Investigation of Orthogonal Turn-Milling for Higher Machining Efficiency and Accuracy: Relationship Between Material Removal Rate and Measured Tool Flank Temperature

2020 ◽  
Author(s):  
Koji Shimanuki ◽  
Akira Hosokawa ◽  
Tomohiro Koyano ◽  
Tatsuaki Furumoto ◽  
Yohei Hashimoto
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Speed Ratio ◽  
3D Cad ◽  
Revolution Speed ◽  
Tool Diameter ◽  
Chip Geometry ◽  
Turn Milling

Abstract Tool flank temperature at various intervals after cutting in dry turn-milling of AISI 1045 steel is measured using a two-color pyrometer with an optical fiber. Complicated undeformed chip geometry, which depends on cutting tool diameter, nose radius, number of tooth, workpiece diameter, tool-work revolution speed ratio, depth of cut, feed per tooth, tool axis offset and cutting distance, is analyzed and visualized by the 3D-CAD system. The effect of cutting parameters associated with material removal rate MRR such as workpiece diameter, workpiece revolution speed and feed rate on tool flank temperature is investigated in this paper. Workpiece diameter affects tool flank temperature, and 10 mm larger diameter causes approximately 40 °C higher temperature in any workpiece revolution speed due to the variation of undeformed chip geometry analyzed by 3D-CAD. Tool flank temperature increases with feed rate and workpiece revolution speed because the cross-sectional cutting area of undeformed chip increases with workpiece revolution speed, and cutting time during the engagement of each flute also increases with feed rate. Almost same values are obtained between the tool flank temperature and the material removal rate MRR when both workpiece revolution speed and feed rate are changed.

scholarly journals Effect of Cutting Parameter on Material Removal Rate and Surface Roughness in Deep Drilling Process

2016 ◽  
Vol 2 (5) ◽  
Author(s):  
Mostafa A. Abdullah  , Ahmed B. Abdulwahhab   ,   Atheer R.
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Cutting Conditions ◽  
Drilling Process ◽  
Tool Diameter ◽  
Twist Drills

In the curents study aimed to assess the effects of cutting conditions  (spindle speed, feed rate, tool diameter) parameters as input impact on material removal rate (MRR) and surface roughness (Ra) as output of steel (AISI 1015). A number of drilling experiments were conducted using the L9 orthogonal array on conventional drilling machine with use feed rate (0.038,0.076,0.203) mm/rev and spindle speed (132,550,930) rpm and tool diameter (11,15,20) mm HSS twist drills under dry cutting conditions. Analysis of variance (ANOVA) was employed to determine the most significant control factors affecting on surface roughness and MRR. The result shown the tool diameter the important factor effect with (64.08%) and (76.12%) on MRR and surface roughness respectively.

Experimental Study on the Surface Roughness with Mill-Grinding SiC Particle Reinforced Aluminum Matrix Composites

2011 ◽  
Vol 188 ◽  
pp. 203-207 ◽  
Author(s):  
Jian Guang Li ◽  
Jin Guang Du ◽  
Hang Zhao
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Aluminum Matrix ◽  
Speed Ratio ◽  
Aluminum Matrix Composites ◽  
Matrix Composites ◽  
Sic Particle

In view of the present machining status of SiC particle reinforced aluminum matrix composites, the electroplated diamond wheel (80# diamond grit) was used for mill-grinding the SiC particle reinforced aluminum matrix composites and the effect of speed ratio (q) and material removal rate (MRR) on surface roughness was studied based on experiments. The experimental results show that surface roughness almost increases with the increase of speed ratio. At the same material removal rate, surface roughness increases when raising material removal rate by raising feed rate singlely or raising depth of mill-grinding singlely; surface roughness has decreasing trend with raising material removal rate by increasing feed rate and depth of mill-grinding at the same time.

EXPERIMENTAL ANALYSIS, STATISTICAL MODELING AND OPTIMIZATION OF EFFECTIVE PARAMETERS ON SURFACE QUALITY IN CORTICAL BONE MILLING PROCESS

2020 ◽  
Vol 20 (04) ◽  
pp. 1950078
Author(s):  
MAHDI QASEMI ◽  
M-MORAD SHEIKHI ◽  
MOJTABA ZOLFAGHARI ◽  
VAHID TAHMASBI
Keyword(s):  
Surface Quality ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Milling Process ◽  
Artificial Joint ◽  
Effective Parameters ◽  
Tool Diameter

Knee joint surgery for artificial joint replacement is common in orthopedic surgeries. In this operation, there is a need to prepare the surface of the cortical bone for mounting the artificial joint. Therefore, milling process is frequently performed. Since the surgeon should be careful not to hurt bone tissue and neurons and also minimize waste of blood, the operation should be performed in the shortest possible time. This study, for the first time, focuses on modeling and optimization of effective parameters of bone milling including cutting speed, feed rate and tool diameter on surface roughness and material removal rate using response surface method. Results showed that in order to achieve maximum surface quality, minimum feed rate, maximum tool diameter and down milling procedure should be selected. On the other hand, the maximum material removal rate coincides with maximum feed rate and tool diameter. Therefore, cutting speed of 3000[Formula: see text]rpm, feed rate of 50[Formula: see text]mm/min, tool diameter of 5[Formula: see text]mm and down milling procedure can satisfy both high surface quality and high material removal rate.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Parametric Study of Micro Machining Three Dimensional Microstructure with the Tiny-Grinding Wheel Based on the EMR Effect

2010 ◽  
Vol 447-448 ◽  
pp. 193-197
Author(s):  
Wei Qiang Gao ◽  
Qiu Sheng Yan ◽  
Yi Liu ◽  
Jia Bin Lu ◽  
Ling Ye Kong
Keyword(s):  
Magnetic Field ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Rotation Speed ◽  
Optical Glass ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Machining Time ◽  
Fluctuation Phenomenon

Electro-magneto-rheological (EMR) fluids, which exhibit Newtonian behavior in the absence of a magnetic field, are abruptly transformed within milliseconds into a Bingham plastic under an applied magnetic field, called the EMR effect. Based on this effect, the particle-dispersed EMR fluid is used as a special instantaneous bond to cohere abrasive particles and magnetic particles together so as to form a dynamical, flexible tiny-grinding wheel to machine micro-groove on the surface of optical glass. Experiments were conducted to reveal the effects of process parameters, such as the feed rate of the horizontal worktable, feeding of the Z axis, machining time and machining gap, on material removal rate of glass. The results indicate that the feed rate of the worktable at horizontal direction has less effect on material removal rate, which shows a fluctuation phenomenon within a certain range. The feed rate of the Z axis directly influences the machining gap and leads to a remarkable change on material removal rate. Larger material removal rate can be obtained when the feeding frequency of Z direction is one time per processing. With the increase of rotation speed of the tool, material removal rate increases firstly and decreases afterwards, and it gets the maximum value with the rotation speed of 4800 rev/min. The machining time is directly proportional to material removal amount, but inversely proportional to material removal rate. Furthermore, material removal rate decreases with the increase of the machining gap between the tool and the workpiece. On the basis of above, the machining mode with the tiny-grinding wheel based on the EMR effect is presented.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

Modeling of Material Removal Mechanism in Micro Electric Discharge Milling of Ti-6Al-4V

2014 ◽  
Vol 592-594 ◽  
pp. 516-520 ◽  
Author(s):  
Basil Kuriachen ◽  
Jose Mathew
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Electric Discharge Milling

Micro EDM milling process is accruing a lot of importance in micro fabrication of difficult to machine materials. Any complex shape can be generated with the help of the controlled cylindrical tool in the pre determined path. Due to the complex material removal mechanism on the tool and the work piece, a detailed parametric study is required. In this study, the influence of various process parameters on material removal mechanism is investigated. Experiments were planned as per Response Surface Methodology (RSM) – Box Behnken design and performed under different cutting conditions of gap voltage, capacitance, electrode rotation speed and feed rate. Analysis of variance (ANOVA) was employed to identify the level of importance of machining parameters on the material removal rate. Maximum material removal rate was obtained at Voltage (115V), Capacitance (0.4μF), Electrode rotational Speed (1000rpm), and Feed rate (18mm/min). In addition, a mathematical model is created to predict the material removal

Increase of material removal rate in peripheral milling by varying feed rate

2008 ◽  
Vol 201 (1-3) ◽  
pp. 486-490 ◽  
Author(s):  
H. Pérez ◽  
J. Rios ◽  
E. Díez ◽  
A. Vizán
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Peripheral Milling

The Quantitative Evaluation on the Lapping Uniformity of Rotated Dual-Plates Lapping Mode

2010 ◽  
Vol 37-38 ◽  
pp. 1534-1539 ◽  
Author(s):  
Ping Zhao ◽  
Wei Yu ◽  
Ke Feng Tang ◽  
Bing Hai Lv ◽  
Ju Long Yuan
Keyword(s):  
Material Removal Rate ◽  
Basic Principle ◽  
Material Removal ◽  
Removal Rate ◽  
Contact Point ◽  
Bearing Steel ◽  
Basic Rule ◽  
Speed Ratio ◽  
Key Factors ◽  
Ball Surface

The lapping trace distribution on ball surface is one of the key factors during the lapping process, which can affect the sphericity of lapping. The Rotated Dual-Plates lapping mode (RDP lapping mode) can achieve better uniformity of lapping trace distribution on precision ball surface, which ensure the results of forming sphere by lapping. Combining with the basic principle of RDP lapping mode, as well as the analysis of the kinematics of the RDP lapping method, this paper puts forward a basic rule about the material removal at the contact point between the ball and the plate with the material removal rate equation of bearing steel, and the improvement of the sphericity which can be simulated, and is defined as the lapping uniformity according to basic rule equation. The influence caused by the lapping pressure and the speed of the plates are considered in the simulation, the surface of ball is triangle grid divided. The uniformity of lapping is evaluated at different speed ratio, and eventually a better curve of the speed ratio can be got, so the lapping uniformity during the RDP lapping mode can finally be accurately evaluated.

scholarly journals The analysis of material removal rate of WEDM miniature gears

2021 ◽  
Vol 41 (3) ◽  
Author(s):  
Ashish Goyal ◽  
Vyom Singh ◽  
Abhishek Patel
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spur Gear ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

Gear fabrication in wire electrical discharge machining (WEDM) plays an important role in manufacturing industries. This paper describes the analysis and optimization of process parameters for the fabrication of spur gear on brass spur gear on brass workpiece (10cmx15cmx6mm) material by wire EDM process. The experiments were performed by using the design of experiment (DoE) approach and the material removal rate (MRR) was analyzed by response surface methodology technique. The effect of input parameters i.e. pulse on time, pulse off time and feed rate on MRR has been investigated. The surface geometry of the gears has been analysed by the Scanning Electron Microscopy (SEM). This study found that 0.4 μs for pulse on time, 60 μs for pulse-off time and 6 mm/min for feed rate provides improved material removal rate. The analysis of variance shows that pulse on time and feed rate are the significant parameters for the wire EDM process. The SEM image exhibits the capability of WEDM to machined miniature gear with a uniform distribution of regular-shaped craters and defect-free flank surface.

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