Cutting forces and surface finish when machining medium hardness steel using CBN tools

2000 ◽  
Vol 40 (3) ◽  
pp. 455-466 ◽  
Author(s):  
Wuyi Chen
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
Medium Hardness

Performance Profiling of Nanoparticulate Graphite Powder as Lubricant in the Machining of AISI 1040 Steel under Variable Machining Conditions

2014 ◽  
Vol 984-985 ◽  
pp. 15-24 ◽  
Author(s):  
S. Srikiran ◽  
K. Ramji ◽  
B. Satyanarayana
Keyword(s):  
Particle Size ◽  
Surface Finish ◽  
Cutting Forces ◽  
Solid Lubricant ◽  
Graphite Powder ◽  
Nano Particles ◽  
Chemical Degradation ◽  
Work Piece ◽  
Tool Temperature ◽  
Cutting Zone

The generation of heat during machining at the cutting zone adversely affects the surface finish and tool life. The heat at the cutting zone, which plays a negative role due to poor thermal conductivity, resistance to wear, high strength at high temperatures and chemical degradation can be overcome by the use of proper lubrication. Advancements in the field of tribology have led to the use of solid lubricants replacing the conventional flood coolants. This work involves the use of nanoparticulate graphite powder as a lubricant in turning operations whose performance is judged in terms of cutting forces, tool temperature and surface finish of the work piece. The experimentation revealed the increase in cutting forces and the tool temperature when the solid lubricant used is decreased in particle size. The surface finish deteriorated with the decrease in particle size of the lubricant in the nanoregime.Keywords-Turning, Solid lubricant, Graphite, Minimum Quantity Lubrication, nano–particles,Weight percentage,Frictioncoefficient.

Through-Tool Coolant Drilling of Aluminum/SiC Metal Matrix Composite1

2000 ◽  
Vol 122 (4) ◽  
pp. 384-388 ◽  
Author(s):  
Stuart Barnes ◽  
Ian R. Pashby
Keyword(s):  
Tool Wear ◽  
Beneficial Effect ◽  
Titanium Nitride ◽  
Surface Finish ◽  
Strong Evidence ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Solid Carbide ◽  
Cutting Operation ◽  
Tool Cooling

Through-tool coolant was applied to the drilling of an aluminum/SiC MMC. Titanium nitride coated, solid carbide drills were used to investigate the effect of the coolant application method on the performance of the drilling operation. Holes were produced dry, with conventional coolant and with through-the tool coolant. The results provided strong evidence that the conventional application of coolant was having no beneficial effect on the cutting operation compared to dry drilling. However, through-tool cooling gave a significant improvement in performance in terms of tool wear, cutting forces, surface finish and the height of the burrs produced. [S0094-4289(00)02104-6]

Effect of Cutting Parameters on Cutting Forces for Different Profile of Cutting

2015 ◽  
Vol 799-800 ◽  
pp. 361-365 ◽  
Author(s):  
Roshaliza Hamidon ◽  
Erry Y.T. Adesta ◽  
Muhammad Riza ◽  
Mohammad Iqbal
Keyword(s):  
Surface Finish ◽  
Orthogonal Array ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Anova Analysis ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Influential Parameters ◽  
Cutting Speeds

In machining operation of mould cavities, the tool travels in various straight and corner profiles following predetermined toolpath. Such condition results in a fluctuation of cutting forces that may produce bad surface finish. The objective of this study is to investigate the most influential parameters on cutting operation for both straight and corner profiles of pocketing operation. Cutting speeds of 150, 200 and 250m/min, feedrates from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were selected for the cutting processes. Taguchi L9 orthogonal array with Pareto ANOVA analysis was employed to analyze the effects of the selected parameters. The result demonstrates there are different effects of cutting parameters on cutting forces for straight and corner profiles. Furthermore, it was found that cutting speed and feedrate are prevailing factors that affected cutting forces for both types of profile.

scholarly journals Machinability evaluation of titanium alloy Ti-6Al-4V obtained by EBM for functional part at medical application

2021 ◽  
Author(s):  
António Festas ◽  
A. Ramos ◽  
J. P. Davim
Keyword(s):  
Titanium Alloy ◽  
Medical Devices ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Forces ◽  
Hip Prosthesis ◽  
Cutting Speed ◽  
Test Sample ◽  
Turning Operations ◽  
Custom Made

Abstract The potential and advantages revealed by the application of 3D manufacturing techniques such as Electron Beam Melting (EBM) in the production of medical devices such as orthopaedic implants are increasing manly in custom made devices. However, the use of milling and turning operations are indispensable on surfaces where surface finish and dimensional accuracy have more demanding requirements. This work aims to evaluate the machinability of titanium alloy test samples submitted to turning operations, to obtain the geometry of a functional cone of the modular component of the hip prosthesis. The differences in cutting forces and surface finish obtained in the turning tests are compared between a wrought Ti-6Al-4V test sample and three obtained by EBM with different thicknesses. To perform the tests, a constant cutting speed of 60m/min was used, feed of 0.1 and 0.2mm/rev and ap of 0.15mm. The cutting forces were measured for each test, also the roughness was measured in the form of Ra, Rt and RzD in each test sample. From the results obtained, EBM test samples presented higher roughness values and lower resulting cutting forces. In both materials, the effect of feed rate is visible. When machining a cone, the passive force and the cutting force become the most influential forces. Generally, when the feed rate value was doubled, the resulting machining forces value increased up to about 50% for both types of materials and the Ra value to approximately 200%. The EBM technology as used form medical devices allow good quality surfaces as the wrought titanium alloy.

Design and Testing of a Micro-Dynamometer for Desktop Micro-Milling Machine

2014 ◽  
Vol 902 ◽  
pp. 267-273 ◽  
Author(s):  
Samir Mekid
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
High Speed ◽  
High Surface ◽  
Chip Thickness ◽  
Micro Milling ◽  
High Tech ◽  
Machining Accuracy ◽  
Microscopic Features ◽  
Better Than

The emerging miniaturized high-tech products are required to have increased functionalities of systems within a volumetric size on the order of 1 cm3. Hence, the parts are mesoscopic with complex microscopic features of a few mm length with machining accuracy of better than 1 micrometer with secured surface integrity as components will require high surface finish, tensile stress and crack free surfaces in order to function reliably. One of the characteristics to be measured is the cutting forces on the parts being machined. This paper will present the design, manufacture and testing of a miniature dynamometer capable of measuring cutting forces within a low range of 50N but with a resolution better than 1 mN and high frequency since the micromachining involves small cutting forces but the spindle rotates at high speed. The dynamometer is capable of measuring forces in five directions (±x, ±y, and z). The instrument was calibrated and exhibit very good results leading to a true validation. This instrument is assembled on a micro milling desktop machine designed in-house. It will not only support predicting the surface finish and chip thickness but also monitoring tool wear evolution and hence prevents/reduce tool breakage known to be one of the main issues in micro-milling.

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.

Cutting forces, tool wear and surface finish in high speed diamond machining

2017 ◽  
Vol 49 ◽  
pp. 293-304 ◽  
Author(s):  
Ekkard Brinksmeier ◽  
Werner Preuss ◽  
Oltmann Riemer ◽  
Rüdiger Rentsch
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Forces ◽  
High Speed ◽  
Diamond Machining

Machining Performance of PM Material Containing MnX Additives1

2000 ◽  
Vol 122 (4) ◽  
pp. 379-383 ◽  
Author(s):  
Stuart Barnes ◽  
Michael J. Nash ◽  
Moh. H. Lim
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
Surface Finish ◽  
Cutting Forces ◽  
Superior Performance ◽  
Machining Performance ◽  
Turning Operation ◽  
Cutting Speeds

A new free-machining additive, MnX, has been reported to improve the machining performance of ferrous powder metallurgy (PM) materials. This work investigated this claim by comparing the performance of three otherwise identical PM materials containing: no additive, conventional manganese sulphide (MnS) additions and the new MnX additive. A turning operation and cutting speeds of 100–250 m/min were used during which cutting forces, tool wear and surface finish were measured. The MnX material was found to exhibit superior performance. However, this was most noticeable at higher cutting speeds and at the lower cutting speeds, differences in performance were substantially reduced. [S0094-4289(00)02004-1]

Turning and Drilling Machinability of Recycled Aluminum Alloys

2016 ◽  
Vol 710 ◽  
pp. 77-82
Author(s):  
Jean Brice Mandatsy Moungomo ◽  
Donatien Nganga Kouya ◽  
Victor Songmene
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloys ◽  
Surface Finish ◽  
Cutting Forces ◽  
Quality Characteristics ◽  
Part Quality ◽  
Aluminum Chips ◽  
Finish Cutting ◽  
Dry And Wet Conditions ◽  
Machining Operations

A great deal of effort and research has been dedicated to recycled aluminum alloys, mainly to recycling processes and to the mechanical properties of recomposed parts; however, very limited work has been oriented towards the machinability of recycled aluminum materials. Recycled and recomposed aluminum parts sometimes need machining to obtain the final usable part shape and for assembly purposes. The acceptability of using recycled materials in design and engineering applications depends not only on their mechanical properties, but also on their machinability. This paper investigates the machinability of recycled aluminum alloys based on surface finish, cutting forces and chip formation. Two recycled foundry aluminum alloys were used: one from aluminum can covers and another from aluminum chips produced during machining. The machining operations investigated included turning and drilling under dry and wet conditions. The two tested recycled aluminum alloys showed different machinability behaviors and different part quality characteristics, suggesting that it would be desirable to consider separating aluminum wastes and chips considered for recycling by origin or type prior to melting and recasting.

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