Force Modeling and Control of SiC Monocrystal Wafer Processing

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
Shujuan Li ◽  
Siming Du ◽  
Aofei Tang ◽  
Robert G. Landers ◽  
Yang Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Control Variable ◽  
Contact Length ◽  
Machining Process ◽  
Model Parameters ◽  
Wire Saw ◽  
The Wire

Wire saws with fixed diamond abrasive are often used to cut hard and brittle materials owning to the wire saw's narrow kerf, low cutting force, and minimal material waste. Typically, the cutting force changes during the operation since the part diameter and the contact length between the wire saw and part (i.e., contact length) continuously change, even if the process parameters (i.e., wire saw velocity, part feed rate, part rotation speed, and wire saw tension) are fixed, leading to wire saw breakage, wafer collapse, and inferior surface roughness. This study addresses this issue by regulating the force via feedback control. The most significant process parameter affecting the normal force, namely, part feed rate, is taken as the control variable. A system identification routine is used to obtain the transfer function relating the normal force and commanded part feed rate and the model parameters are identified online. An adaptive force controller is designed, and simulation and experimental studies for SiC monocrystal wafer wire saw machining are conducted. The results show the dynamic model well characterizes the normal force generated when wire saw machining SiC monocrystal, and the adaptive controller can effectively track various normal reference force trajectories (i.e., constants, ramps, and sine waves). The experimental results demonstrate that the wire saw machining process with adaptive force control can improve the cutting productivity and significantly decrease wafer surface roughness as compared to the cutting process with a constant part feed rate.

Empirical study on ultrasonic assisted turn-milling

2021 ◽  
pp. 095440892110087
Author(s):  
Saeid Amini ◽  
Mohammad Baraheni ◽  
Mohammad Khaki
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotational Speed ◽  
Milling Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Turn Milling

Turn-milling process has been paid attention in order to be used in multi-task machining processes. Moreover, looking for new machining techniques aimed at reducing cutting force is of important. Reducing cutting force in machining processes has the benefits of extending tool life and improving surface quality. One of the new concepts for reducing the cutting force is applying ultrasonic vibration. In this paper, effects of ultrasonic vibration under different machining parameters in turn-milling process of Al-7075 alloy will be investigated. In this order, a special mechanism was designed to apply ultrasonic vibration during machining process. Ultrasonic vibration exertion on the tool reduced cutting force and surface roughness up to 75% and 35%, respectively. Also tool rotational speed increment induced cutting force and surface roughness increment. In addition, tool feed rate and workpiece rotational speed increment caused cutting force and surface roughness increment. Although, feed rate was more influential.

Cutting Performance and Predictive Models for End Milling Aluminum Alloy

2009 ◽  
Vol 83-86 ◽  
pp. 646-653
Author(s):  
Chung Chen Tsao
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Predictive Models ◽  
Feed Rate ◽  
Flank Wear ◽  
End Milling ◽  
Correlation Coefficients ◽  
Helix Angle ◽  
Machining Process

End milling is considered to be one of the most commonly applied for both roughing and finishing operations to make flat surfaces, slots and pockets in precision molds and dies. Predictive models were developed for cutting force, flank wear and surface roughness in end milling aluminum alloy by regression analysis. The correlation coefficients for cutting force, flank wear and surface roughness equations were 91.6 %, 89.8 % and 79.6 %, respectively. The goal of these predictive equations is to become a good assistant to the researcher in understanding the machining process. Through the analysis of variance (ANOVA), however, it can be found that the cutter diameter, the helix angle and the feed rate are the important milling process parameters to obtain the machined quality on cutting force, flank wear and surface roughness. The investigations show that cutting force, flank wear and surface roughness can be improved in end milling aluminum alloy by using the lower cutter diameter, medium helix angle and lower feed rate.

scholarly journals Optimization of Cutting Data and Tool Inclination Angles During Hard Milling with CBN Tools, Based on Force Predictions and Surface Roughness Measurements

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1109 ◽  
Author(s):  
Andrzej Matras ◽  
Wojciech Zębala
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Machining Process ◽  
Free Form ◽  
Inclination Angles ◽  
Cutting Force Components ◽  
Force Components ◽  
Feed Rate Optimization ◽  
Roughness Measurements

This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool inclination angles (lead and tilt angles) and surface roughness are taken into account. The proposed method is based on calculations of the cutting force components and surface roughness measurements. A case study presented in the paper is based on the AISI H13 steel, with hardness 50 HRC and milling with a cubic boron nitride (CBN) tool. The results of the research showed that by modifications of the feed value based on the currently machined cross-sectional area, it is possible to control the cutting force components and surface roughness. During the process optimization, the 9% and 15% increase in the machining process efficiency and the required surface roughness were obtained according to the tool inclination angle and feed rate optimization procedure, respectively.

Theoretical Research on Contact Length in the Rocking Motion Wire Saw

2016 ◽  
Vol 1136 ◽  
pp. 343-349 ◽  
Author(s):  
Hui Huang ◽  
Sheng Long Zheng ◽  
Xi Peng Xu
Keyword(s):  
Line Segment ◽  
Feed Rate ◽  
Contact Length ◽  
Theoretical Research ◽  
Theoretical Equation ◽  
Motion Path ◽  
Wire Saw ◽  
Rocking Motion ◽  
The Wire ◽  
Wire Motion

Rocking motion wire saw with the additional rocking motion of either the wire or the workpiece is a new machining method compared with the traditional wire saw. The length of contact between the wire and the workpiece changes in this new saw process. In this paper, the wire motion and the contact length were theoretically researched. Wire motion path equation with the rocking motion was established. The theoretical equation of the contact length in half a swing period was derived out. The results indicated that the wire motion was a single pendulum movement with a length line segment, which the swing pivot was moved with a feed rate. The contact length had significant changes in half a swing period in the rocking motion wire saw. The contact length varied periodically with the same amplitude in the square ingot sawing, which varied periodically with the variation amplitude in the circle ingot sawing. The contact length with the rocking motion was obviously shorter than the case without the rocking motion for either the square ingot or the circle ingot.

Nature instigated Grey wolf algorithm for parametric optimization during machining (Milling) of polymer nanocomposites

2021 ◽  
pp. 089270572199320
Author(s):  
Prakhar Kumar Kharwar ◽  
Rajesh Kumar Verma
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Polymer Nanocomposites ◽  
Feed Rate ◽  
Fitness Function ◽  
Depth Of Cut ◽  
Multiwall Carbon Nanotube ◽  
Grey Wolf ◽  
Milling Characteristics ◽  
The Impact

The new era of engineering society focuses on the utilization of the potential advantage of carbon nanomaterials. The machinability facets of nanocarbon materials are passing through an initial stage. This article emphasizes the machinability evaluation and optimization of Milling performances, namely Surface roughness (Ra), Cutting force (Fc), and Material removal rate (MRR) using a recently developed Grey wolf optimization algorithm (GWOA). The Taguchi theory-based L27 orthogonal array (OA) was employed for the Machining (Milling) of polymer nanocomposites reinforced by Multiwall carbon nanotube (MWCNT). The second-order polynomial equation was intended for the analysis of the model. These mathematical models were used as a fitness function in the GWOA to predict machining performances. The ANOVA outcomes efficiently explore the impact of machine parameters on Milling characteristics. The optimal combination for lower surface roughness value is 1.5 MWCNT wt.%, 1500 rpm of spindle speed, 50 mm/min of feed rate, and 3 mm depth of cut. For lower cutting force, 1.0 wt.%, 1500 rpm, 90 mm/min feed rate and 1 mm depth of cut and the maximize MRR was acquired at 0.5 wt.%, 500 rpm, 150 mm/min feed rate and 3 mm depth of cut. The deviation of the predicted value from the experimental value of Ra, Fc, and MRR are found as 2.5, 6.5 and 5.9%, respectively. The convergence plot of all Milling characteristics suggests the application potential of the GWO algorithm for quality improvement in a manufacturing environment.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

scholarly journals Influence of Ultrasonic Vibration-Assisted Ball-End Milling on the Cutting Performance of AZ31B Magnesium Alloy

2020 ◽  
Vol 9 (4) ◽  
pp. 271-276
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Biomedical Applications ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Machining Process ◽  
Dry Conditions ◽  
Good Biocompatibility

Magnesium alloys have a tremendous possibility for biomedical applications due to their good biocompatibility, integrity and degradability, but their low ignition temperature and easy corrosive property restrict the machining process for potential biomedical applications. In this research, ultrasonic vibration-assisted ball milling (UVABM) for AZ31B is investigated to improve the cutting performance and get specific surface morphology in dry conditions. Cutting force and cutting temperatures are measured during UVABM. Surface roughness is measured with a white light interferometer after UVABM. The experimental results show cutting force and cutting temperature reduce due to ultrasonic vibration, and surface roughness decreases by 34.92%, compared with that got from traditional milling, which indicates UVABM is suitable to process AZ31B for potential biomedical applications.

Statistical Cutting Force Model for Orthogonal Cutting of Polytetrafluoroethylene (PTFE) Composites

2013 ◽  
Author(s):  
Felicia Stan ◽  
Daniel Vlad ◽  
Catalin Fetecau
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Polynomial Regression ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Force Model

This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA). Statistical models that correlate the cutting force with process variables were developed using ANOVA and polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake face was identified, the former decreasing with an increasing normal force.

Characterisation, Performance and Optimisation of Nanocellulose Metalworking Fluid (MWF) for Green Machining Process

2021 ◽  
Vol 18 (4) ◽  
pp. 9188-9207
Author(s):  
Mahendran Samykano ◽  
J. Kananathan ◽  
K. Kadirgama ◽  
A. K. Amirruddin ◽  
D. Ramasamy ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Machining Process ◽  
Alumina Nanoparticles ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Nanoparticle Concentration

The present research attempts to develop a hybrid coolant by mixing alumina nanoparticles with cellulose nanocrystal (CNC) into ethylene glycol-water (60:40) and investigate the viability of formulated hybrid nanocoolant (CNC-Al2O3-EG-Water) towards enhancing the machining behavior. The two-step method has been adapted to develop the hybrid nanocoolant at various volume concentrations (0.1, 0.5, and 0.9%). Results indicated a significant enhancement in thermal properties and tribological behaviour of the developed hybrid coolant. The thermal conductivity improved by 20-25% compared to the metal working fluid (MWF) with thermal conductivity of 0.55 W/m℃. Besides, a reduction in wear and friction coefficient was observed with the escalation in the nanoparticle concentration. The machining performance of the developed hybrid coolant was evaluated using Minimum Quantity Lubrication (MQL) in the turning of mild steel. A regression model was developed to assess the deviations in the tool flank wear and surface roughness in terms of feed, cutting speed, depth of the cut, and nanoparticle concentration using Response Surface Methodology (RSM). The mathematical modeling shows that cutting speed has the most significant impact on surface roughness and tool wear, followed by feed rate. The depth of cut does not affect surface roughness or tool wear. Surface roughness achieved 24% reduction, 39% enhancement in tool length of cut, and 33.33% improvement in tool life span. From this, the surface roughness was primarily affected by spindle cutting speed, feed rate, and then cutting depth while utilising either conventional water or composite nanofluid as a coolant. The developed hybrid coolant manifestly improved the machining behaviour.

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