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Machining - Science topic

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I have L16 for Machining and some researchers do RSM after GRA using GRG data.
How we can do that?
Thanks
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@Asim You can do GRA irrespective of RSM or L16 Taguchi. GRA is applied where you have multiple responses and if you need to find out the optimal responses
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Dear sir
Today my supervisor asked me whether grinding is under the micromachining or not. Really I'm confused. in the grinding process, we can possible to remove a minimum volume of material but how to we consider its micromachining .....
Please Clear My Query
Kind Regards
S.Sathishkumar
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I think machining a micro-size component is called micro-machining. We can use any machining process to do that.
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I get a peak at 240 Hz in FFT plot of tool vibration. The accelerometr is placed at 45 mm from tool tip during machining. Turning of nickel steel of dia 60 mm and length 300 mm at spindle speed 256 RPM. PCLNR2020K tool holder. Panther conventional precision lathe it is.
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240 Hz is in the audible range. Do you hear any sound while your spindel is rotating? Perharps, it is friction-induced sound, because, for example, spindel is not well oiled.
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I want to continuously change the rigid tool orientation during the machining in Abaqus. what strategy can be used to accommodate tool orientation in Abaqus/Explicit? How can I provide both translation and rotation for the tool simultaneously?
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I got result. Thank you Martin Veidt
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I want to continuously change the rigid tool orientation during the machining process. what strategy can be used to accommodate tool orientation?
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Dear Eldho Paul.
Any strategy can be used. Usually the strategy is based on the recommendations obtained from the production experience.
However, in my opinion, it is advisable to orient the shaping movements of the tool in accordance with the linear and angular dimensions that are specified in the drawing. In general, there are six coordinates (three linear and three angular).
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After elaborate identification of faculty development program I found the following list of programs which can specify the the need for true, comprehensive and complete space-time analysis to address semantic and space-time scales was stressed, using scalable algorithms and infrastructure for large volumes of data. Fourth, means were thought necessary to represent and utilize and analyze data and information quality, reliability, and confidence. This implies the need to determine (1) what information is needed by particular users and the appropriate evaluations methods, and (2) how to make information on certainty or uncertainty useful and to support reasoning with uncertainty and with heterogeneous kinds of information. Lastly, the group discussed the need to develop adaptive visual analytic methods that support a range of users, uses, and devices across a range of interaction science issues; human-algorithm interaction; speed of response to support interaction; sensitivity assessment in real time; and uncertainty representation.
The information can be strengthened provided we can get more analytical information
1. Training for Social Contentedness and Inspiration
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3. Big data Analytics
4. Electric Vehicles
5. IoT(Internet of Things)
6. Waste Technology
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47. Advances in manufacturing
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62. Operation Management
63. CFD-Computational fluid dynamics
64. Hybrid Machining Solutions for typical complex Engineering Applications
65. Apparel Design
66. Human Centric Computing
67. Alternate Fuels
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ورش العمل تتطلب مقومات مادية ومضامين مفيدة لتحقيق نتائج فاعلة
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There is a difficulty during thread turning in H13 material with the help of HSS tools. What could be a suitable tool to cut threads in this material effectively?
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Turning inserts and grades for hardened steel (coromant.com)
Check the above site, and I hope it would help you.
Thanks
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Wire EDM has been used for manufacturing various parts for Space System. Also, Al 6061 T6 is heavily used. Al 6061 T6 being a metal has low outgassing properties. But, does Wire EDM have any effect on this outgassing property? I searched various research papers but did not get any paper which comment on this issue.
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The surface machined by EDM could have several small crater which may affect the Outgassing properties.
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I Need Wire EDM Facility availability in India to perform Machining Titanium Based Alloys By Varying Machining Parameters as part of the project.
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Hi, the dielectric should be considered during your experiments.
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When nanofluid is used in machining as a cutting fluid. What is the effect on the contact angle, surface roughness and cutting force when nanoparticle size as well as concentration is increased ?
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There are some different situation in that. First of all concentration and size can affect the agglomeration and because of that reason nanoparticles become microparticles and are no longer useful, in fact, based on their material they even behave like abrasives. This will lead to increase in surface roughness and cutting forces. Also there are other things like filling effect of nanoparticles (such as fill the gap if there is a microcrack), if their size become higher they can not do that. Also their specific heat changes when their size increase. All these things directly affect the machining outputs like cutting forces, roughness and tool wear.
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Hi everyone,
I'm performing 2D Orthogonal turning of Ti6Al4V sample, although I'm able to see chip formation and run the model smoothly but I can't seem to get serrated chips which actually is my objective.
Cutting Speed : 50m/min, 120m/min & 240m/min.
Feed : 100 microns
Mesh element : CPE4RT
WP & Tool are both 2D planar shells.
I have attached the photos of my modelling herewith. Please help
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The following paper for your reference.
Zheng, Zhongpeng, Chenbing Ni, Yun Yang, Yuchao Bai, and Xin Jin. "Numerical Analysis of Serrated Chip Formation Mechanism with Johnson-Cook Parameters in Micro-Cutting of Ti6Al4V." Metals 11, no. 1 (2021): 102.
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I have 3 inputs and 1 output. I want to perform the action in MATLAB
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Dear Soham;
You may find the code you seek here
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Respected sir
Now i am working for written review article under the topic of Electro chemical machining process which is most important in UCM. This is my first effort for the preparing review articles so i need procedure for writing review article and
1.what are the ethics must be follow during review article reparation....?
2.source available ways and how to utilize available resources with effective .....
Kindly share your suggestions successfully accomplishing my target....
Greatest Regards
S.Sathishkumar
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I have a confusion regarding this matter...
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Yes! 👍 If it is a profile cutting insert for threads without a cross-rake angle.
No. If there is a cross-rake angle on the tool holder, there will be a thread profile error.
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I have observed many papers in optimization of electric discharge machining on different MMC compositions. But, nowhere I found application of EDM for such parts. I want to know which AlSiC compnent used in automobile, aerospace etc. manufactured by using Electric Discharge Machining Process ? Kindly resolve my query with certain references or supporting papers.
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Which AlSiC compnent used in automobile, aerospace etc. manufactured by using Electric Discharge Machining Process ? I have not found any response yet.
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I believe there is some truth to this as the clamping forces prevent the material from deforming. However, when the clamping is released, the material will start to relax and strain change should be able to be measured. The question is, I believe strain can still be read during machining if the strain gauge is fixed to the optimum location, can anyway clarify this either way? Thanks in advance.
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This is not true.
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Also what are the different efficient DOE and Analysis methods w.r.to machining operation with a specially sintered tool?
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This link maybe useful for you for downloading design expert(DX8.0.6) and miniTab 18.1 with crack for longer use
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It would be great if you can give me the details of such journals.
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MDPI Journal of Manufacturing and Materials Processing
Link:
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As a researcher in the field of non-conventional machining processes, such as EDM, ECM, PeP, and the hybrid machining processes that can be derived from them, I would be interested in which of these processes you see as the best option for post-processing additive machining processes. It would be important that the advantages and disadvantages are shown.
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Interesting question. Hypothetically the best post process would be no post process!
WEDM is commonly used to remove parts from build plates in LPBF but I have seen an excellent patent which details synthesis of ceramics at the interface so even metals parts can be 'broken' away from the substrate.
As for the remaining surfaces - I see all of the examples you mention as being necessary in the same way that from a surface integrity and geometrical perspective LPBF parts are essentially equivalent to good quality castings. Therefore I think there is a challenge for designers to create components which take advantage of AM but are easily post processed.
We should also be mindful that for many materials (including the ones I work with) there will be a need for heat treatments to 'CTRL+ATL+DEL' the unfavourable microstructure from process. Syncing post processing with this is also an important consideration. Great question!
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What will happen if electrical discharge machining is done without any dielectric?
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Maybe first clear up a few inaccuracies. In EDM or spark erosion, the discharge channel (plasma channel and border area to the dielectric) is the spark. What you probably mean by a spark are the light phenomena that take place through collisions. The temperature in the plasma channel is not created in addition, but is part of the plasma channel. A large part of this plasma energy is lost in the dielectric and only a few percent of the pulse energy has a melting and evaporating effect on the electrodes.
The fact that no EDM can take place in a vacuum is due to the fact that only small, isolated "discharges" can occur, which require a sufficiently high voltage and easily released electrons on the surface. The vacuum also cannot perform a cooling function or remove particles. The "possible" discharges have no efficiency for a machining process.
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I'm performing a cryogenic turning process.
The temperature are recorded from the thermal imaging camera.
Can I use these temperature values to simulate the flow characteristics and behaviour of the cryogenic coolant?
Is this an acceptable thesis?
Thank you in advance.
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Interesting question. Fluent provides you platform for using different input boundary conditions. But it requires a proper meshing and validation of the experimental results. You somehow have to formulate a process of extracting the input boundary conditions from the IR image.
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I am interested to work on the finite element analysis of materials behavior during machining operations.
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There are basically two approaches in finite-element modeling:
1) The classical engineering approach to FE is linked to the very early FE-codes from the 80s. Representative commercial software of this category are ANSYS and ABAQUS. Representative Open Source software for this category are Calculix and Code Aster.
2) The more modern mathematical approach to FE is represented in the commercial software world by COMSOL. Corresponding Open Source solutions include FeniCS and GetFEM.
I recommend you to read our article about GetFEM to get an overview about its capabilities.
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Reasons why thrust force, temperature and surface roughness increase with feed rate in Machining?
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Increasing feed increases the MRR. Higher MRR means higher volume to cut, this high volume leads to higher friction because of higher contact area between cutting tool face and the workpiece. Higher friction leads higher temprature, also this temprature may cause less sharper cutting tool so this cause poor surface roughness. Also same thing for the thrust force component.
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Studies suggest that we must not use cutting fluids while machining fiber reinforced composites. However, what are the reasons for that? Some studies say that the fluid is trapped and causes the matrix to soften and may increase cracks or damages. But are there any paper suggestion which actually says about the surface integrity that is, do the surface roughness also get affected due to usage of these fluids?
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Hi every body;
Creep feed grinding is one of the grinding methods for parts which were produced by nickel base superalloys. The question is what sort of changes in microstructure would be happened when improper parameters applied for Creep Feed Grinding? I mean during severe creep feed grinding what would be happen? For example something like Gamma Prime deformation, Re-melt Layer, Re-Crystallized Layer and so on.
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Dear Ali Akbar Saghafi please read This article studies experimentally the effects of process parameters (i.e. wheel speed, workpiece speed and depth of cut) on the grindability and surface integrity of cast nickel-based superalloys.
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When I think of a machinable steel, I think of a steel that lends itself to small chips (easy chip breaking) during a machining process such as lathe turning. On the other hand, 304 stainless steel (with it's face-centered cubic crystal structure) is regarded as a very tough steel. My recollection is that machinists detest high quality 304 stainless steel because chips do not break, but instead become long strings of removed material. The lack of chip-breaking for 304 would seem to be an indication of toughness. To make austenitic stainless steel machinable, sulfur is added. Stainless alloy 303 is similar to 304 except with five times the sulfur (0.15 wt% S for 303 vs 0.03 wt% S max for 304). With the high sulfur, 303 stainless is considered "machinable." (https://www.azom.com/article.aspx?ArticleID=2866)
So, are machinability and toughness diametrically opposed? Or is there some steel out there that has been experimentally shown to be BOTH tough and machinable? I would especially be interested to know if there is any "non-destructive" or "minimally destructive" type of toughness evaluation in existence that relies on a "machinability" or "chip length" type of measurement. Thanks!
Nathan
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Dear Sirs, machinability and toughness are technical properties of the materials.
To make a rational comparison or state some correlations we need numbers.
To get numbers we must define repeteable tests for machinability (e.g. Quantity of produced chips per hour in turning with a defined tool, at defined machining conditions) and for toughness (e.g. Charpy V or DWTT tests at defined conditions of temperature, etc.)
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Especially in turning operation using CNC machine.
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This is a well-researched area. There is a lot of publications in the machining and grinding domain. The following is an example of machining of Ti-alloys
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How can i measure the energy consumed during machining operation using a conventional lathe machine? I am aware there are energy analyzers but in situations where you cant afford such? what do you use?
Apart from energy meters and watt meters to capture current, what else can i use?
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There are four ways you can measure/calculate the energy consumed during machining
(i) use a power meter and a stopwatch. Multiply the cutting power (measured by the power meter) with cutting time (measured by the stopwatch). But you have already declared that you do not have energy analyser or power meter.
(ii) use a three-axis cutting force dynamometer. Measure the three components of the cutting forces. Multiply the main cutting force with cutting speed/velocity. This will yield the cutting power. If you multiply cutting power with machining time, you will get cutting energy. But, please note that cutting force dynamometers are more expensive as compared to a power meter.
(iii) use an old-style 3 phase watt-meter. With such a watt-meter also you can measure the cutting power. Such watt-meters directly measures the phase currents, phase voltage and power factor and directly provide the power being drawn by the motor.
(iv) If you do not have access to watt-meter, try to measure the phase currents using ammeters. Measure the phase voltage separately. Assume a value of power factor for a three-phase induction motor (typical motors used in a conventional centre lathe). This will also provide you with the value of cutting power. Then determine the cutting energy as discussed earlier.
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There is a Machining process e.g. Turning/Milling/Drilling . How to measure Specific cutting energy (SCE) during this process. 
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Specific cutting energy in machining is the ratio of power consumption due to machining or cutting to material removal rate.
In turning operation, you may use a 3 axes force dynamometer and measure the three orthogonal components of the cutting force (they are the main cutting force, feed force and radial thrust or back force). The power consumption (in W) can be arrived at by multiplying main cutting force (in N) (which is along the cutting velocity vector) with cutting speed (in m/s). The material removal rate (in mm3/s)can be arrived at by multiplying cutting speed (in mm/s), feed (in mm) and depth of cut (in mm). Their ratio would provide you with the specific cutting energy in J/mm3.
In milling (say, face-milling or end-milling), one can measure the cutting power by using the following three approaches: (i) use a spindle mounted dynamometer to directly measure the cutting torque, (ii) use a three axes dynamometer, measure the three orthogonal components of the cutting force, and then calculate the main/tangential cutting force. Next, you have to calculate the cutting power from the calculated main cutting force and cutting speed and (iii) use a power meter to measure the cutting power. The approaches (i) and (iii) are straight forward. Once you have calculated the cutting power, you may obtain specific cutting energy by dividing the same by material removal rate. Please note that in milling, the material removal rate is NOT exactly (cutting speed x feed x depth of cut).
In drilling, the cutting torque (in N-m) can be directly measured by using an appropriate dynamometer or cutting power can be directly measured by a power meter. The cutting power (if you are using a dynamometer) can be obtained by multiplying cutting torque (in N-m) with angular speed (in rad/s) of the spindle. Diving the cutting power with material removal rate would provide you with specific cutting energy.
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I am considering a Kistler 9317C piezoelectric sensor, but I suppose the 5 kHz natural frequency (which limits the usable frequency) will prevent me from measuring this force which should go to around 1 N in 10μs.
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I would look at devices like PN5FC2 from Thorlabs:
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There is plethora of research work related to performance evaluation of various cutting fluids in conventional machining processes.
What are the new potentialities in the same era which aren't fully explored?
Kindly share some overlooked topics in this regard.
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A lot of work has been done and is being done in the areas of cryogenic machining, high-pressure machining, minimum quantity cooling lubrication(MQCL) (with industrial cutting fluids, vegetable oils and nanofluids). Possibly some hybrid techniques like MQCL with chilled air or low-temperature nitrogen would be attempted and researched.
But the industry would be most happy if they get a solution that is truly dry machining. Thus, more research may be expected in developing coated cutting tool and inserts and ceramic inserts, which can be employed in dry machining. For developing coated cutting tools, technologies like pulse DC closed field unbalanced magnetron sputtering (p-DC-CFUBMS), High Power Impulse Magnetron Sputtering (HiPIMS) and HiPIMS+ are being used and continuously developed.
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Performing simulations of cryogenic machining process
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The FEM software AdvantEdge FEM
The FEM software AdvantEdge FEM helps you to accelerate the development of cutting tools by testing / simulating the application behavior of your tool realistically. The systematic analysis of the simulation results gives you additional information about the machining process with a high level of detail. You can save valuable working time, expensive machine capacities and material costs in machining by moving test trials from the machine tool to the PC.
Analyze cutting parameters, workpiece materials, tool wear, chip formation and chip removal in the simulation. Get an insight into the thermal and mechanical load spectrum of your tools during machining. Analyze the engagement situation between tool and workpiece, as well as the influences of the technological and geometric parameter values ​​of process and tool. This creates the basis for optimizing the entire machining process.
If you use AdvantEdge FEM in conjunction with the ISBE Tool Designer software modules, you have a comprehensive solution from tool design and modeling to virtual tool tests and production on the grinding machine.
Develop innovations - systematically, quickly and efficiently!
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What is the current research trend in machining field?
Can anyone post the answers please
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Current trends in machining are to work on the development of sustainable machining process ( Environmental and Economic sustainability) for machining of advanced materials like superalloys, composite and high strength steels etc.
In this for process sustainability researchers are working on first on advancements in cutting tools like (advanced wear resistant nano-coatings on tools, special composites for fabricating the tool through powder metallurgy, special tool edge geometries/ texturing on the tool rake surface, special arrangements for enhancing the cutting fluid supply near to the cutting zone, cryogenic treatment of tool inserts etc. ), secondly enhancing the damping quality and strength of tool holder through variations in geometry and shapes of tool holder and even some special arrangement of micro holes for enhancing the coolant supply through tool holder, thirdly for process characteristics measurement online condition monitoring, effective cutting zone temperature measurements through embedded thermo-couples, Then researchers are working to use sustainable cutting/ lubrication fluids and methods like use of chilled air through vortex tube, only compressed air, cryogenic cooling, use of edible and non edible oils along with nano-particles and even some advancements in MQL process like use of hybrid fluids and use
Electrostatic Minimum Quantity Lubrication. Then working to ensure best surface characteristics/ integrity of the machined workpiece using advanced measuring techniques like Nano indentation methods, use of TEM and XRD for surface characteristics analysis.
you can refer some of our works
A review of near dry machining/minimum quantity lubrication machining of difficult to machine alloys
Environment-friendly technological advancements to enhance the sustainability in surface grinding- A review
Exploration of graphene assisted vegetables oil based minimum quantity lubrication for surface grinding of TI-6AL-4V-ELI
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Hi,
Please assist me with the following,
I am working with aluminium silicon bronze components (small connectors). As part of their manufacturing process the parts are ink coded and require curing in an oven at 150 deg C for one hour. The oven atmosphere is not controlled.
Prior to the oven treatment the appearance of the parts is uniform, the parts have a gold like appearance. Following the treatment in the oven the parts have deep blue to purple hues appearing on all their surfaces.
I am looking for the cause of this change and to prevent it.
Thank you for reading my query,
Kind regards,
Elie
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To determine the cause, the phase composition of the discolored zone must be determined .
Kind regards,
Jerzy
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EDM is Electric discharge machining and ECM is Electro chemical machining.
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But till now we believe that the operation of non conductive materials is difficult and gives inaccurate result for dimensions.
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What are the parameters of a machining operation that are included within the scope of cutting conditions?
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Generally, only the three controllable parameters are listed as cutting or process parameters and they are (i) cutting speed, (ii) feed and (iii) depth of cut. There are several other controllable parameters, like the tool geometry, machining environment (i.e. the coolant-lubricant and its application parameters). The choice of the cutting tool is also a controllable parameter.
The cutting forces, specific cutting energy, temperature, nature and extent of tool wear, tool life, surface roughness, tolerance, surface integrity are not controllable parameters. They are rather 'responses' of the machining system.
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I am looking for ECDM facility for machining of Non-conducting materials.Can any body please suggest me the availability of the said facility in Bengaluru or Mumbai or Chennai.
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Dear Ravindra sir,
Please visit the below given link. You can find the facility in IIT-R
Thank you
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Normally we say, there is no tool-wear during Electro-Chemical Machining (ECM). Is it so? or is there any other possibilities of tool wear while ECMing?
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There is no tool wear in ECM if there is no short circuit during machining. If short circuit happens, the workpiece and electrode all may be damaged.
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I am working on machining simulation of composite tube on Abaqus. For 3D simulation, we need the Tsai hill failure criteria which is available in fortran. But we are not sure how to compile and run it in Abaqus. Kindly give me any suggestions.
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Vijay Sekar i want to ask you if you can send me the tsai hill criteria subroutine because i need it in my simulation
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Cutting parameters are cutting speed, depth of cut and feed rate.
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  • DOI:
  • 10.1007/s11018-015-0806-z
  • Main parameters:
  • Feed, Machining parameters, Shape of cutting edge, Stiffness of tool system.
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This is structural steel face milled with Ø50 mm tool.
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Doubling the cutting speed seems to be increasing the cutting forces enough to either affect the way heat is moving into the chip or the cutting edges of the inserts are not overlapping as much. If your set up is rigid enough and your machine has enough horsepower, you could try to increase the spindle speed though this may result in unacceptable tool life. Sandvik Coromant has an excellent resource on the different types of tool wear so you can see if your speeds and feeds might result in tool rupture or not. You could also try adding a wiper insert to one of your insert pockets.
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While it is easy to calculate the theoretical values for optimal mass, damping and stiffness for an STMD, making one that meets the requirement is a challenge. Therefore, I would like to know if there is any documentation about the machining and manufacturing of STMD, and also about the required level of precision for these systems since they are very sensitive to uncertainties.
Thanks in advance.
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+/- 1mm
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I am trying to simulate the cutting of concrete (without any reinforcement) using a tool with a nose radius of 0.02 mm. I have modeled concrete in 2d using the damaged plasticity model with the values shown in the pictures attached. My tool is a deformable 2d body with an elastic modulus of 200 GPa.
I have modeled the region of concrete that needs to be cut using a mesh size of 0.05 mm. The concrete part is 10 mm in length and 4 mm in height. Tool is 4mm x 4mm. The mesh is set to be linear, explicit and for plane strain conditions with element deletion option set to true.
I have defined cutting speed using the velocity boundary condition and it is 833 mm/s. The stress units are in MPa. Length units in mm. Am also using ALE domain (standard values) for mesh refinement (thinking it might help). Friction coefficient is set to 0.2.
The problem I am having can be seen in the picture named Problem. It is that the concrete is getting pressed in by the tool (feed force) and the region is buckling under compression and eventually leads to excessive distortion error or a zero mass element error.
In my opinion the problem is in the material model itself that it is not getting crushed under compression. Could someone kindly help me out with this? Thanks a lot in advance.
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Let try it.
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Does the scan speed has an effect on energy density? When the CW laser is focused to a point, the energy density is calculated by dividing Pulse energy by area of the beam spot. But if the laser is scanning at high speed (in Selective laser machining), will it be the same?
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Srini Vasan Christoph Gerhard I need energy density in J/cm^2. I used the following method to calculate. Can you tell whether it is right or not.
Laser specification:
Power: 105 W
Mode: Continuous
Beam diameter: 200 micrometer
Scan speed: 200 mm/s
  • First, I calculated the residence time of the laser spot :
Residence time (s) = Beam diameter (mm) /scan speed (mm/s)
  • Then I calculated Energy
Energy (J)= Laser power (w) * Residence time (sec)
  • Then I calculated the energy density:
Energy density (J/cm^2) = Energy (J) / Area (cm^2)
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at present, I am reading the standard Norsok M-630, some duplex steel must pickling at any conditions, while some dulplex does not need pickling after machining, It is confuse me. why duplex steel does not need pickling after final machining?
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Dear Sky,
Pickle and Passivate are acid chemical treatments for stainless steel, to remove any contaminants, scaling or discolouration. Together they produce a clean and chemically passive oxide surface film ensuring resistance to corrosion. The weldability of duplex steels is good and all common welding methods can be used. Duplex steels are generally characterized by their great resistance. High resistance to traction also means that the properties of fatigue are very good. However, resistance to fatigue depends largely on the shape of the piece. The properties of fatigue in welded joints are also clearly lower.
Duplex steels offer a wide variety of properties of corrosion. The high contents of chromium allow that the corrosion resistance is usually very good in most environments. This applies both to the corrosion by cracks and bite. The great mechanical resistance also implies that the resistance to corrosion under tension is very good. Due to the low carbon content, the time rare intergranular corrosion is a problem. In general terms, the corrosion resistance increases with the increase of the content of nickel, chromium, molybdenum and nitrogen. Some of the major factors that will provide a proper pickling are used pickling liquid, temperature at which there is the pickling, material to etching, and thickness of the oxide. Since nitrogen, molybdenum is there a crorrosion against element, once it is pickled by immersion, chances for dirt on the surface is become nil, hydrogen does not go inside the grain and susceptible intragranular and intergranular corrosion during the machining scaling is not risen much it can be cleaned by paper or cloth and shining is also the same. . So that’s why extra pickling is not required after machining.
For duplex, pickling is utmost necessary but does not need extra pickles after machining.
Ashish
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While I was inspecting a concave surface that is the result of a machining operation I found these defects. I wonder how I should name these.
Thanks in advance.
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In mechanistic modeling of cutting forces in turning, identification of cutting force coefficients and edge coefficients through experiments are very much essential. these coefficients can be determined by regression analysis but in a few cases, the edge coefficients come out to be a negative value so can anyone tell me the physical meaning for this negative value of edge coefficients.
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Read my article:
Sadovski A. Self-organizing Models of Biological and Environmental Systems. J. of Balkan Ecology, vol. 1, No. 2, 15-20, 1998.
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Is it possible to do machining operations on solid graphite? What about its weldability?
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graphite is easily machinable. I have experience working with in the chemical industry. Flanges, nozzles, other special ítems were done. No experience in Welding.
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Normally, for simulating the machining process in software packages like ABAQUS, we use Johnson-Cook strength and damage parameters. Can anyone please suggest how to perform the simulation only with the Johnson-Cook strength parameter and is there any other way to specify the chip separation. Can anyone share related materials?
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It is possible to use Eulerian modeling so that machining is considered as plastic flow around the tool. I supervised a master's thesis on this a few years ago, it worked quite nicely.
It is also possible to do frequent remeshings and remove overlapping material, but for this you need to write your own code:
You can also have a special "sacrificial layer" and use damage parameters only for this.
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The best and easier procedure to learn Ant Colony Algorithm Optimization tool that too implement for machining sciences.
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Talbi's book "Metaheuristics" (ISBN-13: 978-0470278581) describes ACO.
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After machining an alloy using WEDM or any other non traditional machining processes, what kind of analysis can be performed for testing surface and sub surface conditions?
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Dear Vinajak,
it all depends on how much your material is bent. If the crurvature radius is so high that in the specimen can't be considered flat on your salmple holder, I'm afraid it is not.
If the curvature is negligible, XRD is perfect for surface phase analysis and, if your diffractometer can do it, surface residual stress measurement can be performed as well.
If you can cut out small pieces of material and make a single piece always centred by the X ray beam, XRD phase analysis is possible. In this case, however, residual stresses could not be possibly measured, as when you cut a stressed material you can release them.
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Actually i am involve in a research topic related to the aerospace thin wall component , and i will use the above software for Metal cutting simulation under machining process. unfortunately i am feeling trouble to find any kind of learning source on youtube about the above software, further i have also contact the company but their response was negative.
So is there anyone who can help me about the above problem, because i am stuck in my research , your help will be highly appreciated .
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Ok. I will try my best and arrange some contacts.
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We have tried to 3D print the attached drawing for our waterjet nozzle, and some nozzles turned out to be fine but the problem is we cannot reproduce them because they are extremely tiny and also the shape is not a perfect cylinder. Does anybody know any machining method that we can do this or any place that can do this for us? Any help or suggestion is highly appreciated.
Thanks!
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You should conventionally micro-Drill the hole so that it is round. 0.2mm drill can be purchased on the open market. There is a bit of a knack to getting the RPM and feedrate right- the drill supplier can help with that. Drills make a much smoother and more cylindrical hole than EDM.
Example:
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Which dielectric is better for machining by Electrical discharge machining (EDM) ?
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Actually, one can not answer the question because it depends very much on factors such as productivity, wear, surface quality, application in the micro, meso or macro range and probably I have forgotten a few more.
The answer de-ionized water is already wrong, if I want to avoid electrolytic effects during ablation. From an environmental point of view, water seems better, but again the facts mentioned above play a role. The answer Kerosene is completely wrong to my knowledge, because this dielectric for EDM is no longer allowed in many countries. It offered itself in the early stages of research as quickly available and always available, but today has nothing more in practice, as in research to look for. The common permitted hydrocarbon is n-dodecane and the hydrocarbons around the n-dodecane.
For the question of the choice of the dielectric it is also important to know, whether one wants to use the pure ED method or a hybrid method (powder-mixed, EDCM, ...).
The biological dielectrics, which are investigated by some researchers are indeed suitable, but I see in my view, that one must be careful with it. If we destroy nature because of the use of such dielectrics (similar to palm oil), then I would rather stick to the "artificial" hydrocarbons.
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The threads of the bolts and nuts can be processed by machining or thread rolling. Some standards do not allow to use machining. What is the problems in machining?
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Thread rolling is a material displacement process while thread machining is a material removal process. Therefore, machined threads will have discontinuity of 'grain-flow', and increased notch effect which will lead to inferior mechanical properties compared to rolled ones.
The grains of rolled threads will flow along or follow the thread contours and thus reduce the notch effect and increase the fatigue life up to 50% compared to the machined ones.
During thread rolling the material is plastically deformed which results in strain hardening, and increased strength. This gives better adhesive wear resistance.
You can achieve 20% savings on material and machining time with thread rolling compared to thread machining.
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What is latest unconventional machining process with good benefits?
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hi
It depends on the material you want to process and the number of materials you want to process.
However Laser machining and Abrasive Waterjet are one of the best unconventional machining processes.
Laser Machining has capability to process a wide range of materials with extreme precision. However it will affect the material property at the cutting zone.
Abrasive Water Jet is very good process which can process most of the materials especially difficult to machine ones.
There are other processes like ECM,EDM ,USM but have lesser capabilities compared to the above two processes.
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I need to do micro-edm machining process. Where i can do it. kindly tell the availability of micro edm machining in any engineering colleges?
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First of all, it would be important to know what application in Micro-EDM is to be fulfilled.
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While optimizing machining parameters through GRA, in the final step GRG of initial, predicted and experimental parameters were compared to find the effect of GRA. In this regard on what basis the initial parameter combination selection has been made. In articles there is no explanation about this. 
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in several paper about grey relational analysis combined with taguchi methode , I found initial parameter design to compare predictive value in confirmation test . For example : initial factor A1B2C2D1 compare with optimal result A2B2C2D2. Anyone can explain how determine the initial parameter design or initial optimal faktor? I really confuse about this.... Thank you
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I need design procedure and analysis process for press machine tool.
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Shreshtha Bandhu Rastogi sir, thank you for your suggestions.
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Is it possible to machine elastomer using abrasive water jet machining?
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Hello Preeti Maurya
I myself did not water jet cut elastomers but designed seals for marine sliding doors with corner pieces machined out of blocks of closed cell synthetic rubber.
To cut elastomer there is no need for abrasive water jet cutting, just plain water is sufficient.
Obviously, with just a straight jet of water you are very limited with respect to the sort of shape. Most commonly the nozzle is attached to a cartesian gantry robot, therefor only 2D- shapes can be cut. With a 6-axis robot you can angle the cut a bit but still real 3D machining is not possible.
Thickness of 200mm or more is possible, obviously depending on the sort of material you intend to cut.
Made of closed cell synthetic rubber, I got parts with very straight, perfectly clean cuts without any burrs or deformation, perfect for bonding to metal or rubber surfaces.
If you require real 3D- machining you need to go for milling with the sharpest possible cutters at very small wedge angle and high rmp. Such milling tools are normally used for the machining of wood.
Problem is, that the cutting forces do have the tendency to rip and tear at the workpiece resulting in deformation and poor surface quality and tolerance keeping. The stiffness of foam-rubber is extremely low. The stiffer the elastomer the better. Rubber shaft-seals can be machined to impressive tight tolerances.
I read about kryo-frosting elastomer to below its glass transition temperature while machining, but never tried it. The coefficient of thermal expansion is very high on rubber and the like and can ruin the machining tolerances if temperature is not maintained throughout the complete machining process.
Kind regards, Bernward
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Orthogonal machining of GFRP composite material
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Libasse Sow thank so much! This is which I have been searching.
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I need to remove parts of PEEK and PA attached to aluminum substrates without damaging the aluminum surface. Mechanical machining is not possible since it could greatly affect this surface. I was wondering about any solvent which can be suitable for this purpose.
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Dear Dr. Francesco Lambiase ,
below I suggest to you a interesting paper that may help you regarding your question:
Stability of Amorphous PEEK in Organic Solvents
Journal- Chemical Society of Pakistan 40(4):810 (2018)
Projects: Nano Mechanical Characterization and Performance Evaluation of Liquid Crystal Polymers (LCPs)General AFM/surface forces work
Aqeel Ahmad, Tanveer Iqbal, Saima Yasin, Rabia Hanif, Sheema Riaz, Paul F Luckham
Available directly on ResearchGate.
Best regards, Pierluigi Traverso
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Dear all, I am interested to do my Post doctorate in Near Dry Machining / Ecofriendly Nano Cutting fluids, if anyone guide me it would be very much helpful.
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Dear Sir,
Please apply for Neharu-Post Doctorate fellowship for USA, JSPS Post Doctoral Fellowship for Japan, DAAD fellowship for Europe.
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Can any one list the nano cutting fluids used for machining steel alloy?
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Hi
follow Libasse Sow answer.
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Is heat treatment of D2 Steel compulsory before Machining on EDM die sinker for Reasearch?
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It's not compulsory
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Can any one suggest the list of journals to publish a work in Near Dry Machining
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Simply submit "near dry machining" to Google Scholar to find out the answer to your question.
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Dear sir,
I need to develop a high-tech milling process by optimizing the milling process using the control parameters suggested by manufacturers manual, that optimized milling process has to be applied to large scale machining.
I request you to please suggest me the related research work and the exact meaning of high-tech process. Please guide me.
Thanking you,
With due regards,
Vinod.
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Thank you Dr. Milon Selvam Dennison. My objective is to demonstrate and develop a high-tech (optimized) milling process for large scale machining. I have chosen face milling operation on C45 medium carbide steel using carbide cutting tool material. Average surface roughness and MRR are my response parameters. I request to please suggest me the related research for the experimentation part? and also guide me when the carbide cutting tool need to be changed?
Thanking you,
With due regards,
Vinod.
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Hello Dears
Would you introduce me if you know a journal about machining or materials that promptly publish the article?
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International journal of machining and machinability of materials, Machining Science and Technology
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In the experiment model for machining of Inconel 825. The surface roughness and tools wear, both are getting reduced with increase in feed rate.Inconel 825 has work hardening characteristics. i have observed the formation of built up edges at high feed should I proceed with the model or not.. kindly shed the light.
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I think that you need to find cutting parameters that no make built up edge over the cutting edge, because this situation it distorts the process of chip removal, being able to cause an increase in roughness with a decrease in wear.
From my point of view you have to try with "High pressure coolant" process.
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in 2D orthogonal machining model, we assume the plane strain condition and ignores the depth of cut. but to validate the model depth of cut has to be provided. since cutting force also depends on the depth of cut, how can we decide the depth of cut for model validation if we are validating the model by comparing cutting force.
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The depth of cut in machining depends on work piece material, rigidity of the machine set up, cutting tool geometry, etc. For common soft steel, I would suggest start at 1mm of depth of cut in turning to validate model.
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Im currently working on laser assisted machining, which means heating of work piece just prior to work piece.
I have done the sequentially coupled analysis, by doing the thermal analysis first by Dflux subroutine and importing those results during cutting simulation.
When I tried the coupled analysis by defining both laser heating and cutting in single step, only laser heating was happening and tool remains stationary through out the simulation. What could be the error?
Thanks for the suggestions...
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Thanks for the reply sir, @Saeed Behzadi.
Can we define both thermal and stress analysis in a single step using coupled temp displacement procedure?
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Hi, Vinay.... the project looks interesting... are you also taking different machining conditions/environments in it ?
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