Investigations on the effect of Machining parameters on Machining force and roughness in Micro-Milling of Titanium Gr5 and Gr12 alloys under dry Machining conditions using carbide tool

2021 ◽  
Author(s):  
M.S. Kishore Kumar ◽  
B. Gurudatt ◽  
H.N. Reddappa ◽  
R. Suresh
Keyword(s):  
Micro Milling ◽  
Machining Parameters ◽  
Carbide Tool ◽  
Dry Machining ◽  
Machining Conditions ◽  
Machining Force

A Study on the Surface Characteristics with the Vibration Factor in the Micro-Machine

2006 ◽  
Vol 321-323 ◽  
pp. 1605-1608
Author(s):  
Jong Min Kin ◽  
Min Sung Hong ◽  
Bong Suk Kim ◽  
Soo Hun Lee
Keyword(s):  
Great Influence ◽  
Cutting Speed ◽  
Surface Characteristics ◽  
Surface Shape ◽  
System Stability ◽  
Micro Milling ◽  
Machining Parameters ◽  
Machining Conditions ◽  
The Difference ◽  
Micro Machine

In conventional machining, cutting conditions such as cutting speed, feed rate, and depth of the cut have great influence on the surface roughness. In micro machining, however, the surface shape is affected by not only the machining parameters mentioned earlier but also tool stiffness, system stability, and workpiece properties caused by the miniatured structure and cutting tool. Especially, in a micro-machine system, the difference between the cutting forces in the recursive cuts introduces the vibration easily. A high spindle causes instability of the system, increases the temperature in the cutting process, and also changes the tool’s shape. This study introduces a method to predict the surface shape of the workpiece based on the machining conditions in micro milling. The micro-milled surfaces in different machining conditions are predicted by a computer simulation including the vibration model and the simulated results show good agreement with the experimental results.

Micro-Machinability Studies of Single Crystal Silicon Using Diamond End-Mill

2016 ◽  
Author(s):  
Zi Jie Choong ◽  
Dehong Huo ◽  
Patrick Degenaar ◽  
Anthony O’Neill
Keyword(s):  
Size Effect ◽  
Single Crystal Silicon ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Crystal Silicon ◽  
Edge Chipping ◽  
Cutting Energy ◽  
Machining Conditions

This paper presents the research on the machinability studies in micro-milling of (001) silicon wafer. Excessive generation of undesirable surface and subsurface damages such as surface edge chipping often occurs when machined at depth of cut of several hundreds of microns. Ideal machining strategy to reduce the generation of edge chipping is required. Investigations on the effect of machining conditions on the cutting performances and size effect on the specific cutting energy in silicon micro-milling were conducted. These investigations provide understandings on the behavior of cutting mechanism during machining and helps to identify suitable machining parameters for fracture free machining using diamond end mills. Full slot milling were performed along <100> and <110> directions on a (001) surface wafer under various machining conditions. Results show that machined surfaces along <100> were of better quality than those along <110> and is in agreement with previous studies. Furthermore, good machining quality was achieved when machined at depth of cut of 10 μm or feed per tooth of 0.075 μm/tooth, regardless of the machining conditions. In addition, investigation for the size effect on specific cutting energy also shows that brittle mode machining begins when feed per tooth increases beyond 0.4 μm/tooth.

Dry Machining of Inconel 825 Superalloys

2021 ◽  
Vol 11 (4) ◽  
pp. 26-39
Author(s):  
Kshitij Pandey ◽  
Saurav Datta
Keyword(s):  
Tool Wear ◽  
Surface Morphology ◽  
Cutting Force ◽  
Carbide Tool ◽  
Dry Machining ◽  
Machining Performance ◽  
Force Magnitude ◽  
Wear Pattern ◽  
Inconel 825

The present work investigates application feasibility of PVD TiN/TiCN/TiN coated cermet and CVD Al2O3/TiCN coated SiAlON for dry machining of Inconel 825 superalloy. Machining performance is interpreted through cutting force magnitude, tool-tip temperature, and mechanisms of tool wear. Results are compared to that of CVD multi-layer TiN/TiCN/Al2O3/TiN coated WC-Co tool. It is evidenced that SiAlON tool generates lower cutting force but experiences higher tool-tip temperature than other two counterparts. Apart from abrasion and adhesion, carbide tool witnesses coating peeling and ploughing. In contrast, SiAlON tool suffers from inexorable chipping and notching. Wear pattern of cermet tool seems less severe than carbide and SiAlON. Chip's underside surface morphology appears relatively better in case of cermet tool.

scholarly journals Experimental Study on the Influence of Machining Conditions on the Quality of Electrical Discharge Machined Surfaces of aluminum alloy Al5052

Machines ◽  
2020 ◽  
Vol 8 (1) ◽  
pp. 12 ◽  
Author(s):  
Angelos P. Markopoulos ◽  
Emmanouil-Lazaros Papazoglou ◽  
Panagiotis Karmiris-Obratański
Keyword(s):  
Aluminum Alloy ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Parameters ◽  
Machining Processes ◽  
Machining Conditions ◽  
Pulse On Time ◽  
Machined Surfaces

Although electrical discharge machining (EDM) is one of the first established non-conventional machining processes, it still finds many applications in the modern industry, due to its capability of machining any electrical conductive material in complex geometries with high dimensional accuracy. The current study presents an experimental investigation of ED machining aluminum alloy Al5052. A full-scale experimental work was carried out, with the pulse current and pulse-on time being the varying machining parameters. The polishing and etching of the perpendicular plane of the machined surfaces was followed by observations and measurements in optical microscope. The material removal rate (MRR), the surface roughness (SR), the average white layer thickness (AWLT), and the heat affected zone (HAZ) micro-hardness were calculated. Through znalysis of variance (ANOVA), conclusions were drawn about the influence of machining conditions on the EDM performances. Finally, semi empirical correlations of MRR and AWLT with the machining parameters were calculated and proposed.

Measuring of cutting forces and chip shapes based on different machining parameters

Sensor Review ◽  
2018 ◽  
Vol 38 (3) ◽  
pp. 387-390
Author(s):  
Obrad Anicic ◽  
Srdjan Jovic ◽  
Ivica Camagic ◽  
Mladen Radojkovic ◽  
Nenad Stanojevic
Keyword(s):  
Cutting Forces ◽  
Design Methodology ◽  
Machining Process ◽  
Machining Parameters ◽  
Content Type ◽  
Machining Conditions

Purpose The main aim of the study was to measure the cutting forces and chip shapes based on different machining parameters. Design/methodology/approach To get the best optimal machining conditions, it is essential to use the best combination of machining parameters. Although some machining parameters are not important for the process, there are machining parameters which are very important for the machining process. Findings It is essential to determine which machining parameters are the most dominant to make the optimal machining conditions. Originality/value Six different chip shapes are obtained according to ISO standardization. It was determined that the different cutting forces occurred for the different chip shapes.

An analysis on the effect of machining parameters on surface quality during dry machining of Ti-6Al-4V alloy

2020 ◽  
Vol 22 ◽  
pp. 2814-2823
Author(s):  
S. Samsudeensadham ◽  
Dinesh Kumar Suppan ◽  
V. Krishnaraj ◽  
M. Parthiban
Keyword(s):  
Surface Quality ◽  
Machining Parameters ◽  
Dry Machining

Multiresponse optimization of drillability factors and mechanical properties of chitosan-reinforced polypropylene composite

2020 ◽  
pp. 089270572093916
Author(s):  
Nafiz Yaşar ◽  
Mustafa Günay ◽  
Erol Kılık ◽  
Hüseyin Ünal
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Thrust Force ◽  
Flexural Modulus ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Uniaxial Tensile ◽  
Machining Parameters ◽  
Molding Method ◽  
Machining Conditions

In this study, the mechanical and machinability characteristics of chitosan (Cts)-filled polypropylene (PP) composites produced by injection molding method were analyzed. Uniaxial tensile, impact, hardness, and three-point flexural tests were used to observe the influence of Cts filler on the mechanical behavior of PP. For the machinability analysis of these materials, drilling experiments based on Taguchi’s L27 orthogonal array were performed using different drill qualities and machining parameters. Then, machining conditions are optimized through grey relational analysis methodology for machinability characteristics such as thrust force and surface roughness obtained from drilling tests. The results showed that tensile, flexural strength, and percentage elongation decreased while impact strength increased with adding the Cts filler to PP. Moreover, it was determined that the tensile and flexural modulus of elasticity increased significantly and there was a slight increase in hardness. Thrust forces decreased while surface roughness values increased when the Cts filler ratio and feed rate was increased. The optimal machining conditions for minimizing thrust force and surface roughness was obtained as PP/10 wt% Cts material, uncoated tungsten carbide drill, feed rate of 0.05 mm/rev, and cutting speed of 40 m/min. In this regard, PP composite reinforced by 10 wt% Cts is recommended for industrial applications in terms of both the mechanical and machinability characteristics.

COMPLEXITY-BASED ANALYSIS OF THE INFLUENCE OF MACHINING PARAMETERS ON THE SURFACE FINISH OF DRILLED HOLES IN DRILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (06) ◽  
pp. 1950087 ◽  
Author(s):  
ASHFAQ AHAMED ◽  
ATHIF AHAMED ◽  
DILAN KATUWAWALA ◽  
TEOH TIONG EE ◽  
ZI HAN TAN ◽  
...  
Keyword(s):  
Surface Quality ◽  
Fractal Theory ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Machining ◽  
Drilling Operation ◽  
Two Factors ◽  
Machining Operations

Drilling is a famous and widely used machining operation to make holes in the workpiece. The size and surface quality of drilled hole are two factors that should be considered mainly. In this research, we examine the effect of different machining parameters and conditions on the surface quality of generated hole in drilling operation. For this purpose, we employ fractal theory and investigate how the variations of depth of cut and spindle speed affect the complexity of surface texture of drilled holes in wet and dry machining conditions. Based on the obtained results, the increment of depth of cut and spindle speed in case of wet and dry machining causes lower complexity on the generated surface from drilling. In addition, the generated surface from dry machining is more complex than the generated surface from wet machining. The obtained method in this research can be applied to other machining operations in order to investigate the effect of machining parameters and conditions on the surface quality of machined workpiece.

Identification of a Friction Model at the Tool-Chip-Workpiece Interface in Dry Machining of a AISI 1045 Steel With a TiN Coated Carbide Tool

2011 ◽  
Vol 133 (4) ◽  
Author(s):  
Hamdi Ben Abdelali ◽  
Cedric Courbon ◽  
Joël Rech ◽  
Wacef Ben Salem ◽  
Abdelwaheb Dogui ◽  
...  
Keyword(s):  
Friction Model ◽  
Carbide Tool ◽  
Dry Machining ◽  
Sliding Velocity ◽  
Partition Model ◽  
Heat Partition ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The characterization of frictional phenomena at the tool-chip-workpiece interface in metal cutting remains a challenge. This paper aims at identifying a friction model and a heat partition model at this interface during the dry cutting of an AISI1045 steel with TiN coated carbide tools. A new tribometer, based on a modified pin-on-ring system, has been used in order to reach relevant values of pressures, temperatures, and sliding velocities. Additionally a 3D Arbitrary Lagrangian Eulerian model (A.L.E.) numerical model simulating the frictional test has been developed in order to extract local parameters around the spherical pin, such as average contact pressure, average local sliding velocity, and average contact temperature, from experimental macroscopic measurements. A large range of sliding velocities [0.083–5 m/s] has been investigated. It has been shown that friction coefficient and heat partition coefficient are mainly dependant on local sliding velocity at the interface. Three friction regimes have been identified. These experimental and numerical results provide a better understanding of the tribological phenomena along the tool-chip-workpiece interfaces in dry machining of an AISI 1045 steel with a TiN coated carbide tool. Finally a new friction model and heat partition model has been developed for implementation in a numerical cutting model.

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