Experimental study on surface roughness of superalloy GH169 by dry turning with CBN cutting tools

In this study, the experiment was conducted to investigate the advantage of dry machining over wet machining during turning of AISI 1020 steel using cemented carbide tool on a CNC lathe machine. Surface roughness and cutting temperature were measured by VOGEL surface roughness tester and infrared thermometer respectively. The experiments were conducted based on Taguchi L9 orthogonal array design. Surface roughness, cutting temperature, tool life, and machining cost were analyzed graphically. The average surface roughness and cutting temperature achieved with wet machining was 2.01 μm and 26.540C, which was 17.41% and 44.86% respectively, lower than dry machining. The high cutting temperature in dry turning result in short tool life, which was 41.15% shorter than wet turning. The machining cost of wet turning was about 56% greater than the cost of dry turning. The cost of coolant in wet turning is 42.88% greater than that of the cutting tools. The highest cost was shared by tool cost, which was 81.33% of the total cost for dry turning, while 70.00% of the total cost was shared by coolant cost for wet turning. Results revealed that dry turning is more economical than wet turning.

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Study on the Cutting Properties about Magnesium Alloy when Dry Turning with Kentanium Cutting Tools

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.102-104.653 ◽

2010 ◽

Vol 102-104 ◽

pp. 653-657 ◽

Cited By ~ 4

Author(s):

Xu Hong Guo ◽

Li Jun Teng ◽

Wei Wang ◽

Ting Ting Chen

Keyword(s):

Surface Roughness ◽

Magnesium Alloy ◽

Tool Wear ◽

Cutting Force ◽

Feed Rate ◽

Cutting Tools ◽

Cutting Speed ◽

Cutting Depth ◽

Dry Turning ◽

Main Influence

In recent years, the machinability of magnesium alloy is concerned more and more by the public. In this paper, a study on the cutting properties of magnesium alloy AZ91D when dry turning with kentanium cutting tools is presented. It shows the cutting force measured by a data acquisition system which is made up of Kistler9257B piezoelectric crystal sensor dynamometer, Kistler5070A10100 charge amplifier and computer. The effect of cutting parameters on cutting force was studied, and the experimental formula was built. The tool wear and chip characteristics were observed with KYKY-EM3200 electron scanning microscope and EDAX PV9900 alpha ray spectrometer, while the surface roughness of the workpiece was measured with 2205 profilometer. Results showed that the cutting depth was the main influence factor on cutting force, followed by feed rate and cutting speed . The main form of tool wear showed to be diffusive wear and adhesive wear. The feed rate had the main influence on chip form and the workpiece surface roughness, cutting speed was less effective, the cutting depth was the least.

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Experimental study on the surface roughness of dry turning of hardened steel

2011 International Conference on Consumer Electronics, Communications and Networks (CECNet) ◽

10.1109/cecnet.2011.5768529 ◽

2011 ◽

Author(s):

Xiaoguang Wang ◽

Junlan Cheng ◽

Tianyan Ma ◽

Deping Zhang

Keyword(s):

Experimental Study ◽

Surface Roughness ◽

Hardened Steel ◽

Dry Turning

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Study of Surface Roughness of Pieces of Magnesium UNS M11311 Obtained by Dry Turning Using ANOVA

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.967 ◽

2011 ◽

Vol 264-265 ◽

pp. 967-972 ◽

Cited By ~ 4

Author(s):

E.M. Rubio ◽

J.M. Sáenz de Pipaón ◽

M. Villeta ◽

M.A. Sebastián

Keyword(s):

Surface Roughness ◽

Cutting Tools ◽

Fractional Factorial ◽

Cutting Conditions ◽

Dry Turning ◽

Ferrous Metals ◽

Surface Finishes ◽

Tool Coatings ◽

The Mathematical Model

The work presents a study of surface roughness of pieces of magnesium UNS M11311 obtained by dry turning. The study is focused in repair operations of this type of materials when they are used as inserts of metalic hybrid components. Therefore, the main limitations of this research are the values of the cutting conditions used; especially low in comparison with the usually values of these parameters used in the production of the magnesium. The followed methodology consists of a series of tests of dry horizontally turning carried out with tools of different coatings and under different cutting conditions. The design of experiments has been made by means of fractional factorial orthogonal designs and the analysis of the results by the ANOVA method. The principal result is one ranking for the combinations of cutting conditions and tool coatings based on the surface roughness expected given by the mathematical model. As first conclusion, it is possible to affirm that, the best surface finishes are obtained for low feeds. Cutting tools used in the machining of other types of materials (steel, stainless steel) can be used obtaining a quality of the surface finish similar to that obtained with tools for specific use of non-ferrous metals.

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Experimental Study on WEDM Machining of PCD and PCBN Compacts

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.645-646.52 ◽

2015 ◽

Vol 645-646 ◽

pp. 52-57 ◽

Cited By ~ 1

Author(s):

Man Cang Song ◽

Jian Lei Zhang ◽

Chao Yu ◽

Min Jie Wang ◽

Chong Liu ◽

...

Keyword(s):

Experimental Study ◽

Surface Roughness ◽

Particle Size ◽

Superhard Material ◽

Cutting Tools ◽

Interface Layer ◽

Processing Quality ◽

Material Layer

Some typical kinds of PCD and PCBN compacts are selected to be machined by WEDM, and a series of processing tests are taken. After machining, the surface roughness of cutting section, the processing quality of cobalt-rich interface layer and the edge of superhard material layer are measured by surface profiler and 3D microscope. The results show that processing quality is affected by superhard particle size and concentration greatly, and better processing quality can be obtained after several cutting of WEDM. The minimum sharpening allowance of PCD cutting tools can be controlled within 4~15μm after WEDM, and within 10μm for PCBN BNX20, while BZN6000 needs larger follow-up workload of sharpening.

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Experimental Study on Spray Cutting Ni-Based Superalloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.723.317 ◽

2012 ◽

Vol 723 ◽

pp. 317-321

Author(s):

Yu Wang ◽

Yuan Sheng Zhai ◽

Fu Gang Yan ◽

Xian Li Liu

Keyword(s):

Experimental Study ◽

Surface Roughness ◽

Cutting Force ◽

Cutting Tools ◽

Cutting Temperature ◽

Cutting Parameters ◽

Production Mode ◽

Effective Reduction ◽

Reasonable Choice ◽

Base Superalloy

In this paper, the effect of cutting parameters on cutting force, cutting temperature and surface roughness on cutting force, cutting temperature and surface roughness are experimentally studied in spray cutting GH4169 Ni-base superalloy used carbide cutting tools. The results showed that reasonable choice of cutting parameters can effective reduction of cutting force and cutting temperature, and improve the machining surface roughness. Thus realizing clean production mode.

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Surface Roughness Predictive Model of UNS A97075 Aluminum Pieces Obtained by Dry Turning Tests Based on the Cutting Forces

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.217-219.1628 ◽

2012 ◽

Vol 217-219 ◽

pp. 1628-1635 ◽

Cited By ~ 1

Author(s):

Beatriz De Agustina ◽

Eva María Rubio ◽

Miguel Ángel Sebastián

Keyword(s):

Experimental Study ◽

Surface Roughness ◽

Predictive Model ◽

Cutting Forces ◽

Cutting Parameters ◽

Depth Of Cut ◽

Dry Turning ◽

Frequency Domains ◽

Range Of Values ◽

Roughness Measurements

The present work shows an experimental study for a first approach of a surface roughness predictive model of UNS A97075 aluminum pieces obtained by dry turning tests based on the cutting forces. In a first step, a design of experiments (DOE) 25 was employed to analyse the influence of the cutting parameters and type of tool on the surface roughness with the objective to find out a combination of cutting conditions that allow obtaining a range of values of surfaces roughness according to the aeronautical specifications requierements. The factors considered for this design were the feed rate, spindle speed, depth of cut, type of tool (nose radious) and machined length (zone of the workpiece where the surface roughness measurements are taken). The obtained data was analysed by means of the analysis of variance (ANOVA) method. And secondly, with the previous selected conditions selected it was developed by multiple regression a model to predict the surface roughness by measuring the cutting forces generated during the dry turning tests of aluminum alloy UNS A97075 pieces. The predictive model of surface roughness obtained includes statistical values calculated from the forces sygnal in time and frequency domains.

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