Experimental investigations and optimization of machining performance during turning of EN-31 steel using TOPSIS approach

2021 ◽  
Author(s):  
Gurpreet Singh ◽  
Ajay Kumar ◽  
Vivek Aggarwal ◽  
Sehijpal Singh
Keyword(s):  
Experimental Investigations ◽  
Machining Performance ◽  
En 31 ◽  
Topsis Approach

Tolerance-Based Optimization of Sinking EDM for Industrial Seal Slot Manufacture

2021 ◽  
Author(s):  
Timm Petersen ◽  
Markus Zeis ◽  
Thomas Bergs
Keyword(s):  
Electrical Discharge Machining ◽  
Experimental Investigations ◽  
Discharge Energy ◽  
Machining Performance ◽  
Wear Rates ◽  
High Productivity ◽  
Aspect Ratios ◽  
Recast Layer Thickness ◽  
Turbine Vanes ◽  
Working Principle

Abstract Seal plates for turbine vanes significantly reduce gap losses and thus play a major role in increasing the efficiency of turbines. The industrial production of seal slots, which position the seal plates in the turbine vanes, is driven by the need for high productivity in combination with a reliable processing of necessary geometrical and surface integrity features. A machining technology that is able to machine hard-to-cut materials such as nickel-based alloys is electrical discharge machining. Due to its electro-thermal working principle it is able to machine materials independently from their mechanical properties even at high aspect ratios. Achievable removal and wear rates as well as the resulting surface properties strongly depend on the discharge energy. Furthermore, the discharge energy affects the working gap sizes and therefore flushing efficiencies when machining high aspect ratio cavities. This relationship is investigated taking into account various contemporary generator technologies and graphite grades from both published literature and own experimental investigations. Their effect on machining performance focusing on productivity, recast layer thickness and crack formation is quantified. Based on this data a novel empirical model for tolerance-based optimization is developed. The model is used to perform an optimization on an existing serial production and implementation has been proven successful.

Experimental Investigations to Study the Effect of Solid Lubricant MOS2 on the Performance of Hard Turning

2010 ◽  
Author(s):  
Dilbag Singh ◽  
P. Venkateswara Rao
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
Hard Turning ◽  
Solid Lubricant ◽  
Research Work ◽  
Cryogenic Cooling ◽  
Experimental Investigations ◽  
Cutting Fluids ◽  
Machining Performance ◽  
Molybdenum Disulphide

In hard turning, lot of heat is generated due to plastic deformation of the work material, friction at the tool-chip interface and friction between tool and the workpiece. The heat produced in machining adversely affects the quality of the products produced. Cutting fluids have been the conventional choice to deal with this problem. However, due to the environmental restrictions, the use of cutting fluids is restricted. Machining with solid lubricants, cryogenic cooling by liquid nitrogen and minimum quantity lubrication are some of the alternative approaches in this direction. This research work deals with an investigation on using molybdenum disulphide as solid lubricant in order to reduce friction for improving the machining performance and for overcoming some of the limitations that arise due to the use of cutting fluids or while dry hard turning. An experimental setup has been designed and built, and experiments have been conducted to study the effect of using molybdenum disulphide as solid lubricant on surface finish and cutting forces. An improvement in surface finish was observed with molybdenum disulphide assisted hard turning. It was also observed that there was a considerable reduction of cutting forces, thereby reducing the specific energy needed and consequently improving the machining performance.

A Systematic Approach to the Adaptive Control of the Electro-Discharge Machining Process

1978 ◽  
Vol 100 (3) ◽  
pp. 303-309 ◽  
Author(s):  
M. M. Tseng
Keyword(s):  
Adaptive Control ◽  
Process Planning ◽  
Systematic Approach ◽  
Machining Process ◽  
Experimental Investigations ◽  
Machining Performance ◽  
Electric Pulses ◽  
Electro Discharge Machining ◽  
On Line ◽  
Line Process

Electro-discharge machining removes metal with very short lived electric pulses between electrode and workpiece which are immersed in dielectric liquid. With limited feedback available to the operator, the process is very difficult to approach and maintain efficient machining performance. A systematic approach is taken here by applying incomplete process information for off-line process planning and by minicomputer technology for on line adaptive control. Off-line process planning determines the optimal current level and pulse duration for the roughing and finishing. By sensing down feed and pulse efficiency, on line adaptive control adjusts servo voltage and off time. Experimental investigations with two repetitions show that the system can complete the job with a shorter machining time by detecting and responding more efficiently to disturbances in the process than manual control.

scholarly journals Effect of Yttrium and Rhenium Ion Implantation on the Performance of Nitride Ceramic Cutting Tools

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4687
Author(s):  
Dmitrij Morozow ◽  
Zbigniew Siemiątkowski ◽  
Edwin Gevorkyan ◽  
Mirosław Rucki ◽  
Jonas Matijošius ◽  
...  
Keyword(s):  
Ion Implantation ◽  
Cutting Forces ◽  
Cutting Tools ◽  
Metal Vapor ◽  
Vacuum Arc ◽  
Experimental Investigations ◽  
Unexpected Result ◽  
Turning Process ◽  
Machining Performance ◽  
Tool Surface

In the paper, the results of experimental investigations of ion implanted cutting tools performance are presented. The tools, made out of Si3N4 with additives typically used for turning of Ti-6Al-4V alloy, underwent implantation with ions of yttrium (Y+) and rhenium (Re+) using the metal vapor vacuum arc method. Distribution of ions on the tool surface was measured. The cutting tools were tested in turning process with measurement of cutting forces and analysis of wear. A rather unexpected result was the increased wear of the tool after Y+ implantation with 1 × 1017 ion/cm2. It was demonstrated, however, that the tool after Y+ 2 × 1017 ion/cm2 ion implantation provided the best machining performance.

Tolerance-based Optimization of Sinking Edm for Industrial Seal Slot Manufacture

2021 ◽  
Author(s):  
Timm Petersen ◽  
Markus Zeis ◽  
Thomas Bergs
Keyword(s):  
Electrical Discharge Machining ◽  
Experimental Investigations ◽  
Discharge Energy ◽  
Machining Performance ◽  
Wear Rates ◽  
High Productivity ◽  
Aspect Ratios ◽  
Recast Layer Thickness ◽  
Turbine Vanes ◽  
Working Principle

Abstract Seal plates for turbine vanes significantly reduce gap losses and thus play a major role in increasing the efficiency of turbines. The industrial production of seal slots, which position the seal plates in the turbine vanes, is driven by the need for high productivity in combination with a reliable processing of necessary geometrical and surface integrity features. A machining technology that is able to machine hard-to-cut materials such as nickel-based alloys is electrical discharge machining. Due to its electro-thermal working principle it is able to machine materials independently from their mechanical properties even at high aspect ratios. Achievable removal and wear rates as well as the resulting surface properties strongly depend on the discharge energy. Furthermore, the discharge energy affects the working gap sizes and therefore flushing efficiencies when machining high aspect ratio cavities. This relationship is investigated taking into account various contemporary generator technologies and graphite grades from both published literature and own experimental investigations. Their effect on machining performance focusing on productivity, recast layer thickness and crack formation is quantified. Based on this data a novel empirical model for tolerance-based optimization is developed. The model is used to perform an optimization on an existing serial production and implementation has been proven successful.

scholarly journals Minimization of Surface Roughness and Tool Vibration in CNC Milling Operation

2015 ◽  
Vol 2015 ◽  
pp. 1-13 ◽  
Author(s):  
Sukhdev S. Bhogal ◽  
Charanjeet Sindhu ◽  
Sukhdeep S. Dhami ◽  
B. S. Pabla
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Experimental Investigations ◽  
Cnc Milling ◽  
Tool Vibration ◽  
En 31

Tool vibration and surface roughness are two important parameters which affect the quality of the component and tool life which indirectly affect the component cost. In this paper, the effect of cutting parameters on tool vibration, and surface roughness has been investigated during end milling of EN-31 tool steel. Response surface methodology (RSM) has been used to develop mathematical model for predicting surface finish, tool vibration and tool wear with different combinations of cutting parameters. The experimental results show that feed rate is the most dominating parameter affecting surface finish, whereas cutting speed is the major factor effecting tool vibration. The results of mathematical model are in agreement with experimental investigations done to validate the mathematical model.

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