Experimental investigation of magneto rheological damping effect on surface roughness of work piece during end milling process

2012 ◽  
Vol 13 (6) ◽  
pp. 835-844 ◽  
Author(s):  
Gulam Mohd Sayeed Ahmed ◽  
Pinninti Ravinder Reddy ◽  
Nuthalapati Seetharamaiah
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
End Milling ◽  
Milling Process ◽  
Work Piece ◽  
Damping Effect ◽  
Magneto Rheological ◽  
End Milling Process

Machinability of Aluminum Nitride Ceramic Using TiAlN and TiN Coated Carbide Tool Insert

2013 ◽  
Vol 773-774 ◽  
pp. 437-447
Author(s):  
Moola Mohan Reddy ◽  
Alexander Gorin ◽  
Abou Ei Hossein A. Khaled ◽  
D. Sujan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Work Piece ◽  
Carbide Tool ◽  
Coated Carbide ◽  
Cnc End Milling ◽  
End Milling Process

This research presents the performance of Aluminum nitride ceramic in end milling using using TiAlN and TiN coated carbide tool insert under dry machining. The surface roughness of the work piece and tool wear was analyzed in this. The design of experiments (DOE) approach using Response surface methodology was implemented to optimize the cutting parameters of a computer numerical control (CNC) end milling machine. The analysis of variance (ANOVA) was adapted to identify the most influential factors on the CNC end milling process. The mathematical predictive model developed for surface roughness and tool wear in terms of cutting speed, feed rate, and depth of cut. The cutting speed is found to be the most significant factor affecting the surface roughness of work piece and tool wear in end milling process.

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.

Investigation of Chatter Vibration in End-Milling Process by Considering Coupled System Model

2014 ◽  
Vol 939 ◽  
pp. 201-208
Author(s):  
Kosuke Hattori ◽  
Hiroyuki Kodama ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
Cutting Tool ◽  
End Milling ◽  
Milling Process ◽  
Work Piece ◽  
Vibration Modes ◽  
Test Results ◽  
Chatter Vibration ◽  
Simple Method ◽  
Excited Vibration ◽  
End Milling Process

Chatter vibration in cutting processes usually leads to surface finish degradation, tool damage, cutting noise, energy loss, etc. Self-excited vibration particularly seems to be a problem that is easily increased to large vibration. The regenerative effect is considered as one of the causes of chatter vibration. Although the chatter vibration occurs in various types of processing, the end-milling is a typical process that seems to cause the chatter vibration due to a lack of rigidity of one or more parts of the machine tools, cutting tool, and work-piece. The aim of our research is to propose a simple method to control chatter vibration of the end-milling process on the basis of a coupling model integrating the related various elements. In this study, hammering tests were carried out to measure the transfer function of a machine tool and cutting tool system, which seems to cause vibration. By comparing these results, finite elemental method (FEM) analysis models were constructed. Additionally, cutting experiments were carried out to confirm the chatter vibration frequencies in end-milling with a machining center. In the hammering tests, impulse hammer and multiple acceleration pick-ups are connected to a multi-channel FFT analyzer and estimate the natural frequencies and natural vibration modes. A simplified FEM model is proposed by circular section stepped beam elements on the basis of the hammering test results, considering a coupling effect. In comparisons of the calculated results and hammering test results, the vibration modes are in good agreement. As a result, the proposed model accurately predicts the chatter vibration considering several effects among the relating elements in end-milling. Moreover, it can be seen that the chatter vibration is investigated from a viewpoint of the integrating model of the end-milling process.

Predictive Model of Surface Roughness in High-Speed End Milling Process by Factorial Design of Experiments

2007 ◽  
Vol 339 ◽  
pp. 189-194
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao
Keyword(s):  
Surface Roughness ◽  
Design Of Experiments ◽  
Factorial Design ◽  
High Speed ◽  
End Milling ◽  
Milling Process ◽  
Regression Coefficients ◽  
Milling Parameters ◽  
Factorial Design Of Experiments ◽  
End Milling Process

Predictive models are presented for the surface roughness in high-speed end milling of 0.45%C steel and P20 die-mould steel based on statistical test and multiple-regression analysis. The data for establishing model is derived from experiments conducted on a high-speed machining centre by factorial design of experiments. The significances of the regression equation and regression coefficients are tested in this paper. The effects of milling parameters on surface roughness are investigated by analyzing the experimental curves.

Experimental Study on Micro End-Milling Process of Ti-6AL-4V Using Nanofluid Minimum Quantity Lubrication (MQL)

2014 ◽  
Author(s):  
Dae Hoon Kim ◽  
Pil-Ho Lee ◽  
Jung Sub Kim ◽  
Hyungpil Moon ◽  
Sang Won Lee
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nanofluid Minimum Quantity Lubrication ◽  
Micro End Milling ◽  
Milling Forces ◽  
End Milling Process

This paper investigates the characteristics of micro end-milling process of titanium alloy (Ti-6AL-4V) using nanofluid minimum quantity lubrication (MQL). A series of micro end-milling experiments are conducted in the meso-scale machine tool system, and milling forces, burr formations, surface roughness, and tool wear are observed and analyzed according to varying feed per tooth and lubrication conditions. The experimental results show that MQL and nanofluid MQL with nanodiamond particles can be effective to reduce milling forces, burrs and surface roughness during micro end-milling of titanium alloy. In particular, it is demonstrated that smaller size of nanodiamond particles — 35 nm — can be more effective to decrease burrs and surface roughness in the case of nanofluid MQL micro end-milling.

Sign in / Sign up

Export Citation Format

Share Document