Laser beam machining (LBM) is one of the most widely used thermal energy based non-contact type advance machining process which can be applied for almost whole range of materials. Laser beam is focussed for melting and vaporizing the unwanted material from the parent material. It is suitable for geometrically complex profile cutting and making miniature holes in sheetmetal. Among various type of lasers used for machining in industries, CO2 and Nd:YAG lasers are most established. In recent years, researchers have explored a number of ways to improve the LBM process performance by analysing the different factors that affect the quality characteristics. The experimental and theoretical studies show that process performance can be improved considerably by proper selection of laser parameters, material parameters and operating parameters. This paper reviews the research work carried out so far in the area of LBM of different materials and shapes. It reports about the experimental and theoretical studies of LBM to improve the process performance. Several modelling and optimization techniques for the determination of optimum laser beam cutting condition have been critically examined. The last part of this paper discusses the LBM developments and outlines the trend for future research.

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Laser beam machining—A review

This paper presents an overview of the current technological and economical capabilities of electrochemical (ECM-based), electro-physical (EDM-based) and photonic (Laser-/EBM-based) additive and removal processes for turbomachinery component manufacture. Starting with the industrial demands and challenges of today, the technologies are reviewed in detail regarding achievable geometrical precision and surface integrity as well as material removal and deposition rates for conventionally difficult-to-cut Ti- and Ni-based alloys and dedicated steels. Past, existing and future areas of technology application of these advanced non-mechanical manufacturing processes are discussed. The paper focusses on the description of shaping processes therefore excludes pure welding or coating applications.

Turbomachinery component manufacture by application of electrochemical, electro-physical and photonic processes

https://digitalcommons.unl.edu/cgi/viewcontent.cgi?article=1275&context=mechengfacpub

Review of Electrochemical and Electrodischarge Machining

Intrinsically smart, metal matrix composites (MMCs) are lightweight and high-performance materials having ever expanding industrial applications. The structural and the functional properties of these materials can be altered as per the industrial demands. The process technologies indulged in fabrication and machining of these materials attract the researchers and industrial community. Hybrid electric discharge machining is a promising and the most reliable nonconventional machining process for MMCs. It exhibits higher competence for machining complex shapes with greater accuracy. This paper presents an up-to-date review of progress and benefits of different routes for fabrication and machining of composites. It reports certain practical analysis and research findings including various issues on fabrication and machining of MMCs. It is concluded that polycrystalline tools and diamond-coated tools are best suitable for various conventional machining operations. High speed, small depth of cut and low feed ra...

Fabrication and Machining of Metal Matrix Composites: A Review

Today, hybrid manufacturing technology has drawn significant interests from both academia and industry due to the capability to make products in a more efficient and productive way. Although there is no specific consensus on the definition of the term ‘hybrid processes’, researchers have explored a number of approaches to combine different manufacturing processes with the similar objectives of improving surface integrity, increasing material removal rate, reducing tool wear, reducing production time and extending application areas. Thus, hybrid processes open up new opportunities and applications for manufacturing various components which are not able to be produced economically by processes on their own. This review paper starts with the classification of current manufacturing processes based on processes being defined as additive, subtractive, transformative, joining and dividing. Definitions of hybrid processes from other researchers in the literature are then introduced. The major part of this paper reviews existing hybrid processes reported over the past two decades. Finally, this paper attempts to propose possible definitions of hybrid processes along with the authors’ classification, followed by discussion of their developments, limitations and future research needs.

/pdf/a-review-of-hybrid-manufacturing-processes-state-of-the-art-2sia0d73cv.pdf

A review of hybrid manufacturing processes – state of the art and future perspectives

Micro-EDM drilling of tapered holes for industrial applications

Sequential Laser and EDM Micro-drilling for Next Generation Fuel Injection Nozzle Manufacture

Shaped tube electrochemical drilling of good quality holes

Modelling of the electrochemical machining process by the boundary element method

Hydroerosive grinding of small orifice components often creates a feature known, for the purposes of this paper, as a keyhole. The keyhole is created by undesirable erosion close to the entry of a hole, which results in an asymmetrical geometrical form and poor quality. This paper details how the keyhole problem can be eliminated and applied to diesel fuel injection nozzle manufacture.The hydroerosive grinding process consists of a low viscosity fluid, similar to the viscosity of diesel fuel, containing abrasive particles such as silicon carbide and boron carbide. A fuel injection nozzle tends to have five to seven injection holes ranging in diameter from 100 μm to 200 μm. This fluid is passed through the injection holes in a fuel injection nozzle to calibrate the nozzle flowrate, improve surface finish, pre-age the nozzle radius and micro-deburr the hole edge at the fuel inlet, and to improve the flow efficiency of the hole. The paper addresses problems associated with hydroerosive grinding, such...

J. Atkinson

Papers

Micro-EDM drilling of tapered holes for industrial applications

Sequential Laser and EDM Micro-drilling for Next Generation Fuel Injection Nozzle Manufacture

Shaped tube electrochemical drilling of good quality holes

Modelling of the electrochemical machining process by the boundary element method

Improving the geometry and quality of a micro-hole fuel injection nozzle by means of hydroerosive grinding: