Optimal cutting condition determination for desired surface roughness in end milling

2008 ◽  
Vol 41 (5-6) ◽  
pp. 440-451 ◽  
Author(s):  
Chakguy Prakasvudhisarn ◽  
Siwaporn Kunnapapdeelert ◽  
Pisal Yenradee
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Condition ◽  
Optimal Cutting Condition

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

EFFECT OF CUTTING PARAMETERS ON CUTTING ZONE IN CRYOGENIC HIGH SPEED MILLING OF INCONEL 718 ALLOY

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
A. H. Musfirah ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Part Quality ◽  
Cutting Zone ◽  
Coated Carbide

In tribology phenomenon, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in ball end milling process. Experiments were performed using a multi-layer TiAlN/AlCrN-coated carbide inserts under cryogenic and dry cutting condition. A transient milling simulation model using Third Wave Advantedge has been done in order to gain in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can  decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining. Furthermore, the microstructure of machined workpiece revealed that cryogenic cooling also can reduce a plastic deformation at the cutting surface as compared with the dry machining. 

Applicability of Diamond-Coated Tools for Ball End Milling of Sintered Tungsten Carbide

2020 ◽  
Vol 14 (1) ◽  
pp. 18-25
Author(s):  
Haruhiko Suwa ◽  
Soushi Sakamoto ◽  
Masafumi Nagata ◽  
Kazuhiro Tezuka ◽  
Tetsuo Samukawa ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
End Milling ◽  
High Hardness ◽  
High Heat ◽  
Point Of View ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Sintered Tungsten

Sintered tungsten carbide which has high hardness and high heat resistance, has been widely used in molds and dies. Research on the development of a cutting technology for sintered tungsten carbide (sintered WC-Co alloy) has been pursued mainly with the use of a turning process. We focused on building an efficient milling method for sintered tungsten carbide by using diamond-coated ball end tools, and have investigated their basic properties under specific cutting conditions. This study extends our previous work by enhancing cutting distance in the milling of sintered tungsten carbide, especially that with a “fine” WC grain. The surface roughness of cut workpieces is evaluated from the point of view of the quality of surface roughness. A series of cutting experiments under different cutting conditions were carried out, and the possibility of deriving a suitable cutting condition for the ball end milling of sintered tungsten carbide is discussed.

Monitoring and Prediction of Surface Roughness in Ball End Milling with Air Blow Application

2012 ◽  
Vol 538-541 ◽  
pp. 1332-1337 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Regression Analysis ◽  
Cutting Force ◽  
Multiple Regression Analysis ◽  
Prediction Accuracy ◽  
Prediction Interval ◽  
End Milling ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Roughness Model

This paper presents the additional work of the previous research in order to investigate the relations of the cutting conditions and the various air blow applications which affect the surface roughness. The suitable cutting condition is determined for the aluminum (Al6063) with the ball end milling by utilizing the response surface analysis referring to the minimum surface roughness. The cutting force is monitored during the cutting to analyze the surface roughness. The dynamometer is employed and installed on the table of 5-axis CNC maching center to measure the in-process cutting force. The models of surface roughness and cutting force are calculated by using the multiple regression analysis with the least squared method at 95% significant level. The experimentally obtained results showed that the surface roughness can be well explained by the in-process cutting force. The prediction accuracy and the prediction interval have been presented to verify the obtained surface roughness model at 95% confident level.

Optimization of Surface Roughness in Dry Turning of Brass

2013 ◽  
Vol 395-396 ◽  
pp. 1035-1039
Author(s):  
On Uma Lasunon
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Arithmetic Mean ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Average Surface Roughness ◽  
Dry Turning ◽  
Carbide Cutting Tool ◽  
Optimal Cutting Condition

This study aimed to investigate the effect of cutting speed, feed and depth of cut on the arithmetic mean surface roughness (Ra). The optimal cutting condition in dry turning brass with carbide cutting tool was also recommended. The experimentation was designed by using Taguchi Method (L9). Three investigated factors with 3-level each were cutting speed (42, 68 and 110 m/min), feed (0.05, 0.1 and 0.15 mm/rev), and depth of cut (0.15, 0.25 and 0.5 mm). The results indicated that speed and feed were significantly affected at average surface roughness. The optimal cutting conditions were cutting speed at 68 m/min, feed at 0.05 mm/rev and depth of cut at 0.15 mm.

Surface Roughness Prediction in Ball-End Milling Process for Aluminum by Using Air Blow Cutting

2011 ◽  
Vol 418-420 ◽  
pp. 1428-1434 ◽  
Author(s):  
Keerati Karunasawat ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Tool Diameter ◽  
End Milling Process

The objective of this research is to develop the surface roughness and cutting force models by using the air blow cutting of the aluminum in the ball-end milling process. The air blow cutting proposed in order to reduce the use of the cutting fluid. The surface roughness and cuttting force models are proposed in the exponential forms which consist of the cutting speed, the feed rate, the depth of cut, the tool diameter, and the air blow pressure. The coefficients of the surface roughness and cutting force models are calculated by utilizing the multiple regression with the least squared method at 95% significant level. The effects of cutting parameters on the cutting force are investigated and measured to analyze the relation between the surface roughness and the cutting conditions. The experimentally obtained results showed that the cutting force has the same trend with the surface roughness. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

Modeling the surface roughness in face-end milling process by using general insert at stable cutting conditions

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040143
Author(s):  
Le Hong Ky ◽  
Nhu-Tung Nguyen ◽  
Duc Trung Do ◽  
Tien Dung Hoang ◽  
Hoang Anh Le
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Calculation Model ◽  
Milling Process ◽  
Cutting Condition ◽  
End Mill ◽  
Nose Radius ◽  
Developed Surface ◽  
Milling Condition

Predicting the quality of the machined components is the grandiose signification in industrial manufacturing. Calculation of the surface roughness is one of the most important elements to predict the quality of machined parts. In this paper, the surface roughness was modeled in the face-end mill process by using general rhombu insert. In the proposed mathematical model, with the stable milling condition, the surface roughness is formulated by a function of feed rate, and insert geometry such as nose radius and nose angle. An experimental method is proposed based on the stable milling condition to estimate the surface roughness. The developed surface roughness calculation model has been successfully verified by both simulation and experiment with very promising results. The average difference between predicted and experimental results is 7.59%. The proposed model can be applied to predict the surface roughness in face-end mill processes by using general insert at stable cutting condition.

Investigation of Dry Cutting and Applications of Cutting Fluid in Ball-End Milling Process

2011 ◽  
Vol 291-294 ◽  
pp. 3013-3023 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Channarong Rungruang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Ball End Milling ◽  
End Milling Process

In order to realize the environmental hazard, this paper presents the investigation of the machinability of ball-end milling process with the dry cutting, the wet cutting, and the mist cutting for aluminum. The relations of the surface roughness, the cutting force, and the cutting parameters are examined based on the experimental results by using the Response Surface Analysis with the Box-Behnken design. The in-process cutting force is monitored to analyze the relations of the surface roughness and the cutting parameters. The proper cutting condition can be determined easily referring to the minimum use of cutting fluid, and the minimum surface roughness and cutting force of the surface plot. The effectiveness of the obtained surface roughness and cutting force models have been proved by utilizing the analysis of variance at 95% confident level.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

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