1) Magnetic scales are increasingly being used in digital readouts and height masters instead of glass or metal scales due to their advantages in dirty environments. They are not affected by water, oil, vibrations, and maintain their accuracy.
2) Magnetic scales consist of a magnetic tape or strip glued onto an aluminum extrusion. The strip is coated with magnetic material and magnetized. A reader head detects the changing magnetic field to measure displacement.
3) Proper installation is important to maintain accuracy and protect the scale. The surface must be clean and parallel, with sufficient but minimal gap between the reader head and scale.
Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Techniqueijtsrd
The cold work applications like aluminium extrusion, it allows complex shapes to be formed with very smooth surfaces and it is popular for visible architectural applications such as window frames, door frames, roofs, and sign frames should have high toughness, wear resistance, compressive strength, high corrosion resistance, high surface finish and complex profiles. AA 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. This material can satisfy the above requirements, because of its hardness and strength AA 6063 cannot be machined easily through traditional machining processes. Advanced machining processes are used only when there is no suitable traditional machining process to meet necessary requirements efficiently and economically. Among them wire cut EDM is employed because of its tight tolerances and high surface finish. Based on intense literature survey, it was noticed that very few works were reported on WEDM of AA 6063. As a part of our thesis, WEDM of AA 6063 is considered for the study. In this work Pulse on time, pulse off time, peak current, wire speed, wire tension and flushing pressure of dielectric medium are considered as parameters and their effect on performance measures, metal removal rate MRR and surface roughness will be studied through experimental investigation. Using Taguchi approach, considered parameters will be optimized for maximum MRR and minimum for Surface roughness separately. Taguchi method will be applied to generate mean S N ratios to identify the optimum process parameters. Kandukuri Srinivas | K. Anabayan | P. H. J. Venkatesh "Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Technique" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31047.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/31047/optimization-of-wire-cut-edm-of-aluminium-alloy-6063-by-using-taguchi-technique/kandukuri-srinivas
Study of brass wire and cryogenic treated brass wire on titanium alloy using ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Techniqueijtsrd
The cold work applications like aluminium extrusion, it allows complex shapes to be formed with very smooth surfaces and it is popular for visible architectural applications such as window frames, door frames, roofs, and sign frames should have high toughness, wear resistance, compressive strength, high corrosion resistance, high surface finish and complex profiles. AA 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. This material can satisfy the above requirements, because of its hardness and strength AA 6063 cannot be machined easily through traditional machining processes. Advanced machining processes are used only when there is no suitable traditional machining process to meet necessary requirements efficiently and economically. Among them wire cut EDM is employed because of its tight tolerances and high surface finish. Based on intense literature survey, it was noticed that very few works were reported on WEDM of AA 6063. As a part of our thesis, WEDM of AA 6063 is considered for the study. In this work Pulse on time, pulse off time, peak current, wire speed, wire tension and flushing pressure of dielectric medium are considered as parameters and their effect on performance measures, metal removal rate MRR and surface roughness will be studied through experimental investigation. Using Taguchi approach, considered parameters will be optimized for maximum MRR and minimum for Surface roughness separately. Taguchi method will be applied to generate mean S N ratios to identify the optimum process parameters. Kandukuri Srinivas | K. Anabayan | P. H. J. Venkatesh "Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Technique" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31047.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/31047/optimization-of-wire-cut-edm-of-aluminium-alloy-6063-by-using-taguchi-technique/kandukuri-srinivas
Study of brass wire and cryogenic treated brass wire on titanium alloy using ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Laser assisted machining is a recent topic and has drastically reduced cutting forces and tool wear.
The presentation covers intro, setup, comparison of two processes and discussion about advantages and disadvantages of using this technique.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
OPTIMIZATION OF WIRE EDM PARAMETERS TO ACHIEVE A FINE SURFACE FINISHIjripublishers Ijri
Wire Cut Electric Discharge Machining process with a thin wire as an electrode transforms electrical energy to thermal
energy for cutting materials. WEDM is considered as a unique adoption of the conventional EDM process, which uses
an electrode to initialize the sparking process. However, WEDM utilizes a continuously travelling wire electrode made of
thin copper, brass or tungsten of diameter 0.05-0.30 mm, which is capable of achieving very small corner radii. The wire
is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. During
the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and
the wire, eliminating the mechanical stresses during machining.
Inside Matters has 2 main activities: 3D X-Ray Microscopy as a Service and the development of 3D Imaging Software. In this presentation you can find out exactly what we offer.
If you are looking for insights into micro cracks in ceramics, formation of ice crystals in food, porosity of plastics or what the effects are on a microscopic level of pressure on your materials, you should check out this presentation.
Also check out more details on 3D X-Ray Microscopy (also know as Industrial CT Scanning or XRT) on our website www.insidematters.eu
OPTIMIZATIONS OF MACHINING PARAMETER IN WIRE EDM FOR 316L STAINLESS STEEL BY ...IAEME Publication
WEDM is one of the non-traditional method used for the machining complex shape structure and components made up of hard material like composites and HSS. This is an experimental investigation of wire electro-discharge machining (WEDM) of 316L SS. The outstanding characteristics of stainless steel 316L such as their compatibility and noticeable physical, mechanical and biological performance has led to increased application of them in various industries especially in biomedical industries over the last 50 years.316L SS is used extensively for weldments where its immunity to carbide precipitation due to welding assures optimal corrosion resistance. There are some difficulties in machining of stainless steel by conventional machining. On the other hand, unconventional machining process especially Wire electrical discharge machining (WEDM) are more appropriate techniques for machining difficult to machine materials such as stainless steel.
Laser assisted machining is a recent topic and has drastically reduced cutting forces and tool wear.
The presentation covers intro, setup, comparison of two processes and discussion about advantages and disadvantages of using this technique.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
OPTIMIZATION OF WIRE EDM PARAMETERS TO ACHIEVE A FINE SURFACE FINISHIjripublishers Ijri
Wire Cut Electric Discharge Machining process with a thin wire as an electrode transforms electrical energy to thermal
energy for cutting materials. WEDM is considered as a unique adoption of the conventional EDM process, which uses
an electrode to initialize the sparking process. However, WEDM utilizes a continuously travelling wire electrode made of
thin copper, brass or tungsten of diameter 0.05-0.30 mm, which is capable of achieving very small corner radii. The wire
is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. During
the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and
the wire, eliminating the mechanical stresses during machining.
Inside Matters has 2 main activities: 3D X-Ray Microscopy as a Service and the development of 3D Imaging Software. In this presentation you can find out exactly what we offer.
If you are looking for insights into micro cracks in ceramics, formation of ice crystals in food, porosity of plastics or what the effects are on a microscopic level of pressure on your materials, you should check out this presentation.
Also check out more details on 3D X-Ray Microscopy (also know as Industrial CT Scanning or XRT) on our website www.insidematters.eu
OPTIMIZATIONS OF MACHINING PARAMETER IN WIRE EDM FOR 316L STAINLESS STEEL BY ...IAEME Publication
WEDM is one of the non-traditional method used for the machining complex shape structure and components made up of hard material like composites and HSS. This is an experimental investigation of wire electro-discharge machining (WEDM) of 316L SS. The outstanding characteristics of stainless steel 316L such as their compatibility and noticeable physical, mechanical and biological performance has led to increased application of them in various industries especially in biomedical industries over the last 50 years.316L SS is used extensively for weldments where its immunity to carbide precipitation due to welding assures optimal corrosion resistance. There are some difficulties in machining of stainless steel by conventional machining. On the other hand, unconventional machining process especially Wire electrical discharge machining (WEDM) are more appropriate techniques for machining difficult to machine materials such as stainless steel.
Magnetic FLux Control in Induction Systems - Fluxtrol Heat Processing Paper Fluxtrol Inc.
By Dr. Valentin Nemkov - Fluxtrol Inc.
Magnetic flux controllers are widely used in induction heating systems for concentration, shielding or redistribution of
the magnetic field which generates power in the part to be heated. Controllers, made of Soft Magnetic Composites
(SMC), provide accurate heat pattern control, improve parameters of inductors and performance of the entire installation.
In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic
control can provide large energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution
for enhancement of the metallurgical processes. Due to the diversity of applications, service conditions of controllers
are very different including very severe cases. Mechanical, magnetic, electrical, thermal and other properties must be
considered in design and application of SMC. This article describes properties and performance of SMC typically used
in induction heating technology. Several presented case stories are based on more than 20 years of R&D and practical
experience of scientists and practitioners at Fluxtrol, Inc. Presented material may be interesting not only for induction
heating community but also for all people using AC magnetic fields in technological processes.
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
Micron range complex structure in micro electrochemical machining- a revieweSAT Journals
Abstract
The major problem in the micro-manufacturing is concerned with achieving the good dimensional accurate products with the better surface finish, high MRR, no tool wear, absence of stress and no heat-affected zone. Micro-machining proved itself as a promising solution of this major problem. In recent days, industries are regularly looking for fabricating the micro-components which can be able to perform their complex functions in the sensitive areas of electronics, automotive, biomedical and optics. Now a day for miniature components micro-machining plays a very important role, its techniques are excellent to machine any complex shapes with good accuracy and bright surface finish. Material with any value of the hardness can be machined easily with all the offered advantages of micro-machining in the electrochemical micro-machining process (EMM). In this article; review of different methodologies and effect of machining parameters were studied along with different electrolytes; which plays a significant role in electro chemical micro-machining. The objective of this study is to know about the optimum micro-machining parameters for the EMM process and it is also much important to find out the research gap through the different studies. In this study, it has been found out MRR and overcut are depends upon the voltage, electrolyte concentration, IEG, pulse ON/OFF time, pulse duration, pulse frequency, RPM of the tool and flow rate of electrolyte. The proper selections of parameters in EMM are essentials for achieving the overall improvement in the micro-machining operation.
Micron range complex structure in micro electrochemical machining- a revieweSAT Journals
Abstract
The major problem in the micro-manufacturing is concerned with achieving the good dimensional accurate products with the better surface finish, high MRR, no tool wear, absence of stress and no heat-affected zone. Micro-machining proved itself as a promising solution of this major problem. In recent days, industries are regularly looking for fabricating the micro-components which can be able to perform their complex functions in the sensitive areas of electronics, automotive, biomedical and optics. Now a day for miniature components micro-machining plays a very important role, its techniques are excellent to machine any complex shapes with good accuracy and bright surface finish. Material with any value of the hardness can be machined easily with all the offered advantages of micro-machining in the electrochemical micro-machining process (EMM). In this article; review of different methodologies and effect of machining parameters were studied along with different electrolytes; which plays a significant role in electro chemical micro-machining. The objective of this study is to know about the optimum micro-machining parameters for the EMM process and it is also much important to find out the research gap through the different studies. In this study, it has been found out MRR and overcut are depends upon the voltage, electrolyte concentration, IEG, pulse ON/OFF time, pulse duration, pulse frequency, RPM of the tool and flow rate of electrolyte. The proper selections of parameters in EMM are essentials for achieving the overall improvement in the micro-machining operation.
Keywords: Micro-Manufacturing, Micro-Machining, Electrochemical Machining (ECM), Electrochemical Micro-Machining (EMM).
Tool design for Non-Conventional Machining.aman1312
tool design parameter consideration for three non conventional machining process has been discussed. they are Ultrasonic machining, Electrochemical machining.
2. Journal of Management Research and Development (JMRD), ISSN 2248 – 937X (Print) ISSN
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a) The suitable in the dirty environment nearby machine areas. b)It is not water proof,
when glass scales undergo water and cutting oil while using in the systems, the
performance will reduce or breakdown will happen.c)Accuracy will change much
during vibrations.
One of the most commonly used roughness measurement parameter is the Roughness
Average (Ra) or Mean Arithmetic Deviation, which is used to assess the coarseness of the
surface such as those produced by Grinding, Turning, Milling or other Finishing operations.
Fig-1. Type of metallic and glass scales used in digital read out systems.
Rmax & Rz : For some surface it is sometimes desirable to specify the maximum
roughness height Rmax, or the peak-to-valley height, Rz, rather than use the mean height Ra.
The Rmax parameter measures the highest and lowest points of the profile and is particularly
valuable where components are subjected to high stresses. Any large peak-to-valley heights
may be areas likely to suffer from crack propagation. These finishes are not falls in this
category.
2. CONSTRUCTION OF MAGNETIC SCALES
Magnetic scale consists of the magnetic tape which is also called as magnetic band, which
to be magnetized with extruded plastic material section glued on stainless steel strip.Fig.2.
For ease of installation on machine tools, magnetic tape is pu in aluminum extrusion. The
magnetic scales I glued firmly with a double sided tape in the groove and thin of 0.15 mm
thick, stainless steel strip is inserted over the magnetic tape in the aluminum section through
the grooves provided accordingly. There are three basic elements on construction,
Magnetic Scale ,Magnetic Reader Head.,Magnetic Tape.
Fig.2. Type of Magnetic Strip used in Magnetic Scales
These Magnetic scales are based on magnetic principal that magnetism passes through
water, through oil, through wood, paper and dirt. The strip is coated with magnetic material
power such as Barium Ferrite mix. This material directly cannot used in the strip , due to its
breaking nature. So they do glue in the magnetic strip and they will magnetize the same. The
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process is carried by special purpose machines .Fig 2 is a type of magnetic strip used in
magnetic scales which has having unique advantages as follows,
• Magnetic Scales perform will under dirt conditions in shop floor. Coolant and Water
splash exists in machining area , will not affect the scales. Life of magnetic is more
over glass and metallic scales. Accuracy and other measurements will not affect under
vibrations.
2.1 Technical Aspects of Magnetic Scales
The steel backed up magnetic strip is magnetized with the help of a magnetizer for alternate
poles N-S-N-SN-S N-S of desired width 2mm to 10mm.The magnetic sensor is made to
move along the length of the strip at right angle to the poles. The sensor detect the changing
magnetic field and gives voltage signal output.
This voltage signal is further interpolated and the required pulse train output is
obtained along with direction signal. With the help of this pulse train O/P distance
measurement can be obtained. This is a magnetic linear encoder works. Air gap between the
sensor and the magnetic strip is decided depending upon the magnetic field strength and
sensitivity of the sensor. It is normally of the order of 0.5 to 2mm depending upon the pole
pitch, accuracy etc.
2.2 Applications of Magnetic Scales
• It can be used in Digital read out systems along with conventional milling machines.
• Ideal to use in Digital Height masters in the DRO.
• Magnetic Scales also used in conventional lathe DROs.
• Profile projectors, special purpose machines can be used.
3. Reader Head
Fig.3. Type of Magnetic Tape scale with Reader Head.
3.1. Technical Specifications of Magnetic scale:
• Measuring length upto 30 meter , • Electrical ouput 5V TTL quadrate, • Resolution 5
micron, 10 micron, 20 mic, 50 mic & 100 mic , Reference mark optional, • Accuracy + 2
counts per meter at 20°c , • Protection against dust & coolant, • Maximum permissible cable
length - 15 mtrs, • Speed of operation - 10 met/sec (32ft./sec) ,Line driver with
Complimentary output
This is the most important part of the measuring system. It consists of an Aluminum box in
which is housed the electronic including the magnetic sensor. At the bottom of the sensor is a
stainless steel plate to prevent any damage to the sensor due to foreign body and while
operations. From one side of a box a cable with carrying all signal and supply wires.[Ref
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4.Fig.3] This reader also will work in dirt and water even they made such a way to absorb
and work under vibration conditions.
During operations magnetic dust can get collected on the surface of the magnetic scale. It
is always better to remove it otherwise it may damage the reader head. After long use. In
order to avoid it this dust should be scrapped away. In the construction of magnetic scales
special wiper has provided which will remove the dust during displacement which ensures for
better accuracy and readings without error.
4. Technical Specifications of Digital Height Master with Magnetic Scale:
Fig.4. Type of 2D Height Masters used in the industry with Magnetic Scales
•Color Graphical 5.7” size LCD Display,•Animated user friendly GUI
• High Accuracy Optical dual scanning Head Measuring 4 4 4 System,• Motorized
Measuring Carriage,• 3 Point Air Cushion,• Integrated Rechargeable Battery Backup
Provided for Long ,• Operation Time,• RS 232 Data Output,• Online 2D Drawing Plot on
LCD screen and DXF export to PC,• Auxiliary incremental Probe input
5. Safety Factors while installing the magnetic scales in Digital Read out systems:
The place where the scale is to be installed should be thoroughly cleaned from oil, dust,
coolant etc. Appropriate reader head mounting bracket to be designed to fix the reader head
such that it can freely move on the magnetic scale. Scale should be mounted in such a way
that grating sticker on the extrusion should be opposite side. Scale mounting surface of the
machine bed is even within 0.1mm per meter, then mount the scale directly on the bed by
using Allen screws through the holes in the end brackets and the desired positions.
We have ensure the parallelism to full length scale with the dial indicator firmly mounted
on machine and by moving table .If the mounting surface is even then scale mounting blocks
for each need to be manufactured before the installation of each scale. The measuring length
of the scale will vary depend upon the applications. Nonmagnetic portion of the scale at each
end of the scale so that magnetic dust pushed by the wiper will off. Technical specification as
follows,
a. Resolutions with four edge detections : 5,10,20 microns
b. System Accuracy : +/- 10 to 20 microns
c. Repeat Accuracy : +/- 1 count
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d. Scanning Material : Alloy aluminum with statin less steel base.
Mounting bracket for slider location (Fig .3.) should be be decided that slider should move
over the scale for full traverse of the machine slide and equal gap should be maintain between
slider bottom throughout its travel .Generally manual feed is is desirable for better results and
for life of the scale. The slider has to fit with M4 Allen keys firmly. Gap between scale and
slider should be maintained with the help of shim. To achieve this gap put the plastic shim
between the reader head and the bottom. While mounting the reader head we have to ensure
that dimple on the reader head is facing lines sticker on the extrusion.
Providing proper cover to protect scale and sensor for the entire length of the scale to ensure
the reliability and performance of the system. This cover gives protection against oil, coolant,
and metal chips during operations. This cable must be kept out of the way of moving parts of
the machine. The we have to ensure that, it will never get pulled or pushed during machine
operaations.Cable should not bend below radius 60mm during routing. Cable should the
routed nearby inductive load to avoid the electrical noise interference.
5. CONCLUSION
Though there are various types of scales available in the industries, cost of these equipments
has to consider. The role and significance of magnetic scale is inevitable in the engineering
industries as a technology up gradation and quality aspects. The cost per component for this
process is negligible in case of mass production. Even life of glass scale and metallic scale is
very less compare to glass scale. Therefore, cost per product will be less New Technology in
the manufacturing process and and have a edge in the field of metrology.
REFERENCES
1. Hand book for dimensional measurements By T. Farrago.P.18-25, 67-69.
2. www.innovativedro.com
3. Methods on precision finishing by Otech precision GmbH.
4. Metrology and measurements, by Bewoor.P23,54, 36-39
5. www.machine-dro.co.uk
6. Hand book on magnetic materials by, K.H.J.Bushow.
7. Machine tools Practices, by James A.Harvey. P.11,13-15,21,24
8. Text book for manufacturing technology by R.K.Rajput.P.488, P.496.
9. www.givimisure.tradeindia.com
10. New Generation scales, By shah, Chapter 4, P.18-26.
11. Luigi Lugiato Everything You Need to Know About Quantum Optics
12. Roy Tennant Magnetic scales in Digital readout systems.P.4,P.6-8,P.45-52
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