The complex structure of turning aggravates obtaining the desired results in terms of tool wear and surface roughness. The existence of high temperature and pressure make difficult to reach and observe the cutting area. In-direct tool condition, monitoring systems provide tracking the condition of cutting tool via several released or converted energy types, namely, heat, acoustic emission, vibration, cutting forces and motor current. Tool wear inevitably progresses during metal cutting and has a relationship with these energy types. Indirect tool condition monitoring systems use sensors situated around the cutting area to state the wear condition of the cutting tool without intervention to cutting zone. In this study, sensors mostly used in indirect tool condition monitoring systems and their correlations between tool wear are reviewed to summarize the literature survey in this field for the last two decades. The reviews about tool condition monitoring systems in turning are very limited, and relationship between measured variables such as tool wear and vibration require a detailed analysis. In this work, the main aim is to discuss the effect of sensorial data on tool wear by considering previous published papers. As a computer aided electronic and mechanical support system, tool condition monitoring paves the way for machining industry and the future and development of Industry 4.0.

/pdf/a-review-of-indirect-tool-condition-monitoring-systems-and-4xqg1e60db.pdf

A Review of Indirect Tool Condition Monitoring Systems and Decision-Making Methods in Turning: Critical Analysis and Trends.

Investigation of signal behaviors for sensor fusion with tool condition monitoring system in turning

Cooling techniques to improve the machinability and sustainability of light-weight alloys: A state-of-the-art review

Parameter optimization during minimum quantity lubrication milling of TC4 alloy with graphene-dispersed vegetable-oil-based cutting fluid

Multi-objective optimization in WEDM process of graphene – SiC-magnesium composite through hybrid techniques

Measurement and optimization of performance characteristics in turning of Mg alloy under dry and MQL conditions

Measurement and multi-response optimization of turning parameters for magnesium alloy using hybrid combination of Taguchi-GRA-PCA technique

Electrochemical micromachining (EMM) is in the forefront among the non-traditional machining processes that are brought into micromachining domain. The major influencing factors of EMM process are more sensitive at the micro-level machining, and for achieving precision the right combination of parameters is essential. Continuous research works are required to study and analyse every new possible set of variables that can be applied to carry out this machining process. The objective of the present research work is to generate micro-holes using an aluminium composite workpiece through EMM and study the capability of the process to machine such non-homogenous materials. An EMM set-up developed with pulse power facility for experimental purposes was used to carry out the experiments. The experimentation included an aluminium composite containing ceramic reinforcement as work specimen (anode), a hollow brass electrode as the machining tool and the solution of NaCl (sodium chloride) as the ion-conducting medium (electrolyte) to facilitate the process. The effect of input factors like voltage, current and pulse-on time on response parameters such as machining rate (MR) and overcut (RC) was studied from experimental observations. It was a general observation that speeding up the machining rate with higher level input of parameters affects the accuracy of the process outcome. Generally, the response of the EMM process is slow and requires time to produce machining accuracy.

Electrochemical Micromachining of Aluminium Alloy Composite

The objective of the study is to conduct experiments to investigate the performance of Electrochemical Micromachining (EMM) process to drill micro-holes on Copper alloy and analyze the parameters to optimize by Taguchi method. An EMM setup developed in-house is used to conduct the experiments. Copper alloy as workpiece, Stainless Steel needle of sharp conical edge as tool and Sodium Nitrate as electrolyte are used. A Pulse generator is used to supply pulsed current. The input parameters analyzed for optimization are Voltage, Pulse on-time and Electrolyte Concentration. The Material Removal Rate (MRR) and Overcut are taken as output parameters to study the process performance. The experiment was designed according to L9 Orthogonal Array (OA) of Taguchi design. The observations have shown that the MRR increases and the accuracy decreases when the level of input value for any parameter is increased. The process parameters are optimized using Taguchi Analysis.

Micro-ECM drilling of Copper Alloy and Taguchi Optimization

This work involves producing micro holes on Inconel 625 alloy through Electrochemical micromachining (EMM) process. The input parameters investigated are supply voltage, electrolyte concentration and duty ratio. The cathode tool used is a conical tipped stainless steel needle and the electrolyte is acidified sodium nitrate solution. Taguchi design of L9 Orthogonal Array is followed for experimental work. The performance analysis is done through process responses such as machining rate and overcut. The experimental results have given the optimum parameter combination for higher machining rate as 16 V supply voltage, 35 g/lit electrolyte concentration and 45% duty ratio and for lesser overcut as 12V, 35 g/lit and 45% duty ratio. The influence of input parameters on the process is also studied. The multi-objective optimisation technique used has produced 12 V, 30 g/lit and 45% duty ratio as the ideal combination for achieving higher machining rate and lower overcut.

V. Subburam

Papers

Measurement and optimization of performance characteristics in turning of Mg alloy under dry and MQL conditions

Measurement and multi-response optimization of turning parameters for magnesium alloy using hybrid combination of Taguchi-GRA-PCA technique

Electrochemical Micromachining of Aluminium Alloy Composite

Micro-ECM drilling of Copper Alloy and Taguchi Optimization

Performance optimisation of electrochemical micromachining of micro-holes on Inconel 625 alloy