Effect of Tool Nose Radius and Machining Parameters on Cutting Force, Cutting Temperature and Surface Roughness – An Experimental Study of Ti-6Al-4V (ELI)

2020 ◽  
Vol 22 ◽  
pp. 1977-1986 ◽  
Author(s):  
Darshit Shah ◽  
Sanket Bhavsar
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Machining Parameters ◽  
Nose Radius ◽  
Tool Nose Radius

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

Experimental Study on Spray Cutting Ni-Based Superalloy

2012 ◽  
Vol 723 ◽  
pp. 317-321
Author(s):  
Yu Wang ◽  
Yuan Sheng Zhai ◽  
Fu Gang Yan ◽  
Xian Li Liu
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Production Mode ◽  
Effective Reduction ◽  
Reasonable Choice ◽  
Base Superalloy

In this paper, the effect of cutting parameters on cutting force, cutting temperature and surface roughness on cutting force, cutting temperature and surface roughness are experimentally studied in spray cutting GH4169 Ni-base superalloy used carbide cutting tools. The results showed that reasonable choice of cutting parameters can effective reduction of cutting force and cutting temperature, and improve the machining surface roughness. Thus realizing clean production mode.

scholarly journals An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 460
Author(s):  
Canbin Zhang ◽  
Chifai Cheung ◽  
Benjamin Bulla ◽  
Chenyang Zhao
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
Optical Glass ◽  
Contact Point ◽  
Cutting Speed ◽  
Optical Quality ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cutting Geometry

Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0°, 5°, 10°, and 15°, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

OPTIMIZATION OF PROCESS PARAMETERS AFFECTING CUTTING FORCE, POWER CONSUMPTION AND SURFACE ROUGHNESS USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS IN TURNING AISI 1040 STEEL

2021 ◽  
Author(s):  
MAHIR AKGÜN
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Cutting Force ◽  
Cutting Speed ◽  
System Optimization ◽  
Gray Relational Analysis ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Significance Level ◽  
Relational Analysis

This study focuses on optimization of cutting conditions and modeling of cutting force ([Formula: see text]), power consumption ([Formula: see text]), and surface roughness ([Formula: see text]) in machining AISI 1040 steel using cutting tools with 0.4[Formula: see text]mm and 0.8[Formula: see text]mm nose radius. The turning experiments have been performed in CNC turning machining at three different cutting speeds [Formula: see text] (150, 210 and 270[Formula: see text]m/min), three different feed rates [Formula: see text] (0.12 0.18 and 0.24[Formula: see text]mm/rev), and constant depth of cut (1[Formula: see text]mm) according to Taguchi L18 orthogonal array. Kistler 9257A type dynamometer and equipment’s have been used in measuring the main cutting force ([Formula: see text]) in turning experiments. Taguchi-based gray relational analysis (GRA) was also applied to simultaneously optimize the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]). Moreover, analysis of variance (ANOVA) has been performed to determine the effect levels of the turning parameters on [Formula: see text], [Formula: see text] and [Formula: see text]. Then, the mathematical models for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) have been developed using linear and quadratic regression models. The analysis results indicate that the feed rate is the most important factor affecting [Formula: see text] and [Formula: see text], whereas the cutting speed is the most important factor affecting [Formula: see text]. Moreover, the validation tests indicate that the system optimization for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) is successfully completed with the Taguchi method at a significance level of 95%.

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 flow parameters in the dual nozzle CO2-based vortex tube cooling system during turning of Ti-6Al-4V

2021 ◽  
pp. 095440622110574
Author(s):  
Khirod Mahapatro ◽  
P Vamsi Krishna
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Vortex Tube ◽  
Cooling System ◽  
Cutting Temperature ◽  
Nozzle Diameter ◽  
Energy Separation ◽  
Optimum Conditions ◽  
Dry Cutting ◽  
Input Variables

Dual nozzle vortex tube cooling system (VTCS) is developed to improve the machinability of Ti-6Al-4V where cold-compressed CO2 gas is used as a coolant. The cooling effect is produced by the process of energy separation in the vortex tube and the coolant is supplied into the machining zone to remove the generated heat in machining. In this study, the responses such as cutting force (Fz), cutting temperature (Tm), and surface roughness (Ra) are analyzed by considering coolant inlet pressure, cold fraction, and nozzle diameter as input variables. Further optimization is performed for the input variables using the genetic algorithm technique, and the results at optimum conditions are compared with those of dry cutting. From the results, lower cutting force is observed at lower coolant pressure and cold fraction and higher nozzle diameter. The cutting temperature is minimized by increasing coolant pressure and cold fraction and by decreasing nozzle diameter. A better surface finish is observed at high coolant pressure and cold fraction and lower nozzle diameters. It is observed from the response surface method (RSM) that the coolant pressure is most significantly affecting all the responses. At optimum conditions, the cutting temperature and surface roughness are 35.6% and 66.14%, respectively, lower than dry cutting due to the effective cooling and lubricating action of the CO2 gas, whereas cutting force observed under the VTCS is 18.6% higher than that of dry cutting because of the impulse force of the coolant VTCS and thermal softening of the workpiece in dry cutting.

Experimental Investigation for the Multi-objective Optimization of Machining Parameters on AISI D2 Steel Using Particle Swarm Optimization Coupled with Artificial Neural Network

2020 ◽  
Vol 19 (03) ◽  
pp. 589-606 ◽  
Author(s):  
Vipin Gopan ◽  
K. Leo Dev Wins ◽  
Gecil Evangeline ◽  
Arun Surendran
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
Artificial Neural Network ◽  
Cutting Force ◽  
Surface Finish ◽  
Fitness Function ◽  
Machining Parameters ◽  
Swarm Optimization ◽  
Fine Surface ◽  
Aisi D2

High Carbon High Chromium (or AISI D2) Steels, owing to the fine surface finish they produce upon grinding, find lot of applications in die casting. Machining parameters affect the surface finish significantly during the grinding operation. In this context, this work puts an effort to arrive at the optimum machining parameters relating to fine surface finish with minimum cutting force. The material removal caused by the abrasive grinding wheel makes the process a very complex and nonlinear machining operation. In many situations, traditional optimization techniques fail to provide realistic optimum conditions because of the associated complexity. In order to overcome this issue, particle swarm optimization (PSO) coupled with artificial neural network (ANN) is applied in this research work for parameter optimization with the objective of achieving minimum surface roughness and cutting force. The machining parameters selected for the investigation were table speed, cross feed and depth of cut and the responses were surface roughness and cutting force. ANNs, inspired from biological neural networks, are well capable of providing patterns, which are too complex in behavior. The ANN model developed was used as the fitness function for PSO to complete the optimization. Optimization was also carried out using conventional response surface methodology-genetic algorithm (RSM-GA) approach in which regression equation developed with RSM was considered as the fitness function for GA. Confirmatory experiments were conducted and the comparison showed that PSO coupled with ANN is a reliable tool for complex optimization problems.

scholarly journals Analysis of Surface Roughness and Flank Wear Using the Taguchi Method in Milling of NiTi Shape Memory Alloy with Uncoated Tools

Coatings ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1259
Author(s):  
Emre Altas ◽  
Hasan Gokkaya ◽  
Meltem Altin Karatas ◽  
Dervis Ozkan
Keyword(s):  
Surface Roughness ◽  
Shape Memory Alloy ◽  
Shape Memory ◽  
Flank Wear ◽  
Cutting Tools ◽  
Dominant Factor ◽  
Niti Shape Memory Alloy ◽  
Machining Parameters ◽  
Nose Radius ◽  
Dry Cutting

The aim of this study was to optimize machining parameters to obtain the smallest average surface roughness (Ra) and flank wear (Vb) values as a result of the surface milling of a nickel-titanium (NiTi) shape memory alloy (SMA) with uncoated cutting tools with different nose radius (rε) under dry cutting conditions. Tungsten carbide cutting tools with different rε (0.4 mm and 0.8 mm) were used in milling operations. The milling process was performed as lateral/surface cutting at three different cutting speeds (Vc) (20, 35 and 50 m/min), feed rates (fz) (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The effects of machining parameters in milling experiments were investigated based on the Taguchi L18 (21 × 32) orthogonal sequence, and the data obtained were analyzed using the Minitab 17 software. To determine the effects of processing parameters on Ra and Vb, analysis of variance (ANOVA) was used. The analysis results reveal that the dominant factor affecting the Ra is the cutting tool rε, while the main factor affecting Vb is the fz. Since the predicted values and measured values are very close to each other, it can be said that optimization is correct according to the validation test results.

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