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.

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

Machining characteristics of Inconel 718 under several cutting conditions based on Taguchi method

2012 ◽  
Vol 227 (9) ◽  
pp. 1889-1897 ◽  
Author(s):  
R Thirumalai ◽  
JS Senthilkumaar ◽  
P Selvarani ◽  
S Ramesh
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Flank Wear ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Parameters ◽  
Dry Machining ◽  
Noise Factors

Extensive researchers have conducted several experiments in the past for selecting the optimum parameters in machining nickel based alloy – Inconel 718. These experiments conducted so far are dealt with dry machining and flooded coolant machining of nickel alloy Inconel 718. In this research study, the usage of refrigerated coolant is also dealt with and it is compared with dry machining and flooded coolant machining. Cutting speed, feed and depth of cut are considered as the machining parameters. The effectiveness of the refrigerated coolant in machining the heat resistant super alloy material Inconel 718 with respect to these machining parameters are described in this article. The machinability studies parameters were generated with surface roughness and flank wear. The performance of uncoated carbide cutting tool was investigated at various cutting condition under dry, flooded coolant and refrigerated coolant machining. The relationship between the machining parameters and the performance measures were established and using analysis of variance significant machining parameters determined. This article made an attempt to Taguchi optimization technique to study the machinability performances of Inconel 718. Taguchi approach is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer experiments than a factorial design. Taguchi’s optimization analysis indicates that the factors level, its significance to influence the surface roughness and flank wear for the machining processes. Confirmation tests were conducted at an optimal condition to make a comparison between the experimental results foreseen from the mentioned correlations.

Optimization of Surface Roughness by Using Different Cutting Tools for Aluminum Alloy 6063

2020 ◽  
Vol 17 (2) ◽  
pp. 961-966
Author(s):  
Allina Abdullah ◽  
Afiqah Azman ◽  
B. M. Khirulrizwan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Optimum Parameter ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Numerical Control ◽  
Depth Of Cut

This research outlines an experimental study to determine the optimum parameter of cutting tool for the best surface roughness (Ra) of Aluminum Alloy (AA) 6063. For the experiment in this research, cutting parameters such as cutting speed, depth of cut and feed rate are used to identify the effect of both cutting tools which are tungsten carbide and cermet towards the surface roughness (Ra) of material AA6063. The machining operation involved to cut the material is turning process by using Computer Numerical Control (CNC) Lathe machine. The experimental design was designed by Full Factorial. The experiment that had been conducted by the researcher is 33 with 2 replications. The total number of the experiments that had been run is 54 runs for each cutting tool. Thus, the total number of experiments for both cutting tools is 108 runs. ANOVA analysis had been analyzed to identify the significant factor that affect the Ra result. The significant factors that affect the Ra result of AA6063 are feed rate and cutting speed. The researcher used main effect plot to determine the factor that most influenced the surface roughness of AA6063, the optimum condition of surface roughness and the optimum parameter of cutting tool. The factor that most influenced the surface roughness of AA6063 is feed rate. The optimum condition of surface roughness is at the feed rate of 0.05 mm/rev, cutting speed of 600 rpm and depth of cut of 0.10 mm. While the optimum parameter of cutting tool is cermet insert with the lowest value of surface roughness (Ra) result which is 0.650 μm.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

The Effect of Minimal Quantity Lubrication (MQL) on the Surface Roughness of Titanium Alloy Ti-6Al-4V ELI in Turning Process

2010 ◽  
Vol 146-147 ◽  
pp. 1750-1753 ◽  
Author(s):  
C.H. Che Haron ◽  
J.A. Ghani ◽  
Mohd Ali Sulaiman ◽  
L.R. Intan ◽  
M.S. Kasim
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Influence Factor ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Minimum Quantity Lubricant ◽  
Minimal Quantity Lubrication ◽  
Tungsten Carbide Tool

This paper investigates the effect of minimum quantity lubricant (MQL) on the surface roughness of titanium alloy Ti-6Al-4V ELI when turning using uncoated tungsten carbide tool. The response surface method (RSM) design of experiment using Box-behnken was used to accomodate the turning experiment factors and levels. Turning parameters studied were cutting speed (100, 135, 170 m/min), feed rate (0.15, 0.2, 0.25 mm/rev) and depth of cut (0.6, 0.8, 1.0 mm). The results show that the feed rate was the most influence factor controlling the surface roughness produced. The feed rate (F) was found directly proportional with the surface roughness value (Ra) but inversely proportional to the cutting speed (Vc). MINITAB software was used to develop a surface roughness model, and the optimum condition was at 160 m/min of cutting speed, 0.18 mm/rev of feed rate and 1 mm of depth of cut. At the optimum condition low value of 1.54 μm surface roughness was obtained.

scholarly journals Green machining for the dry milling process of stainless steel 304

2019 ◽  
Vol 234 (5) ◽  
pp. 881-899 ◽  
Author(s):  
Trung-Thanh Nguyen ◽  
Mozammel Mia ◽  
Xuan-Phuong Dang ◽  
Chi-Hieu Le ◽  
Michael S Packianather
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Energy Consumption ◽  
Power Factor ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Dry Milling ◽  
Stainless Steel 304

Dry machining represents an eco-friendly method that reduces the environmental impacts, saves energy costs, and protects operator health. This article presents a multi-response optimization which aims to enhance the power factor and decrease the energy consumption as well as the surface roughness for the dry machining of a stainless steel 304. The cutting speed ( V), depth of cut ( a), feed rate ( f), and nose radius ( r) were the processing conditions. The outputs of the optimization are the power factor, energy consumption, and surface roughness. The relationships between inputs and outputs were established using the radial basis function models. The experimental data were normalized, with the use of the Grey relational analysis. The principal component analysis is applied to calculate the weight values of technical responses. The desirability approach is used to observe the optimal values. The results showed that the technical outputs are primarily influenced by the feed rate and cutting speed. The reductions of energy consumption and surface roughness are approximately 34.85% and 57.65%, respectively, and the power factor improves around 28.83%, compared to the initial process parameter settings. The outcomes and findings of the investigated work can be used for further research in sustainable design and manufacturing as well as directly used in the knowledge-based and expert systems for dry milling applications in industrial practices.

Hard Turning of Hot Work Steel X38CRMOV5-3: Evaluation of Surface Roughness and Current Values Using Cutting Parameters

2020 ◽  
Author(s):  
Ali Kemal Cakir
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Motor Current ◽  
Design Factors

This study evaluates the surface roughness and current values using cutting parameters in the turning of AISI H11 being hot work tool steel under dry machining conditions. The selected design factors are the depth of cut, feed rate, cutting speed. A design of experiments was used to carry out this research. The obtained results were analyzed to determine the effects of input parameters on the resultant surface roughness, current using the analysis of variance (ANOVA) and the Response Surface Methodology (RSM). The experimental results showed that increasing feed rate increased the surface roughness, and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate on the surface roughness. Also, the motor current values were influenced by the 38,48% depth of cut, 23,98% cutting speed, 25,52% feed rate, respectively.

scholarly journals Environmental, Economical and Technological Analysis of MQL-Assisted Machining of Al-Mg-Zr Alloy Using PCD Tool

2021 ◽  
Vol 13 (13) ◽  
pp. 7321
Author(s):  
Md. Rezaul Karim ◽  
Juairiya Binte Tariq ◽  
Shah Murtoza Morshed ◽  
Sabbir Hossain Shawon ◽  
Abir Hasan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Energy Consumption ◽  
Function Analysis ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Pcd Tool ◽  
Desirability Function Analysis ◽  
Zr Alloy

Clean technological machining operations can improve traditional methods’ environmental, economic, and technical viability, resulting in sustainability, compatibility, and human-centered machining. This, this work focuses on sustainable machining of Al-Mg-Zr alloy with minimum quantity lubricant (MQL)-assisted machining using a polycrystalline diamond (PCD) tool. The effect of various process parameters on the surface roughness and cutting temperature were analyzed. The Taguchi L25 orthogonal array-based experimental design has been utilized. Experiments have been carried out in the MQL environment, and pressure was maintained at 8 bar. The multiple responses were optimized using desirability function analysis (DFA). Analysis of variance (ANOVA) shows that cutting speed and depth of cut are the most prominent factors for surface roughness and cutting temperature. Therefore, the DFA suggested that, to attain reasonable response values, a lower to moderate value of depth of cut, cutting speed and feed rate are appreciable. An artificial neural network (ANN) model with four different learning algorithms was used to predict the surface roughness and temperature. Apart from this, to address the sustainability aspect, life cycle assessment (LCA) of MQL-assisted and dry machining has been carried out. Energy consumption, CO2 emissions, and processing time have been determined for MQL-assisted and dry machining. The results showed that MQL-machining required a very nominal amount of cutting fluid, which produced a smaller carbon footprint. Moreover, very little energy consumption is required in MQL-machining to achieve high material removal and very low tool change.

scholarly journals Machinability Investigations on Aerospace Custom 450 Alloy Using TiAlN/TiCN, TiCN/TiAlN Coated and Uncoated Carbide Tools

2021 ◽  
Vol 54 (2) ◽  
pp. 325-334
Author(s):  
Sampath Kumar Thepperumal ◽  
Vignesh Margabandu ◽  
Ramanujam Radhakrishnan ◽  
John Rajan Amaladas ◽  
Shri Vignesh Ananthakrishnan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Optimal Level ◽  
Depth Of Cut ◽  
Electron Microscopic ◽  
Utility Concept ◽  
Coated Tool ◽  
Coated Carbide

In this present research, the machinability studies of TiAlN/TiCN, TiCN/TiAlN coated and uncoated inserts were investigated on machining custom 450 alloy. The machining input parameters such as feed rate (f), cutting speed (V) and depth of cut (d) are set using orthogonal array. The machining output parameters such as surface roughness, tool wear and cutting forces were studied for its parametric contribution and it was analyzed using Analysis of Variance (ANOVA). Further, the tool wear obtained was studied using scanning electron microscopic images and energy dispersive spectroscopy analysis was conducted to check the addition of work material elements to the coated tool surface. The results show that, the feed rate is the most contributing factor in deciding resultant forces, surface roughness and tool wear respectively. TiAlN/TiCN coated carbide tool has obtained improved machinability, when compared to TiCN/TiAlN coated carbide and uncoated carbide inserts. To obtain one optimal level for all three responses of three types of tools, multi criteria decision making approach, named utility concept approach is selected. Based on the MCDM analysis, it is found that trial number 4 gives better experimental output of improved surface integrity, lower resultant force and less tool wear for all types of tools.

scholarly journals Determination of Optimum Machining Condition for Surface Roughness Using Historical Data

2018 ◽  
Vol 7 (4.30) ◽  
pp. 73
Author(s):  
Mohd Shahfizal Mohd Ruslan ◽  
Haniff Abdul Rahman ◽  
Jaharah Abdul Ghani ◽  
Che Hassan Che Haron ◽  
Mohd Shahir Kassim ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
High Speed ◽  
Historical Data ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
Radial Depth

Magnesium alloy is one of the lightest materials with a high strength to weight ratio and excellent machinability, which makes it attractive and suitable for various industrial applications such as automotive and aerospace components. For these particular industrial components, the end products require a mirror-like finish. This article details a statistical analysis about the effect of milling parameters on the surface roughness of Magnesium alloy AZ91D in the dry milling process. The historical data approach in the response surface methodology (RSM) was utilized to determine the cause and effect relationship between the input variables and output response. The effect of milling parameter studied was cutting speed (900 – 1400 m/min), feed rate (0.03 - 0.09 mm/tooth), and radial depth of cut (0.2 - 0.3 mm). The results confirmed that the interaction between feed rate and cutting speed is the primary factor controlling the surface evolution. The responses of various factors were plotted using a two-dimensional interaction graph and the cubic empirical model was developed at 95% confidence level. The optimum condition for achieving the minimum surface roughness was a cutting speed of 977 m/min, a feed rate of 0.02 mm/tooth, and an axial depth of cut of 0.29 mm. With this optimum condition, a surface arithmetic roughness of 0.054 μm is expected. This study confirmed that by milling AZ91D at high speed cutting, it is possible to eliminate the polishing process to achieve a super mirror-like finishing.

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