Vortex Tube Impact on Cooling Milling Machining

2012 ◽  
Author(s):  
Basel Alsayyed ◽  
Mohammad O. Hamdan ◽  
Saud Aldajah
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Vortex Tube ◽  
Compressed Air ◽  
Heat Map ◽  
Milling Operations ◽  
Three Samples ◽  
Cutting Operation ◽  
Water Base ◽  
Vortex Tubes

In this paper, the authors will present the use of a vortex tube in cooling milling operations. The focuses will be regarding the surface finish and temperature of the tool during the cutting operation. Three cooling setups, cutting without coolant, cooling with a water base traditional coolant, and cooling with vortex tube will be compared. A Flir E320 UV camera has been used to capture the heat map around the tool during the cutting process. The surface roughness has been measured and analysed for all three samples using Taylor/Hobson Precision Surtronc 3+ apparatus. The findings of this study have shown comparative efficient cooling using the vortex tubes. The vortex tube cooling is also cleaner and can be directed in such a way to collect the chips as they develop with the least mess or no mess. Vortex tubes have no moving parts, and it is very much maintenance free device. Compressed air is needed to feed the vortex tube, which is available usually in any machine shop.

Prediction of Surface Roughness in Compressed Air Jet Assisted High Speed End Milling of Silicon Using Diamond Coated Tools

2012 ◽  
Vol 576 ◽  
pp. 41-45
Author(s):  
A.K.M. Nurul Amin ◽  
M.A. Mahmud ◽  
M.D. Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Surface Finish ◽  
High Speed ◽  
End Milling ◽  
Silicon Wafers ◽  
Compressed Air ◽  
Machining Parameters ◽  
High Quality ◽  
Ductile Mode

The majority of semiconductor devices are made up of silicon wafers. Manufacturing of high-quality silicon wafers includes numerous machining processes, including end milling. In order to end mill silicon to a nano-meteric surface finish, it is crucial to determine the effect of machining parameters, which influence the machining transition from brittle to ductile mode. Thus, this paper presents a novel experimental technique to study the effects of machining parameters in high speed end milling of silicon. The application of compressed air, in order to blow away the chips formed, is also investigated. The machining parameters’ ranges which facilitate the transition from brittle to ductile mode cutting as well as enable the attainment of high quality surface finish and integrity are identified. Mathematical model of the response parameter, the average surface roughness (Ra) is subsequently developed using RSM in terms of the machining parameters. The model was determined, by Analysis of Variance (ANOVA), to have a confidence level of 95%. The experimental results show that the developed mathematical model can effectively describe the performance indicators within the controlled limits of the factors that are being considered.

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.

Modeling of Cutting Process with Cutter Axis Inclination

2011 ◽  
Vol 223 ◽  
pp. 66-74 ◽  
Author(s):  
Takashi Matsumura
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Mechanistic Models ◽  
End Mill ◽  
High Quality ◽  
Ball End Mill ◽  
Milling Operations ◽  
Edge Roughness

Multi-axis controlled machining has been increasing with the demand for high quality in mold manufacturing. The cutter axis inclination should be properly determined in the milling operations. The paper discusses the cutting process of ball end mill with the cutter axis inclination. Two mechanistic models are presented to show the effect of the cutter axis inclination on the tool wear and the surface finish. The actual cutting time during a rotation of the cutter reduces with increasing the cutter axis inclination. Then, the tool is cooled in the non-cutting time. The tool wear is suppressed with reducing the cutting temperature. The surface finish is also improved by increasing cutting velocities with the cutter axis inclination. When the cutter is inclined in the feed direction, the effect of the edge roughness on the surface finish is eliminated. The discussion based on the simulation is verified in the cutting tests for brittle materials.

Roller Burnishing Method with Active Rotation Tool - Better Surface Finish than Conventional Roller Burnishing

2017 ◽  
Vol 749 ◽  
pp. 9-14 ◽  
Author(s):  
Masato Okada ◽  
Yuki Miyagoshi ◽  
Masaaki Otsu
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Surface Finish ◽  
Circumferential Direction ◽  
Theoretical Equation ◽  
Sliding Angle ◽  
Roller Burnishing ◽  
Sliding Direction ◽  
Cylindrical Workpiece ◽  
Sectional Profile

This paper proposes a roller burnishing method that controls the sliding direction of the burnishing tool on the surface of cylindrical workpiece. In this study, the sliding direction was set by inclining the axis of the burnishing tool with respect to the axis of the workpiece and by actively rotating the roller of the burnishing tool. The workpiece was a cylindrical aluminum alloy bar, which was rotated in a bench lathe. The burnished surfaces at several sliding angles between 15º and 90º were evaluated. The sliding direction, which is set according to a theoretical equation, was experimentally obtained for every sliding angle in the range of 15-90º with respect to the circumferential direction of the workpiece. The sectional profile was flattened and surface roughness was decreased with increasing sliding angle. As a result, the burnished surfaces obtained in this work were superior to those obtained in an earlier study by the authors, in which the burnishing tool was not actively rotated.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Study on carbon epoxy composite surfaces machined by abrasive water jet machining

2018 ◽  
Vol 53 (20) ◽  
pp. 2909-2924 ◽  
Author(s):  
Ajit Dhanawade ◽  
Shailendra Kumar
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Process Parameters ◽  
Surface Finish ◽  
Epoxy Composite ◽  
Water Jet ◽  
Machining Parameters ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Pull Out

Traditional machining of carbon epoxy composite material is difficult due to excessive tool wear, excessive stresses and heat generation, delamination, high surface waviness, etc. In the present paper, research work involved in the experimental study of abrasive water jet machining of carbon epoxy composite material is described. The aim of present work is to improve surface finish and studying defects in machined samples. Taguchi's orthogonal array approach is used to design experiments. Process parameters namely hydraulic pressure, traverse rate, stand-off distance and abrasive mass flow rate are considered for this study. Analysis of machined surfaces and kerf quality is carried out using scanning electron microscope to evaluate microscopic features. Further, the effect of machining parameters on surface roughness is investigated using analysis of variance approach. It is found that traverse rate and pressure are most significant parameters to control surface roughness. Optimization of process parameters is performed using grey relational analysis. Thereafter, confirmation tests are carried out to verify the improvement in the surface quality with optimum set of process parameters. It is found that surface finish of machined samples is improved by 10.75% with optimum levels of process parameters. Defects like delamination, fiber pull-out and abrasive embedment are also studied using SEM. It is observed that delamination and fiber pull-out are prominent in samples machined at low pressure and high traverse rate.

Study of the Relationship between Tool Wear and Surface Finish in Turning with Carbide Tool

2014 ◽  
Vol 902 ◽  
pp. 95-100 ◽  
Author(s):  
Heraldo J. Amorim ◽  
Augusto O. Kunrath Neto
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Surface Finish ◽  
Cutting Speed ◽  
Single Equation ◽  
Carbon Steels ◽  
High Dispersion ◽  
Exponential Relationship ◽  
Processed Material ◽  
The Relationship

The aim of this work is to analyze the tool wear effects on surface finish of machined components. Long-term machinability tests were performed for ASTM 1040 and 1045 carbon steels with carbide tools, in which tool wear and surface roughness were periodically evaluated. Surface finish was analyzed as a function of processed material and cutting speed with new machining tool, and a significant influence was found for cutting speed at a confidence interval of 10%. When evaluated as a function of time and tool wear, surface roughness showed an exponential relationship with both variables. However, a high dispersion occurs close to the end of tool life, especially for AISI 1040 steel. Weak influence of cutting speed (for the range of speeds tested) was observed on the relationship between tool wear and surface finish, indicating that a single equation can describe its behavior for all studied conditions. The relationship between the surface roughness and the cutting time was found to be stronger for the ABNT 1040 steel.

Additive manufacturing using fine wire-based laser metal deposition

2019 ◽  
Vol 26 (3) ◽  
pp. 473-483
Author(s):  
Muhammad Omar Shaikh ◽  
Ching-Chia Chen ◽  
Hua-Cheng Chiang ◽  
Ji-Rong Chen ◽  
Yi-Chin Chou ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
High Precision ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
Laser Metal Deposition ◽  
Cross Sectional ◽  
Content Type ◽  
Fine Wire

Purpose Using wire as feedstock has several advantages for additive manufacturing (AM) of metal components, which include high deposition rates, efficient material use and low material costs. While the feasibility of wire-feed AM has been demonstrated, the accuracy and surface finish of the produced parts is generally lower than those obtained using powder-bed/-feed AM. The purpose of this study was to develop and investigate the feasibility of a fine wire-based laser metal deposition (FW-LMD) process for producing high-precision metal components with improved resolution, dimensional accuracy and surface finish. Design/methodology/approach The proposed FW-LMD AM process uses a fine stainless steel wire with a diameter of 100 µm as the additive material and a pulsed Nd:YAG laser as the heat source. The pulsed laser beam generates a melt pool on the substrate into which the fine wire is fed, and upon moving the X–Y stage, a single-pass weld bead is created during solidification that can be laterally and vertically stacked to create a 3D metal component. Process parameters including laser power, pulse duration and stage speed were optimized for the single-pass weld bead. The effect of lateral overlap was studied to ensure low surface roughness of the first layer onto which subsequent layers can be deposited. Multi-layer deposition was also performed and the resulting cross-sectional morphology, microhardness, phase formation, grain growth and tensile strength have been investigated. Findings An optimized lateral overlap of about 60-70% results in an average surface roughness of 8-16 µm along all printed directions of the X–Y stage. The single-layer thickness and dimensional accuracy of the proposed FW-LMD process was about 40-80 µm and ±30 µm, respectively. A dense cross-sectional morphology was observed for the multilayer stacking without any visible voids, pores or defects present between the layers. X-ray diffraction confirmed a majority austenite phase with small ferrite phase formation that occurs at the junction of the vertically stacked beads, as confirmed by the electron backscatter diffraction (EBSD) analysis. Tensile tests were performed and an ultimate tensile strength of about 700-750 MPa was observed for all samples. Furthermore, multilayer printing of different shapes with improved surface finish and thin-walled and inclined metal structures with a minimum achievable resolution of about 500 µm was presented. Originality/value To the best of the authors’ knowledge, this is the first study to report a directed energy deposition process using a fine metal wire with a diameter of 100 µm and can be a possible solution to improving surface finish and reducing the “stair-stepping” effect that is generally observed for wires with a larger diameter. The AM process proposed in this study can be an attractive alternative for 3D printing of high-precision metal components and can find application for rapid prototyping in a range of industries such as medical and automotive, among others.

scholarly journals An Investigation of Milling using a Combination of Electrical Discharge (ED) and Electrochemical (EC) Machining Techniques

2021 ◽  
Vol 9 (VI) ◽  
pp. 3657-3661
Author(s):  
Vishal Gandhi
Keyword(s):  
Surface Roughness ◽  
Anodic Dissolution ◽  
Surface Finish ◽  
Single Machine ◽  
Electrical Discharge ◽  
Spark Erosion

This study investigate the machining operation perform by the combination of EDM and ECM process. Since in case of EDM the surface finish obtain is not as good as required so next machining operation is done by ECM. As we have, in EDM metal is removed from the workpiece through spark erosion and in ECM metal removed by anodic dissolution in the electrolyte. Both the process is done simultaneously in single machine changing the potential on anode and cathode and the medium. The EDM surface of 1μ mm Ra is improved to 0.2μ mm Ra by applying ECM. The surface roughness of a machined hole is improved to 0.07 mm Ra by applying 2 min of ECM lapping. Both the process is done simultaneously.

scholarly journals An Investigation To Achieve a Good Surface Integrity in WEDM of Ti-6242 Super Alloy

2021 ◽  
Author(s):  
Sonia Ezeddini ◽  
Wajdi Rajhi ◽  
Mohamed Boujelbene ◽  
Emin Bayraktar ◽  
Sahbi Ben Salem
Keyword(s):  
Surface Roughness ◽  
Pulse Duration ◽  
Surface Integrity ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Good Surface ◽  
Pulse On Time ◽  
Super Alloy

Abstract Ti-6242 is a super alloy which exhibits the best creep resistance among available titanium alloys and is widely used in the manufacture by WEDM of aircraft engine turbomachinery components. However, the final quality of wire EDMed surface is a great challenge as it is affected by various factors that need optimization for surface integrity and machine efficiency improvement. The aim of this study is to investigate the effect of a set of cutting process parameters such as pulse on time (Ton), servo voltage (U), feed rate (S) and flushing pressure (p) on surface roughness (SR) when machining Ti-6242 super alloy by WEDM process using a brass tool electrode and deionized water as a dielectric fluid. WEDM experiments were conducted, and SR (Ra) measurement was carried out using a 3D optical surface roughness-meter (3D–SurfaScan). As a tool to optimize cutting parameters for SR improvement, Taguchi's signal‐to‐noise ratio (S/N) approach was applied using L9 (3^4) orthogonal array and Lower-The-Better (LTB) criteria. Substantially, the findings from current investigation suggest the application of the values 0.9 µs, 100V, 29 mm/min, and 60 bar for Ton, U, S and p cutting parameters, respectively, for producing a good surface finish quality. Percent contributions of the machining parameters on SR (Ra) assessed based on ANOVA analysis are 62.94%, 20.84%, 11.46% and 4.74% for U, S, Ton and p, respectively. Subsequently, accurate predictive model for SR (Ra) is established based on response surface analysis (RSA). The contour plots for SR (Ra) indicate that when flushing pressure p converges to a critical value (80 bar), a poor-quality surface finish is highly expected with the excessive increase in U and S. Electron microscope scanning (SEM) observations have been performed on machined surface for a wide range of cutting parameters to characterize wire EDMed surface of Ti-6242. SEM micrographs indicate that the machined surface acquires a foamy structure and shows white layer and machining-induced damage that the characteristics are highly dependent on cutting parameters. At high servo-voltage, the decrease in pulse on time Ton and feed rate S results in a large decrease in overall machining-induced surface damage. Moreover, for high servo-voltage and feed rate levels, it has been observed that pulse on time could play a role of controlling the surface microcracks density. In fact, the use of a low pulse duration of cut combined with high servo-voltage and feed rate has been shown to inhibit surface microcracks formation giving the material surface a better resistance to cracking than at high pulse duration.

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