Unconventional machining

Abrasive waterjet machining (AWJM) is a new machining process, the advantages of which include low cutting temperatures, no heat damage to the material being cut, minimal dust, and low cutting forces. This paper presents a state of the art review of research in this new process. The main topics discussed are mechanics of material removal, productivity, cutting forces, surface quality and nozzle wear.

Understanding the exact nature of erosion of workpiece materials by abrasive waterjet machining (AWJM) is still confused, although it is important for successful modeling of this promising process. This paper presents a first attempt to model the AWJM process using the powerful tool of the finite element method (FEM) in order to explain the abrasive particle-workpiece interaction. Also the model predicts the behaviour of the process. The main objective is to develop an FE model which would enable to predict the depth of cut without any cutting experiments. The new model takes into account the precise representation of the constitutive behaviour of the workpiece material under AWJ dynamic loading conditions which was ignored in previous AWJM models in which the flow stress was represented by a constant value. Additionally, deformations, stresses and strains occurring in the workpiece material in the vicinity of the cutting interface as a result of the erosion impact by AWJ, could be obtained. In the present model, forces acting on the abrasive particle need not be initially determined, as in previous AWJM studies, as they are automatically calculated at each time step. The results show that the finite element method is a useful tool in predicting abrasive-material interaction and AWJ depth of cut.

Laser Beam Machining (LBM) is one of the most advanced machining processes that is used for shaping, cutting and machining the virtually whole varieties of engineering materials. In LBM, the surface roughness and kerf taper significant factors affects the product characteristics and quality of the product. During this analysis work, the impact of process parameters like cutting speed, frequency and Gas pressure surface roughness (Ra) of steel (AISI 321 stainless steel) material in laser cutting machining. L9 orthogonal array was generated for fractional factorial design (Taguchi analysis) for better understanding of the interaction among the process parameters. The values of surface roughness for steel were calculated by Regression model equations, Taguchi Analysis and Genetic Algorithm were employed to the parametric analysis of the experimental data. Taguchi analysis gives the optimum values of surface roughness and kerf taper, which are 2.2981 µm and 0.1637° respectively. Genetic algorithm was used for providing a set of optimum values for both outputs simultaneously.

Laser beam machining (LBM) is one in all the advanced machining processes that used for shaping virtually whole variety of engineering materials. In LBM, surface roughness is one in all necessary response that affects the product characteristics and quality of the product. During this analysis work, the impact of process parameters like cutting speed, frequency and duty cycle surface roughness (Ra) for steel material in laser cutting mentioned. L 27 orthogonal array was generated for full factorial style to better understanding of interaction among the process parameters. The values of surface roughness for steel were calculated by victimization model equations and Central Composite design of Response Surface Methodology (RSM) employed to parametric analysis of the experimental data. 1. Introduction Emergence of advanced engineering materials, rigorous design needs, and complex form and weird size of work piece prohibit the employment of conventional machining ways. Hence, it absolutely understands to develop some nonconventional machining ways called advanced machining processes. LBM is one among the advanced machining processes that are used for shaping nearly whole vary of engineering materials. There are lot of applications of LASER is in cutting of metals and non-metals, soft and difficult to machine (DTM) materials. The laser directed at the specified surface and wrapped around to cut the materials within the desired form. LBM is a non-conventional machining method, so it needs high investment and offers poor efficiency; therefore high attention needed for higher utilization of resources. The values of process parameters determined to yield the specified product quality and conjointly to maximize the method performances. In LBM, there are several factors like beam parameters, material parameters and machining parameters that affects the assorted quality characteristics, e.g. surface roughness, Heat Affected Zone (HAZ), recast layer, etc. design experimental approach used as superior from alternative approach as a result of it's a systematic and scientific manner of coming up with the experiments, assortment and analysis the info with restricted use of accessible resources. Nd: YAG and CO2 were most generally used for LBM application. Type the first days of the high power laser, Nd: YAG laser were solely accessible inperiodical mode whereas CO 2 laser were accessible each in periodical and continuous (CW) mode. Now a day's each laser varieties accessible as periodical and CW [2, 3]. Sivarao et al. [4] have through an experiment investigated the impact of surface roughness on steel having thickness 6 millimeter with numerous parameters like cutting speed, frequency and duty cycle and he find a RSM based model equation for this experiment. They found that surface roughness was extremely tormented by cutting speed and duty cycle; thus these two are the foremost affecting parameters and concluded that at high cutting speed and low duty cycle, best roughness are very often achieved. Once comparison of the information between the calculated and determined values for surface roughness they found that the deviation error between the expected and determined values isn't over than 15%, it implies that mathematical model obtained for surface roughness is reliable. During this analysis work, the impact of method parameters like cutting speed, frequency and duty cycle surface roughness (Ra) for steel material in optical maser cutting is mentioned. L-27 orthogonal array was selected for full factorial design to higher understanding of interaction

Laser Beam Machining (LBM) is one of the most advanced machining processes that is used for shaping, cutting and machining the virtually whole varieties of engineering materials. In LBM, the surface roughness and kerf taper significant factors affects the product characteristics and quality of the product. During this analysis work, the impact of process parameters like cutting speed, frequency and Gas pressure surface roughness (Ra) of steel (AISI 321 stainless steel) material in laser cutting machining. L9 orthogonal array was generated for fractional factorial design (Taguchi analysis) for better understanding of the interaction among the process parameters. The values of surface roughness for steel were calculated by Regression model equations, Taguchi Analysis and Genetic Algorithm were employed to the parametric analysis of the experimental data. Taguchi analysis gives the optimum values of surface roughness and kerf taper, which are 2.2981 µm and 0.1637° respectively. Genetic algorithm was used for providing a set of optimum values for both outputs simultaneously.