In traditional Computer Numerical Control (CNC) systems, machining parameters are usually selected prior to machining according to handbooks or user’s experience. These practices tend to select conservative parameters in order to avoid machining failure and assure product quality specifications. Less conservative practices try to find optimal machining parameters off-line to increase process pr...

Optimization of cutting parameters is valuable in terms of providing high precision and efficient machining. One of the effects of cutting force in the end milling operation with low diameter tool (during metal cutting) is tool deflection. Assuming that machining errors mostly arise from tool deflection, attempt was made to optimize machining parameters using Genetic Algorithm (GA) so as to min...

Nowadays, the rapid development of CAD systems’ programming environments results in the creation of multiple downstream applications, which are developed and becoming increasingly available. CAD based manufacturing simulations is gradually following the same trend. Drilling is the most popular holemaking process used in a variety of industries. A specially built piece of software that deals wit...

Surface integrity (SI) plays a very important role in functional performance. It is dependent on a large number of machining parameters. The major concern of industry is to know which combination of machining parameters provides the best SI of machined components. Traditionally, surface roughness is considered to be the principal parameter to assess the SI of a machined part. However, residual ...

The experimental investigations of the tool wear in turning of EN 31 alloy steel at different cutting parameters are reported in this paper. Mathematical model has been developed for flank wear using response surface methodology. This mathematical model correlates independent cutting parameters viz. cutting speed, feed rate and depth of cut with dependent parameters of flank wear. This model is...

Background: Wire Electrical discharge machining (WEDM) has higher capability for cutting complex shapes with high precision for very hard materials without using high cost of cutting tools. During the WEDM process, the wire behaves like a metal string, straightened by two axial pulling forces and deformed laterally by a sum of forces from the discharge process. Major forces acting on the wire c...

The present investigation proposes a hybrid technique: Taguchi method, response surface methodology (RSM) and genetic algorithm (GA), to analyze, model and predict vibration and surface roughness in traverse cut cylindrical grinding of aluminum alloy. Experiments have been conducted as per L9 orthogonal array of Taguchi methodology using several levels of the grinding parameters. Analysis of va...

Background: Electrical Discharge Machining (EDM) is a well-established non-conventional machining process for the machining of electrically conductive and difficult-to-machine materials. But its applications are limited because of the slow machining rate and poor surface finish. Powder mixed EDM (PMEDM) is unitary of the recent progresses in the EDM process in which powder particles mixed in th...

A mathematical model of the surface roughness has been developed by using response surface methodology (RSM) in grinding of AISI D2 cold work tool steels. Analysis of variance (ANOVA) was used to check the validity of the model. Low and high value for work speed and feed rate are decided from design of experiment. The influences of all machining parameters on surface roughness have been analyze...

In this paper, wire electric discharge machining (WEDM) of Titanium alloy (Ti-4.5Al-2V) is studied. In WEDM, the prime objective in cutting operation is to achieve the highest possible cutting speed along with desirable surface finish without sacrificing productivity. It is evident that a high material removal rate and a very good surface finish can never be achieved simultaneously in WEDM. Sel...