Measuring of cutting forces and chip shapes based on different machining parameters

Sensor Review ◽  
2018 ◽  
Vol 38 (3) ◽  
pp. 387-390
Author(s):  
Obrad Anicic ◽  
Srdjan Jovic ◽  
Ivica Camagic ◽  
Mladen Radojkovic ◽  
Nenad Stanojevic
Keyword(s):  
Cutting Forces ◽  
Design Methodology ◽  
Machining Process ◽  
Machining Parameters ◽  
Content Type ◽  
Machining Conditions

Purpose The main aim of the study was to measure the cutting forces and chip shapes based on different machining parameters. Design/methodology/approach To get the best optimal machining conditions, it is essential to use the best combination of machining parameters. Although some machining parameters are not important for the process, there are machining parameters which are very important for the machining process. Findings It is essential to determine which machining parameters are the most dominant to make the optimal machining conditions. Originality/value Six different chip shapes are obtained according to ISO standardization. It was determined that the different cutting forces occurred for the different chip shapes.

Analyzing of the sensitivity of chip formation during machining process

Sensor Review ◽  
2017 ◽  
Vol 37 (4) ◽  
pp. 448-450 ◽  
Author(s):  
Srdjan Jovic ◽  
Dragan Lazarevic ◽  
Aleksa Vulovic
Keyword(s):  
Chip Formation ◽  
Design Methodology ◽  
Fuzzy Inference ◽  
Machining Process ◽  
Machining Parameters ◽  
Important Indicator ◽  
Inference System ◽  
Content Type ◽  
Neuro Fuzzy

Purpose The paper aims to analyze chip formation during machining process since it can be a very important indicator for the quality of the machining process, as some chip forms can be undesirable. Design/methodology/approach It is essential to determine the sensitivity of the chip formation on the basis of different machining parameters. The main goal of the study was to analyze the sensitivity of the chip formation during the machining process by using adaptive neuro-fuzzy inference system (ANFIS). Findings According to the results, the chip formation is the most sensitive to feed rate. Originality/value Different cutting tests were performed to monitor the chip formation on the basis of the cutting forces and the cutting displacement. ANFIS was used to estimate the sensitivity of the chip formation during the cutting process on the basis of different parameters.

Analysis and optimisation of machinability behavior of GFRP composites using fuzzy logic

2015 ◽  
Vol 11 (1) ◽  
pp. 102-119 ◽  
Author(s):  
Jenarthanan Poornachary Mugundhu ◽  
Suresh Subramanian ◽  
Ajay Subramanian
Keyword(s):  
Fuzzy Logic ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Mechanical And Thermal Properties ◽  
Machining Parameters ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Useful Life

Purpose – Glass fibre reinforced plastics (GFRP) contain two phases of materials with drastically distinguished mechanical and thermal properties, which brings in complicated interactions between the matrix and the reinforcement during machining. Surface quality and dimensional precision will greatly affect parts during their useful life especially in cases where the components will be in contact with other elements or materials during their useful life. The purpose of this paper is to discuss the application of the Taguchi method with fuzzy logic to optimise the machining parameters for machining of GFRP composites with multiple characteristics. Design/methodology/approach – The machining tests were performed on a CNC milling machine using solid carbide (K10) End mill cutting tool with three different helix angles. Experiments were planned using Taguchi’s orthogonal array with the cutting conditions prefixed. Findings – The machining parameters, namely, helix angle of the end mill cutter, spindle speed, feed rate, depth of cut, and work piece fibre orientation (specially applied to the GFRP composites) were optimised with considerations of multiple response characteristics, including machining force, material removal rate, and delamination. The results from confirmation runs indicated that the determined optimal combination of machining parameters improved the performance of the machining process. Originality/value – Multi-response optimisation of machinability behaviour of GFRP composites using fuzzy logic has not been attempted previously.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

Analysis of Thrust Force and Torque in Drilling Process of Particle Board

2015 ◽  
Vol 818 ◽  
pp. 233-238
Author(s):  
Krzysztof Szwajka
Keyword(s):  
Mathematical Models ◽  
Cutting Forces ◽  
Thrust Force ◽  
Surface Characteristics ◽  
Cutting Parameters ◽  
Machining Process ◽  
Drilling Process ◽  
Machining Parameters ◽  
Particle Board ◽  
Wood Based Composite

Particleboard is a wood based composite extensively used in wood working. Drilling is the most commonly used machining process in furniture industries. The surface characteristics and the damage free drilling are significantly influenced by the machining parameters. The thrust force developed during drilling play a major role in gaining the surface quality and minimizing the delamination tendency. In this study trials were made eighteen durability tools for different values of the parameters analyzed cut. Based on the results obtained from the study, the effect of cutting parameters selected signals of axial force and torque cutting. Proposed mathematical models using ANOVA, allowing to estimate the cutting forces.

Analysis and optimisation of machinability behaviour of CFRP composites using fuzzy logic

2015 ◽  
Vol 44 (1) ◽  
pp. 48-55 ◽  
Author(s):  
M.P. Jenarthanan ◽  
R. Jeyapaul
Keyword(s):  
Fuzzy Logic ◽  
Taguchi Method ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Content Type ◽  
Cfrp Composites

Purpose – The purpose of this paper is to analyse and optimise the machinability behaviour of Carbon Fibre Reinforced Polymer (CFRP) composites with multiple performance characteristics using the Taguchi method with fuzzy logic. Design/methodology/approach – A multi-response performance index (MRPI) was used for optimisation. The machining parameters, viz., tool geometry (helix angle of the endmill cutter), spindle speed, feed rate and depth of cut, were optimised with consideration of multiple performance characteristics, viz., machining force and material removal rate. Findings – The results from confirmation runs indicated that the determined optimal combination of machining parameters improved the performance of the machining process. Originality/value – The machinability behaviour of CFRP composites during milling of CFRP composites using Taguchi method with fuzzy logic has not been previously analysed.

Minimized Wear and Debris Generation Through Optimized Machining of Co-Cr-Mo Alloys for Use in Metal-on-Metal Hip Implants

2012 ◽  
Author(s):  
Ashish Deshpande ◽  
Shu Yang ◽  
Dave Puleo ◽  
David Pienkowski ◽  
Oscar Dillon ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Wear Debris ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Conditions ◽  
Metal On Metal ◽  
Tool Edge

More than 380,000 hips are replaced with total joint prostheses each year in the U.S. Wear debris generated by metal-on-metal implant designs is of concern due to potential adverse biological effects arising from chronic exposure of human tissue to the wear debris. This paper presents a new methodology for optimizing the wear performance of prosthesis made of Co-Cr-Mo alloys by varying tool edge geometry and machining conditions to alter the wear behavior of this alloy, while also controlling the residual stresses induced during the machining process. The machining process causes inhomogeneous inelastic deformations near the surface layer of machined parts which create residual stresses in the surface of machined components. Residual stresses in the machined surface and the subsurface are affected by cutting tool material, tool geometry, workpiece, tool-work interface conditions, and the cutting parameters such as feed rate, depth of cut and cutting speed. In the current work, residual stresses were measured using X-ray diffraction technique (XRD). The surface residual stresses in two directions (radial and hoop) were measured on the machined pins after machining with different machining conditions, but prior to the wear test. Wear behavior of Co-Cr-Mo alloy pin specimens, produced from machining with varying tool edge geometry and machining conditions, was studied using a custom-made biaxial motion pin-on-disc tribological testing system in which the pin specimen is immersed in a simulated bio-fluid environment. Wear-induced weight loss (± 10 μg) and changes in surface roughness (± 0.001 μm) were obtained at 100,000 cycle intervals upto 500,000 cycles. Metallographic analysis was performed on the machined pin specimens to analyze the microstructure and microhardness before and after testing. The rate of wear for the specimens was lowest for those pins where the change of the subsurface microhardness was small due to prevention of additional steady state wear after the initial run-in wear in the wear tester. A combination or response surface methodology and genetic algorithm (GA) was used in to optimize the various machining parameters for minimized wear generation. The optimal combination of the four machining parameters (feed 0.18mm/rev, nose radius 0.6 mm, cutting speed 27.6 m/min and depth of cut 0.38) produced the largest compressive residual stresses on the surface and subsurface of the implants thereby reducing the wear/debris generation by about fifty percent.

Analysis of Machinability of Ti- and Ni-Based Alloys

2012 ◽  
Vol 188 ◽  
pp. 330-338 ◽  
Author(s):  
Agostino Maurotto ◽  
Anish Roy ◽  
Vladimir I. Babitsky ◽  
Vadim V. Silberschmidt
Keyword(s):  
Surface Quality ◽  
Cutting Forces ◽  
Material Removal ◽  
Process Zone ◽  
Machining Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Rates ◽  
Conventional Machining

Efficient machining of advanced Ti- and Ni-based alloys, which are typically difficult-to-machine, is a challenge that needs to be addressed by the industry. During a typical machining operation of such alloys, high cutting forces imposed by a tool on the work-piece material lead to severe deformations in the process zone, along with high stresses, strains and temperatures in the material, eventually affecting the quality of finished work-piece. Conventional machining (CT) of Ti- and Ni-based alloys is typically characterized by low depths of cuts and relatively low feed rates, thus adversely affecting the material removal rates (MRR) in the machining process. In the present work, a novel machining technique, known as Ultrasonically Assisted Turning (UAT) is shown to dramatically improve machining of these intractable alloys. The developed machining process is capable of high MRR with an improved surface quality of the turned work-piece. Average cutting forces are significantly lower in UAT when compared to those in traditional turning techniques at the same machining parameters, demonstrating the capability of vibration-assisted machining as a viable machining method for the future.

Force control approaches research for robotic machining based on particle swarm optimization and adaptive iteration algorithms

2018 ◽  
Vol 45 (1) ◽  
pp. 141-151 ◽  
Author(s):  
Shouyan Chen ◽  
Tie Zhang
Keyword(s):  
Particle Swarm Optimization ◽  
Particle Swarm ◽  
Machining Process ◽  
Machining Parameters ◽  
Control Parameters ◽  
Pd Control ◽  
Swarm Optimization ◽  
Content Type ◽  
Robotic Machining ◽  
Intelligent Approach

Purpose The purpose of this paper is to reduce the strain and vibration during robotic machining. Design/methodology/approach An intelligent approach based on particle swarm optimization (PSO) and adaptive iteration algorithms is proposed to optimize the PD control parameters in accordance with robotic machining state. Findings The proposed intelligent approach can significantly reduce robotic machining strain and vibration. Originality value The relationship between robotic machining parameters is studied and the dynamics model of robotic machining is established. In view of the complexity of robotic machining process, the PSO and adaptive iteration algorithms are used to optimize the PD control parameters in accordance with robotic machining state. The PSO is used to optimize the PD control parameters during stable-machining state, and the adaptive iteration algorithm is used to optimize the PD control parameters during cut-into state.

Engineering manipulation at nanoscale: further functional specifications

2019 ◽  
Vol 17 (3) ◽  
pp. 572-590 ◽  
Author(s):  
Samir Mekid ◽  
Salem Bashmal
Keyword(s):  
Design Methodology ◽  
Machining Process ◽  
Nano Structure ◽  
Content Type ◽  
Control Techniques ◽  
Design Concepts ◽  
Basic Functions ◽  
Motion Characteristics ◽  
Complex Features ◽  
Research And Education

Purpose Novel nanomaterials and nano-devices require further functional aspects that can be designed and supported using new nanomanipulation techniques allowing specific functions at the design phase. The nano-manipulator becomes a key instrument for technology bridging sub-nano to mesoscale. The integration of various operations in nano-devices requires sub-nanometer precision and highly stable manipulator. This paper aims to review various design concepts of recent nanomanipulators, their motion characteristics, basic functions, imagine and automation with control techniques for the sake of establishing new design features based on recent requirements. Design/methodology/approach The paper reviews various existing nanomanipulators, their motion characteristics, basic functions, imagine and automation with control techniques. This will support precision machine design methodology and robotics principles. Findings The availability of a nano-precision instrument with integrated functions has proved to be extremely helpful in addressing various fundamental problems in science and engineering such as exploring, understanding, modeling and testing nano-machining process; exact construction of nano-structure arrays; and inspection of devices with complex features. Originality/value New functional specifications have emerged from this review to support the design and make of new advanced nanomanipulators with more features availability to support manipulation within the same reference datum needed for research and education.

Estimation of tool wear according to cutting forces during machining procedure

Sensor Review ◽  
2018 ◽  
Vol 38 (2) ◽  
pp. 176-180 ◽  
Author(s):  
Obrad Anicic ◽  
Srdjan Jovic ◽  
Nenad Stanojevic ◽  
Mladen Marsenic ◽  
Branko Pejovic ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Machining Parameters ◽  
Experimental Conditions ◽  
Experimental Procedure ◽  
Content Type ◽  
Chip Shape ◽  
Universal Microscope ◽  
The Given ◽  
The Relationship

Purpose The main purpose of the study was to analyze the relationship between cutting forces and tool wear during turning of steel 30CrNiMo8. Design/methodology/approach It is very important to find the optimal machining conditions to increase the tool life and to improve product quality. Width of tool wear was measured by universal microscope. Findings During experimental procedure, one chip shape was obtained for the given machining parameters. Results showed negligible tool wear for the given experimental conditions. In other words, the tool wear is negligible for one chip shape. Originality/value To increase tool wear, there are different chip shapes.

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