rotary ultrasonic machining has been discussed. It also highlights the effects of diverse input parameters on performance of RUM. The MRR always increases with spindle speed; Tool Feed Rate and ultrasonic power. The surface roughness improved with spindle speed but worse with Tool Feed Rate and ultrasonic power. The chipping size reduced with spindle speed but increase with Tool Feed Rate and ultrasonic power. The cutting force reduces with spindle speed and ultrasonic power but increases with Tool Feed. Various advancements in RUM has also discussed. A new technique for drilling called robotic rotary ultrasonic drilling (RRUD) was developed. The application area of rotary ultrasonic machining (RUM) in micro domain has also been highlighted. It is extensively useful for generation of micro feature like micro hole, micro channel, complex micro cavity etc. on various materials such as quartz, glass, SiC, and Al2O3.

  • Parametric Optimization of Micro Ultrasonic Drilling of Quartz Based on RSM
    Lecture Notes on Multidisciplinary Industrial Engineering, 2019
    Co-Authors: Sushil Kumar, Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Micro ultrasonic machining is the process for micro hole drilling on hard and brittle materials like ceramic, glass, quartz, silicon, etc. Quartz has wide applications in microelectromechanical systems (MEMS), lenses, pressure and flow sensors, and micro-optical systems. In the present research work, optimization of the process parameters for responses such as material removal Rate, overcut, and taper angle during micro ultrasonic drilling has been performed utilizing the developed empirical relationship between the responses and process parameters. Three different process parameters— power rating, abrasive slurry concentration, and Tool Feed Rate were considered for this experimental investigation. The parametric studies have also been made based on response surface plot. Based on multi-objective optimization, optimal parametric setting for maximum material removal Rate, minimum overcut and minimum taper angle have been obtained.

Gilles Dessein - One of the best experts on this subject based on the ideXlab platform.

  • Simulation Tool of the HSM machine dynamic behavior
    2020
    Co-Authors: El Bechir Msaddek, Zoubeir Bouaziz, Maher Baili, Gilles Dessein
    Abstract:

    High speed machining is a milling operation in industrial production of aeronautic parts, molds and dies. The parts production is being reduced because of the slowing down of the machining resulting from the Tool path discontinuity machining stRategy. In this article, we propose a simulation Tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting Tool Feed Rate. Afterwards, a simulation method, based on numerical calculation Tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones, for the same examples.

  • Modeling and simulation of high-speed milling centers dynamics
    The International Journal of Advanced Manufacturing Technology, 2011
    Co-Authors: El Bechir Msaddek, Zoubeir Bouaziz, Maher Baili, Gilles Dessein
    Abstract:

    High-speed machining is a milling operation in industrial production of aeronautic parts, molds, and dies. The parts production is being reduced because of the slowing down of the machining resulting from the Tool path discontinuity machining stRategy. In this article, we propose a simulation Tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting Tool Feed Rate. Afterwards, a simulation method, based on numerical calculation Tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones for the same examples.

  • Modeling and simulation of high-speed milling centers dynamics
    The International Journal of Advanced Manufacturing Technology, 2010
    Co-Authors: El Bechir Msaddek, Zoubeir Bouaziz, Maher Baili, Gilles Dessein
    Abstract:

    International audienceHigh-speed machining is a milling operation in industrial production of aeronautic parts, molds, and dies. The parts production is being reduced because of the slowing down of the machining resulting from the Tool path discontinuity machining stRategy. In this article, we propose a simulation Tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting Tool Feed Rate. Afterwards, a simulation method, based on numerical calculation Tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones for the same examples

Biswanath Doloi - One of the best experts on this subject based on the ideXlab platform.

  • Micro hole fabrication on quartz using ultrasonic micromachining process
    International Journal of Precision Technology, 2020
    Co-Authors: Sushil Kumar, B. Hansda, Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Ultrasonic micromachining (USMM) has immense potential for micro-machining on quartz which is used in different field of applications such as optics, metrology and micro electro mechanical system (MEMS) etc. In this paper the influences of process parameters such as power rating, abrasive slurry concentration and Tool Feed Rate on material removal Rate (MRR), overcut and taper angle of the micro hole on quartz by USMM have been investigated. Stainless steel of grade 304 has been selected as the micro-Tool material for ultrasonic micro drilling on quartz. The higher value of MRR of 0.4235 mm/min has been obtained at power rating of 400 W, abrasive slurry concentration of 40% and Tool Feed Rate of 1.2 mm/min. The lower value of overcut of 55 µm and taper angle of 0.600 of micro hole have been obtained at abrasive slurry concentration of 20%, power rating of 300 W and Tool Feed Rate of 1 mm/min.

  • Optimisation of ultrasonic machining of zirconia bio-ceramics using genetic algorithm
    International Journal of Manufacturing Technology and Management, 2020
    Co-Authors: Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Ultrasonic machining is one of the most extensively used non-traditional machining processes for the machining of non-conductive, brittle materials such as carbides, glasses and bio-ceramics. The present paper includes the investigation into surface roughness of machined of hexagonal holes and material removal Rate during ultrasonic machining of zirconia bio-ceramics. The response surface methodology was employed for developing empirical models. Abrasive grit size, abrasive slurry concentration, power rating and Tool Feed Rate have been considered as controlling parameters of ultrasonic machining process. Multi-objective optimisation has been carried out for minimising surface roughness of hole surface and maximising material removal Rate during hexagonal profile generation by USM. However, for searching out the best optimal solution, genetic algorithm (GA) is used. Unlike traditional optimisation techniques, GA is strong and performs well in multi objective optimisation problems. Using genetic algorithm, maximum MRR of 0.2365 g/min and minimum surface roughness of 0.58 μm were obtained at the optimal parametric combination such as abrasive grit size of 57 μm, abrasive slurry concentration of 42 g/l, power rating of 492 W and Tool Feed Rate of 0.88 mm/min.

  • Rotary Ultrasonic Machining–New StRategy of Cutting and Finishing
    Materials Forming Machining and Tribology, 2020
    Co-Authors: Sushil Kumar, Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Rotary ultrasonic machining (RUM) is an abrasive based advanced machining technique for cutting and finishing of various hard and fragile materials like ceramic, ceramics composite, glass, titanium and its alloy etc. RUM is the development over stationary ultrasonic machining for enhancement of MRR, geometrical accuracy and surface roughness. The basic mechanism of RUM is the combination of ultrasonic machining and conventional diamond grinding. In this chapter development, principle, mechanism, setup details of rotary ultrasonic machining has been discussed. It also highlights the effects of diverse input parameters on performance of RUM. The MRR always increases with spindle speed; Tool Feed Rate and ultrasonic power. The surface roughness improved with spindle speed but worse with Tool Feed Rate and ultrasonic power. The chipping size reduced with spindle speed but increase with Tool Feed Rate and ultrasonic power. The cutting force reduces with spindle speed and ultrasonic power but increases with Tool Feed. Various advancements in RUM has also discussed. A new technique for drilling called robotic rotary ultrasonic drilling (RRUD) was developed. The application area of rotary ultrasonic machining (RUM) in micro domain has also been highlighted. It is extensively useful for generation of micro feature like micro hole, micro channel, complex micro cavity etc. on various materials such as quartz, glass, SiC, and Al2O3.

  • Parametric Optimization of Micro Ultrasonic Drilling of Quartz Based on RSM
    Lecture Notes on Multidisciplinary Industrial Engineering, 2019
    Co-Authors: Sushil Kumar, Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    Micro ultrasonic machining is the process for micro hole drilling on hard and brittle materials like ceramic, glass, quartz, silicon, etc. Quartz has wide applications in microelectromechanical systems (MEMS), lenses, pressure and flow sensors, and micro-optical systems. In the present research work, optimization of the process parameters for responses such as material removal Rate, overcut, and taper angle during micro ultrasonic drilling has been performed utilizing the developed empirical relationship between the responses and process parameters. Three different process parameters— power rating, abrasive slurry concentration, and Tool Feed Rate were considered for this experimental investigation. The parametric studies have also been made based on response surface plot. Based on multi-objective optimization, optimal parametric setting for maximum material removal Rate, minimum overcut and minimum taper angle have been obtained.

  • Fabrication of stepped hole on zirconia bioceramics by ultrasonic machining
    Machining Science and Technology, 2016
    Co-Authors: Biswanath Doloi, Bijoy Bhattacharyya
    Abstract:

    ABSTRACTZirconia (ZrO2) is a highly biocompatible ceramic material providing fracture strength properties that allow application as dental implants in biomedical engineering. In this present research, experimental analysis has been made for generating stepped hole on zirconia bioceramics with desired quality using ultrasonic machining (USM) process. Four independent controllable input process parameters are abrasive grain diameter, power rating, concentration of abrasive slurry, and Tool Feed Rate. Material removal Rate (MRR), overcut of larger diameter (OLD) hole, and overcut of smaller diameter (OSD) hole of stepped hole are considered as the responses. Response surface methodology (RSM) is used for modeling the performance of USM process. Multiobjective optimization has been performed to maximize the MRR and minimize the OLD hole and OSD hole of stepped holes. All the responses are improved at the optimal parametric condition and verified by confirmation test. The present research opens up the applicat...

C. F. Cheung - One of the best experts on this subject based on the ideXlab platform.

  • A multi-spectrum analysis of surface roughness formation in ultra-precision machining
    Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology, 2020
    Co-Authors: C. F. Cheung
    Abstract:

    The formation of surface roughness in ultra-precision diamond turning is investigated using a multi-spectrum analysis method. The features on a diamond turned surface are extracted and analyzed by the spectrum analysis of its surface roughness profiles measured at a finite number of radial sections of the turned surface. It is found that the Tool Feed Rate, the spindle rotational speed, the Tool geometry, the material properties, as well as the relative Tool-work vibration are not the only dominant components contributing to the generation of surface roughness. The material induced vibration caused by the variation of material crystallography is another major factor. The vibration causes a significant variation of the frequency of the surface modulation of the machined surface. With the use of the multi-spectrum analysis method, it is possible to conjecture the patterns of this vibration as well as to evaluate the properties of the workpiece materials.

  • An investigation of surface roughness formation in ultra-precision machining of Al6061/SiCp metal matrix composites
    Key Engineering Materials, 2000
    Co-Authors: C. F. Cheung, Maneesha Vinodini Ramesh, W B Lee, K.c. Chan, Shimpei To
    Abstract:

    This paper deals with an investigation of the process factors and the material factors affecting the surface roughness formation in ultra-precision machining of Al6061/15SiC p metal matrix composites. The process factors involve machining conditions such as the spindle speed, Feed Rate and depth of cut. The material factors considered are the presence of SiC reinforcement, the swelling of Tool marks as well as the surface integrity such as pits and cracks. Experimental results indicate that pits and cracks are formed on the cutting surfaces in ultra-precision machining of the composites. The amount of pits and cracks increases with decreasing spindle speed and increasing Tool Feed Rate. Under low spindle speed condition, the amount of pits and cracks are found to increase with increasing depth of cut whereas these are not noticeable at high spindle speed condition. Significant swelling of Tool marks is also observed under various cutting conditions. This finding is further confirmed with the use of power spectrum analysis technique. © 2000 Trans Tech Publications.

El Bechir Msaddek - One of the best experts on this subject based on the ideXlab platform.

  • Simulation Tool of the HSM machine dynamic behavior
    2020
    Co-Authors: El Bechir Msaddek, Zoubeir Bouaziz, Maher Baili, Gilles Dessein
    Abstract:

    High speed machining is a milling operation in industrial production of aeronautic parts, molds and dies. The parts production is being reduced because of the slowing down of the machining resulting from the Tool path discontinuity machining stRategy. In this article, we propose a simulation Tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting Tool Feed Rate. Afterwards, a simulation method, based on numerical calculation Tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones, for the same examples.

  • Modeling and simulation of high-speed milling centers dynamics
    The International Journal of Advanced Manufacturing Technology, 2011
    Co-Authors: El Bechir Msaddek, Zoubeir Bouaziz, Maher Baili, Gilles Dessein
    Abstract:

    High-speed machining is a milling operation in industrial production of aeronautic parts, molds, and dies. The parts production is being reduced because of the slowing down of the machining resulting from the Tool path discontinuity machining stRategy. In this article, we propose a simulation Tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting Tool Feed Rate. Afterwards, a simulation method, based on numerical calculation Tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones for the same examples.

  • Modeling and simulation of high-speed milling centers dynamics
    The International Journal of Advanced Manufacturing Technology, 2010
    Co-Authors: El Bechir Msaddek, Zoubeir Bouaziz, Maher Baili, Gilles Dessein
    Abstract:

    International audienceHigh-speed machining is a milling operation in industrial production of aeronautic parts, molds, and dies. The parts production is being reduced because of the slowing down of the machining resulting from the Tool path discontinuity machining stRategy. In this article, we propose a simulation Tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting Tool Feed Rate. Afterwards, a simulation method, based on numerical calculation Tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones for the same examples