Mustafizur Rahman - Academia.edu (original) (raw)

Papers by Mustafizur Rahman

Research paper thumbnail of Modelling and experimental investigation on the effect of nanopowder-mixed dielectric in micro-electrodischarge machining of tungsten carbide

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2010

Micro-electrodischarge machining (micro-EDM) is one of the most effective methods used in die and... more Micro-electrodischarge machining (micro-EDM) is one of the most effective methods used in die and mould industries for machining difficult-to-cut tool and die materials such as tungsten carbide (WC). The quality and integrity of the surface finish resulting from the micro-EDM process in die and mould making can have a significant impact on the product performance. The present study intends to investigate the feasibility of improving the surface finish in micro-EDM of WC in a dielectric mixed with graphite (Gr), aluminium (Al), and alumina (Al2O3) nanopowders. The mechanism of powder-mixed micro-EDM is presented theoretically in terms of the effect of additive powder characteristics on the dielectric breakdown and gap width. In addition, the effect of the nanopowders’ mixed dielectric on surface topography, average surface roughness ( Ra), peak-to-valley roughness ( Rmax), material removal rate (MRR), and electrode wear ratio (EWR) was studied experimentally. It has been shown theore...

Research paper thumbnail of A Review of Electrolytic In-Process Dressing (ELID) Grinding

Key Engineering Materials, 2009

ELID Grinding, since its introduction over two decades ago, has helped in material removal of har... more ELID Grinding, since its introduction over two decades ago, has helped in material removal of hard and difficult-to-cut engineering materials. A gist of the important research milestones on the process has been organized in this report. The hybrid process of ELID Grinding has a simultaneous electrolytic reaction and grinding action. Electrolysis takes place between the conductive anodic wheel and highly conductive cathode in presence of a special electrolyte. The resulting anodic oxide wears off easily to allow efficient grinding. The different parameters involved in electrolysis complicate the mechanism of grinding and makes it significantly different from conventional grinding. Different variants of the process have also been reported, though the basic philosophy of operation is the same as basic ELID. Several authors have also suggested mathematical explanations, among other fundamental studies, that provide further insight. The basic components of the process, machine tool, powe...

Research paper thumbnail of An Experimental Study on Microcutting of Soda-Lime Glass by Milling Process

Key Engineering Materials, 2010

Glass is an important engineering material. It is widely used in semiconductor, optical, micro-el... more Glass is an important engineering material. It is widely used in semiconductor, optical, micro-electronics and many other fields. However, glass is not amenable to machining with conventional approach because of its low fracture toughness. To achieve high quality surface finish on optical components, glass must be machined in ductile mode. Compared to single point cutting processes, end-milling can achieve improved material removal rate in machining fracture free surface on brittle material. This paper presents the results of an experimental investigation into microcutting of glass by end-milling. Side-cutting tests have been performed on soda-lime glass workpiece at multiple feeds and radial depth of cuts to obtain fracture free machined surface. The tests were designed to investigate the effect of feed per edge and radial depth of cut on the cutting mechanism at low cutting speed. Experimental results indicate that feed per edge is the most dominant factor that dictates the occurr...

Research paper thumbnail of Nano-precision measurement of diamond tool edge radius for wafer fabrication

Journal of Materials Processing Technology, 2003

Research paper thumbnail of Modeling of the Effect of Machining Parameters on Maximum Thickness of Cut in Ultrasonic Elliptical Vibration Cutting

Journal of Manufacturing Science and Engineering, 2011

In recent years, the ultrasonic elliptical vibration cutting (UEVC) technique has been found to b... more In recent years, the ultrasonic elliptical vibration cutting (UEVC) technique has been found to be an efficient method for the ultraprecision machining of hard and brittle materials. During the machining at a given nominal depth of cut (DOC), the UEVC technique, because of its inherent mechanism, effectively reduces the thickness of cut (TOC) of the workpiece material through overlapping vibration cycles. For the ductile machining of hard and brittle materials, this TOC plays a critical role. However, the relationships between the nominal DOC, the TOC, and the relevant machining parameters have not yet been studied. In this study, the role playing machining parameters for the TOC are firstly investigated and then theoretical relations are developed for predicting the maximum TOC (TOCm) with respect to the relevant machining parameters. It is found that four machining parameters, namely, workpiece cutting speed, tool vibration frequency, and tangential and thrust directional vibratio...

Research paper thumbnail of Using neural network for tool condition monitoring based on wavelet decomposition

International Journal of Machine Tools and Manufacture, 1996

... For the tool condition monitoring, the cutting conditions (cutting speed, feed rate and cutti... more ... For the tool condition monitoring, the cutting conditions (cutting speed, feed rate and cutting depth) are also the features related to tool wear. ... [4] LI Burke and S. Rangwala, Tool condition monitoring in metal cutting: a neural network approach, J. Intelligent Mfg 2, 269280 (1991). ...

Research paper thumbnail of A fundamental study on the mechanism of electrolytic in-process dressing (ELID) grinding

International Journal of Machine Tools and Manufacture, 2002

Research paper thumbnail of A predictive model of the critical undeformed chip thickness for ductile–brittle transition in nano-machining of brittle materials

International Journal of Machine Tools and Manufacture, 2013

Research paper thumbnail of Feature analysis in tool condition monitoring: a case study in titanium machining

International Journal of Computer Applications in Technology, 2012

ABSTRACT Due to the rapid wear of the cutting tools when machining titanium alloy, tool condition... more ABSTRACT Due to the rapid wear of the cutting tools when machining titanium alloy, tool condition monitoring (TCM) is most useful to avoid workpiece damage and maximise machining productivity. This paper uses sensor signals and feature analysis to identify a feature set for effective TCM. Firstly, basic requirements of sensor signals in tool condition identification are discussed, and the suitability of two candidate signals (acoustic emission and cutting force) commonly employed for machining monitoring are critically analysed. Their effectiveness in TCM is investigated based on extracted features of these signals, singly or in combination. Experimental results based on titanium machining, which is an expensive process with high tool wear, indicate that this proposed method is capable to determine a suitable sensing method and an effective feature set to identify tool condition.

Research paper thumbnail of Compound and Hybrid Micromachining

Comprehensive Materials Processing, 2014

In recent years, the demands of microfeatures and microshapes coming from electronics, medical ap... more In recent years, the demands of microfeatures and microshapes coming from electronics, medical applications, and aviation industries has increased rapidly. Miniaturization is an indispensible and vital direction to obtain thinner, smaller, and lighter products. Applications include microholes for fiber optics, micronozzles for jet engines, micromold and die for micro-optic and microfluidic devices, etc. Hence, the well-established machining processes need to be innovated for these microapplications.

Research paper thumbnail of Cutting performance of diamond tools during ultra-precision turning of electroless-nickel plated die materials

Journal of Materials Processing Technology, 2003

This study is an attempt (a) to observe the wear characteristic of diamond tool with 200 km cutti... more This study is an attempt (a) to observe the wear characteristic of diamond tool with 200 km cutting distance and to study the effects of wear on the surface roughness and cutting forces and (b) to optimize various cutting parameters such as depth of cut, feed rate, spindle speed and phosphorus content. The experimental results showed that tool wear was not so significant although some defects on rake face were observed after cutting 15.6km. Further cutting showed that the surface roughness increases with cutting distance, and that the cutting forces were larger than thrust force at the beginning of cutting, but after cutting 130km thrust force became larger and increased rapidly. It was also observed that forces increase with the increase of depth of cut, spindle speed and feed rate, and decrease with the increase of phosphorus content of the plating. Depth of cut has no significant effect on surface roughness, while it increases with increase of feed rate and decreases with the increase of percentage of phosphorus content in the workpieces. In case of spindle speed, surface roughness decreases with the increase of spindle speed up to a certain value and then starts to increase with the increase of spindle speed.

Research paper thumbnail of Type Role of Mechanical Engineers in Sustainable Development

Journal of Mechanical Engineering, 2013

For development to be sustainable, it should be able to meet the needs of the present withoutcomp... more For development to be sustainable, it should be able to meet the needs of the present withoutcompromising the ability of future generations to meet their own needs. Generally, development is consideredunsustainable when insufficient attention is paid to the economic, environmental and social consequences. Aprerequisite for development is growth and that is directly related to production or output of a country. Ifproduction is done via a sustainable path it can maintain the sustainability of development. Mechanical andManufacturing Engineers predominantly shoulder manufacturing. As mechanical engineering is somewhatconsidered the “merging ground” of all forms of engineering, the level of mechanical engineering can be areliable barometer for measuring the development in a country. Thus mechanical engineers play a vital role indevelopment in countries across the globe. This paper highlights the role, responsibilities and necessarycontributions required by mechanical engineers to achiev...

Research paper thumbnail of An Overview of High-speed Machining of Titanium Alloys

Proceedings of International Conference on Leading Edge Manufacturing in 21st century : LEM21

Titanium alloys have been widely used in the aerospace, biomedical and automotive industries beca... more Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very diencult to machine them due to their poor machinability, which has led many large cempanies to invest much in developing techniques to minimize machining cost. During machining oftitanium alloys, their poor therrnal conductivity results in the higher temperature closer to the cutting edge, and there exists strong affTmity between the tool and worlrpiece material. When machining titanium alloys with the conventional tools, the wear rate progresses rapidly, and the cutting speed is generally diencult to be over 60mlmin. Other types of tool materials, including cerarnic, diamond, and cubic boron ninide (CBN), are highly reactive with titanium alloys at higher temperature, and consequently they are not effective to be used in HSM of titanium alloys. The binder-less CBN (BCBN) tools, which neither have any binder nor a sintering agent or a catalyst, have a remarlcal)ly longer tool life than conventional CBN inserts under all cutting conditions (up to 400mfmin). The BCBN appears to become a new cutring tool material for HSM oftitanium alloys both economically and functionally. In order to get deeper understanding ofHSM oftitanium alloys, the generation of mathematical models is essential, Therefore, analytical models are needed to be established to predict the machining pararneters for HSM of titanium alloys. This paper aims to give an overview of recent developments in machining and HSM oftitanium alloys, geometrical modeling ofHSM and cutting force models for HSM of titanium alloys.

Research paper thumbnail of A comparative study on the performance of sinking and milling micro-EDM for nanofinishing of tungsten carbide

International Journal of Nanomanufacturing

... J. Nanomanufacturing, Vol. ... Biographical notes: MP Jahan is a PhD candidate at the Departm... more ... J. Nanomanufacturing, Vol. ... Biographical notes: MP Jahan is a PhD candidate at the Department of Mechanical Engineering at the ... and optimisation; product data capture, prototyping, design and manufacture; and automated and integrated manufacturing system modelling and ...

Research paper thumbnail of In-Process Monitoring System for Machining Environment Based on Heat Flux Sensing

JSME international journal. Ser. 3, Vibration, control engineering, engineering for industry

Research paper thumbnail of Efficient dressing of the wheel in ELID grinding by controllable voltage with force feed back

International Journal of Advanced Manufacturing Technology, 2010

Electrolytic in-process dressing (ELID) grinding is a new method for achieving ultraprecision sur... more Electrolytic in-process dressing (ELID) grinding is a new method for achieving ultraprecision surface on hard and brittle materials. In ELID grinding, pulsed direct current voltage is applied on the metal-bonded diamond wheels to ensure constant protrusion of sharp cutting grits throughout the grinding cycle. The peak dressing voltage is kept constant irrespective of the wheel sharpness in conventional ELID grinding, which may lead to overdressing of the grinding wheel. Grinding force ratio (which is also known as K value) is an indicator for the grit sharpness. In this paper, a new approach of wheel dressing has been proposed where the peak dressing voltage is varied according to the change in the K value during grinding. A Kistler three-component dynamometer has been used to monitor the grinding force ratio in real time for this purpose. The methodology to implement the new "dressing-on-demand" concept has been discussed thoroughly in this paper. The experimental comparison with the conventional ELID grinding has also been carried out to prove the advantages of the proposed system.

Research paper thumbnail of Enhanced surface integrity and dimensional accuracy in Micro-EDM drilling using D-shaped electrode

Research paper thumbnail of A study on ultrasonic elliptical vibration cutting of tungsten carbide

Journal of Materials Processing Technology, May 1, 2009

Sintered tungsten carbide (WC) is a versatile metal matrix composite (MMC) material widely used i... more Sintered tungsten carbide (WC) is a versatile metal matrix composite (MMC) material widely used in the tool manufacturing industries. Machining of this material with conventional cutting (CC) method is a real challenge compared to other difficult-to-cut materials. Ultrasonic elliptical vibration cutting (UEVC) method is a novel and non-conventional cutting technique which has been successfully applied to machine such intractable materials for the last decade. However, few studies have been conducted on cutting of WC using single point diamond tool (SPDT) applying the UEVC technique. This paper presents an experimental study on UEVC of sintered WC (∼15% Co) using polycrystalline diamond (PCD) tools. Firstly, experiments have been carried out to investigate the effect of cutting parameters in the UEVC method in terms of cutting force, flank wear, surface finish while cutting sintered WC. The tests have revealed that the PCD tools in cutting of WC by the UEVC method results in better cutting performance at 4 m depth of cut (DOC) as compared to both a lower DOC (e.g. 2 m) and a higher DOC (e.g. 6 or 8 m). Moreover, the cutting performance improves with the decrease in both the feed rate and cutting speed in the UEVC method like conventional turning (CT) method. A minimum surface roughness, R a of 0.036 m has been achieved on an area of about 1257 mm 2 with the UEVC performance. The CT method has also been employed to compare its cutting performance against the UEVC method. It has been observed that the UEVC method results in better cutting performances in all aspects compared to the CT method. Theoretical analysis on the UEVC method and analysis of the experimental results have been carried out to explain the reasons of better surface finish at 4 m DOC and better cutting performance of the UEVC method.

Research paper thumbnail of Optimization of cutting parameters in micro end milling operations in dry cutting condition using genetic algorithms

Int J Adv Manuf Technol, 2006

... studies depth of cut is not considered as an active decision variable, thus restricting ... d... more ... studies depth of cut is not considered as an active decision variable, thus restricting ... described and the methodology followed for optimization (genetic algorithms) and the optimization model will ... eventually results in a greater proportion of the helix face of the cutter participating ...

Research paper thumbnail of CBN tool wear in ductile cutting of tungsten carbide

Wear, Aug 1, 2003

ABSTRACT

Research paper thumbnail of Modelling and experimental investigation on the effect of nanopowder-mixed dielectric in micro-electrodischarge machining of tungsten carbide

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2010

Micro-electrodischarge machining (micro-EDM) is one of the most effective methods used in die and... more Micro-electrodischarge machining (micro-EDM) is one of the most effective methods used in die and mould industries for machining difficult-to-cut tool and die materials such as tungsten carbide (WC). The quality and integrity of the surface finish resulting from the micro-EDM process in die and mould making can have a significant impact on the product performance. The present study intends to investigate the feasibility of improving the surface finish in micro-EDM of WC in a dielectric mixed with graphite (Gr), aluminium (Al), and alumina (Al2O3) nanopowders. The mechanism of powder-mixed micro-EDM is presented theoretically in terms of the effect of additive powder characteristics on the dielectric breakdown and gap width. In addition, the effect of the nanopowders’ mixed dielectric on surface topography, average surface roughness ( Ra), peak-to-valley roughness ( Rmax), material removal rate (MRR), and electrode wear ratio (EWR) was studied experimentally. It has been shown theore...

Research paper thumbnail of A Review of Electrolytic In-Process Dressing (ELID) Grinding

Key Engineering Materials, 2009

ELID Grinding, since its introduction over two decades ago, has helped in material removal of har... more ELID Grinding, since its introduction over two decades ago, has helped in material removal of hard and difficult-to-cut engineering materials. A gist of the important research milestones on the process has been organized in this report. The hybrid process of ELID Grinding has a simultaneous electrolytic reaction and grinding action. Electrolysis takes place between the conductive anodic wheel and highly conductive cathode in presence of a special electrolyte. The resulting anodic oxide wears off easily to allow efficient grinding. The different parameters involved in electrolysis complicate the mechanism of grinding and makes it significantly different from conventional grinding. Different variants of the process have also been reported, though the basic philosophy of operation is the same as basic ELID. Several authors have also suggested mathematical explanations, among other fundamental studies, that provide further insight. The basic components of the process, machine tool, powe...

Research paper thumbnail of An Experimental Study on Microcutting of Soda-Lime Glass by Milling Process

Key Engineering Materials, 2010

Glass is an important engineering material. It is widely used in semiconductor, optical, micro-el... more Glass is an important engineering material. It is widely used in semiconductor, optical, micro-electronics and many other fields. However, glass is not amenable to machining with conventional approach because of its low fracture toughness. To achieve high quality surface finish on optical components, glass must be machined in ductile mode. Compared to single point cutting processes, end-milling can achieve improved material removal rate in machining fracture free surface on brittle material. This paper presents the results of an experimental investigation into microcutting of glass by end-milling. Side-cutting tests have been performed on soda-lime glass workpiece at multiple feeds and radial depth of cuts to obtain fracture free machined surface. The tests were designed to investigate the effect of feed per edge and radial depth of cut on the cutting mechanism at low cutting speed. Experimental results indicate that feed per edge is the most dominant factor that dictates the occurr...

Research paper thumbnail of Nano-precision measurement of diamond tool edge radius for wafer fabrication

Journal of Materials Processing Technology, 2003

Research paper thumbnail of Modeling of the Effect of Machining Parameters on Maximum Thickness of Cut in Ultrasonic Elliptical Vibration Cutting

Journal of Manufacturing Science and Engineering, 2011

In recent years, the ultrasonic elliptical vibration cutting (UEVC) technique has been found to b... more In recent years, the ultrasonic elliptical vibration cutting (UEVC) technique has been found to be an efficient method for the ultraprecision machining of hard and brittle materials. During the machining at a given nominal depth of cut (DOC), the UEVC technique, because of its inherent mechanism, effectively reduces the thickness of cut (TOC) of the workpiece material through overlapping vibration cycles. For the ductile machining of hard and brittle materials, this TOC plays a critical role. However, the relationships between the nominal DOC, the TOC, and the relevant machining parameters have not yet been studied. In this study, the role playing machining parameters for the TOC are firstly investigated and then theoretical relations are developed for predicting the maximum TOC (TOCm) with respect to the relevant machining parameters. It is found that four machining parameters, namely, workpiece cutting speed, tool vibration frequency, and tangential and thrust directional vibratio...

Research paper thumbnail of Using neural network for tool condition monitoring based on wavelet decomposition

International Journal of Machine Tools and Manufacture, 1996

... For the tool condition monitoring, the cutting conditions (cutting speed, feed rate and cutti... more ... For the tool condition monitoring, the cutting conditions (cutting speed, feed rate and cutting depth) are also the features related to tool wear. ... [4] LI Burke and S. Rangwala, Tool condition monitoring in metal cutting: a neural network approach, J. Intelligent Mfg 2, 269280 (1991). ...

Research paper thumbnail of A fundamental study on the mechanism of electrolytic in-process dressing (ELID) grinding

International Journal of Machine Tools and Manufacture, 2002

Research paper thumbnail of A predictive model of the critical undeformed chip thickness for ductile–brittle transition in nano-machining of brittle materials

International Journal of Machine Tools and Manufacture, 2013

Research paper thumbnail of Feature analysis in tool condition monitoring: a case study in titanium machining

International Journal of Computer Applications in Technology, 2012

ABSTRACT Due to the rapid wear of the cutting tools when machining titanium alloy, tool condition... more ABSTRACT Due to the rapid wear of the cutting tools when machining titanium alloy, tool condition monitoring (TCM) is most useful to avoid workpiece damage and maximise machining productivity. This paper uses sensor signals and feature analysis to identify a feature set for effective TCM. Firstly, basic requirements of sensor signals in tool condition identification are discussed, and the suitability of two candidate signals (acoustic emission and cutting force) commonly employed for machining monitoring are critically analysed. Their effectiveness in TCM is investigated based on extracted features of these signals, singly or in combination. Experimental results based on titanium machining, which is an expensive process with high tool wear, indicate that this proposed method is capable to determine a suitable sensing method and an effective feature set to identify tool condition.

Research paper thumbnail of Compound and Hybrid Micromachining

Comprehensive Materials Processing, 2014

In recent years, the demands of microfeatures and microshapes coming from electronics, medical ap... more In recent years, the demands of microfeatures and microshapes coming from electronics, medical applications, and aviation industries has increased rapidly. Miniaturization is an indispensible and vital direction to obtain thinner, smaller, and lighter products. Applications include microholes for fiber optics, micronozzles for jet engines, micromold and die for micro-optic and microfluidic devices, etc. Hence, the well-established machining processes need to be innovated for these microapplications.

Research paper thumbnail of Cutting performance of diamond tools during ultra-precision turning of electroless-nickel plated die materials

Journal of Materials Processing Technology, 2003

This study is an attempt (a) to observe the wear characteristic of diamond tool with 200 km cutti... more This study is an attempt (a) to observe the wear characteristic of diamond tool with 200 km cutting distance and to study the effects of wear on the surface roughness and cutting forces and (b) to optimize various cutting parameters such as depth of cut, feed rate, spindle speed and phosphorus content. The experimental results showed that tool wear was not so significant although some defects on rake face were observed after cutting 15.6km. Further cutting showed that the surface roughness increases with cutting distance, and that the cutting forces were larger than thrust force at the beginning of cutting, but after cutting 130km thrust force became larger and increased rapidly. It was also observed that forces increase with the increase of depth of cut, spindle speed and feed rate, and decrease with the increase of phosphorus content of the plating. Depth of cut has no significant effect on surface roughness, while it increases with increase of feed rate and decreases with the increase of percentage of phosphorus content in the workpieces. In case of spindle speed, surface roughness decreases with the increase of spindle speed up to a certain value and then starts to increase with the increase of spindle speed.

Research paper thumbnail of Type Role of Mechanical Engineers in Sustainable Development

Journal of Mechanical Engineering, 2013

For development to be sustainable, it should be able to meet the needs of the present withoutcomp... more For development to be sustainable, it should be able to meet the needs of the present withoutcompromising the ability of future generations to meet their own needs. Generally, development is consideredunsustainable when insufficient attention is paid to the economic, environmental and social consequences. Aprerequisite for development is growth and that is directly related to production or output of a country. Ifproduction is done via a sustainable path it can maintain the sustainability of development. Mechanical andManufacturing Engineers predominantly shoulder manufacturing. As mechanical engineering is somewhatconsidered the “merging ground” of all forms of engineering, the level of mechanical engineering can be areliable barometer for measuring the development in a country. Thus mechanical engineers play a vital role indevelopment in countries across the globe. This paper highlights the role, responsibilities and necessarycontributions required by mechanical engineers to achiev...

Research paper thumbnail of An Overview of High-speed Machining of Titanium Alloys

Proceedings of International Conference on Leading Edge Manufacturing in 21st century : LEM21

Titanium alloys have been widely used in the aerospace, biomedical and automotive industries beca... more Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very diencult to machine them due to their poor machinability, which has led many large cempanies to invest much in developing techniques to minimize machining cost. During machining oftitanium alloys, their poor therrnal conductivity results in the higher temperature closer to the cutting edge, and there exists strong affTmity between the tool and worlrpiece material. When machining titanium alloys with the conventional tools, the wear rate progresses rapidly, and the cutting speed is generally diencult to be over 60mlmin. Other types of tool materials, including cerarnic, diamond, and cubic boron ninide (CBN), are highly reactive with titanium alloys at higher temperature, and consequently they are not effective to be used in HSM of titanium alloys. The binder-less CBN (BCBN) tools, which neither have any binder nor a sintering agent or a catalyst, have a remarlcal)ly longer tool life than conventional CBN inserts under all cutting conditions (up to 400mfmin). The BCBN appears to become a new cutring tool material for HSM oftitanium alloys both economically and functionally. In order to get deeper understanding ofHSM oftitanium alloys, the generation of mathematical models is essential, Therefore, analytical models are needed to be established to predict the machining pararneters for HSM of titanium alloys. This paper aims to give an overview of recent developments in machining and HSM oftitanium alloys, geometrical modeling ofHSM and cutting force models for HSM of titanium alloys.

Research paper thumbnail of A comparative study on the performance of sinking and milling micro-EDM for nanofinishing of tungsten carbide

International Journal of Nanomanufacturing

... J. Nanomanufacturing, Vol. ... Biographical notes: MP Jahan is a PhD candidate at the Departm... more ... J. Nanomanufacturing, Vol. ... Biographical notes: MP Jahan is a PhD candidate at the Department of Mechanical Engineering at the ... and optimisation; product data capture, prototyping, design and manufacture; and automated and integrated manufacturing system modelling and ...

Research paper thumbnail of In-Process Monitoring System for Machining Environment Based on Heat Flux Sensing

JSME international journal. Ser. 3, Vibration, control engineering, engineering for industry

Research paper thumbnail of Efficient dressing of the wheel in ELID grinding by controllable voltage with force feed back

International Journal of Advanced Manufacturing Technology, 2010

Electrolytic in-process dressing (ELID) grinding is a new method for achieving ultraprecision sur... more Electrolytic in-process dressing (ELID) grinding is a new method for achieving ultraprecision surface on hard and brittle materials. In ELID grinding, pulsed direct current voltage is applied on the metal-bonded diamond wheels to ensure constant protrusion of sharp cutting grits throughout the grinding cycle. The peak dressing voltage is kept constant irrespective of the wheel sharpness in conventional ELID grinding, which may lead to overdressing of the grinding wheel. Grinding force ratio (which is also known as K value) is an indicator for the grit sharpness. In this paper, a new approach of wheel dressing has been proposed where the peak dressing voltage is varied according to the change in the K value during grinding. A Kistler three-component dynamometer has been used to monitor the grinding force ratio in real time for this purpose. The methodology to implement the new "dressing-on-demand" concept has been discussed thoroughly in this paper. The experimental comparison with the conventional ELID grinding has also been carried out to prove the advantages of the proposed system.

Research paper thumbnail of Enhanced surface integrity and dimensional accuracy in Micro-EDM drilling using D-shaped electrode

Research paper thumbnail of A study on ultrasonic elliptical vibration cutting of tungsten carbide

Journal of Materials Processing Technology, May 1, 2009

Sintered tungsten carbide (WC) is a versatile metal matrix composite (MMC) material widely used i... more Sintered tungsten carbide (WC) is a versatile metal matrix composite (MMC) material widely used in the tool manufacturing industries. Machining of this material with conventional cutting (CC) method is a real challenge compared to other difficult-to-cut materials. Ultrasonic elliptical vibration cutting (UEVC) method is a novel and non-conventional cutting technique which has been successfully applied to machine such intractable materials for the last decade. However, few studies have been conducted on cutting of WC using single point diamond tool (SPDT) applying the UEVC technique. This paper presents an experimental study on UEVC of sintered WC (∼15% Co) using polycrystalline diamond (PCD) tools. Firstly, experiments have been carried out to investigate the effect of cutting parameters in the UEVC method in terms of cutting force, flank wear, surface finish while cutting sintered WC. The tests have revealed that the PCD tools in cutting of WC by the UEVC method results in better cutting performance at 4 m depth of cut (DOC) as compared to both a lower DOC (e.g. 2 m) and a higher DOC (e.g. 6 or 8 m). Moreover, the cutting performance improves with the decrease in both the feed rate and cutting speed in the UEVC method like conventional turning (CT) method. A minimum surface roughness, R a of 0.036 m has been achieved on an area of about 1257 mm 2 with the UEVC performance. The CT method has also been employed to compare its cutting performance against the UEVC method. It has been observed that the UEVC method results in better cutting performances in all aspects compared to the CT method. Theoretical analysis on the UEVC method and analysis of the experimental results have been carried out to explain the reasons of better surface finish at 4 m DOC and better cutting performance of the UEVC method.

Research paper thumbnail of Optimization of cutting parameters in micro end milling operations in dry cutting condition using genetic algorithms

Int J Adv Manuf Technol, 2006

... studies depth of cut is not considered as an active decision variable, thus restricting ... d... more ... studies depth of cut is not considered as an active decision variable, thus restricting ... described and the methodology followed for optimization (genetic algorithms) and the optimization model will ... eventually results in a greater proportion of the helix face of the cutter participating ...

Research paper thumbnail of CBN tool wear in ductile cutting of tungsten carbide

Wear, Aug 1, 2003

ABSTRACT