Sensitivity analysis of the surface integrity of monocrystalline silicon to grinding speed with same grain depth-of-cut

2020 ◽  
Vol 8 (1) ◽  
pp. 97-106
Author(s):  
Ping Zhou ◽  
Zi-Guang Wang ◽  
Ying Yan ◽  
Ning Huang ◽  
Ren-Ke Kang ◽  
...  
Keyword(s):  
Sensitivity Analysis ◽  
Surface Integrity ◽  
Monocrystalline Silicon ◽  
Depth Of Cut ◽  
Grinding Speed

Study on Edge Contact Area and Surface Integrity of Workpiece in Point Grinding Process

2009 ◽  
Vol 407-408 ◽  
pp. 577-581
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
High Speed ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Edge Contact ◽  
Cylindrical Grinding ◽  
Theoretic Foundations

During cylindrical grinding process, the geometric configuration and size of the edge contact area between the grinding wheel and workpiece have the heavy effects on the workpiece surface integrity. In consideration of the differences between the point grinding and the conventional high speed cylindrical grinding, the geometric and mathematic models of the edge contact area in point grinding were established. Based on the models, the numerical simulation for the edge contact area was performed. By means of the point grinding experiment, the effect mechanism of the edge contact area on the ground surface integrity was investigated. These will offer the applied theoretic foundations for optimizing the point grinding angles, depth of cut, wheel and workpiece speed, geometrical configuration and size of CBN wheel and some other grinding parameters in point grinding process.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

scholarly journals Surface Integrity Investigation to Determine Rough Milling Effects for Assessment of Machining Allowance for Subsequent Finish Milling of Alloy 718

2021 ◽  
Vol 5 (2) ◽  
pp. 48
Author(s):  
Jonas Holmberg ◽  
Anders Wretland ◽  
Johan Berglund ◽  
Tomas Beno ◽  
Anton Milesic Karlsson
Keyword(s):  
Surface Integrity ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Milling Operations ◽  
Milling Operation ◽  
Machining Allowance ◽  
Rough Milling

The planned material volume to be removed from a blank to create the final shape of a part is commonly referred to as allowance. Determination of machining allowance is essential and has a great impact on productivity. The objective of the present work is to use a case study to investigate how a prior rough milling operation affects the finish machined surface and, after that, to use this knowledge to design a methodology for how to assess the machining allowance for subsequent milling operations based on residual stresses. Subsequent milling operations were performed to study the final surface integrity across a milled slot. This was done by rough ceramic milling followed by finish milling in seven subsequent steps. The results show that the up-, centre and down-milling induce different stresses and impact depths. Employing the developed methodology, the depth where the directional influence of the milling process diminishes has been shown to be a suitable minimum limit for the allowance. At this depth, the plastic flow causing severe deformation is not present anymore. It was shown that the centre of the milled slot has the deepest impact depth of 500 µm, up-milling caused an intermediate impact depth of 400 µm followed by down milling with an impact depth of 300 µm. With merged envelope profiles, it was shown that the effects from rough ceramic milling are gone after 3 finish milling passes, with a total depth of cut of 150 µm.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Model-based sensitivity analysis of machining-induced residual stress under minimum quantity lubrication

2015 ◽  
Vol 231 (9) ◽  
pp. 1528-1541 ◽  
Author(s):  
Xia Ji ◽  
Steven Y Liang
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Mixture Ratio ◽  
Minimum Quantity

This article presents a sensitivity analysis of residual stress based on the verified residual stress prediction model. The machining-induced residual stress is developed as a function of cutting parameters, tool geometry, material properties, and lubrication conditions. Based on the residual stress predictive model, the main effects of the cutting force, cutting temperature, and residual stress are quantitatively analyzed through the cosine amplitude method. The parametric study is carried out to investigate the effects of minimum quantity lubrication parameters, cutting parameters, and tool geometry on the cutting performances. Results manifest that the cutting force and residual stress are more sensitive to the heat transfer coefficient and the depth of cut, while the cutting temperature is more sensitive to the cutting speed. Large maximum compressive residual stress is obtained under a lower flow rate of minimum quantity lubrication, small depth of cut, and the proper air–oil mixture ratio. This research can support the controlling and optimization of residual stress in industrial engineering by strategically adjusting the application parameters of minimum quantity lubrication.

scholarly journals Structuring of Bioceramics by Micro-Grinding for Dental Implant Applications

Micromachines ◽  
2019 ◽  
Vol 10 (5) ◽  
pp. 312 ◽  
Author(s):  
Pablo Fook ◽  
Daniel Berger ◽  
Oltmann Riemer ◽  
Bernhard Karpuschewski
Keyword(s):  
Dental Implant ◽  
Surface Integrity ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Machining Parameters ◽  
Metal Implants ◽  
Peripheral Speed ◽  
Grinding Processes ◽  
Recent Developments ◽  
Diamond Grain

Metallic implants were the only option for both medical and dental applications for decades. However, it has been reported that patients with metal implants can show allergic reactions. Consequently, technical ceramics have become an accessible material alternative due to their combination of biocompatibility and mechanical properties. Despite the recent developments in ductile mode machining, the micro-grinding of bioceramics can cause insufficient surface and subsurface integrity due to the inherent hardness and brittleness of these materials. This work aims to determine the influence on the surface and subsurface damage (SSD) of zirconia-based ceramics ground with diamond wheels of 10 mm diameter with a diamond grain size (dg) of 75 μm within eight grinding operations using a variation of the machining parameters, i.e., peripheral speed (vc), feed speed (vf), and depth of cut (ae). In this regard, dental thread structures were machined on fully sintered zirconia (ZrO2), alumina toughened zirconia (ATZ), and zirconia toughened alumina (ZTA) bioceramics. The ground workpieces were analysed through a scanning electron microscope (SEM), X-ray diffraction (XRD), and white light interferometry (WLI) to evaluate the microstructure, residual stresses, and surface roughness, respectively. Moreover, the grinding processes were monitored through forces measurement. Based on the machining parameters tested, the results showed that low peripheral speed (vc) and low depth of cut (ae) were the main conditions investigated to achieve the optimum surface integrity and the desired low grinding forces. Finally, the methodology proposed to investigate the surface integrity of the ground workpieces was helpful to understand the zirconia-based ceramics response under micro-grinding processes, as well as to set further machining parameters for dental implant threads.

Surface integrity in laser-assisted machining of Ti6Al4V

2020 ◽  
pp. 095440622097825
Author(s):  
O Kalantari ◽  
MM Fallah ◽  
F Jafarian ◽  
SR Hamzeloo
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Laser Source ◽  
Depth Of Cut ◽  
Thermal Source ◽  
Laser Assisted Machining

In laser-assisted machining (LAM), the laser source is focused on the workpiece as a thermal source and locally increases the workpiece temperature and makes the material soft ahead of the cutting tool so using this method, the machining forces are reduced, which causes improving the surface quality and cutting tool life. Machinability of advanced hard materials is significantly low and conventional methods do not work effectively. Therefore, utilizing an advanced method is inevitable. The product life and performance of complex parts of the leading industry depends on surface integrity. In this work, the surface integrity features including microhardness, grain size and surface roughness (Ra) and also the maximum cutting temperature were investigated experimentally in LAM of Ti-6Al-4V. According to the results, cutting speed has inverse effect on the effectiveness of LAM process because with increasing speed (15 to 63 m/min), temperature decreases (524 °C to 359 °C) and surface roughness increases (0.57 to 0.71 μm). Enhancing depth of cut and feed has direct effect on the process temperature, grain size, microhardness and surface roughness.

Investigations on surface roughness and microhardness of turned AM alloy

2020 ◽  
pp. 095440622097616
Author(s):  
Sunil Dutta ◽  
NSK Reddy
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Average Roughness ◽  
Study Results ◽  
Superior Surface ◽  
Input Variables ◽  
Response Variables

Manufacturers in different sectors look for materials exhibiting good mechanical properties, high machinability, and superior surface integrity. The machinability of Mg alloys is one of the vital aspects which requires an exhaustive survey during their selection for different applications. The study examines the surface integrity of a fabricated AM alloy (Mg alloy with 7 wt%Al-0.9 wt%Mn) through dry turning. During the experiments, the input variables of turning viz. cutting speed( v), depth of cut (DOC), and feed( f) is altered and applied to the workpiece. The data obtained for the two response variables viz. surface roughness and microhardness accentuate the maximum influence of feed, followed by DOC and speed. For validation a two-stage methodology was adopted; In the first stage, the validation was done with the help of Analysis of variance (ANOVA); the results show the % contribution of feed, speed, and DOC on average roughness is 66.94%, 5.91%, and 27.23% and on microhardness is 47%, 8.3%, and 44.57%, respectively. Subsequently, in the second stage, the surface plots are drawn for both the response variables to ascertain the ANOVA outcomes; the shape of the plots corroborates the experimental and ANOVA results. The study results provide vital insights for parameter selection to get improved results on surface roughness and microhardness during machining of AM alloy.

Finite Element Simulation of Precision Cutting Monocrystalline Silicon

2013 ◽  
Vol 662 ◽  
pp. 99-102 ◽  
Author(s):  
Li Qiu Shi ◽  
Xiao Wen Li ◽  
Feng Yu
Keyword(s):  
High Surface ◽  
Cutting Speed ◽  
Monocrystalline Silicon ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Tool Edge Radius ◽  
Transition Mechanism ◽  
Edge Radius ◽  
Tool Edge ◽  
Optimization Of Cutting Parameters

Monocrystalline silicon is typical of hard brittle materials, a high surface quality can be obtained in ductile-regime cutting. The success of the turning process depends on optimizing the machining parameters such as the tool edge radius, tool rake angles, depth of cut and cutting speed, etc. In this study, based on the ductile–brittle transition mechanism, the optimization of cutting parameters were determined with the commercial, general purpose FEA software Msc.Marc. The result demonstrates that the value of temperature is minimum when the tool rake angle is in the range of -15º～-30º. Smaller tool edge radius was selected while maintaining quality of tool edge radius and tool life. As long as beyond the range of cutting speed 6 ~ 8 mm/s, smaller residual stress can be obtain.

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