Modern Hybrid Machining and Super Finishing Processes (Sustainable Manufacturing Technologies)

Cover
Half Title
Series
Title
Copyright
Contents
About the Editors
List of Contributors
Preface
Chapter 1 A Brief Review on Electrochemical Discharge Machining Process
	1.1 Introduction
	1.2 Electrochemical Discharge Machining (ECDM)
		1.2.1 Electrochemical Discharge Drilling (ECDD)
		1.2.2 Electrochemical Discharge Turning (ECDT)
		1.2.3 Electrochemical Discharge Milling
		1.2.4 Electrochemical Discharge Dressing
		1.2.5 Wire Electrochemical Discharge Machining (WECDM)
		1.2.6 Die-sinking Electrochemical Discharge Machining (DS-ECDM)
		1.2.7 Electrochemical Discharge Trepanning
	1.3 ECDM-Based Triplex Hybrid Methods
		1.3.1 Powder Mixed ECDM (PM-ECDM)
		1.3.2 Rotary Electrochemical Discharge Machining (R-ECDM)
		1.3.3 Electrochemical Discharge Grinding (ECDG)
		1.3.4 Vibration-Assisted Electrochemical Discharge Machining (VAECDM)
		1.3.5 Magnetic Field–Assisted Electrochemical Discharge Machining (MAECDM)
	1.4 Effects of Process Parameters
		1.4.1 Electrolyte Properties
		1.4.2 Tool Electrode Properties
		1.4.3 Gas Film Properties
	1.5 Future Prospective of ECDM Process
	1.6 Conclusion
Chapter 2 A Review of Process Parameters of Rotary Ultrasonic Machining
	2.1 Introduction of Advanced Machining Process
		2.1.1 Evaluation of USM to RUSM
	2.2 Rotary Ultrasonic Machining Principle
	2.3 Components of Rotary Ultrasonic Machining
		2.3.1 Ultrasonic Spindle
		2.3.2 Ultrasonic Power
		2.3.3 Data Acquisition System
		2.3.4 Coolant
	2.4 Mechanism of Rotary Ultrasonic Machining
	2.5 Applications of RUSM
	2.6 Process Parameters and the Response of RUSM
		2.6.1 Material Removal Rate
		2.6.2 Surface Roughness
		2.6.3 Tool Wear Rate
	2.7 Summary
	2.8 Conclusion
		2.8.1 Material Removal Rate (MRR)
		2.8.2 Surface Roughness (SR)
		2.8.3 Tool Wear Rate (TWR)
Chapter 3 Effect of Minimum Quantity Lubrication (MQL) Method on Machining Characteristics for Ductile Substrates: A Future Direction
	3.1 Outlook to the Machining Process
	3.2 Machining Conditions
		3.2.1 Flood Machining
		3.2.2 Dry Machining
		3.2.3 MQL Machining
		3.2.4 Minimum Quantity Lubrication (MQL) Technique
	3.3 MQL Input Characteristics
		3.3.1 Coolant Flow Rate (CFR)
		3.3.2 Nozzle Tool Distance
		3.3.3 Nozzle Elevation Angle (NEA)
	3.4 Performance Characteristics
		3.4.1 Material Removal Rate (MRR)
		3.4.2 Surface Roughness (SR)
		3.4.3 Surface Texture
	3.5 Review on the Performance Characteristics Parameters
		3.5.1 Cost of Cutting Fluid
		3.5.2 Environment and Human Health
		3.5.3 Workpiece Specification, Mode of Cooling, and Other Output Characteristics
	3.6 Conclusion and Future Scope
Chapter 4 Comprehensive Study on Electrochemical Discharge Machining
	4.1 Introduction
		4.1.1 History of ECDM
		4.1.2 Working Principle of ECDM
		4.1.3 Distinct Process Parameters of ECDM
		4.1.4 Applied DC Voltage
		4.1.5 Types of Electrolyte
		4.1.6 Effect of Adding Abrasives
		4.1.7 Inter-electrode Gap
	4.2 Distinct Types of Materials Used in ECDM
		4.2.1 Glass, Ceramics
		4.2.2 Super Alloy
		4.2.3 Composites
		4.2.4 Steel Plates
	4.3 ECDM Variants
		4.3.1 Electrochemical Discharge Milling
		4.3.2 Electrochemical Discharge Drilling
		4.3.3 Electrochemical Discharge Turning
		4.3.4 Electrochemical Discharge Dressing
		4.3.5 Environmental Concern and Material Removal Mechanism
	4.4 Future Scope
	4.5 Conclusion
		4.5.1 Declaration of Competing Interest
		4.5.2 Acknowledgement
Chapter 5 Advancement of Abrasive-Based Nano-Finishing Processes: Principle, Challenges, and Current Applications
	5.1 Introduction
	5.2 Different Abrasive-Based Nano-Finishing Processes
		5.2.1 Traditional Finishing Operations
		5.2.2 Advanced Finishing Operations
	5.3 Abrasive Flow Machining (AFM) Process
		5.3.1 Abrasive Media
	5.4 Chemical Mechanical Polishing (CMP)
	5.5 Other Abrasive Based Finishing Operations
	5.6 Research Challenges of Advanced Abrasive-Based Finishing Processes
	5.7 Conclusions
Chapter 6 Defects during Conventional Machining of Polymer Composites: A Review
	6.1 Introduction to Machining of Polymer Composite Materials
	6.2 Literature Survey
	6.3 Defects during Conventional Machining of Composites
	6.4 Non-conventional Machining of Polymer Composites
	6.5 Conclusions
Chapter 7 Optimization of Machining Parameter Using Electric Discharge Machining on Fabricated Aluminium-Based Metal Matrix Composite
	7.1 Introduction
	7.2 Experimental Detail
		7.2.1 Fabrication of Work Materials
		7.2.2 Property Analysis of Al/(SiCp + Al2O3p)—MMC
	7.3 Tensile Test
	7.4 Density Test
		7.4.1 Procedure Followed to Measure Density
	7.5 Hardness Test
	7.6 Experimental Conditions and Procedure
	7.7 Results and Discussions
		7.7.1 Parametric Interaction Effect on Surface Roughness Height
	7.8 Parametric Interaction Effect on MRR
		7.8.1 Single Objective Optimization for SR
		7.8.2 Single Objective Optimization for MRR
	7.9 Conclusion and Future Outlook
	7.10 Future Scope
Chapter 8 Experimental Investigation on Surface Texture of Inconel-800 with Hybrid Machining Method Using Optimization Technique
	8.1 Introduction
	8.2 Materials and Methods
		8.2.1 RSM
	8.3 Results and Discussions
		8.3.1 Investigation of SR
	8.4 SEM Micrograph Analysis
	8.5 Conclusion
Chapter 9 Advanced Finishing Processes for Cylindrical Surface Finishing: A Review
	9.1 Introduction
	9.2 Cylindrical Surface Finishing Processes
		9.2.1 Conventional Finishing Processes
		9.2.2 Lapping
		9.2.3 Honing
		9.2.4 Grinding
	9.3 Advanced Finishing Processes without Externally Controlled Forces
		9.3.1 Abrasive Flow Finishing (AFF) Process
		9.3.2 Elastic Emission Machining (EEM) Process
		9.3.3 Chemo-mechanical (CMP) Process
	9.4 Advanced Finishing Processes with Externally Controlled Forces
		9.4.1 Magnetic Abrasive Finishing (MAF) Process
		9.4.2 Static Flexible Magnetic Abrasive Brush (S-FMAB) Process
		9.4.3 Magnetic Float Polishing (MFP) Process
	9.5 Magnetorheological Fluid (MRF)
	9.6 Conclusion
Index