The selection of optimum process parameters is crucial for advanced machining processes, as these processes incur high initial investment, tooling cost, and operating and maintenance costs. In this paper, a review of machining process parameters for different materials is done in ultrasonic machining (USM). Machining of Different materials like ceramics, Glass Porcelain, Titanium, is done by di...

A machining operation is basically termed a material removal process, where material is removed in the form of chips. In a machining operation, the output parameter is achieved by controlling various input parameters. This paper discusses the effects of various input parameters in abrasive Jet machining (AJM) on the output parameter(Metal Removal Rate [MRR).This paper presents an extensive revi...

Milling of fiber reinforced polymer composites is of great importance for integrated composites with other mating parts. Improper selection of cutting process parameters, excessive cutting forces and other machining conditions would result in rejection of components. Therefore, machining conditions are optimized to reduce the machining forces and damages. This work reports practical experiments...

This paper reports on the evaluation of a high resolution micro ultrasonic machining (HR-μUSM) process suitable for post fabrication trimming of complex 3D microstructures made from fused silica. Unlike conventional USM, the HR-μUSM process aims for low machining rates, providing high resolution and high surface quality. The machining rate is reduced by keeping the micro-tool tip at a fixed dis...

We present two methods for process planning of 2.5D machined parts. The first method is based on feature recognition from a 3D model. We embedded the shape and the machining method of two generic classes of machining features in a set of OPS5 rules to form a machining feature recognizer. When successfully recognizing a machining feature, machining instructions, in terms of the tool entrance fac...

Process planning plays an important role for ensuring machining quality, reducing production cost, and shortening leading time. Since there are many uncertainty factors for manufacturing resources in a changing manufacturing environment, especially for small batch manufacturing of large scale parts requiring long process planning time, manufacturing companies are facing significant challenges o...

This paper presents a functional microstructured surface, named Polar Microstructure. Polar microstructure is a three dimensional (3D) structured surface possessing a pattern of distribution of latitude and longitude micro-topographies with geometrical characteristics, which is similar to that in the Earth’s north or south pole. The spacing of its small surface features can achieve form accurac...

Micro-electric discharge machining (μ-EDM) is an important manufacturing process that is able to produce components and tools with micro-features. Improvement to this process has resulted in the use of powder mixed dielectric (PMD), which results in better surface quality and faster machining time. However, the presence of conductive powder in the dielectric fluid negatively affects the accurac...

This thesis presents a new method for Computer Aided Process Planning (CAPP) for a subtractive Rapid Prototyping (RP) process. The “CNC-RP” process uses a 4-axis CNC machining center to create parts with flat end-mills. The objective is to determine the optimal system parameters for the RP process those that enable parts to be created in a shorter amount of time. Two main contributions make thi...

A process-planning model (PP model) is proposed to convert the geometric features into manufacture machining operations and sequence the machining operations of the part in a feasible and effective order. The process-planning model (PP model) construct a feature framework that makes a mapping from geometric features into machining operations. A semantic net named the Precedence-Relations-Net is...