scholarly journals Optimization of Milling Process by Taguchi-PSI Method

2021 ◽  
Vol 309 ◽  
pp. 01019
Author(s):  
He Le Hoang Anh ◽  
Trinh Kieu Tuan ◽  
Nguyen Huu Quang ◽  
Nguyen Huu Luan ◽  
Tran Minh Truong ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Milling Process ◽  
Steel Type ◽  
Economic Significance ◽  
Vertical Milling Machine ◽  
Chinese Standard ◽  
Psi Method

060A4 steel (Chinese standard) is a steel with good machinability, which is very popularly used in mechanical engineering. Therefore, the study of solutions for improvement of quality and productivity when machining this steel type has great technical and economic significance. In this study, the multi-objective optimization process has been performed when milling this steel type on a vertical milling machine. The cutting tool is a face milling cutter made of High Speed Steel (HSS) material. The effect of spindle speed, feed rate, and cutting depth on surface roughness has been found. The combination of the Taguchi method and PSI method has been applied to determine the optimal value of three input parameters to simultaneously ensure the two criteria of the minimum surface roughness and the maximum Material Removal Rate (MRR). The works which will be done by the authors of this article in the near future has also been presented in the last part of this study.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

scholarly journals Optimization of Boring Process Parameters in Manufacturing of Polyacetal Bushing using High Speed Steel

2019 ◽  
Vol 130 ◽  
pp. 01031 ◽  
Author(s):  
The Jaya Suteja ◽  
Yon Haryono ◽  
Andri Harianto ◽  
Esti Rinawiyanti
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Optimum Result ◽  
Edge Angle

Polyacetal is commonly used as bushing material because of its low coefficient of friction and self lubricant characteristics. The polyacetal is machined by using boring process to produce bushing in certain surface roughness. The objectives of this research are to optimize three independent parameters (depth of cut, feed rate and principal cutting edge angle) of boring process of polyacetal using high speed steel tool to achieve the highest material removal rate and the required surface roughness. Response Surface Methodology is used to investigate the influence of the parameters and optimize the boring process. The research shows that the influence of the boring process parameters on polyacetal is similar compared to on metal. The result reveals that the optimum result is achieved by applying the value of depth of cut, feed rate, and principal cutting edge angle is 2.9 × 10–3 m, 0.229 mm rev–1, and 99.1° respectively. By applying these values, the maximum material rate removal achieved in this research is 1263.4 mm3 s–1 and the surface roughness achieved is 1.57 × 10–6 m.

scholarly journals Investigation on Effect of Material Hardness in High Speed CNC End Milling Process

2015 ◽  
Vol 2015 ◽  
pp. 1-6 ◽  
Author(s):  
N. V. Dhandapani ◽  
V. S. Thangarasu ◽  
G. Sureshkannan
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Cutting Tool ◽  
End Milling ◽  
Removal Rate ◽  
Milling Process ◽  
Depth Of Cut ◽  
Study Results ◽  
Cnc End Milling ◽  
End Milling Process

This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the operator on floor is based on suggested values of the tool manufacturer or by trial and error method. This paper describes effect of various parameters on the surface roughness characteristics of the precision machining part. The prediction method suggested is based on various experimental analysis of parameters in different compositions of input conditions which would benefit the industry on standardization of high speed CNC end milling processes. The results show a basis for selection of parameters to get better results of surface roughness values as predicted by the case study results.

Optimasi Multirespon Purwarupa Electrical Discharge Machine (EDM) Menggunakan Metode Taguchi-Grey Relational Analysis

2019 ◽  
Vol 11 (01) ◽  
pp. 26-32
Author(s):  
Angga Sateria ◽  
Eko Yudo ◽  
Zulfitriyanto Zulfitriyanto
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Processes ◽  
Relational Analysis ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

EDM is one of the nonconventional machining processes when making workpieces with conventional machining processes is difficult. This process has been used effectively in machining hard, high-strength and high temperature materials such as high speed steel (HSS) materials. In this study, prototype of EDM machines was carried out with engine variables such as current (A), pulse on time (µs) and pulse off time (µs). The material used is high speed steel (HSS) material used in cutting tools such as turning tools and milling tools. Surface roughness and material removal rate are responses observed to determine the quality of material remaval. The quality characteristic of the surface roughness response is "smaller is better" and the quality characteristics of the material removal rate response is "larger is better. The purpose of this study is to determine the best process parameter level to achieve the required performance characteristics in the material removal process using prototype EDM machines using the gray relational analysis (GRA) method, three process parameters are selected such as current, pulse on time, and pulse off time. The taguchi 3 x 3 x 3 design is used as an experimental design.The best parameter level obtained is current 40 ampere, pulse on time 200 µs, pulse off time 20 µs.

Effect of Powder-Mixed Dielectric on EDM Process Performance

2020 ◽  
Vol 38 (8A) ◽  
pp. 1226-1235
Author(s):  
Safa R. Fadhil ◽  
Shukry. H. Aghdeab
Keyword(s):  
Silicon Carbide ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Transformer Oil ◽  
Dielectric Fluid ◽  
Peak Current ◽  
Powder Concentration ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 µs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 µs, and 10 g/l), and better Ra was (3.51 µm) at (10 A, 50 µs, and 10 g/l).

Characteristic properties of AlTiN and TiN coated HSS materials

2015 ◽  
Vol 67 (2) ◽  
pp. 172-180 ◽  
Author(s):  
Mumin Sahin ◽  
Cenk Misirli ◽  
Dervis Özkan
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Wear Properties ◽  
Content Type ◽  
X Ray ◽  
Number Of Cycles ◽  
Future Work

Purpose – The purpose of this paper is to examine mechanical and metallurgical properties of AlTiN- and TiN-coates high-speed steel (HSS) materials in detail. Design/methodology/approach – In this study, HSS steel parts have been processed through machining and have been coated with AlTiN and TiN on physical vapour deposition workbench at approximately 6,500°C for 4 hours. Tensile strength, fatigue strength, hardness tests for AlTiN- and TiN-coated HSS samples have been performed; moreover, energy dispersive X-ray spectroscopy and X-ray diffraction analysis and microstructure analysis have been made by scanning electron microscopy. The obtained results have been compared with uncoated HSS components. Findings – It was found that tensile strength of TiAlN- and TiN-coated HSS parts is higher than that of uncoated HSS parts. Highest tensile strength has been obtained from TiN-coated HSS parts. Number of cycles for failure of TiAlN- and TiN-coated HSS parts is higher than that for HSS parts. Particularly TiN-coated HSS parts have the most valuable fatigue results. However, surface roughness of fatigue samples may cause notch effect. For this reason, surface roughness of coated HSS parts is compared with that of uncoated ones. While the average surface roughness (Ra) of the uncoated samples was in the range of 0.40 μm, that of the AlTiN- and TiN-coated samples was in the range of 0.60 and 0.80 μm, respectively. Research limitations/implications – It would be interesting to search different coatings for cutting tools. It could be the good idea for future work to concentrate on wear properties of tool materials. Practical implications – The detailed mechanical and metallurgical results can be used to assess the AlTiN and TiN coating applications in HSS materials. Originality/value – This paper provides information on mechanical and metallurgical behaviour of AlTiN- and TiN-coated HSS materials and offers practical help for researchers and scientists working in the coating area.

Effect of Machining Parameters and Wear Mechanism in Milling Mold Steel AISI-P20 and AISI-1050

2014 ◽  
Vol 590 ◽  
pp. 294-298
Author(s):  
Pichai Janmanee ◽  
Somchai Wonthaisong ◽  
Dollathum Araganont
Keyword(s):  
Wear Mechanism ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi P20 ◽  
Steel Aisi ◽  
Quality Surface

In this study, effect of machining parameters and wear mechanism in milling process of mold steel AISI-P20 and AISI-1050, using 10 mm twin flute type end mill diameter. The experimental results found that characteristics of milling surfaces and wear of the mill end were directly influenced by changes of parameters for all test conditions. As a result, the quality of milling surfaces also changed. However, mould steels which had the good quality surface is AISI-1050, with roughnesses of 2.120 μm. Quality milling surfaces were milled by using the most suitable parameter feed rate of 45 mm/min, a spindle speed of 637 rpm and a cut depth level of 3 mm, for both grades. Moreover, material removal rate and duration of the milling process, the milling end mills affect wear of the edge in every bite when the feed rate is low, high speed and level depth of cut at least. It was found that limited wear less will affect the surface roughness (Ra) represents the good quality surface.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

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