scholarly journals Taguchi Optimisation In Machining EN18 Using Coated Tool Under Dry and MQL Condition

2020 ◽  
Vol 184 ◽  
pp. 01013
Author(s):  
Kosaraju Satynarayana ◽  
Are Swathi ◽  
Kesari Neeraja ◽  
Madipali Samaikhya ◽  
Kumkuma Rajkiran
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Production Systems ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Turning Process ◽  
Anova Analysis ◽  
Coated Tool ◽  
The Mathematical Model ◽  
Minimum Quality

Turning is one of the initial basic machining operation that prevails in assembly and production process. Modern techniques have been practices in rapid and eco-friendly production systems. Present study deals with the investigation of turning process on EN 18 steel which is been shown its existence in automobiles industries. Turning operation was performed using a coated tool insert with varying cutting speed (100, 125 and 150 mm/min), feed rate (0.05, 0.5, 0.15 mm/rev) and depth of cut (0.4, 0.8, 1.2 mm) at both dry and MQL conditions. The results obtained was compared to optimize the effect of minimum quality lubrication on surface roughness. Experimentally it was observed that speed of 100 m/min with combination of feed of 0.05 mm/rev and 0.4 mm depth of cut was found to be optimized for surface roughness in both the cases. The mathematical model generated for surface roughness and MRR for both dry and MQL turning models having better regression fit as it closer to 100. From ANOVA analysis feed was proved to be the highest contributing factor for surface roughness and for MRR speed is the most significant factor for both dry and MQL turning

scholarly journals Study and Optimisation of Process Parameter in Turning Of EN 45 - Spring Steel Material Under Dry And MQL Conditions

2020 ◽  
Vol 184 ◽  
pp. 01051
Author(s):  
Kosaraju Satynarayana ◽  
Kumkuma Rajkiran ◽  
Kalemula Sai Kiran
Keyword(s):  
Experimental Data ◽  
Mathematical Model ◽  
Surface Roughness ◽  
Spring Steel ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Steel Material ◽  
Magnetic Steel ◽  
Minimum Quality

Minimum quality lubrication has shown a noticeable changes with machining outcomes. MQL is one of updated technologies that have been prevailing in contributions towards production and environment enhancement. Present papers deals with the turning of EN 45 steel material which is commonly known to be spring material. En 45 one of the magnetic steel material with low manganese and high amount of carbons is turned under dry and MQL condition. DOE has been prepared with L9 taguchi. Machining factors of speed (75, 100, 125 m/min), feed (0.1, 0.2, 0.3 mm/rev) and depth of cut (0.3, 0.6, 0.9 mm). The surface roughness were optimized by considering the machining parameters of speed, feed, and depth of cut. For both the condition dry and MQL it was observed that speed at 125m/min, feed at 0.1 and depth of cut at 0.3mm was found optimum condition. The regression equation and mathematical model was generated using the experimental data. Furthermore the ANOVA analysis was performed and observed that in case of dry turning speed found to be most influencing parameter and in case of MQL turning Feed was found to be most influencing parameter.

Investigating and Modeling the Machinability of Al 6061 Using Response Surface Methodology

2015 ◽  
Vol 761 ◽  
pp. 267-272
Author(s):  
Basim A. Khidhir ◽  
Ayad F. Shahab ◽  
Sadiq E. Abdullah ◽  
Barzan A. Saeed
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Feed Rate ◽  
Cutting Speed ◽  
Effect Of Temperature ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process

Decreasing the effect of temperature, surface roughness and vibration amplitude during turning process will improve machinability. Mathematical model has been developed to predict responses of the surface roughness, temperature and vibration in relation to machining parameters such as the cutting speed, feed rate, and depth of cut. The Box-Behnken First order and second-order response surface methodology was employed to create a mathematical model, and the adequacy of the model was verified using analysis of variance. The experiments were conducted on aluminium 6061 by cemented carbide. The direct and interaction effect of the machining parameters with responses were analyzed. It was found that the feed rate, cutting speed, and depth of cut played a major role on the responses, such as the surface roughness and temperature when machining mild steel AISI 1018. This analysis helped to select the process parameters to improve machinability, which reduces cost and time of the turning process.

scholarly journals Experimental investigation in machining EN18 using coated tool under dry and MQL condition

2020 ◽  
Vol 184 ◽  
pp. 01060
Author(s):  
Kosaraju Satynarayana ◽  
Kumkuma Rajkiran ◽  
Kalemula Sai Kiran
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Optimum Condition ◽  
Large Scale ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Coated Tool ◽  
Three Factor ◽  
Minimum Quality

EN 18 is one of the versatile metal that exists its presences in all the industrial, transportation and building equipment’s. Machining of these material is done on large scale and consumes a whole lot of lubrication unit. Present paper discuss regarding the usage and substitutional to flood coolant systems by minimum quality lubrication ((MQL) systems for economical friendly green machining operation. Using three-factor parameters speed (50, 75, 100 m/min), feed (0.05, 0.1, 0.15 mm/rev) and depth of cut (0.4, 0.8, 1.2 mm) are varied and turned on the EN 18 steel. The experimental outcomes of surface roughness is discussed with comparison with dry machining and ST-CUT 54 MQL machining. It was observed that with MQL turning the roughness produce better compared to dry machining. The optimum condition was found to be cutting speed at 100m/min, feed at 0.05mm/rev and depth of cut at 0.4mm. The outcomes are useful for improved machining industrial practices.

Study of Factors Effecting Surface Roughness and Tool Tip Temperature in Step Turning Using Factorial Technique

2015 ◽  
Vol 15 (4) ◽  
pp. 319-326
Author(s):  
Kondapalli Siva Prasad
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Regression Analysis ◽  
Process Parameters ◽  
Depth Of Cut ◽  
Turning Process ◽  
Nose Radius ◽  
Five Factors ◽  
The Mathematical Model ◽  
Anova Technique

AbstractThe paper focuses on the effect of various process parameters like spindle speed, feed, depth of cut, nose radius and machining condition on the Tool tip temperature and surface roughness in step turning process is investigated by using Factorial Technique. Five factors- Two levels are used and total 32 experiments are performed. The coefficients are calculated by using regression analysis and the model is constructed. The adequacy of the developed model is checked using Analysis of Variance (ANOVA) technique. By using the mathematical model the main and interaction effect of various process parameters on tool tip temperature and surface roughness are studied.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Thermal hardening and calculation of the mathematical model of face milling of parts made of steel 95X18-Sh to improve the quality of the surface layer

2021 ◽  
pp. 200-206
Author(s):  
I.N. Sedinin ◽  
V.F. Makarov
Keyword(s):  
Mathematical Model ◽  
Cutting Speed ◽  
Physical And Mechanical Properties ◽  
Face Milling ◽  
Experiment Planning ◽  
Depth Of Cut ◽  
Machined Surface ◽  
The Mathematical Model ◽  
Full Factorial

It is considered the complex of operations of the technological process for the heat treatment of steel 95X18-Sh, as a result of which the material of the samples increases the hardness to 59...61 HRC, and also improves the physical and mechanical properties. A full-scale full factorial experiment of face milling of samples was carried out using the method of mathematical planning. In the experiments, a high-precision machine and a carbide cutting tool were used. To calculate the values of the roughness function, the following are taken as independent variables: cutting speed, feed per tooth and depth of cut. In order to determine the coefficients of the linear equation, a central compositional orthogonal plan of the second order for three factors was used. A matrix of levels of variation of independent variable factors and a matrix of experiment planning were compiled. A regression analysis of the obtained experimental statistical data was carried out using the Microsoft Excel, Statistica and Wolfram Alpha programs. As a result of the calculations, a mathematical model of the roughness of the machined surface and optimal cutting conditions were determined.

scholarly journals Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2998 ◽  
Author(s):  
Kubilay Aslantas ◽  
Mohd Danish ◽  
Ahmet Hasçelik ◽  
Mozammel Mia ◽  
Munish Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Cutting Speed ◽  
Small Diameter ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Depth Of Cut ◽  
Turning Process ◽  
Micro Turning

Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.

scholarly journals Developing an Analytical Model and Computing Tool for Optimizing Lapping Operations of Flat Objects Made of Alloyed Steels

Materials ◽  
2020 ◽  
Vol 13 (6) ◽  
pp. 1343 ◽  
Author(s):  
Tudor Deaconescu ◽  
Andrea Deaconescu
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Material Properties ◽  
Depth Of Cut ◽  
Operation Optimization ◽  
Abrasive Grains ◽  
Finishing Process ◽  
Real World Applications ◽  
The Mathematical Model

Lapping is a finishing process where loose abrasive grains contained in a slurry are pressed against a workpiece to reduce its surface roughness. To perform a lapping operation, the user needs to set the values of the respective lapping conditions (e.g., pressure, depth of cut, the rotational speed of the pressing lap plate, and alike) based on some material properties of the workpiece, abrasive grains, and slurry, as well as on the desired surface roughness. Therefore, a mathematical model is needed that establishes the relationships among the abovementioned parameters. The mathematical model can be used to develop a lapping operation optimization system, as well. To this date, such a model and system are not available mainly because the relationships among lapping conditions, material properties of abrasive grains and slurry, and surface roughness are difficult to establish. This study solves this problem. It presents a mathematical model establishing the required relationships. It also presents a system developed based on the mathematical model. In addition, the efficacy of the system is also shown using a case study. This study thus helps systematize lapping operations in regard to real-world applications.

Performance Test of Cryogenically Treated and Coated Tungsten Carbide Cutting Inserts

2015 ◽  
Vol 813-814 ◽  
pp. 575-580 ◽  
Author(s):  
Y.P. Deepthi ◽  
K. Prakash Marimuthu ◽  
K. Raghavendra Ravi Kiran
Keyword(s):  
Surface Roughness ◽  
Performance Test ◽  
White Cast Iron ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Optimum Number ◽  
Anova Analysis ◽  
Tool Condition ◽  
Cutting Inserts

Production cost is dependent on the life of the Tool. Because of enormous heat generation during the material removal process, life of the tool decreases. Tool life will be enhanced by cryogenic treatment which minimises the temperature at tool tip interface. Taguchi technique was employed to get optimum number of experiments for turning white cast iron after the cryogenic treatment and before cryogenic treatment. The correlation between four main factors such as speed, feed, depth of cut, tool condition and responses such as surface roughness, tool tip temperature were analysed. Mathematical model was formulated for tool tip temperature, and surface roughness. The error for the mathematically formulated model was observed to be less than 5%.The present work indicates that cryogenically treated tool have better surface finish . From the anova analysis it is inferred that tool tip temperature and surface roughness substantially reduced while using cryogenically treated tool. It was observed that cutting forces was more influenced by cutting speed of the tool followed by tool condition. Hardness of the tool insert showed improvement because of coatings.

In-Process Monitoring and Prediction of Surface Roughness in CNC Turning Process

2011 ◽  
Vol 199-200 ◽  
pp. 1958-1966 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
Cutting Speed ◽  
Least Square ◽  
Depth Of Cut ◽  
Turning Process ◽  
Roughness Model ◽  
Force Ratio ◽  
Cnc Turning Process

The objective of this research is to propose a practical model to predict the in-process surface roughness during the turning process by using the cutting force ratio. The proposed in-process surface roughness model is developed based on the experimentally obtain result by employing the exponential function with six factors of the cutting speed, the feed rate, the rank angle the tool nose radius, the depth of cut, and the cutting force ratio. The multiple regression analysis is utilized to calculate the regression coefficients with the use of the least square method. The prediction accuracy of the in-process surface roughness model has been verified to monitor the in-process predicted surface roughness at 95% confident level. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It has been proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

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