Search

Micromachining of difficult-to-machine materials is of prime focus nowadays. One such material is Titanium, which has numerous applications in aerospace, chemical, and biomedical industries. The micromachining of Titanium has become the need of the day because of its exhilarating properties. This investigation employs a tailor-made electrolyte sonicated micro-electrochemical discharge machining (ES-µ-ECDM) system to generate microholes in a commercially pure titanium plate with a thickness of 1000 µm. The machining chamber is the ultrasonication unit (36 kHz) with process parameters voltage (V), concentration (wt%), and duty factor (DF) chosen at three levels. The FCC-RSM-based DOE is selected for experimentation to study the machining characteristics like material removal rate, overcut, and circularity. Through holes were achieved at parameters of 80 V, 25 wt%, and 60% DF and 80 V, 30 wt%, and 50% DF. The incorporation of ultrasonication into the system enhanced electrolyte replenishment and evacuation of the debris at the machining vicinity. The assistance technique improved the gas film stabilization around the tool enabling uniform machining. The multi-response optimization is performed using the MOJAYA algorithm to obtain Pareto optimal solutions, and the MADM (R-method) is employed to obtain the optimal parameter. The optimal parameter was found to be 69 V, 30 wt%, and 50% DF, at which the machined microhole was found to have a circularity of 0.9615 with minimal surface defects.

Wire rope isolators (WRI) effectively isolate shocks and vibrations, making them an ideal choice for many industries, including military and aerospace. A sizeable experimental program was conducted to investigate the cyclic hysteretic behavior of WRIs in all possible loading directions. The test matrix included several isolators subjected to different load-displacement amplitudes at varying rates and other geometries and sizes of the WRIs themselves. This study evaluates the effective stiffness and damping characteristics of WRIs in both the tension/compression (or vertical) and shear/roll (or lateral) directions through laboratory tests and mathematical modeling. It was found that the wire rope diameter significantly influences the stiffness of the WRI more than the other geometric characteristics. Additionally, the damping characteristics of the WRI were found to be correlated to the height-to-width ratio for a given wire rope diameter. The cyclic loading tests showed that, unlike in the lateral directions, in the vertical direction, the load-displacement hysteresis loops are asymmetric. Therefore, the original Bouc-Wen model of hysteresis was used for the lateral direction. A modified version of the same model was developed to simulate the observed asymmetric hysteretic behavior in the vertical direction.

We present an enhancement to the existing elliptical leaf spring (ELS) for improved damping and energy dissipation capabilities. The ELS consists of a high tensile stainless steel elliptical leaf spring with polymer or rubber compound. This device is conceived as a shock and vibration isolator for equipment and lightweight structures. The enhancement to the ELS consists of a lead spring plugged vertically between the leaves (referred to as lead-rubber elliptical leaf spring (LRELS)). The lead is shown to produce hysteretic damping under plastic deformations. The LRELS isolator is shown to exhibit nonlinear hysteretic behavior. In both horizontal directions, the LRELS showed symmetrical rate independent behavior but undergoes stiffening behavior under large displacements. However, in the vertical direction, the LRELS behavior is asymmetric, exhibiting softening behavior in compression and stiffening behavior in tension. Mathematical models based on the Bouc-Wen model, describing the hysteretic behavior of the proposed isolator, are developed and numerically calibrated using a series of finite element analyses. The LRELS is found to be effective in the in-plane and vertical directions. The improved damping and energy dissipation of the LRELS is provided from the hysteretic damping of the lead spring.