The liquid metal flow and the solidification behaviours in a multi-cavity casting mould of two automotive cast parts were simulated in three dimensions. The commercial code, FLOW-3D® was used because it can track the front of the molten metal by a Volume of Fluid (VOF) method and allows complicated parts to be modeled by the Fractional Area/Volume Obstacle Representation (FAVOR) meth...

Laser assisted machining is an alternative to conventional machining of hard and/or difficult-to-process materials which involves pre-heating of a focused area with a laser beam over the surface of the workpiece to cause localized thermal softening along the path of the cutting action. The main advantage that laser assisted machining has over conventional machining is the increased material rem...

Aluminum extrusion die manufacturing is a critical task for productive improvement and increasing potential of competition in aluminum extrusion industry. It causes to meet the efficiency not only consistent quality but also time and production cost reduction. Die manufacturing consists first of die design and process planning in order to make a die for extruding the customer’s requirement prod...

The use of a minimum quantity of lubrication (MQL) with extremely low consumption of lubricant in machining processes has been reported as a technologically and environmentally feasible alternative to conventional flood cooling. In hot machining, the external heat source is applied during machining that will assist to increase machining performance. Many external heating techniques are availabl...

Ultrasonic machining (USM) is a mechanical material removal process used to erode holes and cavities in hard or brittle work pieces by using shaped tools, high-frequency and an abrasive slurry. This paper addresses the concept and development of an expert system (ES) for hard and brittle material, such as glass, quartz, diamond, carbides, semi conducting materials, ceramic and graphite which ca...

During these last years, the evolution of the machining speed of the EDM processes has become a key challenge for this technology. The recent progress made on the spark generators leads to a higher production speed in all processes such wire EDM, die-sinking, drilling, milling, etc. Nevertheless, if the electrical process is developing fast, many limiting factors still remain under investigatio...

machining operation is one of the most applicable processes for the manufacturing of industrial parts. usually, the quality of finished part in turning operation is measured in terms of surface roughness. in turn, surface quality is determined by machining parameters and tool geometry specifications. the main objective of this study is to model and optimize machining parameters and tool geometr...

INTRODUCTION Free-form surfaces are used in product design, either to deliver certain functionality, or for aesthetic purposes. The realization of models with free-form surfaces involves metal removal processes whose output is either the desired product, or a die/mould cavity for the desired product. This process is affected by various sources of error, which cause the geometry of the manufactu...

Electrical discharge machining process, is one of the most widely used methods for machining, the electrically conductive parts. In this way the tool is not in contact with the workpiece and the hardness of workpiece does not affect the machining speed. In Electrical Discharge Machining process, selection of the correct machining parameters are effective in final cost and the quality of the pro...

the making of ear mould for hearing aids is generally considered to be a safe process. however, there are a few reported cases of complications caused during mould making. we report the case of a man with 69 years age, where the process of making the mould for a hearing aid led to the perforation of the tympanic membrane and pouring of mould material into the middle ear, necessitating surgical ...