The Factors Influenced to Surface Finish in Milling for Hardened Medium Carbon Steel: JIS S50C

2011 ◽  
Vol 383-390 ◽  
pp. 7133-7137 ◽  
Author(s):  
Komson Jirapattarasilp ◽  
Sittichai Kaewkuekool ◽  
Worapong Phongphatrawut
Keyword(s):  
Surface Roughness ◽  
Carbon Steel ◽  
Surface Quality ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Medium Carbon ◽  
High Cutting Speed ◽  
Full Factorial Experimental Design

The aim of this research was to study factors, which was influenced on surface roughness in vertical milling of hardened medium carbon steel. The specimen was medium carbon steel grade JIS S50C that was hardened at 56± 2 HRC. Full factorial experimental design was conducted by 3 factors and 3 levels (33 design) with 2 replications. Studied factors were consisted of cutting speed, feed rate, and air coolant pressure. The results revealed that influenced factor affected to surface roughness was cutting speed and feed rate which showed significantly different. Higher cutting speed would cause on better surface quality. On the other hand, poorer surface quality was produced by higher feed rate. However, factors interaction were found between cutting speed with air coolant pressure and feed rate with air coolant pressure that significantly influenced to surface roughness. The interaction of high cutting speed with high air coolant pressure would be better quality of surface finish and lower feed rate with high air coolant pressure would be better surface quality.

The Effect of Hard Milling on Surface Finish of Medium Carbon Steel

2014 ◽  
Vol 904 ◽  
pp. 213-216 ◽  
Author(s):  
Phasit Chutrakul ◽  
Komson Jirapattarasilp
Keyword(s):  
Carbon Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Milling Process ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Hard Milling ◽  
Medium Carbon ◽  
Vertical Milling

This research was to study the effect of hard milling on the surface finish of medium carbon steel. The sample specimen was selected to AISI 1050. The vertical milling process was chosen to experiment, which used insert PVD carbide tool. The experiment was applied on factors: cutting speed, depth of cut and feed rate and they were consisted of three levels. The factorial design on 33 experiments was applied. The surface roughness average (Ra) was indicated for surface finish. The experiment results were analyzed by ANOVA. The main factors and factors interaction that affected to surface finish were investigated. Effect of cutting speed, feed rate and depth of cut on surface finish of harden medium carbon steel was discussed.

scholarly journals PREDICTION OF TANGENTIAL CUTTING FORCE IN END MILLING OF MEDIUM CARBON STEEL BY COUPLING DESIGN OF EXPERIMENT AND RESPONSE SURFACE METHODOLOGY

1970 ◽  
Vol 40 (2) ◽  
pp. 95-103 ◽  
Author(s):  
Md. Anayet Patwari ◽  
A.K.M. Nurul Amin ◽  
Waleed F. Faris
Keyword(s):  
Response Surface Methodology ◽  
Carbon Steel ◽  
Cutting Force ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Medium Carbon

The present paper discusses the development of the first and second order models for predicting the tangential cutting force produced in end-milling operation of medium carbon steel. The mathematical model for the cutting force prediction has been developed, in terms of cutting parameters cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). All the individual cutting parameters affect on cutting forces as well as their interaction are also investigated in this study. The second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth of cut and, finally, by the cutting speed. Central composite design was employed in developing the cutting force models in relation to primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The adequacy of the predictive model was verified using ANOVA at 95% confidence level. This paper presents an approach to predict cutting force model in end milling of medium carbon steel using coated TiN insert under dry conditions and full immersion cutting.Keywords: Tangential Cutting Forces; RSM; coated TiN; model.DOI: 10.3329/jme.v40i2.5350Journal of Mechanical Engineering, Vol. ME 40, No. 2, December 2009 95-103

Optimization of Surface Roughness in End Milling of Medium Carbon Steel under the Influence of Magnets Attached to the Machine Spindle

2012 ◽  
Vol 576 ◽  
pp. 115-118
Author(s):  
A.K.M. Nurul Amin ◽  
Syidatul Akma ◽  
Maizatul Akma ◽  
M.D. Arif
Keyword(s):  
Surface Roughness ◽  
Carbon Steel ◽  
Metal Cutting ◽  
Permanent Magnets ◽  
End Milling ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Medium Carbon

One of the major technological parameters in metal cutting is surface roughness. It is an unavoidable, and often, unwanted by-product of all machining operations, especially end milling. Surface roughness is directly related to product quality and performance, operation cost, machining accuracy, and chatter. Today’s stringent customer requirements demand machined parts with minimum (mirror finished) products. Hence, the prediction, modeling, and optimization of surface roughness is a quintessential concern in machining research and industrial endeavor. This research was undertaken in order to determine whether end milling of medium carbon steel performed using chosen ranges of cutting parameter and under magnetic field generated by permanent magnets could effectively improve surface roughness. A small central composite design with five levels and an alpha value of 1.4142, in Response Surface Methodology, was used in developing the relationship between cutting speed, feed, and depth of cut, with surface roughness. Design-Expert 6.0 software was utilized to develop the quadratic empirical mathematical model for surface roughness. The experiments were performed under two different conditions. The first condition was cutting under normal conditions, while the other one was cutting under the application of magnetic fields from two permanent magnets. Medium carbon steel was used as the work material. The resultant average surface roughness was found to be reduced by a maximum of 59% due to magnet application.

Study the Effect of Vegetable-Based Lubricant on Surface Roughness during Milling Operation by Using Response Surface Methodology

2014 ◽  
Vol 548-549 ◽  
pp. 336-343
Author(s):  
Aishah Adam Siti ◽  
Yih Loong Yap
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Quality ◽  
Sunflower Oil ◽  
Feed Rate ◽  
Cutting Speed ◽  
Machining Process ◽  
High Cutting Speed ◽  
Milling Operation

Milling is a common machining process with high cutting speed and material removal rate. High cutting speed tends to generate heat at the interface between tool and workpiece. This may reduce the surface quality of the workpiece and reduce the tool life. The application of conventional cutting fluid to reduce friction and heat between tool and workpiece may produce numerous environmental problems. The vegetable-based lubricant as an alternative for measuring the effect on surface quality during milling operation is studied. The relation between machining parameters such as spindle speed, feed rate, depth of cut and lubricants is analyzed by using Analysis of Variance (ANOVA) and Response Surface Methodology (RSM). The optimization of surface quality is analyzed by using Box-Behnken Design of RSM. The research focused on using sunflower oil as lubricant during machining process using mild steel solid block with TiCN coated HSS tools and using synthetic oil as comparison. Surface roughness for using sunflower oil as lubricant is 0.457 μm which lower compared to synthetic oil with 0.679 μm. Feed rate and spindle speed give the most significant effect to the surface roughness during milling operation. The application of vegetable-based oil as lubricant gives better surface quality, prevent tool wear and offer environmental advantages.

INFLUENCE THE QUENCHING AND TEMPERING ON THE MICROSTRUCTURE, MECHANICAL PROPERTIES AND SURFACE ROUGHNESS, OF MEDIUM CARBON STEEL

2018 ◽  
Vol 18 (1) ◽  
pp. 125-135
Author(s):  
Sattar H A Alfatlawi
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Surface Roughness ◽  
Carbon Steel ◽  
Cold Water ◽  
Medium Carbon Steel ◽  
Medium Carbon ◽  
Heating And Cooling ◽  
Treatment Processes ◽  
Quenching And Tempering

One of ways to improve properties of materials without changing the product shape toobtain the desired engineering applications is heating and cooling under effect of controlledsequence of heat treatment. The main aim of this study was to investigate the effect ofheating and cooling on the surface roughness, microstructure and some selected propertiessuch as the hardness and impact strength of Medium Carbon Steel which treated at differenttypes of heat treatment processes. Heat treatment achieved in this work was respectively,heating, quenching and tempering. The specimens were heated to 850°C and left for 45minutes inside the furnace as a holding time at that temperature, then quenching process wasperformed in four types of quenching media (still air, cold water (2°C), oil and polymersolution), respectively. Thereafter, the samples were tempered at 200°C, 400°C, and 600°Cwith one hour as a soaking time for each temperature, then were all cooled by still air. Whenthe heat treatment process was completed, the surface roughness, hardness, impact strengthand microstructure tests were performed. The results showed a change and clearimprovement of surface roughness, mechanical properties and microstructure afterquenching was achieved, as well as the change that took place due to the increasingtoughness and ductility by reducing of brittleness of samples.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

scholarly journals Analysis and Optimization of Ceramic Cutting Tool In Hard Turning of EN-31 Using Factorial Design

2012 ◽  
pp. 53-58
Author(s):  
Chetan Darshan ◽  
Lakhvir Singh ◽  
APS Sethi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
Feed Rate ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Good Surface ◽  
En 31

Manufacturers around the globe persistently looking for the cheapest and quality manufactured machined components to compete in the market. Good surface quality is desired for the proper functioning of the produced parts. The surface quality is influenced by cutting speed, feed rate and depth of cut and many other parameters. In the present study attempt has been made to evaluate the performance of ceramic inserts during hard turning of EN-31 steel. The analysis of variance is applied to study the effect of cutting speed, feed rate and depth of cut on Flank wear and surface roughness. Model is found to be statically significant using regression model, while feed and depth of cut are the factor affecting Flank wear and feed is dominating factors for surface roughness. The analysis of variance was used to analyze the input parameters and there interactions during machining. The developed model predicted response factor at 95% confidence level.

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