Effect of Turning Parameters on Tool Wear, Surface Roughness and Metal Removal Rate of Alumina Reinforced Aluminum Composite

Optimization in turning means determination of the optimal set of the machining parameters to satisfy the objectives within the operational constraints. These objectives may be the minimum tool wear, the maximum metal removal rate (MRR), or any weighted combination of both. The main machining parameters which are considered as variables of the optimization are the cutting speed, feed rate, depth of cut, and nose radius. The optimum set of these four input parameters is determined for a particular job-tool combination of 7075Al alloy-15 wt. % SiC (20–40 μm) composite and tungsten carbide tool during a single-pass turning which minimizes the tool wear and maximizes the metal removal rate. The regression models, developed for the minimum tool wear and the maximum MRR were used for finding the multiresponse optimization solutions. To obtain a trade-off between the tool wear and MRR the, a method for simultaneous optimization of the multiple responses based on an overall desirability function was used. The research deals with the optimization of multiple surface roughness parameters along with MRR in search of an optimal parametric combination (favorable process environment) capable of producing desired surface quality of the turned product in a relatively lesser time (enhancement in productivity). The multi-objective optimization resulted in a cutting speed of 210 m/min, a feed of 0.16 mm/rev, a depth of cut of 0.42 mm, and a nose radius of 0.40 mm. These machining conditions are expected to respond with the minimum tool wear and maximum the MRR, which correspond to a satisfactory overall desirability.

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Optimization of MRR and Surface Roughness of AlMg3 (AA5754) Alloy in CNC Lathe Machine by Using Taguchi Method

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.877.110 ◽

2018 ◽

Vol 877 ◽

pp. 110-117 ◽

Cited By ~ 1

Author(s):

Poornesh Kumar Chaturvedi ◽

Harendra Kumar Narang ◽

Atul Kumar Sahu

Keyword(s):

Surface Roughness ◽

Taguchi Method ◽

Metal Removal ◽

Removal Rate ◽

Surface Condition ◽

Point Of View ◽

Depth Of Cut ◽

Metal Removal Rate ◽

Cnc Lathe ◽

Lathe Machine

Quality of the product is the major concern in manufacturing industries from customers as well as producers point of view. There are number of factors in the product such as surface condition, height, weight, length, width etc., which may be consider for the measurement of the quality. Surface roughness and Metal Removal Rate (MRR) are the two main outcomes on which numerous researchers have applied different approaches for several years to get optimum results. In this study, Taguchi Method is applied for getting optimum parameters settings for Surface roughness and Metal Removal Rate (MRR) in case of turning AlMg3 (AA5754) in CNC Lathe machine, which is an aluminum alloy having diameter 20 mm and length 100 mm. The three parameters i.e. spindle speed, feed rate and depth of cut with 3 levels are taken as the process variables and the working ranges of these parameters for conducting experiments are selected based on Taguchi’s L9 Orthogonal Array (OA) design. To analyze the significant process parameters; main effect plots for data means and for S/N ratio are generated using Minitab statistical software.

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Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

10.21203/rs.3.rs-408151/v1 ◽

2021 ◽

Author(s):

Dragan Rodic ◽

Marin Gostimirovic ◽

Milenko Sekulic ◽

Borislav Savkovic ◽

Branko Strbac

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Material Removal Rate ◽

Electrical Discharge ◽

Material Removal ◽

Metal Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Positive Effects ◽

Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

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Effect of the Al2O3 powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405420921721 ◽

2020 ◽

Vol 234 (12) ◽

pp. 1538-1548 ◽

Cited By ~ 1

Author(s):

Hossam M Yehia ◽

Mohamed Hakim ◽

Ahmed El-Assal

Keyword(s):

Surface Roughness ◽

Metal Removal ◽

Removal Rate ◽

Lower Surface ◽

Maximum Effect ◽

Metal Removal Rate ◽

Powder Addition ◽

Different Depths ◽

Electrochemical Grinding ◽

Better Than

The integrated electrochemical grinding machining has received wide acceptance in the aircraft turbine industry for the machining of blades, vanes, and honeycomb seal rings. Also, medical devices, instruments and forceps, shells, precision nozzles, instrument coupling, and air rotor motors that produced from stainless steel and new materials have all successfully been accomplished with electrochemical grinding. To improve the metal removal rate and to reduce the surface roughness ( Ra) of the electrochemical grinding at high voltages, an integration between the alumina abrasive jet and the electrochemical grinding machining has been performed. The effect of the Al2O3 abrasive content on the metal removal rate and the Ra of the K110 alloy steel using Everite electrochemical grinding 618 at different voltages, different feed rates, different electrolyte NaCl concentrations, and different depths of the cut were successfully investigated. The results revealed that the abrasive electrochemical grinding was better than the electrochemical grinding results. The maximum effect of the Al2O3 on the metal removal rate was achieved at 5 wt.%. The current density in the machining gap was affected by the addition of the Al2O3, where it was decreased at percentages over 5-wt.% Al2O3. The abrasive electrochemical grinding resulted in lower surface roughness than the electrochemical grinding process.

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EXPERIMENTAL INVESTIGATIONS INTO THE INFLUENCING PARAMETERS OF ELECTROCHEMICAL MACHINING OF AISI 202

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686708001486 ◽

2008 ◽

Vol 07 (02) ◽

pp. 337-343 ◽

Cited By ~ 7

Author(s):

T. SEKAR ◽

R. MARAPPAN

Keyword(s):

Surface Roughness ◽

Metal Removal ◽

Removal Rate ◽

Electrochemical Machining ◽

High Energy ◽

Experimental Investigations ◽

Metal Removal Rate ◽

Hard Materials ◽

Influencing Parameters ◽

Traditional Process

Electrochemical machining (ECM) is a non-traditional process used mainly to cut hard or difficult to cut metals, where the application of a more traditional process is not convenient. Those difficult to cut metals demand high energy to form chips, which can result in thermal effects due to the high temperatures inherent to the process in the chip–tool interface. In traditional processes, the heat generated during the cut is dissipated to the tool, chip, workpiece and environment, affecting the surface integrity of the workpiece, mainly for those hard materials. In this work, experimental investigations have been made on the various influencing parameters involved in the Metal removal rate (MRR) and Surface roughness using ECM on AISI 202 steel. The major intervening parameters are studied and the relationship between the parameters has been determined to achieve maximum metal removal rate and minimum surface roughness by using NaNO 3-Aqua solution.

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An overview of conventional and non-conventional techniques for machining of titanium alloys

Manufacturing Review ◽

10.1051/mfreview/2020029 ◽

2020 ◽

Vol 7 ◽

pp. 34 ◽

Cited By ~ 1

Author(s):

Samuel Ranti Oke ◽

Gabriel Seun Ogunwande ◽

Moshood Onifade ◽

Emmanuel Aikulola ◽

Esther Dolapo Adewale ◽

...

Keyword(s):

Surface Roughness ◽

Wear Rate ◽

Tool Wear ◽

Titanium Alloys ◽

Metal Removal ◽

Removal Rate ◽

High Volume ◽

Future Research ◽

Tool Wear Rate ◽

The Common

Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

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Influence of Polarity of Electro Discharge Machine (EDM) on Surface Roughness (SR) and Metal Removal Rate (MRR) of Low Carbon Steel

Engineering and Technology Journal ◽

10.30684/etj.v38i7a.469 ◽

2020 ◽

Vol 38 (7A) ◽

pp. 975-983

Author(s):

Shahad A. Taqi ◽

Saad K. Shather

Keyword(s):

Surface Roughness ◽

Metal Removal ◽

Removal Rate ◽

Low Carbon Steel ◽

Negative Electrode ◽

Tool Electrode ◽

Metal Removal Rate ◽

Low Carbon ◽

Discharge Machine ◽

Multiple Variables

Electro discharge machining (EDM) is one of a thermal process that is used for remove of metal from the workpiece by spark erosion. The work of this machine depends on multiple variables. One of the more influential variants on this machine is the change of polarity and the use of this variable is not wide and the research depends on the polarity of the machinist. Essentially, the polarity of the tool (electrode) is positive and the workpiece is negative, this polarity can be reversed. This paper focuses on the influence of changing the polarity (positive and negative) on the surface roughness and metal removal rate by using different parameters (current, voltages, polarity and Ton). Experiments show that the positive electrode gives (best surface roughness = 1.56 µm when the current = 5 Am and Ton = 5.5 µs) and (best metal removal rate = 0.0180 g/min when the current = 8 Am and Ton = 25 µs). Negative electrode gives (best surface roughness = 0.46 µm when the current = 5 Am and Ton = 5.5 µs) and (best metal removal rate = 0.00291 g/min when the current = 8 Am and Ton = 25 µs).

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surface roughness,metal removal Effect of Wire Diameter, Feeding Rate, Pulse (on/off) Time on Surface Roughness and Metal Removal Rate for Cr-Mo Steel (SCM425H) During Wire Electrical Discharge Machine (WEDM) Cutting Operation

Engineering and Technology Journal ◽

10.30684/etj.v38i6a.524 ◽

2020 ◽

Vol 38 (6A) ◽

pp. 854-860

Author(s):

Saad K. Shather ◽

Sami A. Hammood ◽

Noor Al-Huda A. Hussain ◽

Noor H. Hasson

Keyword(s):

Surface Roughness ◽

Electrical Discharge ◽

Feeding Rate ◽

Metal Removal ◽

Removal Rate ◽

Electrical Discharge Machine ◽

Wire Diameter ◽

Metal Removal Rate ◽

Discharge Machine ◽

Off Time

Increase the demand to produce complex shapes with high quality and dimensional accuracy such as production aerospace, cars, die sinking has been leading to increase the demand to use the non- traditional cutting operations such as wire electro-discharge machine (WEDM) rather than using the traditional operations. An idea to understand the effect of wire diameter, wire feed, pulsing (on/off) time on surface roughness, and metal removal rate of Cr-Mo steel during wire electrical discharge machining was investigated. Two Steel alloy samples with dimensions of (60 x50 x 20)mm were cut into four rectangular spaces with (5x10x20)mm at one side of each sample using wire cut (EDM) machine with a wire diameter of 0.25 mm and feeding rate 2 m/min for sample 1 and a 0.3 mm diameter and 3 m/min feeding rate for sample 2. Pulse (on, off) time was (110, 50), (112, 52), (115, 55), (116, 57) corresponds to space 1, space 2, space 3, and space 4 in both steel block. Surface roughness and metal removal rate measurements were estimated. The results showed that wire diameter, feeding rate, and pulse (on, off) time is proportional with metal removal rate, while reversed with surface roughness. The wire diameter of 0.3 mm and a feeding rate of 3m/min enhanced better surface quality and productivity. Pulse (on, off) time is the most effective parameter. Best duration time was recorded at the values (116, 57).

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