Muneer Khan Mohammed

A Hybrid Machining Process Combining Micro-EDM and Laser Beam Machining of Nickel–Titanium-Based Shape Memory Alloy

Micro-electrical discharge machining (EDM) is a slow process as compared to laser machining, on the contrary laser machining lacks good surface quality. To overcome the drawbacks of both these processes, this paper suggests a hybrid machining process which combines laser and micro-EDM processes for drilling microholes in advanced engineering materials such as Nickel–Titanium (Ni–Ti)-based shape memory alloy. To achieve the objective of the suggested hybrid process, pilot holes are drilled with laser machine and rimmed out by micro-EDM drilling. The suggested process requires investigation of various combinations of micro-EDM drilling process conditions to obtain optimum machining parameters for the hybrid process. It has been found that the proposed hybrid machining process resulted in 50–65% reduction in machining time without affecting the quality of microholes as compared to the standard micro-EDM process.

Effect of melt parameters on density and surface roughness in electron beam melting of gamma titanium aluminide alloy

Purpose Electron beam melting (EBM) is one of the potential additive manufacturing technologies to fabricate aero-engine components from gamma titanium aluminide (γ-TiAl) alloys. When a new material system has to be taken in to the fold of EBM, which is a highly complex process, it is essential to understand the effect of process parameters on the final quality of parts. This paper aims to understand the effect of melting parameters on top surface quality and density of EBM manufactured parts. This investigation would accelerate EBM process development for newer alloys. Design/methodology/approach Central composite design approach was used to design the experiments. In total, 50 specimens were built in EBM with different melt theme settings. The parameters varied were surface temperature, beam current, beam focus offset, line offset and beam speed. Density and surface roughness were selected as responses in the qualifying step of the parts. After identifying the parameters which were statistically significant, possible reasons were analyzed from the perspective of the EBM process. Findings The internal porosity and surface roughness were correlated to the process settings. Important ones among the parameters are beam focus offset, line offset and beam speed. By jointly deciding the total amount of energy input for each layer, these three parameters played a critical role in internal flaw generation and surface evolution. Research limitations/implications The range selected for each parameter is applicable, in particular, to γ-TiAl alloy. For any other alloy, the settings range has to be suitably adapted depending on physical properties such as melting point, thermal conductivity and thermal expansion co-efficient. Practical implications This paper demonstrates how melt theme parameters have to be understood in the EBM process. By adopting a similar strategy, an optimum window of settings that give best consolidation of powder and better surface characteristics can be identified whenever a new material is being investigated for EBM. This work gives researchers insights into EBM process and speeds up EBM adoption by aerospace industry to produce critical engine parts from γ-TiAl alloy. Originality/value This work is one of the first attempts to systematically carry out a number of experiments and to evaluate the effect of melt parameters for producing γ-TiAl parts by the EBM process. Its conclusions would be of value to additive manufacturing researchers working on γ-TiAl by EBM process.

Effect of Energy Input on Microstructure and Mechanical Properties of Titanium Aluminide Alloy Fabricated by the Additive Manufacturing Process of Electron Beam Melting

Titanium aluminides qualify adequately for advanced aero-engine applications in place of conventional nickel based superalloys. The combination of high temperature properties and lower density gives an edge to the titanium aluminide alloys. Nevertheless, challenges remain on how to process these essentially intermetallic alloys in to an actual product. Electron Beam Melting (EBM), an Additive Manufacturing Method, can build complex shaped solid parts from a given feedstock powder, thus overcoming the shortcomings of the conventional processing techniques such as machining and forging. The amount of energy supplied by the electron beam has considerable influence on the final build quality in the EBM process. Energy input is decided by the beam voltage, beam scan speed, beam current, and track offset distance. In the current work, beam current and track offset were varied to reflect three levels of energy input. Microstructural and mechanical properties were evaluated for these samples. The microstructure gradually coarsened from top to bottom along the build direction. Whereas higher energy favored lath microstructure, lower energy tended toward equiaxed grains. Computed tomography analysis revealed a greater amount of porosity in low energy samples. In addition, the lack of bonding defects led to premature failure in the tension test of low energy samples. Increase in energy to a medium level largely cancelled out the porosity, thereby increasing the strength. However, this trend did not continue with the high energy samples. Electron microscopy and X-ray diffraction investigations were carried out to understand this non-linear behavior of the strength in the three samples. Overall, the results of this work suggest that the input energy should be considered primarily whenever any new alloy system has to be processed through the EBM route.

Assessment of finite element and smoothed particles hydrodynamics methods for modeling serrated chip formation in hardened steel

This study aims to perform comparative analyses in modeling serrated chip morphologies using traditional finite element and smoothed particles hydrodynamics methods. Although finite element models are being employed in predicting machining performance variables for the last two decades, many drawbacks and limitations exist with the current finite element models. The problems like excessive mesh distortions, high numerical cost of adaptive meshing techniques, and need of geometric chip separation criteria hinder its practical implementation in metal cutting industries. In this study, a mesh free method, namely, smoothed particles hydrodynamics, is implemented for modeling serrated chip morphology while machining AISI H13 hardened tool steel. The smoothed particles hydrodynamics models are compared with the traditional finite element models, and it has been found that the smoothed particles hydrodynamics models have good capabilities in handling large distortions and do not need any geometric or mesh-based chip separation criterion.

Microchannels Fabrication in Alumina Ceramic Using Direct Nd:YAG Laser Writing

Ceramic microchannels have important applications in different microscale systems like microreactors, microfluidic devices and microchemical systems. However, ceramics are considered difficult to manufacture owing to their wear and heat resistance capabilities. In this study, microchannels are developed in alumina ceramic using direct Nd:YAG laser writing. The laser beam with a characteristic pulse width of 10 µs and a beam spot diameter of 30 µm is used to make 200 µm width microchannels with different depths. The effects of laser beam intensity and pulse overlaps on dimensional accuracy and material removal rate have been investigated using different scanning patterns. It is found that beam intensity has a major influence on dimensional accuracy and material removal rate. Optimum parameter settings are found using grey relational grade analysis. It is concluded that low intensity and low to medium pulse overlap should be used for better dimensional accuracy. This study facilitates further understanding of laser material interaction for different process parameters and presents optimum laser process parameters for the fabrication of microchannel in alumina ceramic.

Assessment of Direct Laser Writing using Nd YAG Lasers for Microfluidic Applications

The rapid growth in the use of Micro/Nano products in variety of industries such as Micro electromechanical systems (MEMS), microelectronics, Biomedical/Bio-MEMS, automotive (motion sensors), telecommunications etc, has demanded new micro manufacturing methods. The challenge with the manufacturing of Microfluidic devices/biochips is that they often make use of broad range of materials within a single chip, making it difficult to manufacture these devices with conventional photolithographic based techniques. Laser processing of materials has proved to be an important tool for the development of these devices because of the accuracy, flexibility and the most important one material independence it offers. This research focus on optimization of laser process parameters for the machining of Microfluidic channels with AISI 1045 steel. Design of experiments (DOE) technique was used in order to study the effect of laser process parameters on rectangular and semicircular cross-section channels.