scholarly journals The Grey Theory Combining the Taguchi Method for the Best Parameters: A Case Study of Polishing M300 Steel

2019 ◽  
Vol 2019 ◽  
pp. 1-13
Author(s):  
Xiaojun Wu ◽  
Yang Yang ◽  
Xin Tong ◽  
Xiao Shu ◽  
Yan Li
Keyword(s):  
Grain Size ◽  
Feed Rate ◽  
Removal Rate ◽  
Parameters Optimization ◽  
Machining Parameters ◽  
Chromium Alloy ◽  
Cutting Depth ◽  
Grinding Speed ◽  
Orthogonal Experiments ◽  
Five Axis

M300 steel, as high-chromium alloy steel with strong wear resistance and corrosion resistance, is widely used in the manufacture of complex profile molds and aerospace military equipment such as missile parts. However, there are still some problems such as the contradiction between productivity and surface quality in the polishing process for M300 steel. Therefore, in order to solve these problems, surface polishing experiments on M300 steel, single-factor and orthogonal experiments, and parameters’ optimization were studied. In this paper, orthogonal experiments are conducted for four selected machining parameters: grain size (A), grinding speed (B), cutting depth (C), and feed rate (D) on a grinding machine. The experiment and parameters’ optimization of the ball type abrasive tool polishing M300 were investigated by a five-axis machining center, electronic analytical balance, and three-dimensional surface topographer, and the optimal process parameters and preferred intervals were optimized. The optimal parametric condition obtained for simultaneous minimization of surface roughness (Ra) and maximization of material removal rate (MRR) is as follows: grain size=#320, grinding speed=4500 r/min, cutting depth=0.4 mm, and feed rate=80 mm/s. The above parametric combination has been validated by confirmatory tests.

Study on the Material Removal Rate of Nano-ZrO2 Ceramics under Ultrasonic Vibration Assisted Diamond Fly-Cutting

2018 ◽  
Vol 932 ◽  
pp. 30-35
Author(s):  
Yan Yan Yan ◽  
Yi Fan Lv ◽  
Jun Li Liu
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Cutting Depth ◽  
Four Levels

According to the removal mechanism of ductile regime machining of nanoZrO2 ceramics and the dynamic characteristics of ultrasonic vibration assisted diamond flying cutting (UVADFC), the model of the material removal rate (MRR) of nanoZrO2 ceramics under UVADFC and diamond flying cutting (DFC) have been proposed by infinitesimal method,. In this paper, the experiment of three factors and four levels was carried out to study the relationships between MRR and the machining parameters (cutting depth , spindle speed n and feed rate c). The results of the experiment shows that UVADFC is a cost-effective method which is applied to the machining of nanoZrO2 ceramics, and the MRR of nanoZrO2 ceramics under UVADFC is 1.3-2 times greater than that of DFC, and the degree of the factors significantly influence on the MRR of nanoZrO2 ceramics are feed rate, cutting depth, spindle speed in a sequence whether it is DFC or UVADFC. The results will shed more light on the material removal mechanism of UVADFC.

Effect of Machining Parameters and Wear Mechanism in Milling Mold Steel AISI-P20 and AISI-1050

2014 ◽  
Vol 590 ◽  
pp. 294-298
Author(s):  
Pichai Janmanee ◽  
Somchai Wonthaisong ◽  
Dollathum Araganont
Keyword(s):  
Wear Mechanism ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi P20 ◽  
Steel Aisi ◽  
Quality Surface

In this study, effect of machining parameters and wear mechanism in milling process of mold steel AISI-P20 and AISI-1050, using 10 mm twin flute type end mill diameter. The experimental results found that characteristics of milling surfaces and wear of the mill end were directly influenced by changes of parameters for all test conditions. As a result, the quality of milling surfaces also changed. However, mould steels which had the good quality surface is AISI-1050, with roughnesses of 2.120 μm. Quality milling surfaces were milled by using the most suitable parameter feed rate of 45 mm/min, a spindle speed of 637 rpm and a cut depth level of 3 mm, for both grades. Moreover, material removal rate and duration of the milling process, the milling end mills affect wear of the edge in every bite when the feed rate is low, high speed and level depth of cut at least. It was found that limited wear less will affect the surface roughness (Ra) represents the good quality surface.

Optimal Grinding Condition of ZrO2 Ferrule for Optical Fiber Connector Using the Taguchi Method

2005 ◽  
Vol 297-300 ◽  
pp. 1545-1550 ◽  
Author(s):  
Chang Min Suh ◽  
Sang Chun Kim ◽  
Jung Sik Chae
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Optical Fiber ◽  
Feed Rate ◽  
Diamond Wheel ◽  
Cutting Depth ◽  
Maximum Surface ◽  
Grinding Speed ◽  
Optical Fiber Connector

In this paper, the effects of chamfering conditions on the surface roughness of ZrO2 ferrule applied to an optical fiber connector were investigated. The mesh number of the diamond wheel, the grinding speed of the spindle, the feed rate, and the initial cutting depth during grinding chamfer were regarded as the main parameters that have an effect on the surface roughness. Among these parameters, optimal combinations for chamfering conditions were obtained by using the Taguchi method. In addition, analytic values for maximum surface roughness (Rmax) estimated by the theoretical equations which were derived from the formative model of surface roughness on the grinding chamfer were compared with those of the experiments.

Modeling of Material Removal Mechanism in Micro Electric Discharge Milling of Ti-6Al-4V

2014 ◽  
Vol 592-594 ◽  
pp. 516-520 ◽  
Author(s):  
Basil Kuriachen ◽  
Jose Mathew
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Electric Discharge Milling

Micro EDM milling process is accruing a lot of importance in micro fabrication of difficult to machine materials. Any complex shape can be generated with the help of the controlled cylindrical tool in the pre determined path. Due to the complex material removal mechanism on the tool and the work piece, a detailed parametric study is required. In this study, the influence of various process parameters on material removal mechanism is investigated. Experiments were planned as per Response Surface Methodology (RSM) – Box Behnken design and performed under different cutting conditions of gap voltage, capacitance, electrode rotation speed and feed rate. Analysis of variance (ANOVA) was employed to identify the level of importance of machining parameters on the material removal rate. Maximum material removal rate was obtained at Voltage (115V), Capacitance (0.4μF), Electrode rotational Speed (1000rpm), and Feed rate (18mm/min). In addition, a mathematical model is created to predict the material removal

Influence of Processing Parameters on Surface Roughness in Micro Mill-Grinding Aluminium Alloy 6061

2014 ◽  
Vol 1017 ◽  
pp. 495-499
Author(s):  
Ya Dong Gong ◽  
Chao Wang ◽  
Jun Cheng ◽  
Xue Long Wen ◽  
Guo Qiang Yin
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Feed Rate ◽  
Processing Parameters ◽  
Micro Milling ◽  
Processing Conditions ◽  
Cutting Depth ◽  
Orthogonal Experiments ◽  
Alloy 6061 ◽  
Better Than

Orthogonal experiments of micro mill-grinding were conducted on aluminium alloy 6061. Electroplated CBN compound tools were used in machining. Surface topography and roughness of the machined workpieces were measured and analyzed. Influence rules of radial cutting depth,feed rate and spindle speed on surface roughness in micro mill-grinding were studied. The results were compared with those in micro milling. It shows that the influence rules of processing parameters on surface roughness in micro mill-grinding are approximately same with those in micro milling. And in the same processing conditions, the surface roughness of micro mill-grinding is better than that of micro milling. The minimum value of surface roughness Ra of micro mill-grinding is 0.609μm in the experiments.

Influence of Machining Parameters on Surface Roughness in WEDM Titanium Alloy

2013 ◽  
Vol 701 ◽  
pp. 349-353 ◽  
Author(s):  
J.B. Saedon ◽  
Paul J.R. Ding J.R. ◽  
M.S.M. Shawal ◽  
H. Husain ◽  
M.S. Meon
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Feed Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Thermo Electric ◽  
Peak Current ◽  
Wire Tension

Wire electrical discharge machining (WEDM) is a material removal process of electrically conductive materials by the thermo-electric source of energy .This kind of machining extensively used in machining of materials with highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using wire electro-discharge machining with brass wire diameter 0.25mm.The objective of this work is to study the influence of three machining parameters namely peak current (IP), feed rate (FC) and wire tension (WT) to material removal rate and surface roughness followed by suggesting the best operating parameters towards good surface finish. A full factorial experimental design was used with variation of peak current, feed rate and wire tension, with results evaluated using analysis of variance (ANOVA) techniques. Parameter levels were chosen based on best practice and results from preliminary testing. Main effects plots and percentage contribution ratios (PCR) are included for the main factors and their interactions. Peak current was shown to have the greatest effect on surface roughness (33% PCR).

FRACTAL-BASED ANALYSIS OF THE EFFECT OF MACHINING PARAMETERS ON SURFACE FINISH OF WORKPIECE IN TURNING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (04) ◽  
pp. 1950043 ◽  
Author(s):  
GEEVIN JITHMAL PATHIRANAGAMA ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Quality ◽  
Surface Finish ◽  
Feed Rate ◽  
Fractal Theory ◽  
Complex Structure ◽  
Spindle Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
Machined Surface ◽  
Turning Operation

Analysis of workpiece surface quality is one of the major issues in manufacturing engineering. Turning operation is a famous machining operation that is widely used in machining of materials. In this research, we investigate the surface finish of machined workpiece from turning operation. For this purpose, we employ fractal theory to study the complex structure of machined workpiece’s surface in different conditions. The applied parameters include the variations of cutting depth, feed rate and spindle speed in wet and dry machining conditions. Based on the obtained results, we found the correlation between the increment of fractal dimension of machined surface and the increment of cutting depth, feed rate and spindle speed in wet machining condition. The obtained results will be discussed in relation with the complexity of machined surface. The employed method of analysis in this research can be widely applied to the analysis of the effect of different machining parameters and conditions on the surface quality of machined workpiece in case of different machining operations.

Modeling and Experimental Study on Cutting Force of Diamond Circular Saw in Cutting Granite Using Response Surface Methodology

2013 ◽  
Vol 652-654 ◽  
pp. 2191-2195 ◽  
Author(s):  
Zheng Mei Zhang ◽  
Hai Wen Xiao ◽  
Gui Zhen Wang ◽  
Shu Zhong Zhang ◽  
Shu Qin Zhang
Keyword(s):  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
Cutting Speed ◽  
Feed Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
First Order ◽  
Circular Saw

Based on experiment of sawing Wulian red granite with diamond circular saw, the relations between the cutting force with machining parameters are studied. Cutting speed, feed rate and cutting depth are considered as the process parameters. The cutting force in sawing granite operation are measured and the experimental results are then analyzed using response surface methodology. From the analysis, it is seen that the cutting force Fx , Fy and Fz are reduced with the increase of cutting speed and increased with the increase of feed rate and cutting depth, and the mathematical models of the cutting force are developed. By ANOVA for the cutting force models, It is concluded that the models are significant at 95% confidence level and the significant effects are the first-order of cutting speed, feed speed, cutting depth and the quadratic of cutting depth.

Experimental Study on Five-Axis Machining Parameter for NAK80 Die Steel

2008 ◽  
Vol 594 ◽  
pp. 226-234
Author(s):  
Cheng Shun Chen ◽  
Chi Hui Huang
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Tool Path ◽  
Spherical Surface ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Optimal Parameters ◽  
Die Steel ◽  
Contact Points ◽  
Five Axis

The surface quality and contouring accuracy of die cavities directly influences the surface roughness of the products. Different types of complex surfaces of products have become popular in product design in recent years and consequently 5-axis machining techniques become a mainstream in the manufacturing of the die and moulds used in products mentioned above, because of their features and flexibility. This research applies Taguchi method to find out a set of optimal machining parameters in five-axis milling process. The table rotating-tilting type five-axis machine is used to perform the experimental cutting. The cavity of die is modeled as convex half spherical surface, and the material of die is NAK 80 die steel. The four parameters studied are cutting speed, feed rate, tool paths, and contact points, and each of these factors has three levels. The target of this study is the feature of smaller-the-better that is minimization of the surface roughness. The experimental results show that the optimal parameters are moderate cutting speed and contact points, higher feed rate, five-axis tool path. ANOVA analysis indicates that the tool path influences the surface roughness most, which accounts for about 86%. Using optimal parameters to machine a roughly machined concave spherical surface can reach its roughness to 0.234μm, and the roundness error about 0.0314mm. It is believed that the results and method presented in the paper give a good reference for industry applied.

scholarly journals Optimization of Machining Parameters for Milling Zirconia Ceramics by Polycrystalline Diamond Tool

Materials ◽  
2021 ◽  
Vol 15 (1) ◽  
pp. 208
Author(s):  
Xuefeng Yan ◽  
Shuliang Dong ◽  
Xianzhun Li ◽  
Zhonglin Zhao ◽  
Shuling Dong ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Diamond Tool ◽  
Flank Wear ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Zirconia Ceramics ◽  
Cutting Depth ◽  
Tool Flank Wear

Zirconia ceramics are widely used in many fields because of their excellent physical and mechanical properties. However, there are some challenges to machine zirconia ceramics with high processing efficiency. In order to optimize parameters for milling zirconia ceramics by polycrystalline diamond tool, finite element method was used to simulate machining process based on Johnson-Cook constitutive model. The effects of spindle speed, feed rate, radial and axial cutting depth on cutting force, tool flank wear and material removal rate were investigated. The results of the simulation experiment were analyzed and optimized by the response surface method. The optimal parameter combination was obtained when the spindle speed, feed rate, radial and axial cutting depth were 8000 r/min, 90.65 mm/min, 0.10 mm and 1.37 mm, respectively. Under these conditions, the cutting force was 234.81 N, the tool flank wear was 33.40 μm when the milling length was 60 mm and the material removal rate was 44.65 mm3/min.

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