Non-traditional machining: a review on methods employed in advanced materials treatment

Abstract

This article guides the reader through the latest publications about non-traditional machining processes, also revealing those which present hybrid methods, developed for promoting bigger efficiency and economic advantage in non-conventional machining execution. There is, also, attention to micromachining, a micrometer scale application in dimensions, but with big prospections in modern industry. International articles published from 2014 to 2019 in knowledge bases of Science Direct, CAPES, MDPI, SAGE and IEEExplore referring to methods and new technologies developed in this field are evaluated. The studies expansion in this segment are necessary since engineering materials or micromachining applications are not well finished by conventional methods and advanced methods can be slow, expensive or even poorly researched since there are no articles that study absolutely all processes. The optimization techniques, however, gives a new vision to maximum utilization possible of the presented techniques.

References

KUMAR, S.; HIREMATH, S. A Review on Abrasive Flow Machining (AFM). Procedia Technology, Elsevier BV, v. 25, p. 1297-1304, 2016.



SAHU, N.; ANDHARE, A. Multiobjective optimization for improving machinability of Ti-6Al-4V using RSM and advanced algorithms. Journal of Computational Design and Engineering, Elsevier BV, v. 6, p. 1-12, 2019.



BAI, W.; ROY, A.; SUN, R. Enhanced machinability of SiC-reinforced metal-matrix composite with hybrid turning. Journal of Materials Processing Tech., Elsevier BV, v. 268, p. 149-161, 2019.



EL-HOFY, H. Advanced Machining Processes: Nontraditional and Hybrid Machining Processes.
MCGRAW HILL/IRWIN PROFESSIONAL, 2005. ISBN: 0071453342.



FU, C.; LIU, J.; GUO, Y. A Comparative Study on White Layer Properties by Laser Cutting vs. Electrical Discharge Machining of Nitinol Shape Memory Alloy. Procedia CIRP, Elsevier BV, v. 42, p. 246-251, 2016.


MOLITORIS, M.; PITEĽ , J; HOŠOVSKÝ, A. A Review of Research on Water Jet with Slurry Injection. Procedia Engineering, Elsevier BV, v. 149, p. 333-339, 2016.



GOUD, M.; SHARMA, A.; JAWALKAR, C. A review on material removal mechanism in electrochemical discharge machining (ECDM) and possibilities to enhance the material removal rate. Precision Engineering, Elsevier BV, v. 45, p. 1-17, 2016.



SINGH, T.; DVIVEDI, A. Developments in electrochemical discharge machining: A review on electrochemical discharge machining, process variants and their hybrid methods. International Journal of Machine Tools and Manufacture, Elsevier BV, v. 105, p. 1-13, 2016.



WANG, J.; ZHANG, J.; FENG, P. Damage formation and suppression in rotary ultrasonic machining of hard and brittle materials: A critical review. Ceramics International, Elsevier BV, v. 44, p. 1227-1239, 2018.


AICH, U.; BANERJEE, S.; BANDYOPADHYAY, A. Abrasive Water Jet Cutting of Borosilicate Glass. Procedia Materials Science, Elsevier BV, v. 6, p. 775-785, 2014.



MCGEOUGH, J. Cutting of Food Products by Ice-particles in a Water-jet. Procedia CIRP, Elsevier BV, v. 42, p. 863-865, 2016.



PAUL, L.; HIREMATH, S. Experimental and Theoretical Investigations in ECDM Process: An Overview. Procedia Technology, Elsevier BV, v. 25, p. 1242-1249, 2016.


CHE, J.; ZHOU, T.; ZHU, X. Experimental study on horizontal ultrasonic electrical discharge machining. Journal of Materials Processing Technology, Elsevier BV, v. 231, p. 312-318, 2016.



CHAVOSHI, S.; LUO, X. Hybrid micro-machining processes: A review. Precision Engineering, Elsevier BV, v. 41, p. 1-23, 2015.



KUMAR, A.; HIREMATH, S. Improvement of Geometrical Accuracy of Micro Holes Machined Through Micro Abrasive Jet Machining. Procedia CIRP, Elsevier BV, v. 46, p. 47-50, 2016.



XU, Y.; CHEN, J.; JIANG, B. Investigation of micro-drilling using electrochemical discharge machining with counter resistant feeding. Journal of Materials Processing Technology, v. 257, p. 141-147, 2018.


FEUCHT, F.; KETELAER, J.; WOLFF, A. Latest Machining Technologies of Hard-to-cut Materials by Ultrasonic Machine Tool. Procedia CIRP, Elsevier BV, v. 14, p. 148-152, 2014.



HAN, Y.; LIU, Z.; CAO, Z. Mechanism study of the combined process of electrical discharge machining ablation and electrochemical machining in aerosol dielectric. Journal of Materials Processing Technology, Elsevier BV, v. 254, p. 221-228, 2018.


MANJAIAH, M.; NARENDRANATH, S.; ABKARI, J. Optimization of Wire Electro Discharge Machining Parameters to Achieve Better MRR and Surface Finish. Procedia Materials Science, Elsevier BV, v. 5, p. 2665-2644, 2014.



SRIKANTH, D.; SREENIVASARAO, M. Metal Removal and Kerf Analysis in Abrasive Jet Drilling of Glass Sheets. Procedia Materials Science, Elsevier BV, v. 6, p. 1303-1311, 2014.



LIU, J.; GUO, Y. Process Capability of Wire-EDM of NiTi Shape Memory Alloy at Main Cut and Trim Cut Modes. Procedia Manufacturing, Elsevier BV, v. 1, p. 904-914, 2015.



BRECHER, C.; DU BOIS-REYMOND, F.; NITTINGER, J. Qualifying multi-technology machine tools for complex machining processes. CIRP Journal of Manufacturing Science and Technology, Elsevier BV, v. 13, p. 1-14, 2016.


PATEL, J.; FENG, Z.; VILLANUEVA, P. Quality Enhancement with Ultrasonic Wave and Pulsed Current in Electrochemical Machining. Procedia Manufacturing, Elsevier BV, v. 10, p. 662-673, 2017.



MANJAIAH, M.; NARENDRANATH, S.; BASAVARAJAPPA, S. Review on non-conventional machining of shape memory alloys. Transactions of Nonferrous Metals Society of China, Elsevier BV, v. 24, p. 12-21, 2014.



KOVAČEVIĆ, M.; MADIĆ, M.; RADOVANOVIĆ, M. Software prototype for solving multi-objective machining optimization problems: Application in non-conventional machining processes. Expert Systems with Applications, Elsevier BV, v. 41, p. 5657-5668, 2014.

JERMAN, M.; ORBANIĆ, H.; LEBAR, A. Measuring the Water Temperature Changes in Ice Abrasive Water Jet Prototype. Procedia Engineering, Elsevier BV, v. 149, p. 163-168, 2016.



KOZAK, J.; ZYBURA-SKRABALAK, M. Some Problems of Surface Roughness in Electrochemical Machining ECM. Procedia CIRP, v. 42, p. 101-106, 2016.



CHEN, C.; LI, J.; ZHAN, S. Study of Micro Groove Machining by Micro ECM. Procedia CIRP, Elsevier BV, v. 42, p. 418-422, 2016.



SHUKLA, R.; SINGH, D. Experimentation investigation of abrasive water jet machining parameters using Taguchi and Evolutionary optimization techniques. Swarm and Evolutionary Computation, Elsevier BV, v. 32, p. 167-183, 2017.



PAL, V.; CHOUDHURY, S. Surface Characterization and Machining of Blind Pockets on Ti6Al4V by Abrasive Water Jet Machining. Procedia Materials Science, Elsevier BV, v. 5, p. 1584-1592, 2014.



RAO, R.; RAI, D.; BALIC, J. A multi-objective algorithm for optimization of modern machining processes. Engineering Applications of Artificial Intelligence, Elsevier BV, v. 61, p. 103-125, 2017.



SIHAG, N.; KALA, P.; PANDEY, P. Chemo Assisted Magnetic Abrasive Finishing: Experimental Investigations. Procedia CIRP, Elsevier BV, v. 26, p. 539-543, 2015.



MISHRA, V.; GOEL, H.; MULIK, R. Determining work-brush interface temperature in magnetic abrasive finishing process. Journal of Manufacturing Processes, Elsevier BV, v. 16, p. 248-256, 2014.



PATEL, D.; TANDON, P. Experimental investigations of thermally enhanced abrasive water jet machining of hard-to-machine metals. CIRP Journal of Manufacturing Science and Technology, Elsevier BV, v. 10, p. 92-101, 2015.


CHABROL, G.; CICERON, A.; TWARDOWSKI, P. Investigation of diffractive optical element femtosecond laser machining. Applied Surface Science, Elsevier BV, v. 374, p. 375-378, 2016.



JI, R.; LIU, Y.; DIAO, R. Influence of Electrical Resistivity and Machining Parameters on Electrical Discharge Machining Performance of Engineering Ceramics. PloS ONE, Public Library of Science (PLoS), v. 9, p. 11, 2014.



YANG, G.; WANG, B.; TAWFIQ, K. Electropolishing of surfaces: theory and applications. Surface Engineering, Informa UK Limited, v. 33, p. 149-166, 2016.



MENG, L.; ZENG, Y.; ZHU, D. Investigation on Wire Electrochemical Micro Machining of Ni-based Metallic Glass. Electrochimica Acta, Elsevier BV, v. 233, p. 274-283, 2017.



MISHRA, S.; YADAVA, V. Laser Beam MicroMachining LBMM: A review. Optics and Lasers in Engineering, Elsevier BV, v. 73, p. 89-122, 2015.


GUPTA, V.; PANDEY, P.; GARG, M. Minimization of Kerf Taper Angle and Kerf Width Using Taguchi’s Method in Abrasive Water Jet Machining of Marble, Procedia Materials Science, Elsevier BV, v. 6, p. 140-149, 2014.

GOSWAMI, D.; CHAKRABORTY, S. Multi-objective optimization of electrochemical discharge machining processes: a posteriori approach based on bird mating optimizer. OPSEARCH, Springer Nature, v. 54, p. 306-335, 2016.



RAO, R.; KALYANKAR, V. Optimization of modern machining processes using advanced optimization techniques: a review. The International Journal of Advanced Manufacturing Technology, Springer Nature, v. 73, p. 1159-1188, 2014.


JIAO, A.; QUAN, H.; LI, Z. Study on improving the trajectory to elevate the surface quality of plane magnetic abrasive finishing. The International Journal of Advanced Manufacturing Technology, Springer Nature, v. 80, p. 1613-1623, 2015.



ARIF, S.; KAUTEK, W. Pulse laser machining and particulate separation from high impact polystyrene. Applied Surface Science, Elsevier BV, v. 288, p. 9-14, 2014.


XU, K.; ZENG, Y.; LI, P. Vibration assisted wire electrochemical micro machining of array micro tools. Precision Engineering, Elsevier BV, v. 47, p. 487-497, 2017.


ZHOU, K.; CHEN, Y.; DU, Z. Surface integrity of titanium part by ultrasonic magnetic abrasive finishing. The International Journal of Advanced Manufacturing Technology, Springer Nature, v. 80, p. 997-1005, 2015.


ZHANG, G.; GUO, J.; MING, W. Study of the machining process of nano-electrical discharge machining based on combined atomistic-continuum modeling method. Applied Surface Science, Elsevier BV, v. 290, p. 359-367, 2014.



NEUENSCHWANDER, B.; JAEGGI, B.; SCHMID, M. Surface Structuring with Ultra-short Laser Pulses: Basics, Limitations and Needs for High Throughput. Physics Procedia, Elsevier BV, v. 56, p. 1047-1058, 2014.



PAUL, L.; HIREMATH, S. Improvement in Machining Rate with Mixed Electrolyte in ECDM Process. Procedia Technology, Elsevier BV, v. 25, p. 1250-1256, 2016.


GENG, D.; ZHANG, D.; LI, Z. Feasibility study of ultrasonic elliptical vibration-assisted reaming of carbon fiber reinforced plastics/titanium alloy stacks. Ultrasonics, Elsevier BV, v. 75, p. 80-90, 2017.


KUMAR, A.; HIREMATH, S. Machining of Micro-holes on Sodalime Glass Using Developed Micro-abrasive Jet Machine (micro-AJM), Procedia Technology, Elsevier BV, v. 25, p. 1234-1241, 2016.


HAN, F.; CHEN, W.; YING, W. Effects of Polarization on Machining Accuracy in Pulse Electrochemical Machining, Procedia CIRP, Elsevier BV, v. 68, p. 493-498, 2018.


LIN, Y.; HUNG, J.; LEE, H. Machining Performances of Electrical Discharge Machining Combined with Abrasive Jet Machining. Procedia CIRP, Elsevier BV, v. 68, p. 162-167, 2018.



PRAMANIK, A.; BASAK, A.; ISLAM, M. Electrical discharge machining of 6061 aluminium alloy. Transactions of Nonferrous Metals Society of China, Elsevier BV, v. 25, p. 2866-2874, 2015.


SRIKANTH, D.; RAO, M. Application of Taguchi’s Response Surface methodology in Optimization for Machining of Ceramics with Abrasive Jet Machining. Materials Today: Proceedings, Elsevier BV, v. 2, p. 3308-3317, 2015.



UCHIYAMA, M.; HASEGAWA, T. Machining of Small Curved Hole Using Electrochemical Machining Process. Procedia CIRP, Elsevier BV, v. 68, p. 694-698, 2018.



KUMAR, A.; HIREMATH, S. Improvement of Geometrical Accuracy of Micro Holes Machined Through Micro Abrasive Jet Machining. Procedia CIRP, Elsevier BV, v. 46, p. 47-50, 2016.



RAJURKAR, K.; HADIDI, H.; PARITI, J. Review of Sustainability Issues in Non-Traditional Machining Processes. Procedia Manufacturing, Elsevier BV, v. 7, p. 714-720, 2017.



JANCZEWSKI, Ł .; TOBOŁA, D.; BROSTOW, W. Effects of ball burnishing on surface properties of low density polyethylene. Tribology International, Elsevier BV, v. 93, p. 36-42, 2016.



JAWAHIR, I.; ATTIA, H.; BIERMANN, D. Cryogenic manufacturing processes. CIRP Annals, Elsevier BV, v. 65, p. 713-736, 2016.



PAL, V.; CHOUDHURY, S. Fabrication of texturing tool to produce array of square holes for EDM by abrasive water jet machining. The International Journal of Advanced Manufacturing Technology, Springer Nature, v. 85, p. 2061-2071, 2015.


MORKAVUK, S.; KÖKLÜ, U.; BAĞCI, M. Cryogenic machining of carbon fiber reinforced plastic (CFRP) composites and the effects of cryogenic treatment on tensile properties: A comparative study. Composites Part B: Engineering, Elsevier BV, v. 147, p. 1-11, 2018.



SACHIN, B.; NARENDRANATH, S.; CHAKRADHAR, D. Effect of Cryogenic Diamond Burnishing on Residual Stress and Microhardness of 17-4 PH Stainless Steel. Materials Today: Proceedings, Elsevier BV, v. 5, p. 18393-18399, 2018.



KUMAR, S.; YOGANATH, V.; KRISHNA, P. Machinability of Hardened Alloy Steel using Cryogenic Machining. Materials Today: Proceedings, Elsevier BV, v. 5, p. 8159-8167, 2018.



SANCHEZ, L.; GIARETTA, F.; NOGUEIRA, L. Effect of Hot Burnishing Aided by Infrared Radiation on the Modification of Surface and Subsurface of AISI 1045 Steel. Procedia CIRP, Elsevier BV, v. 58, p. 463-468, 2017.



SHARMA, A.; MOHANTY, C.; PARDASANI, K. Finite Element Analysis of Cryogenically Treated EDM. Materials Today: Proceedings, Elsevier BV, v. 5, p. 19367-19373, 2018.



TANG, J.; LUO, H.; QI, Y. The effect of cryogenic burnishing on the formation mechanism of corrosion product film of Ti-6Al-4V titanium alloy in 0.9% NaCl solution. Surface and Coatings Technology, Elsevier BV, v. 345, p. 123-131, 2018.



AYYAPPAN, S.; SIVAKUMAR, K.; KALAIMATHI, M. Electrochemical machining of 20MnCr5 alloy steel with magnetic flux assisted vibrating tool. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, SAGE Publications, v. 231, p.1956-1965, 2015.



VALDIVIELSO, A.; LACALLE, L.; URBIKAIN, G. Detecting the key geometrical features and grades of carbide inserts for the turning of nickel-based alloys concerning surface integrity. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, SAGE Publications, v. 230, p. 3725-3742, 2016.



GOUD, M.; SHARMA, A. A three-dimensional finite element simulation approach to analyze material removal in electrochemical discharge machining. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, SAGE Publications, v. 231, p. 2417-2428, 2016.



GNANAVELBABU, A.; SARAVANAN, P.; RAJKUMAR, K. Effect of Abrasive Waterjet Machining Parameters on Hybrid AA6061-B4C-CNT Composites. Materials Today: Proceedings, Elsevier BV, v. 5, p. 13438-13450, 2018.



EL-HOFY, M.; HELMY, A.; ESCOBAR-PALAFOX, G. Abrasive Water Jet Machining of Multidirectional CFRP Laminates. Procedia CIRP, Elsevier BV, v. 68, p. 535-540, 2018.


KAYNAK, Y.; GHARIBI, A. Progressive Tool Wear in Cryogenic Machining: The Effect of Liquid Nitrogen and Carbon Dioxide. Journal of Manufacturing and Materials Processing, MDPI AG, v. 2, p. 31, 2018.


MAUROTTO, A.; SCENINI, F.; KRAEMER, B. Laser Irradiation Effects in Simulated Laser-Assisted Machining of Type 316L SS. Journal of Manufacturing and Materials Processing, MDPI AG, v. 2, p. 45, 2018.



OβWALD, K.; LOCHMAHR, I.; BAGCI, Y. Investigation into Hand Scraping: A Microanalysis. Journal of Manufacturing and Materials Processing, MDPI AG, v. 2, p. 76, 2018.



PARMAR, M.; JAMES, S. Experimental and Modeling Study of Liquid-Assisted-Laser Beam Micromachining of Smart Ceramic Materials. Journal of Manufacturing and Materials Processing, MDPI AG, v. 2, p. 28, 2018.



LIANG, Z.; LIAO, S.; WEN, Y. Working parameter optimization of strengthen waterjet grinding with the orthogonal-experiment-design-based ANFIS. Journal of Intelligent Manufacturing, Springer Nature, v. 30, p. 833–854, 2016.



WANG, F.; ZHAO, J.; LV, Y. Precise vibrating electrochemical machining of a diamond-shaped hole with side-wall insulation. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, SAGE Publications, v. 232, p. 2987-2997, 2017.
Published
2019-04-22
How to Cite
BRASIL, Beatriz Silva; MOURA, Lorena Braga; ROCHA NETO, Ajalmar Rego. Non-traditional machining: a review on methods employed in advanced materials treatment. Journal of Mechatronics Engineering, [S.l.], v. 2, n. 1, p. 8 - 34, apr. 2019. ISSN 2595-3230. Available at: <http://jme.ojs.galoa.net.br/index.php/jme/article/view/24>. Date accessed: 23 may 2019. doi: https://doi.org/10.21439/jme.v2i1.24.