Improving the Economics of Machining PMMCs

1999 ◽  
Author(s):  
Mariam S. El-Gallab ◽  
Mateusz P. Sklad
Keyword(s):  
Mathematical Model ◽  
Surface Finish ◽  
Experimental Work ◽  
Feed Rate ◽  
Tool Material ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Optimum Cutting

Abstract It is the purpose of this paper to present a mathematical model for the prediction of surface finish during turning 20%SiC/Al particulate metal matrix composites (PMMCs). The surface finish relation to the cutting parameters (tool material, tool geometry, speed, feed rate and depth of cut) is further employed in a general form for tool life in order to arrive at optimum cutting parameters that would cost the least and yet meet the surface roughness requirements. A simple C++ program has been developed to find the optimum cutting conditions iteratively. The mathematical models quantify the results of an extensive experimental work on oblique turning of the SiC/Al PMMCs. The results of the experimental work reveal that increasing the feed rate up to 0.55 mm/rev. improves the tool wear rate. This is attributed to the reduced area of contact between the tool surface and the abrading SiC particles. Further increases in the feed rate results in tool failure by edge chipping. The optimum cutting conditions arrived at by the mathematical model yield 21–37% cost reduction when compared to the currently employed cutting parameters.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Optimum Cutting Conditions for Turned Components

1992 ◽  
Vol 206 (1) ◽  
pp. 15-31 ◽  
Author(s):  
J A Arsecularatne ◽  
S Hinduja ◽  
G Barrow
Keyword(s):  
Dynamic Instability ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Objective Criterion ◽  
Nc System ◽  
Optimum Cutting ◽  
Allowable Range ◽  
Optimum Depth ◽  
Rough Turning

This paper describes the procedures used in a technologically orientated numerically controlled (NC-) system to determine the optimum culling conditions automatically for turning, drilling, grooving, threading and parting-off operations. In rough turning, the optimum depth and feed combination is determined using a direct search procedure on the allowable depth/feed region for chip control. The system determines the optimum depth of cut, feed and velocity for each pass in multi-pass turning on the basis of a user-selected objective criterion and a number of technological limitations that may apply to the process, such as machine power, dynamic instability, allowable range of depths and feeds for the tool and workholding limitations which include axial slip, circumferential slip and component throw-out. A user-friendly manual option is also provided which allows the user to specify the cutting parameters. Examples are given to illustrate how these procedures determine the optimum cutting conditions. A comparison between the machining costs and times using cutting conditions obtained from handbooks and the aforementioned procedures shows that for all the operations considered, there are cost and time savings when the cutting conditions obtained by the latter are used.

scholarly journals Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4327 ◽  
Author(s):  
Muhammad Abas ◽  
Bashir Salah ◽  
Qazi Salman Khalid ◽  
Iftikhar Hussain ◽  
Abdur Rehman Babar ◽  
...  
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Virgin Olive Oil ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Signal To Noise ◽  
Shape Deviations ◽  
Measuring Machine ◽  
Tungsten Carbide Tool

Precise, economical and sustainable cutting operations are highly desirable in the advanced manufacturing environment. For this aim, the present study investigated the influence of cutting parameters (i.e., the cutting speed (c), feed rate (f), depth of cut (d) and positive rake angle (p)) and sustainable cutting conditions (dry and minimum quantity lubricant (MQL)) on cutting forces (i.e., feed force (Ff), tangential forces (Ft), radial force (Fr) and resultant cutting forces (Fc) and shape deviations (i.e., circularity and cylindricity) of a 6026-T9 aluminum alloy. The type of lubricant and insert used are virgin olive oil and uncoated tungsten carbide tool. Turning experiments were performed on a TAKISAWA TC-1 CNC lathe machine and cutting forces were measured with the help of a Kistler 9257B dynamometer. Shape deviations were evaluated by means of a Tesa Micro-Hite 3D DCC 474 coordinate measuring machine (CMM). Experimental runs were planned based on Taguchi mixture orthogonal array design L16. Analysis of variance (ANOVA) was performed to study the statistical significance of cutting parameters. Taguchi based signal to noise (S/N) ratios are applied for optimization of single response, while for optimization of multiple responses Taguchi based signal to noise (S/N) ratios coupled with multi-objective optimization on the basis of ratio analysis (MOORA) and criteria importance through inter-criteria correlation (CRITIC) are employed. ANOVA results revealed that feed rate, followed by a depth of cut, are the most influencing and contributing factors for all components of cutting forces (Ff, Ft, Fr, and Fc) and shape deviations (circularity and cylindricity). The optimized cutting parameters obtained for multi responses are c = 600 m/min, f = 0.1 mm/rev, d = 1 mm and p = 25°, while for cutting conditions, MQL is optimal.

scholarly journals Influence of the Cutting Parameters on the Surface Roughness when Machining Hardened Steel with Ceramic and PCBN Cutting Tools

2015 ◽  
Vol 13 ◽  
pp. 19-22 ◽  
Author(s):  
Gabriel Benga ◽  
Danut Savu ◽  
Adrian Olei
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Bearing Steel ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Cutting Regimes

The paper presents the influence of various cutting regimes on the surface roughness, when a hardened bearing steel has been machined using both ceramic and PCBN cutting tools. There were used different cutting conditions varying cutting speed, feed rate and depth of cut in order to determine the influence of each cutting parameter on the surface finish.

Optimization of Cutting Parameters for Turning Operation of Titanium Alloy Ti-6Al-4V Material Workpiece Using the Taguchi Method

2013 ◽  
Vol 685 ◽  
pp. 57-62
Author(s):  
Seyyed Pedram Shahebrahimi ◽  
Abdolrahman Dadvand
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Taguchi Method ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Material Tool

One of the most important issues in turning operations is to choose suitable parameters in order to achieve a desired surface finish. The surface finish in machining operation depends on many parameters such as workpiece material, tool material, tool coating, machining parameters, etc. The purpose of this research is to focus on the analysis of optimum cutting parameters to get the lowest surface roughness in turning Titanium alloy Ti-6Al-4V with the insert with the standard code DNMG 110404 under dry cutting condition, by the Taguchi method. The turning parameters are evaluated as cutting speed of 14, 20 and 28 m/min, feed rate of 0.12, 0.14 and 0.16 mm/rev, depth of cut of 0.3, 0.6 and 1 mm, each at three levels. The Experiment was designed using the Taguchi method and 9 experiments were conducted by this process. The results are analyzed using analysis of variance method (ANOVA). The results of analysis show that the depth of cut has a significant role to play in producing lower surface roughness that is about 63.33% followed by feed rate about 30.25%, and cutting speed has less contribution on the surface roughness. Also it was realized that with the use of the confirmation test, the surface roughness improved by 227% from its initial state.

scholarly journals Characterization and Modeling of Surface Roughness and Burr Formation in Slot Milling of Polycarbonate

2020 ◽  
Vol 4 (2) ◽  
pp. 59 ◽  
Author(s):  
David Adeniji ◽  
Julius Schoop ◽  
Shehan Gunawardena ◽  
Craig Hanson ◽  
Muhammad Jahan
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Surface Finish ◽  
Feed Rate ◽  
Micro Milling ◽  
Burr Formation ◽  
Great Promise ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Thermoplastic Material

Thermoplastic materials hold great promise for next-generation engineered and sustainable plastics and composites. However, due to their thermoplastic nature and viscoplastic material response, it is difficult to predict the properties of surfaces generated by machining. This is especially problematic in micro-channel machining, where burr formation and excessive surface roughness lead to poor component-surface integrity. This study attempts to model the influence of size effects, which occur due to the finite sharpness of any cutting tool, on surface finish and burr formation during micro-milling of an important thermoplastic material, polycarbonate. Experimental results show that the depth of cut does not affect either surface finish or burr formation. A proposed new sideflow model shows the dominant effect of cutting-edge radius and feed rate on surface finish, while tool edge roughness, coating and feed rate have the most pronounced influence on burr formation. Overall, a good agreement between the experimental data and the proposed size effect model for the machining of thermoplastic material was found. Based on these results, tool geometry and process parameters may be optimized for improved surface integrity of machined thermoplastic components.

Optimization of Cutting Parameters for End Milling AlSi/AlN Metal Matrix Composite Using the Taguchi Method

2013 ◽  
Vol 773-774 ◽  
pp. 429-436 ◽  
Author(s):  
Siti Haryani Tomadi ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron ◽  
Abdul Razak Daud
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Matrix Composite ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Optimum Cutting ◽  
Optimization Of Cutting Parameters

In this paper, the optimization of cutting parameters is investigated to assess surface roughness and cutting force in the end milling of AlSi/AlN metal matrix composite. Eighteen experiments (L18) with five factors (cutting speed, feed rate, depth of cut, volume of particle reinforcement, and type of coated insert) were performed based on Taguchi designs of the experiment method. Two types of coating (TiB2 and TiN/TiCN/TiN) of the carbide cutting tool were employed to machine various volumes of AlN particle (5%, 7% and 10%) reinforced AlSi alloy matrix composite under dry cutting conditions. Signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were applied to investigate the optimum cutting parameters and their significance. The S/N analysis of the obtained results showed that the optimum cutting conditions for the cutting force were; A2 (triple coating of the insert), B2 (cutting speed: 200m/min), C1 (feed rate: 0.6mm/tooth), D1 (axial depth: 0.6mm) and E1 (5% reinforcement). At the mean time, the optimum cutting conditions for surface roughness were; A1 (single coating of insert), B3 (cutting speed: 250m/min), C2 (feed rate: 0.75mm/tooth), D1 (axial depth: 0.6mm) and E1 (5% reinforcement).The study confirmed that, with a minimum number of experiments, the Taguchi method is capable of determining the optimum cutting conditions for the cutting force and surface roughness for this new material under investigation.

scholarly journals Optimal Machining Parameters for Achieving the Desired Surface Roughness in Turning of Steel

2012 ◽  
Vol 9 (1) ◽  
pp. 37 ◽  
Author(s):  
LB Abhang ◽  
M Hameedullah
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Engineering Sciences

 Due to the widespread use of highly automated machine tools in the metal cutting industry, manufacturing requires highly reliable models and methods for the prediction of output performance in the machining process. The prediction of optimal manufacturing conditions for good surface finish and dimensional accuracy plays a very important role in process planning. In the steel turning process the tool geometry and cutting conditions determine the time and cost of production which ultimately affect the quality of the final product. In the present work, experimental investigations have been conducted to determine the effect of the tool geometry (effective tool nose radius) and metal cutting conditions (cutting speed, feed rate and depth of cut) on surface finish during the turning of EN-31 steel. First and second order mathematical models are developed in terms of machining parameters by using the response surface methodology on the basis of the experimental results. The surface roughness prediction model has been optimized to obtain the surface roughness values by using LINGO solver programs. LINGO is a mathematical modeling language which is used in linear and nonlinear optimization to formulate large problems concisely, solve them, and analyze the solution in engineering sciences, operation research etc. The LINGO solver program is global optimization software. It gives minimum values of surface roughness and their respective optimal conditions. 

Wear Analysis of Silicon Nitride (Si3N4) Cutting Tool in Dry Machining of T6061 Aluminium Alloy

2012 ◽  
Vol 268-270 ◽  
pp. 563-567 ◽  
Author(s):  
Tasnim Firdaus Ariff ◽  
Nurul Syamira Shafie ◽  
Zamzahariah Mahamad Zahir
Keyword(s):  
Silicon Nitride ◽  
Aluminium Alloy ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Optimum Cutting ◽  
Cutting Speeds

Dry machining is an eco-friendly machining process and its importance in the manufacturing industries should be taken seriously. Machining without the use of any cutting fluid is becoming increasingly more popular due to concerns regarding the safety of the environment and reducing cost. Dry and wet turning of T6061 aluminium alloy was performed on a lathe by using Silicon Nitride (Si3N4) inserts as the cutting tool. Tool wear behaviour of Si3N4 cutting tool were studied with the aim of finding the optimum cutting conditions for both dry and wet machining. Machining was performed at four different cutting speeds; 292, 388, 518 and 689 m/min using two different cutting parameters (feed rate, f = 0.2 mm/rev, depth of cut, d = 0.1 mm and f = 0.4 mm/rev, d = 0.2 mm). Material removal rate (MRR) was also obtained and the temperature at the tool-chip interface were measured using an infrared (IR) thermometer as to see the effect of temperature rise during machining. Dry machining with smaller cutting parameters resulted in lower wear rates by 37 to 48% for all four cutting speeds. Nevertheless, reduction of wear rate by 38 to 57% was found from wet machining. The optimum cutting speed for both dry and wet machining of T6061 aluminium alloy using Si3N4 cutting tool was found to be 518 m/min for both cutting parameters. However, the optimum cutting parameters are apparently with the feed rate of 0.4 mm/rev and depth of cut of 0.2 mm. At the optimum cutting speed, the tool tip temperature for dry machining was higher than wet machining by 40 and 51% for f = 0.2 mm/rev and f = 0.4 mm/rev respectively. Dry machining of T6061 Aluminium alloy can be more suitable particularly at higher cutting speed with interrupted cutting operations.

scholarly journals Effect of Turning Parameters and Reinforcement on the Surface Roughness of Hybrid Aluminium Metal Matrix Composite

2019 ◽  
Vol 9 (1) ◽  
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Matrix Material ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Pure Aluminium ◽  
Machining Time

Since last two decades, technology has changed rapidly in each industry from consumer goods to aerospace. To quench the thrust of technology advancement of industries, the research community has to develop the novel materials. As a part of the ongoing process of material development and machinability study, present work was carried out to find out the effect of various cutting parameters on surface roughness and machining time of aluminium Hybrid Metal Matrix Composites (AHMMCs). In this study, pure aluminium was used as a matrix material while; B4C, Mg, Ti and Graphite were used as reinforcement. It was observed that 2202 RPM spindle speed, 0.18 mm/rev feed rate and 1.1 mm depth of cut are the optimum turning parameters with PCD insert. While machining of same composites using carbide insert, optimum spindle speed, feed rate and depth of cut are 2091 RPM, 0.19 mm/rev and 1.1 mm respectively. Moreover, PCD insert provides better surface finish compared to carbide coated insert for same cutting conditions. Moreover, the effect of reinforcement particles presence on the surface finish was also investigated and it was concluded that reinforcement presence reduces the surface roughness considerably. Particularly presence of Mg and graphite reduces surface finish significantly.

Sign in / Sign up

Export Citation Format

Share Document