Effect of Spindle Speed, Feed Rate and Cooling Medium on the Burr Structure of Aluminium through Milling

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

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Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽

10.3390/met11060854 ◽

2021 ◽

Vol 11 (6) ◽

pp. 854

Author(s):

Muhammad Aamir ◽

Khaled Giasin ◽

Majid Tolouei-Rad ◽

Israr Ud Din ◽

Muhammad Imran Hanif ◽

...

Keyword(s):

Feed Rate ◽

Surface Defects ◽

Thrust Force ◽

Cutting Tools ◽

Chip Thickness ◽

Cutting Parameters ◽

Spindle Speed ◽

Machining Process ◽

Tool Geometry ◽

Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1115.12 ◽

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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Experiments of Drilling Titanium Alloy with Varying Operation Parameters

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.748.254 ◽

2017 ◽

Vol 748 ◽

pp. 254-258

Author(s):

Chang Yi Liu ◽

Bai Shou Zhang ◽

Suman Shrestha

Keyword(s):

Titanium Alloy ◽

Feed Rate ◽

Thrust Force ◽

Maximum Amount ◽

Spindle Speed ◽

Drilling Process ◽

Process Variables ◽

Experimental Cutting ◽

Operation Parameters ◽

Titanium Alloy Ti6al4v

Drilling experiments of titanium alloy Ti6Al4V were conducted. Taking the speed and feed as the process variables, a set of experimental cutting forces are obtained and compared. From the experimental results it is concluded that within the experimental extent the thrust force and torque of drilling process rises with the feed rate. The lower spindle speed resulted in the greater amount of thrust. Feed rates have greater influence on the thrust force than the spindle speed. The combination of greater feed rate and lower spindle speed results in the maximum amount of thrust. However, combination of greater feed rate and spindle speed resulted in maximum amount of torque.

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Optimization of Surface Roughness in Deep Hole Drilling using Moth-Flame Optimization

ELEKTRIKA- Journal of Electrical Engineering ◽

10.11113/elektrika.v18n3-2.195 ◽

2019 ◽

Vol 18 (3-2) ◽

pp. 62-68

Author(s):

Anis Farhan Kamaruzaman ◽

Azlan Mohd Zain ◽

Razana Alwee ◽

Noordin Md Yusof ◽

Farhad Najarian

Keyword(s):

Surface Roughness ◽

Optimization Algorithm ◽

Feed Rate ◽

Spindle Speed ◽

Hole Drilling ◽

P Value ◽

Machining Parameters ◽

Deep Hole ◽

Deep Hole Drilling ◽

Moth Flame Optimization Algorithm

This study emphasizes on optimizing the value of machining parameters that will affect the value of surface roughness for the deep hole drilling process using moth-flame optimization algorithm. All experiments run on the basis of the design of experiment (DoE) which is two level factorial with four center point. Machining parameters involved are spindle speed, feed rate, depth of hole and minimum quantity lubricants (MQL) to obtain the minimum value for surface roughness. Results experiments are needed to go through the next process which is modeling to get objective function which will be inserted into the moth-flame optimization algorithm. The optimization results show that the moth-flame algorithm produced a minimum surface roughness value of 2.41µ compared to the experimental data. The value of machining parameters that lead to minimum value of surface roughness are 900 rpm of spindle speed, 50 mm/min of feed rate, 65 mm of depth of hole and 40 l/hr of MQL. The ANOVA has analysed that spindle speed, feed rate and MQL are significant parameters for surface roughness value with P-value <0.0001, 0.0219 and 0.0008 while depth of hole has P-value of 0.3522 which indicates that the parameter is not significant for surface roughness value. The analysis also shown that the machining parameter that has largest contribution to the surface roughness value is spindle speed with 65.54% while the smallest contribution is from depth of hole with 0.8%. As the conclusion, the application of artificial intelligence is very helpful in the industry for gaining good quality of products.

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Penerapan Metode Taguchi untuk Optimasi Setting Parameter CNC Milling Terhadap Kekasaran Permukaan Material

Jurnal Teknologi dan Rekayasa Manufaktur ◽

10.48182/jtrm.v2i2.70 ◽

2020 ◽

Vol 2 (2) ◽

pp. 49-60

Author(s):

Farizi Rachman Farizi Rachman ◽

Bayu Wiro K ◽

Tri Andi Setiawan ◽

Pradita Nurkholies

Keyword(s):

Feed Rate ◽

Base Plate ◽

Spindle Speed ◽

Depth Of Cut ◽

Cnc Milling ◽

End Mill

Industri manufaktur di Indonesia semakin meningkat seiring dengan tingkat kebutuhan manusia yang beraneka ragam dan memicu berkembangnya teknologi, salah satunya industri proses permesinan atau machining. Kualitas produk yang baik dapat dilihat dari tingkat kekasaran permukaannya karena kekasaran permukaan dapat mempengaruhi performa yang berkaitan dengan aspek fungsional dari produk. Pada penelitian ini telah dilakukan optimasi setting parameter CNC milling terhadap kekasaran permukaan pada material S50C dengan end mill HSS diameter 8 mm. Material S50C banyak digunakan dalam manufaktur mesin seperti mekanis base plate, roda gigi, standart punch head dan komponen mesin lainnya. Penelitian ini menggunakan metode Taguchi. Parameter yang digunakan yaitu spindle speed, Feed rate dan depth of cut dengan cairan pendingin sebagai variabel konstan. Parameter optimum untuk mendapatkan nillai kekasaran yang rendah yaitu spindle speed 1100 rpm, feed rate 46 mm/min dan depth of cut 0.5 mm. Dengan taraf signifikansi 0.1 menunjukkan bahwa spindle speed berpengaruh secara signifikan dengan kontribusi 38.42% diikuti feed rate dengan kontribusi 34.16%.

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Characterizing the Effect of Cutting Condition, Tool Path, and Heat Treatment on Cutting Forces of Selective Laser Melting Spherical Component in Five-Axis Milling

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4039381 ◽

2018 ◽

Vol 140 (5) ◽

Cited By ~ 4

Author(s):

Amir Mahyar Khorasani ◽

Ian Gibson ◽

Moshe Goldberg ◽

Guy Littlefair

Keyword(s):

Heat Treatment ◽

Production Process ◽

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

Tool Path ◽

Annealing Temperature ◽

Spindle Speed ◽

Cutting Condition ◽

Scallop Height

Additive manufacturing (AM), partly due to its compatibility with computer-aided design (CAD) and fabrication of intricate shapes, is an emerging production process. Postprocessing, such as machining, is particularly necessary for metal AM due to the lack of surface quality for as-built parts being a problem when using as a production process. In this paper, a predictive model for cutting forces has been developed by using artificial neural networks (ANNs). The effect of tool path and cutting condition, including cutting speed, feed rate, machining allowance, and scallop height, on the generated force during machining of spherical components such as prosthetic acetabular shell was investigated. Also, different annealing processes like stress relieving, mill annealing and β annealing have been carried out on the samples to better understand the effect of brittleness, strength, and hardness on machining. The results of this study showed that ANN can accurately apply to model cutting force when using ball nose cutters. Scallop height has the highest impact on cutting forces followed by spindle speed, finishing allowance, heat treatment/annealing temperature, tool path, and feed rate. The results illustrate that using linear tool path and increasing annealing temperature can result in lower cutting force. Higher cutting force was observed with greater scallop height and feed rate while for higher finishing allowance, cutting forces decreased. For spindle speed, the trend of cutting force was increasing up to a critical point and then decreasing due to thermal softening.

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Evaluation of CFRP Hole Quality in Low Frequency Vibration-Assisted Dry Drilling of CFRP/Ti Stacks

Volume 4: Processes ◽

10.1115/msec2018-6382 ◽

2018 ◽

Cited By ~ 1

Author(s):

Haojun Yang ◽

Yan Chen ◽

Jiuhua Xu

Keyword(s):

Feed Rate ◽

Kinematic Model ◽

Mechanical Damage ◽

Low Frequency ◽

Spindle Speed ◽

Hole Quality ◽

Drilling Force ◽

Low Frequency Vibration ◽

The Impact ◽

Conventional Drilling

Low frequency vibration assisted drilling (LFVAD) is regarded as one of the most promising process in CFRP/Ti stacks drilling. This work carries the investigation of the difference between conventional drilling and LFVAD based on kinematic model. The experiments are conducted under varied vibration amplitude to a specific feed rate, also under varying spindle speeds, feed rates when the ratio of amplitude to feed rate is fixed. Then the hole quality of CFRP is evaluated based on the analysis of drilling force, chip morphology, chip extraction. The results show that there is rarely no difference between conventional drilling and LFVAD in drilling mechanism when the drilling diameter is over 1 mm. Because the impact effect caused by drill vibration is already weak. It is found that the severe mechanical damage of the CFRP holes surface could be significantly reduced due to the fragmented chips obtained in vibration drilling. The maximum instantaneous feed rate combined with feed rate and amplitude plays a significant role in CFRP hole quality. Lower maximum instantaneous feed rate results in better hole wall quality and less entry delamination. Spindle speed has no visible influence on entry delamination, while higher spindle speed improves the hole surface quality due to the resin coating phenomenon.

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Effect of Process Parameters on Hole Diameter Accuracy in High Pressure Through Coolant Peck Drilling Using Taguchi Technique

International Journal of Materials Forming and Machining Processes ◽

10.4018/ijmfmp.2018010102 ◽

2018 ◽

Vol 5 (1) ◽

pp. 12-31 ◽

Cited By ~ 1

Author(s):

Hanmant V. Shete ◽

Madhav S. Sohani

Keyword(s):

Feed Rate ◽

High Performance ◽

Manufacturing Industry ◽

Spindle Speed ◽

Hole Diameter ◽

Taguchi Technique ◽

Machining Center ◽

Analysis Of Results ◽

Optimal Values ◽

Peck Drilling

Machining with pressurized coolant is nowadays widely accepted technique in the manufacturing industry, especially in high performance machining conditions. The data on the effects of variation of high coolant pressure in drilling operation is limited. This paper presents the effect of high coolant pressures along with spindle speed, feed rate and peck depth on hole diameter accuracy. Experiments were performed on EN9 steel with TiAIN coated through coolant drill on CNC vertical machining center. Taguchi technique was employed for design of experiments and analysis of results. Results showed that the higher values of optimal coolant pressure and spindle speed were demanded for drilling at bottom of hole as compared to that for drilling at top of hole. The optimal values of feed rate and peck depth were same for both the cases of drilling at top and bottom of hole. Use of high coolant pressure in drilling permits higher peck depth for better hole diameter control which results in reduced cycle time and hence production cost.

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