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Advanced Machining and Micromachining Processes

Edited by Sandip Kunar, Norfazillah Binti Talib and Gurudas Mandal
Series: Advances in Production Engineering
Copyright: 2025   |   Status: Published
ISBN: 9781394301690  |  Hardcover  |  
586 pages
Price: $225 USD
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One Line Description
This book offers a comprehensive overview of the fundamentals, principles, and latest innovations in advanced machine and micromachining processes.

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.

Description
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 micromachinin g in MEMS fabrication.

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Author / Editor Details
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 Binto 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 Mandel, 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.

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Table of Contents
Preface
1. Overview of Advanced Machining and Micromachining Processes
M. Abdur Rahman, Serajul Haque and N. Sri Rangarajalu
1.1 Introduction
1.1.1 Classification of Advanced Machining and Micromachining Processes
1.1.1.1 Mechanical Machining
1.1.1.2 Abrasive Waterjet Machining (AWJM)
1.1.1.3 Abrasive Jet Machining (AJM)
1.1.1.4 Ultrasonic Machining (USM)
1.1.1.5 Grinding and Superfinishing
1.2 Electrical Machining
1.2.1 Electrical Discharge Machining (EDM)
1.2.2 Wire-Electrical Discharge Machining (Wire-EDM)
1.2.3 Electrochemical Machining (ECM)
1.2.4 Electrochemical Grinding (ECG)
1.3 Thermal Machining
1.3.1 Laser Beam Machining (LBM)
1.3.2 Plasma Arc Machining (PAM)
1.3.3 Electron Beam Machining (EBM)
1.4 Chemical Machining
1.4.1 Chemical Machining (CHM)
1.4.2 Photochemical Machining (PCM)
1.5 Mechanical Micromachining
1.5.1 Micro-Milling
1.5.2 Abrasive Water Jet Micromachining (AWJMM)
1.5.3 Abrasive-Assisted Machining
1.6 Electrical Micromachining
1.6.1 Electrical Discharge Micromachining (EDMM)
1.6.2 Electro-Chemical Discharge Machining (ECDM)
1.7 Thermal Micromachining
1.7.1 Laser Beam Micromachining (LBM)
1.7.2 Plasma Arc Micromachining
1.7.3 Laser-Assisted Micromachining
1.8 Chemical Micromachining
1.8.1 Chemical Micromachining (CMM)
1.8.2 Electrochemical Micromachining (ECMM)
1.8.3 Chemo-Mechanical Polishing (CMP)
1.9 Ultrasonic Micromachining
1.9.1 Ultrasonic Micromachining (USMM)
1.9.2 Ultrasonic-Assisted Micromachining (UAMM)
1.10 Other Micromachining Processes
1.10.1 Focused Ion Beam Machining (FIBM)
1.10.2 Ion Beam Micromachining (IBMM)
1.11 Future Directions and Emerging Technologies
1.11.1 Challenges and Considerations
1.11.2 The Following are Some Additional Trends that are Likely to Shape the Future of Micromachining
1.12 Conclusion
References
2. Abrasive Jet Machining
Jagadeesha T. and Sandip Kunar
2.1 Introduction
2.2 Description of Process
2.3 Equipment Description
2.4 Process Parameters
2.5 Process Capabilities
2.6 Application of Abrasive Jet Machining
2.7 Benefits of Abrasive Jet Machining (AJM)
2.8 Drawbacks of Abrasive Jet Machining
2.9 Characteristics of AJM
2.9.1 The Influence of the Abrasive Flow Rate and Particle Size on the Material Removal Rate (MRR)
2.9.2 Impact of Abrasive Particle Density and Exit Gas Velocity
2.9.3 Influence of the Mixing Ratio on Material Removal Rate (MRR)
2.9.4 Nozzle Pressure’s Impact on MRR
2.9.5 Stand-Off Distance (SOD)
2.10 Mechanics of Cutting in AJM
References
3. Water Jet Machining
Jagadeesha T. and Sandip Kunar
3.1 Introduction
3.2 Description of Process
3.3 Description of Equipment
3.3.1 Hydraulic Pump
3.3.2 Intensifier
3.3.3 Accumulator
3.3.4 Nozzles
3.3.5 High Pressure Tubing
3.3.6 Catcher
3.4 Process Parameters
3.4.1 Jet Nozzle
3.4.2 Jet Fluid
3.4.3 Target Material
3.4.4 Material Removal Rate (MRR)
3.4.5 Geometry and Finish of Work Piece
3.4.6 Wear Rate of Nozzle
3.5 Process Capability
3.5.1 Cutting and Slitting
3.5.2 Cable Stripping
3.5.3 Deburring
3.6 Applications of WJM
3.7 Advantages of WJM
3.8 Disadvantages of WJM
3.9 Worked Examples
References
4. Electric Discharge Machining
Jagadeesha T. and Sandip Kunar
4.1 Introduction
4.2 Description of Process
4.3 Basic Requirement of EDM Process
4.4 Description of Equipment
4.5 Types of Generators
4.6 Electrode Material
4.7 Choice of Dielectric Fluid
4.8 EDM Tool Design
4.8.1 Choice of Machining Operation
4.8.2 Choice of Electrode Material
4.8.3 Machine Settings
4.8.4 Under Sizing and Length of Electrode
4.8.5 Machining Time
4.9 Process Parameters
4.10 Machining Characteristics
4.11 Process Capabilities of EDM
4.12 Characteristics of Spark-Eroded Surfaces
4.13 Applications of EDM
4.14 Advantages of EDM
4.15 Disadvantages of EDM
4.16 Factors to be Considered in EDM Machine Tool Selection
References
5. Wire-Electric Discharge Machining
Jagadeesha T. and Sandip Kunar
5.1 Introduction
5.2 Description of Process
5.3 Equipment
5.4 Process Parameters of Wire EDM
5.5 Process Capability of Wire EDM
5.6 Difference Between Wire EDM and EDM
5.7 Applications of Wire EDM
5.8 Advantages of Wire EDM
5.9 Disadvantages of Wire EDM
5.10 Process Parameters in Wire EDM
5.11 Worked Examples
References
6. Laser Beam Machining
Jagadeesha T. and Sandip Kunar
6.1 Introduction
6.2 Lasing Action and Population Inversion
6.3 Methods to Achieve Population Inversion
6.4 Types of Lasers
6.5 Description of Process
6.6 Beam Parameters
6.7 Process Capability
6.8 Applications of LBM
6.9 Advantages of LBM
6.10 Disadvantages of LBM
6.11 Comparison Between EBM and LBM
References
7. Plasma Arc Machining
Jagadeesha T. and Sandip Kunar
7.1 Introduction
7.2 Plasma Generation
7.3 Description of Process
7.4 Description of Equipment
7.5 Modes of Operation of DC Plasma Torches
7.6 Methods to Make Arcs More Stable
7.7 Parameters that Influence PAM Performance
7.7.1 The Parameters Related to the Design and Operation of the Torch
7.7.2 Parameters Associated with Physical Configuration of the Setup
7.7.3 Parameters Related to the Setting in Which Work is Performed
7.8 Capability to Process
7.9 Applications of Plasma Arc Machining
7.10 Advantages of PAM
7.11 Disadvantages of PAM
7.12 Safety Precautions to be Taken in PAM
References
8. Ion Beam Machining
Jagadeesha T. and Sandip Kunar
8.1 Introduction
8.2 Description of Process
8.3 Description of Equipment
8.4 Process Characteristics
8.5 Applications of IBM
8.6 Advantages of IBM
8.7 Disadvantages of IBM
References
9. Electrochemical Machining
Thavasilingam K., Sakthimurugan D., Giridharan K., Praveen Kumar A. and Meenatchisundaram P.
9.1 Introduction
9.2 Electrochemical Machining Techniques
9.2.1 Electrolytic and Electrolytic-Plasma Machining
9.2.2 Tool Electrode Design
9.3 Process Parameters and Control
9.3.1 Voltage, Current, and Electrolyte Composition
9.3.2 Temperature and pH Control
9.4 Material Specifications in ECM
9.4.1 ECM Applied in Metals and Alloys
9.4.2 ECM Applied in Insulating Materials
9.4.3 Surface Finish and Microstructure
9.5 Advancements in ECM Technology
9.5.1 Hybrid Approaches
9.5.2 Nano-ECM and Emerging Trends
9.6 Conclusion
References
10. Ultrasonic Machining
Jagadeesha T. and Sandip Kunar
10.1 Introduction
10.2 Process Description
10.3 Description of Equipment
10.4 Tool Feed Mechanism
10.5 Abrasive Slurry
10.6 Liquid Media
10.7 Process Parameters
10.8 Process Capability
10.9 Applications
10.10 Advantages of USM
10.11 Disadvantages of USM
10.12 Mechanism of Material Removal in Ultrasonic Machining Operation
10.13 Recent Developments in USM
References
11. Electron Beam Machining
Jagadeesha T. and Sandip Kunar
11.1 Introduction
11.2 Theory of EBM
11.2.1 Mechanics of Material Removal in EBM
11.3 Equipment
11.4 Mathematics of Electron Beam Machining
11.5 Mechanics of EBM
11.6 Process Parameter of Electron Beam Machining
11.7 Application of EBM
11.8 Advantages of EBM
11.9 Disadvantages of EBM
11.10 Worked Out Examples
References
12. Chemical Machining
Jagadeesha T. and Sandip Kunar
12.1 Introduction
12.2 General Description of Chemical Machining Process
12.3 Five Steps of Chemical Machining
12.4 Elements of Process
12.5 Influence of Etchant Medium
12.6 Chemical Blanking
12.7 Accuracy of Chemical Blanking
12.8 Applications of Chemical Machining
12.9 Advantages of CHM
12.10 Disadvantages of CHM
12.11 Selection of Maskant
12.12 Selection of Etchants
12.13 Chemical Milling
12.13.1 Process Steps for Chemical Milling
12.13.2 Process Characteristics
12.13.3 Process Parameters of Chemical Milling
12.13.4 Applications of Chemical Milling
12.13.5 Advantages of Chemical Milling
12.13.6 Disadvantages of Chemical Milling
12.14 Chemical Engraving
12.15 Photochemical Blanking
12.15.1 Photo Chemical Blanking Process
12.15.2 Applications of Photo Chemical Machining (PCM)
12.15.3 Advantages of PCM
12.15.4 Disadvantages of PCM
12.16 Worked Examples
References
13. Electrogrinding
Chika Oliver Ujah, Nebechi Kate Obiora and Daramy V.V. Kallon
13.1 Introduction
13.1.1 Overview of Electrochemical Grinding (ECG)
13.1.2 Evolution of ECG for Machining
13.1.3 Comparison Between ECG and Electrochemical Machining (ECM)
13.2 Electrochemical Grinding Operational Parameters
13.2.1 Machining Voltage
13.2.2 Electrolyte Concentration
13.2.3 Duty Cycle
13.2.4 Tool Feed Rate
13.2.5 Temperature of the Electrode
13.2.6 Current
13.2.7 Material Removal Rate (MRR)
13.2.7.1 Mathematical Correlations of Material Removal Rate
Due to Abrasive Process in ECG
13.3 Process and Working Principles of Electrochemical Grinding
13.3.1 Electrochemical Processes
13.3.2 Rotating Grinding Wheel
13.3.3 Material Removal
13.4 Components of Electrochemical Grinding Machines
13.4.1 Conductive Grinding Wheel
13.4.2 Electrolyte Fluid
13.4.3 DC Power Supply
13.4.4 Pump and Filter
13.4.5 Pressure Gauge
13.4.6 Flow Meter
13.5 Grinding Methods of ECG
13.5.1 Internal Grinding
13.5.2 Cylindrical Grinding
13.6 Variations of Electrochemical Grinding in Research Stage
13.6.1 Wire Electrochemical Grinding
13.6.2 Inner-Jet Electrochemical Grinding
13.6.3 Ultrasonic-Assisted Electrochemical-Drill Grinding
13.6.4 Pulsed Electrochemical Grinding
13.6.5 Abrasive Electrochemical Grinding (AECG)
13.6.6 Electrochemical Mill-Grinding (ECMG)
13.6.7 Internal Cylindrical Plunge Electrochemical Grinding (ICPECG)
13.6.8 Electrochemical Face Grinding (ECFG)
13.7 Industrial Applications of ECG
13.7.1 Grinding High-Powered Blades
13.7.2 Sharpening Hypodermic Needles
13.7.3 Grinding Tungsten and Carbide Tool Bits
13.7.4 Grinding of Cutting Tools
13.7.5 Production of Thin-Walled Tube
13.7.6 Aerospace
13.7.7 Bearing Raceways
13.7.8 Energy Sector
13.8 Advantages and Challenges of Electrochemical Grinding
13.9 Grinding Processes
13.9.1 Conventional Grinding
13.9.2 Abrasive Flow Machining (AFM)
13.9.3 Water-Jet Machining
13.9.4 Laser Grinding
13.10 Summary and Recommendation
References
14. Photochemical Machining
Sandip Kunar, Jagadeesha T., Gurudas Mandal, Norfazillah Talib, Akhilesh Kumar Singh and Itha Veeranjaneyulu
14.1 Introduction
14.2 Contextual
14.3 PCM Process
14.4 Mechanism of Etching
14.5 Steps for Experimental Designing
14.6 Process Parameters
14.7 Parametric Effect
14.8 Analysis of Machined Surfaces
14.9 Conclusion
14.10 Scope for Future Work
References
15. Abrasive-Assisted Micromachining
Rayappa Shrinivas Mahale, Krishnamurthy Goggi, Vaibhav Raibole, K.B. Jagadeeshgouda and Prashant Kakkamari
15.1 Introduction
15.1.1 Literature Survey
15.2 Erosion Mechanism
15.2.1 Abrasive Particle Characteristics
15.2.2 Material Properties
15.2.3 Micromachining Parameters
15.2.4 Interaction Between Abrasive Particles and Workpiece
15.3 Erosion Mechanisms in AAM Explanation
15.3.1 Particle Impact and Cutting Mechanisms
15.3.2 Fatigue Damage from Repetitive Impacts
15.3.3 Factors Influencing Erosion Rate
15.3.4 Variability of Erosion Across Materials
15.4 Existing Erosion Models
15.4.1 Introduction to Erosion Models
15.4.2 Overview of Existing Erosion Models
15.4.3 Relevance of Existing Erosion Models to AAM
15.4.4 Importance of Specialized Erosion Models for AAM
15.5 Development of AAM Erosion Models
15.5.1 Introduction to Model Development
15.5.2 Incorporating Process Parameters Into Models
15.5.3 Considering Material Responses in Models
15.5.4 Data Collection and Analysis for Model Development
15.6 Verification and Validation of AAM Erosion Models
15.6.1 Introduction to Verification and Validation
15.6.2 Verification Process for AAM Erosion Models
15.6.3 Experimental Techniques for Measuring Erosion
15.6.4 Comparison of Model Predictions with Experimental Data
15.7 Applications of Erosion Models
15.7.1 Role of Erosion Models in Process Optimization
15.7.2 Tool Wear Prediction and Management
15.7.3 Quality Improvement Through Erosion Modeling
15.8 Advancements in Erosion Modeling Techniques
15.8.1 Future Directions in Erosion Modeling for AAM
15.9 Concluding Remarks and Implications for AAM Erosion Modeling
References
16. Abrasive Water Jet Micromachining: Pushing the Micro-Frontier Further—
A Glimpse at Recent Advancements
M. Abdur Rahman, Mohamed Bak Kamaludeen, T. R. Tamilarasan, N. Rajmohan and S. Loganathan
16.1 Introduction
16.2 The Essence of AWJMM: A Powerful Blend of Water and Grit
16.2.1 Abrasive Water Jet Micromachining Setup
16.2.2 Advantages of AWJMM
16.2.3 Unveiling the Applications of AWJMM
16.3 Some Prominent Research Works on Abrasive Water Jet Micromachining
16.3.1 The Intricacies of Submerged and Dry Abrasive Water Jet (AWJ) Micromilling
16.3.2 Predicting Microfeature Profiles in ASJM of Borosilicate Glass
16.3.3 Micromilling Metals with Water: Submerged or Not?
16.3.4 High-Aspect-Ratio Fins via Abrasive Water Jet Micromachining
16.3.5 Narrowing Down AWJ Micromachining with Metal Masks
16.3.6 Predicting Microchannel Profiles in ASJM of Ductile Materials
16.3.7 Predicting Microchannel Machining with Abrasive Water Jets: A New Model Emerges
16.3.8 Air’s Influence on Abrasive Micromachining: Less Waviness, Narrower Channels
16.4 Conclusion
16.5 A Glimpse Into the Future: What Lies Ahead for AWJMM?
References
17. Micro-Electrical Discharge Machining: State of Art
M. Sivakumar, C. T. Justus Panicker, R. Karthikeyan and G. Suresh
17.1 Introduction
17.2 Principles of Micro-EDM
17.2.1 Working Principle
17.2.2 Gap Phenomena of Micro-EDM
17.2.3 Contrasting Macro-EDM from Micro-EDM
17.3 Major Components of Micro-Electrical Discharge Machining
17.3.1 Resistor-Capacitor (RC) Pulse Generators
17.3.2 Servo Control System
17.3.3 Dielectric Circulation System
17.4 Process and Machining Parameters of Micro-Electrical Discharge Machining
17.4.1 Process Parameters of Micro-EDM
17.4.2 Non-Electrical Process Parameters of Micro-Electrical Discharge Machining
17.4.3 Machining Characteristics of Micro-Electrical Discharge Machining
17.5 Major Varieties of Electrical Discharge Micromachining
17.5.1 Micro-Wire Electro-Discharge Machining (μ-WEDM)
17.5.2 Micro-Electrical Discharge Grinding (Micro-EDG)
17.6 Hybrid Type of Electrical Discharge Micromachining
17.6.1 Simultaneous Micro-EDM and Micro-ECM (SEDCM)
17.6.2 Ultrasonic Cavitation-Assisted Micro-EDM
17.7 Summary
References
18. Electrochemical Micromachining
Bikash Ghoshal and Daya Shankar Diwakar
18.1 Introduction
18.1.1 Electrochemical Machining Process Overview
18.2 Overview of Electrochemical Micromachining
18.3 Electrochemistry of Electrochemical Micromachining
18.3.1 Metal Removal Mechanism in Electrochemical Micromachining
18.3.1.1 Metal Removal Rate Based on the Double Layer Model
18.3.1.2 MRR Equation for EMM Based on Pulsed Wave Form
18.3.2 Evolution of Shape in Electrochemical Micromachining
18.4 Machining Conditions in Electrochemical Micromachining
18.4.1 Power Supply in Electrochemical Micromachining
18.4.2 Electrolytes in Electrochemical Micromachining
18.4.3 Role of Inter-Electrode Gap in Machining Accuracy
18.5 Electrochemical Micromachining Set Up
18.5.1 Machining Unit
18.5.2 Power Supply Unit
18.5.3 Data Collection System
18.6 Fabrication of Different Microtools in Electrochemical Micromachining
18.7 Process of Measurement of Microfeatures
18.8 Application of Electrochemical Micromachining
18.9 Conclusions
18.10 Future Research Opportunities
References
19. Ultrasonic Micromachining
Pradeepkumar Krishnan
19.1 Introduction
19.2 Principles of Ultrasonic Micromachining
19.3 Equipment for Ultrasonic Micromachining
19.4 Process Parameters in Ultrasonic Micromachining
19.5 Applications of Ultrasonic Micromachining
19.6 Advantages and Limitations of Ultrasonic Micromachining
19.6.1 Advantages
19.6.2 Limitations
19.7 Recent Advancements and Emerging Trends
19.7.1 Latest Advancements
19.7.2 Emerging Trends
19.8 Conclusions
Acknowledgment
References
20. Laser Surface Modification of Implant Materials: An Insight
V. K. Bupesh Raja, Sathish Kannan, Jayaprakash Jeyaraju, V. Selvarani, Abel J. Francis and A. Jayaganthan
20.1 Introduction
20.2 Fundamentals of Laser Surface Modification
20.3 Laser Surface Modification Techniques
20.3.1 Laser Surface Melting and Re-Solidification
20.3.2 Laser Ablation
20.3.3 Laser Cladding and Alloying
20.3.4 Laser Surface Texturing
20.3.5 Laser-Induced Surface Patterning
20.3.6 Laser Surface Alloying and Nitriding
20.3.7 Comparison of Different Laser Surface Modification Techniques
20.4 Applications of Laser Surface Modification in Implant Materials
20.4.1 Surface Modification of Metallic Implants Using Laser Techniques
20.4.2 Enhancement of Biocompatibility and Osteointegration Through Laser Surface Modification
20.4.3 Surface Modification of Polymer-Based Implants Using Laser Techniques
20.4.4 Laser Surface Modification for Controlled Drug Delivery from Implant Surfaces
20.5 Characterization of Laser-Modified Surfaces
20.5.1 Techniques for Characterizing Laser-Modified Surfaces
20.5.1.1 Scanning Electron Microscopy (SEM)
20.5.1.2 Atomic Force Microscopy (AFM)
20.5.1.3 X-Ray Photoelectron Spectroscopy (XPS)
20.5.1.4 X-Ray Diffraction (XRD)
20.5.2 Analysis of Surface Morphology, Roughness, and Composition
20.5.3 Evaluation of Mechanical Properties and Surface Wettability
20.6 Challenges and Future Perspectives
20.6.1 Challenges and Limitations Associated with Laser Surface Modification Techniques
20.6.2 Strategies for Overcoming Challenges and Optimizing Laser Surface Modification Processes
20.6.2.1 Process Optimization
20.6.2.2 Multi-Step Processing
20.6.2.3 Material Selection and Design
20.6.2.4 Surface Pre-Treatment
20.6.3 Emerging Trends and Future Directions in Laser Surface Modification of Implant Materials
20.6.3.1 Advanced Laser Technologies
20.6.3.2 Functional Surface Designs
20.6.3.3 Innovative Materials and Composites
20.7 Conclusion
References
21. Ion Beam Processing: A Brief Review
Pravin Pawar, Amaresh Kumar and Raj Ballav
21.1 Introduction
21.2 Focused Ion Beam Process
21.2.1 Introduction of Focused Ion Beam
21.2.2 Focused Ion Beam Milling
21.2.3 Focused Ion Beam Machining
21.2.4 Focused Ion Beam Fabrication
21.2.5 Focused Ion Beam Etching
21.2.6 Focused Ion Beam Deposition
21.3 Ion Beam Process
21.3.1 Ion Beam Machining
21.3.2 Ion Beam Etching
21.3.3 Ion Beam Deposition
21.3.4 Ion Beam Figuring
21.4 Developed Ion Beam Process
21.5 Combined Ion Beam Process
21.6 Conclusion
22. Parametric Optimization in Electrochemical Discharge Machining of Microchannel on Glass Using Multiple Tool Passes
Rithwik Shankar Raj, Neeraj Bagi, Jinka Ranganayakulu, A. Bharatish and K. Venkata Rao
22.1 Introduction
22.1.1 Applications of Glass-Based Microfluidic Devices
22.1.2 Material Removal in ECDM
22.1.3 Electrolyte Type and Influence of Electrolytes
22.1.4 ECDM Process Parameters and Statistical Analysis
22.2 Methodology Adopted to Machine Microchannel
22.3 Experimentation
22.3.1 Step-by-Step Procedure for Conducting the Experiments
22.3.2 Experimental Results
22.3.2.1 Characterization of Microchannels
22.3.3 Grey Relational Analysis
22.4 Multi-Response Optimization
22.4.1 Calculation of S/N Ratio for the Responses
22.4.2 Normalization of S/N Ratio Values
22.4.3 Calculation of GRC and GRG
22.4.4 Calculation of Optimal Levels for Process Parameters Using Multi-Response Performance Index (MRPI)
22.5 Conclusions
References
23. Abrasive Water Jet Machining
Ashok K.G., Ajith D., Raju M. and Thiagarajan S.
23.1 Introduction
23.2 Elements of Abrasive Water Jet Machining
23.2.1 High-Pressure Hydro Jet Production
23.2.2 Hydro Pump Systems
23.2.3 Pressure Amplifiers
23.2.4 Abrasive Particles
23.2.5 Nozzle Geometry
23.2.6 Abrasive Blending and Distribution
23.3 Process Variables and Operating Factors in AWJM
23.3.1 Water Flow Rate and Pressure
23.3.2 Abrasive Particle Size and Velocity
23.3.3 Standoff Length
23.3.4 Traverse Velocity
23.4 Abrasive Water Jet Machining Applications
23.4.1 Automotive Industry
23.4.2 Aerospace Industry
23.4.3 Profiling and Metal Cutting
23.4.4 Machining of Composite Materials
23.4.5 Glass Machining
23.5 Advantages of Abrasive Water Jet Machining
23.6 Challenges and Limitations
23.6.1 Challenges
23.6.2 Limitations
23.7 Recent Trends and Developments in AWJM
23.8 Conclusion
References
24. Effect of Ultrasonic Vibration-Assisted Micromachining on the Surface
Properties of Difficult-to-Machine Materials
P. Jeyapandiarajan, Joel J., S. Arulvel, E. Venkatesaperumal, D. Vignesh and Sreethul Das
Nomenclature
24.1 Introduction
24.2 The Technique of UVAMM
24.3 UVAMM of Difficult-To-Machine Materials
24.3.1 UVAMM of Traditional Metallic Alloys
24.3.2 UVAMM of Superalloys
24.3.3 UVAMM of Brittle Materials
24.3.4 UVAMM for Generation of Textured Surfaces
24.4 Conclusion
24.4.1 Salient Points
24.4.2 Challenges and Future Scope
References
25. A Significant Impact of Laser-Assisted Micromachining on Tribological
Properties of High Strength Alloys
E. Venkatesaperumal, P. Jeyapandiarajan, S. Arulvel, J. Joel and Jayakrishna Kandasamy
25.1 Introduction
25.2 Road Map of Laser-Assisted Micromachining
25.3 Micromachining
25.3.1 Micromilling
25.3.2 Microgrinding
25.3.3 Microturning
25.3.4 Microdrilling
25.4 Lasers in Micromachining
25.5 Methodology of Laser-Assisted Micromachining
25.6 Laser-Assisted Micromachining
25.6.1 Laser-Assisted Micromilling
25.6.1.1 Laser_Power and Its Effect on Tool Wear
25.6.1.2 Laser Assistance on Residual Stress
25.6.1.3 Laser Assistance on Surface Irregularity
25.6.2 Laser-Assisted Microgrinding
25.6.2.1 Effect of Laser on Tribological Properties
25.6.3 Laser-Assisted Microturning
25.6.3.1 Laser Assistance on Tribological Properties
Summary
Scope for Future Work
References
26. Abrasive Flow Finishing
Sandip Kunar, Jagadeesha T., Gurudas Mandal and Norfazillah Talib
26.1 Introduction
26.2 Significant Process Parameters
26.2.1 Number of Cycles
26.2.2 Extrusion Pressure
26.2.3 Media Flow Volume
26.2.4 Media Flowrate
26.2.5 Media Viscosity
26.2.6 Abrasive Particle Size and Concentration
26.2.7 Rheology of the Media
26.2.8 Initial Surface Condition
26.3 Classification of AFF Method
26.3.1 One-Way AFF Method
26.3.2 Two-Way AFF Method
26.3.3 Orbital AFF Method
26.4 Equipment
26.5 Process
26.6 Application of Special Techniques
26.7 Hybrid AFF Processes
26.8 Monitoring of AFF Process
26.9 Advantages and Limitations of AFF
26.10 Applications of AFF
26.10.1 Automotives
26.10.2 Dies and Molds
26.11 Summary
26.12 Conclusion
References
27. Elastic Emission Machining
Sandip Kunar, Jagadeesha T., Gurudas Mandal and Norfazillah Talib
27.1 Introduction
27.2 Principle of EEM
27.3 Numerically Controlled Elastic Emission Machining
27.4 Conclusion
References
28. Magnetic Abrasive Finishing Process
Sandip Kunar, Jagadeesha T., Gurudas Mandal and Norfazillah Talib
28.1 Introduction
28.2 Primary Components of MAF
28.3 MAF Principles
28.4 Working Principle of MAF
28.5 Process Parameters in MAF
28.6 Magnetic Abrasive Preparation
28.7 MAF Tools
28.7.1 Finishing Tools for Outer Surface
28.7.2 Finishing Tools for Internal Surface
28.8 Types of Magnetic Abrasive Finishing Process
28.8.1 Flat Magnetic Abrasive Finishing Method
28.8.2 Cylindrical Magnetic Abrasive Finishing Method
28.8.3 Hybrid Magnetic Abrasive Finishing Method
28.8.4 Electrolytic Magnetic Abrasive Finishing Method
28.8.5 Vibration-Assisted Magnetic Abrasive Finishing
28.9 Advantages of Magnetic Abrasive Finishing
28.10 Disadvantages of Magnetic Abrasive Finishing
28.11 Applications of Magnetic Abrasive Finishing
28.12 Surface Finish Improvement in MAF
28.13 Challenges and Future Directions
28.14 Conclusions
References
29. Experimental Analysis of EDM Process While Machining Ti-VT20 Alloy
Pritam Pain, Goutam Kumar Bose, Dipankar Bose and Sourav Giri
29.1 Introduction
29.2 Experimental Investigation
29.2.1 Machining Setup
29.2.2 Machining Parameters
29.2.3 Performance Measures
29.3 Experimental Result Analysis
29.3.1 Analysis of the Result Using ANN
29.3.2 Result Analysis Using GA
29.3.3 Multi-Objective Optimization Using Fuzzy Grey Relational Analysis
29.4 Results and Discussion
29.5 Conclusion
References
30. Estimation of Machining Performance and Machining Characteristics Using Artificial Neural Network in Wire Electric Discharge Machine for Titanium & P-20 Materials
Prathik Jain S., Sundaramahalingam A., Sudhagara Rajan S., Chethan K. N., Rudresh Addamani and Ugrasen G.
30.1 Introduction
30.2 Experimental Setup
30.2.1 Acoustic Emission (AE) Sensors
30.3 Artificial Neural Network (ANN)
30.4 Results and Discussion
30.4.1 Selection of Response Parameters: AE Signals
30.4.2 Effects of SR, EW, and AE Signals on Titanium and P-20 Material Parameters
30.4.3 Raw Data Analysis
30.4.3.1 Variation of Pon and C in Determining Titanium Grade-2 and P-20 Tool Steel Materials’ Workpiece Status, Electrode Condition and Machining Performance
30.4.4 Estimation of Machining Characteristics and Machining Performance Using Artificial Neural Network (ANN) for Titanium and P-20 Tool Steel Material
30.4.4.1 Estimation of Minimum and Maximum Pulse on Time for SR and AERMS of Titanium and P-20 Tool Steel Materials
30.4.4.2 Estimation of Minimum and Maximum Current for EW and AERMS of Titanium and P-20 Tool Steel Materials
30.5 Conclusion
References
31. Chemical-Based Bulk Machining and Fabrication of Silicon Microstructures:
An Overview
Sumanta Banerjee
31.1 Silicon: Material for Integrated Circuits and MEMS
31.2 Overview of Microelectromechanical Systems
31.3 Silicon Wafers Fabrication: Procedural Stages
31.3.1 Crystal Growth and Doping
31.3.2 Ingot Trimming, Grinding, and Slicing
31.3.3 Polishing, Cleaning, and Packaging
31.4 Silicon Microfabrication Processes
31.4.1 Wafer Cleaning
31.4.2 Thin-Film Formation
31.4.2.1 Reactive Growth (or Thermal Oxidation)
31.4.2.2 Chemical Vapor Deposition (CVD)
31.4.2.3 Physical Vapor Deposition
31.4.3 Photolithography
31.4.4 Etching: Overview and Types
31.4.4.1 Silicon Wet Isotropic Etching
31.4.4.2 Silicon Wet Anisotropic Etching
31.4.4.3 Silicon Dry Etching
31.4.5 Local Oxidation of Silicon
31.4.6 Micromachining
31.4.7 Doping
31.4.8 Silicon Direct Wafer Bonding: Overview and Types
31.4.8.1 Hydrophilic Bonding of Silicon
31.4.8.2 Hydrophobic Bonding of Silicon
31.5 State-of-Art Application Areas and Present/Futuristic Trends
References
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