Mechatronic Systems Design and Solid Materials

Methods and Practices

Satya Bir Singh, Prabhat Ranjan, Alexander V. Vakhrushev, A. K. Haghi, Satya Bir Singh, Prabhat Ranjan, Alexander V. Vakhrushev, A. K. Haghi

• Publisher: Apple Academic Press
• Year: 2021
• eBook ISBN: 9781000067828
• Edition: 1
• Topic: Tecnologia e ingegneria
• Subtopic: Meccanica

This volume elaborates on mechatronics as the synergistic integration of mechanical engineering with electronics and intelligent computer control in the design and manufacturing of industrial products and processes. It considers the integration of mechanical systems (mechanical elements, components, machines), electronic systems (microelectronics, sensor and actuator technology), and information technology. The book's chapters present the principles of mechatronic systems design and solid materials in small elementary steps, provide an abundance of examples, and feature problems that are as practical as possible without becoming too involved with many extraneous details.

CHAPTER 1
Parametric Study and Optimization of Parameters in Powder Mixed Wire-EDM Using Taguchi Analysis

SWARUP S. DESHMUKH,¹ ARJYAJYOTI GOSWAMI,² RAMAKANT SHRIVASTAVA,³ and VIJAY S. JADHAV⁴

¹Research Scholar, Department of Mechanical Engineering, National Institute of Technology Durgapur, Durgapur, West Bengal – 713209, India, E-mail: [email protected]

²Assistant Professor, Department of Mechanical Engineering, National Institute of Technology Durgapur, Durgapur, West Bengal – 713209, India, E-mail: [email protected]

³Associate Professor, Mechanical Engineering Department, Government College of Engineering Karad, Karad, Maharashtra – 415124, India, E-mail: [email protected]

⁴Professor, Mechanical Engineering Department, Government College of Engineering Karad, Karad, Maharashtra – 415124, India, E-mail: [email protected]

ABSTRACT

Machining of materials has been an important and highly useful process catering to the needs of humans. With the advent of new and novel materials, the conventional approaches to machining are no longer sufficient and the industry is continuously shifting from traditional to non traditional machining processes. The powder mixed wire electric discharge machining (pwEDM) is the modified version of the wire electric discharge machining (wEDM). In wEDM, powder is added into the dielectric fluid through mechanical stirring. The outputs obtained in pwEDM are largely dependent on the properties of the powder, which is added to the dielectric fluid. The physical, electrical, and thermal properties of powder play an important role in determining the material removal rate (MRR) and surface roughness (Ra) of the machined component.

This study is focused on reducing the surface roughness and increasing the material removal rate of the machined specimen (i.e., AISI 4140). In this experimentation graphite powder of particle size, 25 µm was added in the dielectric fluid. The main reasons behind the addition of graphite powder were its high thermal conductivity and low density. Owing to the high thermal conductivity, the graphite powder dissipates more heat from the cutting area, which reduces the crater size, as compared to the normal w-EDM. This phenomenon helps in improving the surface quality. Also, the low density of the graphite powder ensures that it mixes properly with the dielectric fluid.

The input process parameters considered in this experimentation are pulse on time (T_ON), pulse off time (T_OFF), servo voltage (SV), wire feed (WF), and powder concentration (PC). The response variables that are considered in this experimentation are material removal rate (MRR), and surface roughness (Ra). The experiments were conducted as per the Taguchi methodology using the L27 orthogonal array.

It was observed that after the selection of parameters as per Taguchi methodology the surface roughness reduced by 49.51% and the material removal rate increased by 73.51%.

1.1 INTRODUCTION

Machining can be defined as the process of selective removal of work material to impart the desired shape and hence a desired functionality to the work material. Machining is a very useful process, which has been frequently utilized throughout the history of humans. Arguably, the earliest example of machining was when the primitive human picked up a stone and selectively chiseled away the edges to generate what was the first tool in the history of human civilization [1]. Soon our ancestors realized that by selective removal of material from a chosen substrate one can develop a particular tool for a specific purpose, which can reduce the effort and increase the benefit of a process.

With the progress of civilization, the demand and needs of human beings also increased. In order to fulfill the needs, the work material and the machining process also improved and increasingly became more capable as well as efficient. With the invention of the steam engine (1775), civilization entered a new age. The output of the machines as well as the processing capabilities increased many folds as compared to earlier machining methods. At this time the most commonly used material in the industry was steel (different variants) and the tool used for selective removal of the work material was carbide. But, as technology progressed, different materials were chosen for generating specific components, which were to be used in highly specialized applications. Different industries like the automobile industry, shipbuilding, aviation, etc., started using different grades of materials.

The use of different materials combined with an increase in demand (owing to World War I and World War II) led to the next stage in the industrial revolution wherein CNC machines were developed and implemented. Different CNC machine tools like CNC lathe, CNC milling, CNC drilling, etc., were developed. Apart from being highly f...

Table of contents

• Cover
• Half Title
• Title Page
• Copyright Page
• About the Editors
• Contents
• Contributors
• Abbreviations
• Preface
• 1. Parametric Study and Optimization of Parameters in Powder Mixed Wire-EDM Using Taguchi Analysis
• 2. Three and Four Precision Position Graphical and Analytical Synthesis Procedure Mechanism Design for Agricultural Tillage Operation
• 3. Mechanics of Metal Removal in Abrasive Jet Machining
• 4. Evaluating the Mass Sensing Characteristics of SWCNC
• 5. Mechanics and Material Removal Modeling and Design of Velocity Transformers in Ultrasonic Machining
• 6. Pre‑Strain in VHB 4910 Dielectric Elastomer Towards Kinetics of Crystallization
• 7. End Life Cycle Recycling Policy Framework for Commercially Available Solar Photovoltaic Modules and Their Environmental Impacts
• 8. Simulation of Multilayer Atom Nanostructures for Spinmechatronics
• 9. Modeling of Deformation and Fracture Process of Layered Nanocomposites
• 10. Elastoplastic Modeling of an Orthotropic Boron-Aluminum Fiber-Reinforced Composite Thick-Walled Rotating Cylinder Subjected to a Temperature Gradient
• Index