Effects of SiO2-Al2O3-ZrO2 Tri-hybrid Nanofluids on Surface Roughness and Cutting Temperature in End Milling Process of Aluminum Alloy 6061-T6 Using Uncoated and Coated Cutting Inserts with Minimal Quantity Lubricant Method

2021 ◽  
Author(s):  
W. Safiei ◽  
M. M. Rahman ◽  
A. R. Yusoff ◽  
M. N. Arifin ◽  
W. Tasnim
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Inserts ◽  
Minimal Quantity ◽  
Hybrid Nanofluids ◽  
End Milling Process ◽  
Alloy 6061

Monitoring of Surface Roughness Based on Cutting Force and Cutting Temperature in Ball-End Milling Process by Utilizing Response Surface Analysis

2015 ◽  
Vol 799-800 ◽  
pp. 324-328
Author(s):  
Panrawee Yaisuk ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Process ◽  
Depth Of Cut ◽  
Tool Diameter ◽  
End Milling Process

The surface roughness is monitored using the cutting force and the cutting temperature in the ball-end milling process by utilizing the response surface analysis with the Box-Behnken design. The optimum cutting condition is obtained referring to the minimum surface roughness, which is the spindle speed, the feed rate, the depth of cut, and the tool diameter. The models of cutting force ratio and the cutting temperature are proposed and developed based on the experimental results. It is understood that the surface roughness is improved with an increase in spindle speed, feed rate and depth of cut. The cutting temperature decreases with an increase in tool diameter. The model verification has showed that the experimentally obtained surface roughness model is reliable and accurate to estimate the surface roughness.

scholarly journals Evaluation Of Cutting Force in End Milling Process of Aluminum Alloy 6061-T6 Using Tungsten Carbide Inserts with MQL Method Utilizing Hybrid Nanofluid

2021 ◽  
Vol 84 (1) ◽  
pp. 111-125
Author(s):  
Wahaizad Safiei ◽  
Md Mustafizur Rahman ◽  
Ahmad Razlan Yusoff ◽  
Wajiha Tasnim ◽  
Zetty Akhtar Abd Malek
Keyword(s):  
Aluminum Alloy ◽  
Tungsten Carbide ◽  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Working Fluid ◽  
Hybrid Nanofluid ◽  
Cutting Zone ◽  
End Milling Process ◽  
Alloy 6061

As an alternative to conventional metal working fluid in the end milling process, a combination of newly developed tri-hybrid SiO2-Al2O3-ZrO2 in aqueous-based nanofluid was delivered to the cutting zone using the MQL technique. The liquid has excellent thermal-rheology properties that can offer effective cooling and lubricating during the process. The tri-hybrid nanofluid application is environmentally safe, thus promoting sustainable manufacturing compared to the conventional working fluid. In this experimental study, the cutting forces were investigated comprehensively. Tri-hybrid nanofluid presents in atomizing conditions using the minimum quantity lubricant (MQL) technique at the cutting zone. Industrial standard inserts, namely uncoated, CVD TiCN-Al2O3 and PVD TiAlTaN tungsten carbide used in the experiments. End milling process variables were cutting speed, feed rate, depth of cut, MQL flow rate and nanofluid concentrations. The response data were analyzed statistically based on the design of experiment and regression models were developed for each response according to response surface methodology. Higher cutting force was observed at extreme machining parameters, which regards to higher material removal rate. During the cutting process of Aluminum Alloy 6061-T6, the cutting force, Fr measured was between 16 Newton and 30 Newton. The cutting force in Y-axes (Fy) demonstrates a higher magnitude than others due to the cutting feed of AA6061-T6 in the Y direction. CVD TiCN-Al2O3 tungsten carbide exhibited higher cutting force (Fy) due to coated hardness and tool failures mechanism on both rake and flank face as the wear phenomenon will increase the land contact area. In summary, the resultant cutting force (Fr) was recorded below 30 Newton, indicating the significant improvement in the end milling process. For future experimental works, the cutting force can be explored by considering different nanofluids, extreme machining conditions and brittle material.

Modeling and Experimental Analysis the Effect of Minimum Chip Thickness on Cutting Temperature in Micro-End-Milling Process

2010 ◽  
Vol 102-104 ◽  
pp. 506-510 ◽  
Author(s):  
Ying Chun Liang ◽  
Kai Yang ◽  
Qing Shun Bai ◽  
W.Q. Chen
Keyword(s):  
Aluminum Alloy ◽  
End Milling ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Milling Process ◽  
Depth Of Cut ◽  
Minimum Chip Thickness ◽  
Micro End Milling ◽  
Simulation Results ◽  
End Milling Process

In this paper, the effect of minimum chip thickness on cutting temperature in micro-end- milling of aluminum alloy Al2024-T6 using a tungsten-carbide cutter are investigated and analyzed. The three-dimensional coupled thermal-mechanical finite element model is adopted to determine the effects of varying depth of cut on cutting temperature considering size effects. The simulation results show that the cutting temperature in micro-end-milling is lower than those occurring in conventional milling processes. When the depth of cut is approximately 40% of the cutting edge radius, there is no chip formation. The maximum temperature occurs at the contact region between micro cutting edge and workpiece, which shows an obvious size effect. The experimental verification of the simulation model is carried out on a micro-end-milling process of aluminum alloy 2024-T6 with a high precision infrared camera. The influence of various cutting depths on cutting temperature has been verified in experiments. The experimental measurements results are in a good agreement with the simulation results.

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.

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.

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