This book offers a comprehensive overview of the fundamentals, principles, and latest innovations in advanced machine and micromachining processes.
Businesses are continually seeking innovative advanced machining and micromachining techniques that optimize efficiency while reducing environmental harm. This growing competitive pressure has spurred the development of sophisticated design and production concepts. Modern machining and micromachining methods have evolved to accommodate the use of newer materials across diverse applications, while ensuring precise machining accuracy.
The primary aim of this book is to explore and analyze various approaches in modern machining and micromachining processes, with a focus on their effectiveness and application in successful product development. Consequently, the book emphasizes an industrial engineering perspective.
This book covers a range of advanced machining and micromachining processes that can be utilized by the manufacturing industry to enhance productivity and contribute to socioeconomic development. Additionally, it highlights ongoing research projects in the field and provides insights into the latest advancements in advanced machining and micromachining techniques.
The 31 chapters in the book cover the following subjects: abrasive jet machining; water jet machining; principles of electro discharge machining; wire-electro discharge machining; laser beam machining; plasma arc machining; ion beam machining; electrochemical machining; ultrasonic machining; electron beam machining; electrochemical grinding; photochemical machining process; abrasive-assisted micromachining; abrasive water jet micromachining; electro discharge machining; electrochemical micromachining; ultrasonic micromachining; laser surface modification techniques; ion beam processes; glass workpiece micromachining using electrochemical discharge machining; abrasive water jet machining; ultrasonic vibration-assisted micromachining; laser micromachining’s role in improving tool wear resistance; stress; and surface roughness in high-strength alloys; abrasive flow finishing process; elastic emission machining; magnetic abrasive finishing process; genetic algorithm for multi-objective optimization in machining; machining of Titanium Grade-2 and P-20 tool steel; and wet bulk micromachining in MEMS fabrication.
Audience
The book is intended for a wide audience including mechanical, manufacturing, biomedical, and industrial engineers and R&D researchers involved in advanced machining and micromachining technology.
Preface xxiii 1 Overview of Advanced Machining and Micromachining Processes 1 M. Abdur Rahman, Serajul Haque and N. Sri Rangarajalu 2 Abrasive Jet Machining 23 Jagadeesha T. and Sandip Kunar 3 Water Jet Machining 35 Jagadeesha T. and Sandip Kunar 4 Electric Discharge Machining 47 Jagadeesha T. and Sandip Kunar 5 Wire-Electric Discharge Machining 65 Jagadeesha T. and Sandip Kunar 6 Laser Beam Machining 77 Jagadeesha T. and Sandip Kunar 7 Plasma Arc Machining 93 Jagadeesha T. and Sandip Kunar 8 Ion Beam Machining 107 Jagadeesha T. and Sandip Kunar 9 Electrochemical Machining 115 Thavasilingam K., Sakthimurugan D., Giridharan K., Praveen Kumar A. and Meenatchisundaram P. 10 Ultrasonic Machining 127 Jagadeesha T. and Sandip Kunar 11 Electron Beam Machining 143 Jagadeesha T. and Sandip Kunar 12 Chemical Machining 159 Jagadeesha T. and Sandip Kunar 13 Electrogrinding 177 Chika Oliver Ujah, Nebechi Kate Obiora and Daramy V.V. Kallon 14 Photochemical Machining 203 Sandip Kunar, Jagadeesha T., Gurudas Mandal, Norfazillah Talib, Akhilesh Kumar Singh and Itha Veeranjaneyulu 15 Abrasive-Assisted Micromachining 215 Rayappa Shrinivas Mahale, Krishnamurthy Goggi, Vaibhav Raibole, K.B. Jagadeeshgouda and Prashant Kakkamari 16 Abrasive Water Jet Micromachining: Pushing the Micro-Frontier Further--A Glimpse at Recent Advancements 251 M. Abdur Rahman, Mohamed Bak Kamaludeen, T. R. Tamilarasan, N. Rajmohan and S. Loganathan 17 Micro-Electrical Discharge Machining: State of Art 273 M. Sivakumar, C. T. Justus Panicker, R. Karthikeyan and G. Suresh 18 Electrochemical Micromachining 295 Bikash Ghoshal and Daya Shankar Diwakar 19 Ultrasonic Micromachining 323 Pradeepkumar Krishnan 20 Laser Surface Modification of Implant Materials: An Insight 333 V. K. Bupesh Raja, Sathish Kannan, Jayaprakash Jeyaraju, V. Selvarani, Abel J. Francis and A. Jayaganthan 21 Ion Beam Processing: A Brief Review 349 Pravin Pawar, Amaresh Kumar and Raj Ballav 22 Parametric Optimization in Electrochemical Discharge Machining of Microchannel on Glass Using Multiple Tool Passes 377 Rithwik Shankar Raj, Neeraj Bagi, Jinka Ranganayakulu, A. Bharatish and K. Venkata Rao 23 Abrasive Water Jet Machining 395 Ashok K.G., Ajith D., Raju M. and Thiagarajan S. 24 Effect of Ultrasonic Vibration-Assisted Micromachining on the Surface Properties of Difficult-to-Machine Materials 415 P. Jeyapandiarajan, Joel J., S. Arulvel, E. Venkatesaperumal, D. Vignesh and Sreethul Das 25 A Significant Impact of Laser-Assisted Micromachining on Tribological Properties of High Strength Alloys 429 E. Venkatesaperumal, P. Jeyapandiarajan, S. Arulvel, J. Joel and Jayakrishna Kandasamy 26 Abrasive Flow Finishing 447 Sandip Kunar, Jagadeesha T., Gurudas Mandal and Norfazillah Talib 27 Elastic Emission Machining 463 Sandip Kunar, Jagadeesha T., Gurudas Mandal and Norfazillah Talib 28 Magnetic Abrasive Finishing Process 467 Sandip Kunar, Jagadeesha T., Gurudas Mandal and Norfazillah Talib 29 Experimental Analysis of EDM Process While Machining Ti-VT20 Alloy 483 Pritam Pain, Goutam Kumar Bose, Dipankar Bose and Sourav Giri 30 Estimation of Machining Performance and Machining Characteristics Using Artificial Neural Network in Wire Electric Discharge Machine for Titanium & P-20 Materials 505 Prathik Jain S., Sundaramahalingam A., Sudhagara Rajan S., Chethan K. N., Rudresh Addamani and Ugrasen G. 31 Chemical-Based Bulk Machining and Fabrication of Silicon Microstructures: An Overview 527 Sumanta Banerjee References 550 Index 553
Sandip Kunar, PhD, is an assistant professor in the Department of Mechanical Engineering, Aditya Engineering College, A.P., India. He has published more than 50 research papers in various reputed international journals, national and international conference proceedings, 16 book chapters, and 10 books as well as two patents. His research interests include non-conventional machining processes, micromachining processes, advanced manufacturing technology, and industrial engineering. Norfazillah Binti Talib, PhD, is a senior lecturer in the Department of Manufacturing Engineering, Faculty of Mechanical and Manufacturing Engineering, University Tun Hussien Onn Malaysia, Parit Raja, Johar, Malaysia. She has also been appointed the Head of the Precision Machining Research Center. She has published numerous papers in reputable journals, book chapters, and proceedings from conferences and has filed one patent. Her research interests include sustainable manufacturing processes, bio-based lubricants, and tribology. Gurudas Mandal, PhD, is an assistant professor in the Department of Metallurgical Engineering, Kazi Nazrul University, West Bengal, India. He has about 25 technical research publications in international journals, eight conference proceedings and 10 book chapters, as well as one patent.
