Prediction of cutting force, tool wear and surface roughness of Al6061/SiC composite for end milling operations using RSM

2013 ◽  
Vol 27 (9) ◽  
pp. 2813-2822 ◽  
Author(s):  
S. Jeyakumar ◽  
K. Marimuthu ◽  
T. Ramachandran
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Milling Operations

Application of tri-hybridized carbonaceous nanocutting fluids in an end milling operation by the minimum quantity lubrication technique

2021 ◽  
pp. 135065012110438
Author(s):  
S. Vignesh ◽  
U. Mohammed Iqbal
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
End Milling ◽  
Hexagonal Boron Nitride ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Work Piece ◽  
Cutting Fluids ◽  
Minimum Quantity ◽  
Milling Operations

This paper is concentrated on the exploration of carbonaceous nanocutting fluids with the concept of tri-hybridization with improved lubricative and cooling properties by using multi-walled carbon nanotubes, hexagonal boron nitride , and graphene nanoparticles with neat cold-pressed coconut oil in a fixed volumetric proportion. The rheological properties of the nanofluids were studied to assess their performance in real-time end milling operations using an AA7075 work piece on a CNC lathe machine under a minimum quantity lubrication environment. At the outset, the carbonaceous nanofluids gave good performance when compared to conventional cutting fluids. Furthermore, the surfaces of the tribo-pairs and the chips formed were analyzed using a profilometer and high-end microscopes. The results obtained from the experiments confirm that the tri-hybridized carbonaceous nanolubricant has reduced the cutting force, tool wear, and surface roughness when correlated to monotype nanofluids. The scanning electron microscope images of the surface and tool were studied and it was found that the surface quality was maintained while end milling with tri-hybridized carbonaceous nanofluid. Improvement of ∼17%, 20% and 25% in cutting forces, surface roughness and tool wear was found in tri-hybrid fluid when compared to other fluids. Thus, the present work indicates that the addition of carbon-based nanoparticles with coconut oil has offered better performance and is found to be a credible alternative to existing conventional cutting fluids.

scholarly journals Investigating the Design of Condition Monitoring Systems to Evaluate Surface Roughness under the Variability in Tool Wear and Fixturing Conditions

2013 ◽  
Vol 572 ◽  
pp. 467-470 ◽  
Author(s):  
Jabbar Abbas ◽  
Amin Al-Habaibeh ◽  
Dai Zhong Su
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Condition Monitoring ◽  
End Milling ◽  
Milling Operations ◽  
Different Types ◽  
Machined Parts ◽  
Condition Monitoring Systems ◽  
Condition Monitoring System

Surface finish of machined parts in end milling operations is significantly influenced by process faults such as tool wear and tool holding (fixturing system). Therefore, monitoring these faults is considerably important to improve the quality of the product. In this paper, an investigation is presented to design the condition monitoring system to evaluate the surface roughness of the workpiece under effects of gradual tool wear and different types of the fixturing system. Automated Sensor and Signal Processing Selection (ASPS) approach is implemented and tested to determine the sensitivity of the sensory signals to estimate surface roughness under the variable conditions in comparison to surface roughness measurement device. The results indicate that the system is capable of detection the change and the trend in surface roughness. However, the sensitive features are found to be different based on the change in the fixturing system.

scholarly journals Influence of Ultrasonic Vibration-Assisted Ball-End Milling on the Cutting Performance of AZ31B Magnesium Alloy

2020 ◽  
Vol 9 (4) ◽  
pp. 271-276
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Biomedical Applications ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Machining Process ◽  
Dry Conditions ◽  
Good Biocompatibility

Magnesium alloys have a tremendous possibility for biomedical applications due to their good biocompatibility, integrity and degradability, but their low ignition temperature and easy corrosive property restrict the machining process for potential biomedical applications. In this research, ultrasonic vibration-assisted ball milling (UVABM) for AZ31B is investigated to improve the cutting performance and get specific surface morphology in dry conditions. Cutting force and cutting temperatures are measured during UVABM. Surface roughness is measured with a white light interferometer after UVABM. The experimental results show cutting force and cutting temperature reduce due to ultrasonic vibration, and surface roughness decreases by 34.92%, compared with that got from traditional milling, which indicates UVABM is suitable to process AZ31B for potential biomedical applications.

Influence of cutting speed on cutting force, flank temperature, and tool wear in end milling of Ti-6Al-4V alloy

2013 ◽  
Vol 70 (9-12) ◽  
pp. 1835-1845 ◽  
Author(s):  
Junzhan Hou ◽  
Wei Zhou ◽  
Hongjian Duan ◽  
Guang Yang ◽  
Hongwei Xu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed

Intelligent Monitoring and Prediction of Surface Roughness in Ball-End Milling Process

2011 ◽  
Vol 121-126 ◽  
pp. 2059-2063 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Angsumalin Senjuntichai
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Roughness Model ◽  
Force Ratio ◽  
Tool Diameter ◽  
End Milling Process

In order to realize the intelligent machines, the practical model is proposed to predict the in-process surface roughness during the ball-end milling process by utilizing the cutting force ratio. The ratio of cutting force is proposed to be generalized and non-scaled to estimate the surface roughness regardless of the cutting conditions. The proposed in-process surface roughness model is developed based on the experimentally obtained data by employing the exponential function with five factors of the spindle speed, the feed rate, the tool diameter, the depth of cut, and the cutting force ratio. The prediction accuracy and the prediction interval of the in-process surface roughness model at 95% confident level are calculated and proposed to predict the distribution of individually predicted points in which the in-process predicted surface roughness will fall. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It is proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

Supervision of Tool Wear and Surface Quality During End Milling Operations

1994 ◽  
Vol 27 (4) ◽  
pp. 507-512 ◽  
Author(s):  
H. Konrad ◽  
R. Isermann ◽  
H.U. Oette
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
End Milling ◽  
Milling Operations

INVESTIGATION OF WIPER INSERTS EFFECTS IN TURNING AND MILLING PROCESSES

2021 ◽  
pp. 2150111
Author(s):  
MURAT KIYAK
Keyword(s):  
Surface Roughness ◽  
Cost Saving ◽  
Tool Wear ◽  
Feed Rate ◽  
Turning Process ◽  
Nose Radius ◽  
Turning Operations ◽  
Effective Factors ◽  
Milling Operations ◽  
The Many

The surface roughness is a crucial factor in machining methods. The most effective factors on surface roughness are feed rate and tool nose radius. Due to the many advantages of wiper (multi-nose radius) inserts, their importance and use has been increasing recently. The purpose of this paper is to investigate the effect of wiper inserts on surface roughness and tool wear. In this study, conventional inserts and wiper inserts were experimentally compared separately in milling and turning operations. Compared to conventional inserts, the surface roughness values obtained using wiper inserts improved by 33% in turning operations and approximately 40% in milling operations. It was observed that the production time in the turning process was reduced by about 25% in the case of using wiper inserts compared to the use of conventional inserts. In milling, this ratio was determined to be approximately 43% due to the fact that it has multiple cutting edge. It has been observed that the use of wiper inserts in machining methods creates a significant time and cost saving advantage.

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