Energy Efficiency in Thermally Assisted Machining of Titanium Alloy: A Numerical Study

2013 ◽  
Author(s):  
Jianfeng Ma ◽  
Xianchen Ge ◽  
Shuting Lei
Keyword(s):  
Energy Efficiency ◽  
Titanium Alloy ◽  
Total Energy ◽  
Numerical Study ◽  
Cutting Speed ◽  
Operating Conditions ◽  
Energy Utilization ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Cutting Energy

This study investigates the energy utilization and efficiency in thermally assisted machining (TEM) of a titanium alloy using numerical simulation. AdvantEdge FEM is used to conduct the simulation of orthogonal machining of the workpiece. Thermal boundary conditions are specified to approximate laser preheating of the workpiece material. The effects of operating conditions (preheat temperature, cutting speed, depth of cut, and rake angle) on mechanical cutting energy, preheat energy, and energy efficiency are investigated. The results show that preheating the workpiece reduces the cutting energy but increases the total energy in TEM. There is significant potential to maximize total energy efficiency in TEM by optimal design of heating strategies and machining conditions.

Energy Efficiency in Thermally Assisted Machining of Titanium Alloy: A Numerical Study

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
J. Ma ◽  
X. Ge ◽  
S. Lei
Keyword(s):  
Energy Efficiency ◽  
Titanium Alloy ◽  
Total Energy ◽  
Numerical Study ◽  
Cutting Speed ◽  
Operating Conditions ◽  
Energy Utilization ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Cutting Energy

This study investigates the energy utilization and efficiency in thermally assisted machining (TAM) of a titanium alloy using numerical simulation. AdvantEdge finite element method (FEM) is used to conduct the simulation of orthogonal machining of the workpiece. Thermal boundary conditions are specified to approximate laser preheating of the workpiece material. The effects of operating conditions (preheat temperature, cutting speed, depth of cut, and rake angle) on mechanical cutting energy, preheat energy, and energy efficiency are investigated. The results show that preheating the workpiece reduces the cutting energy but increases the total energy in TAM. There is significant potential to maximize total energy efficiency in TAM by optimal design of heating strategies and machining conditions.

Life Prediction of Cutting Tool by the Workpiece Cutting Condition

2011 ◽  
Vol 223 ◽  
pp. 554-563 ◽  
Author(s):  
Noemia Gomes de Mattos de Mesquita ◽  
José Eduardo Ferreira de Oliveira ◽  
Arimatea Quaresma Ferraz
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Operating Conditions ◽  
Production Costs ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Workpiece Material ◽  
The Cost

Stops to exchange cutting tool, to set up again the tool in a turning operation with CNC or to measure the workpiece dimensions have direct influence on production. The premature removal of the cutting tool results in high cost of machining, since the parcel relating to the cost of the cutting tool increases. On the other hand the late exchange of cutting tool also increases the cost of production because getting parts out of the preset tolerances may require rework for its use, when it does not cause bigger problems such as breaking of cutting tools or the loss of the part. Therefore, the right time to exchange the tool should be well defined when wanted to minimize production costs. When the flank wear is the limiting tool life, the time predetermination that a cutting tool must be used for the machining occurs within the limits of tolerance can be done without difficulty. This paper aims to show how the life of the cutting tool can be calculated taking into account the cutting parameters (cutting speed, feed and depth of cut), workpiece material, power of the machine, the dimensional tolerance of the part, the finishing surface, the geometry of the cutting tool and operating conditions of the machine tool, once known the parameters of Taylor algebraic structure. These parameters were raised for the ABNT 1038 steel machined with cutting tools of hard metal.

Wear Behavior of Carbide Inserts in Face Milling TA19 Alloy

2012 ◽  
Vol 426 ◽  
pp. 339-343 ◽  
Author(s):  
Qiu Lin Niu ◽  
X.J. Cai ◽  
Zhi Qiang Liu ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Titanium Alloy ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Aircraft Engine ◽  
Face Milling ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Crater Wear ◽  
Stable Conditions ◽  
Carbide Inserts

As a typical high strength material, titanium alloy Ti-6Al-2Sn-4Zr- 2Mo-0.1Si (TA19) is used to manufacturing the compressor power-brake of aircraft engine and the aircraft skin. All the machining experiments were carried out on a CNC-milling center under the stable conditions of cutting speed, feed rate, and depth of cut. The performance and wear mechanisms of coated- and uncoated carbide tools have been investigated in this paper to evaluate the machinability of TA19 in face milling. The three tools used were PVD-TiN+TiAlN, CVD-TiN+Al2O3+TiCN and uncoated carbide inserts. The results indicated that PVD coating had the best performance than other tool materials in milling titanium alloy TA19, and the cutting force and the wear value were the smallest than that for CVD-coated and uncoated tools. The failure types of PVD-, CVD- and uncoated inserts were the crater wear and micro tipping; the crater wear and tipping; tipping. Abrasive wear and adherent wear were the predominant mechanism of PVD-TiN+TiAlN carbide insert in face milling TA19 alloy. For CVD- and uncoated carbide, adherent wear was predominant.

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.

The Effect of Minimal Quantity Lubrication (MQL) on the Surface Roughness of Titanium Alloy Ti-6Al-4V ELI in Turning Process

2010 ◽  
Vol 146-147 ◽  
pp. 1750-1753 ◽  
Author(s):  
C.H. Che Haron ◽  
J.A. Ghani ◽  
Mohd Ali Sulaiman ◽  
L.R. Intan ◽  
M.S. Kasim
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Influence Factor ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Minimum Quantity Lubricant ◽  
Minimal Quantity Lubrication ◽  
Tungsten Carbide Tool

This paper investigates the effect of minimum quantity lubricant (MQL) on the surface roughness of titanium alloy Ti-6Al-4V ELI when turning using uncoated tungsten carbide tool. The response surface method (RSM) design of experiment using Box-behnken was used to accomodate the turning experiment factors and levels. Turning parameters studied were cutting speed (100, 135, 170 m/min), feed rate (0.15, 0.2, 0.25 mm/rev) and depth of cut (0.6, 0.8, 1.0 mm). The results show that the feed rate was the most influence factor controlling the surface roughness produced. The feed rate (F) was found directly proportional with the surface roughness value (Ra) but inversely proportional to the cutting speed (Vc). MINITAB software was used to develop a surface roughness model, and the optimum condition was at 160 m/min of cutting speed, 0.18 mm/rev of feed rate and 1 mm of depth of cut. At the optimum condition low value of 1.54 μm surface roughness was obtained.

Optimization of Cutting Parameters Based on Specific Cutting Energy Consumption for Aluminum 6010 by Using the Analysis of Variance (ANOVA)

2016 ◽  
Vol 842 ◽  
pp. 14-18
Author(s):  
Sri Raharno ◽  
Yatna Yuwana Martawirya ◽  
Heng Rath Visith ◽  
Jeffry Aditya Cipta Wijaya
Keyword(s):  
Energy Consumption ◽  
Analysis Of Variance ◽  
Minimum Energy ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Manufacturing Industries ◽  
Depth Of Cut ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Minimum Energy Consumption

Manufacturing industries have consumed 30% of the total world energy. The main energy source used in those manufacturing industries is the electricity generated from fossil fuels such as oil, gas, and coal as a result in causing the environmental and economic issues. This paper presents an experimental study in order to get the minimum energy consumption during turning of aluminum 6010 with the conventional machine tool under dry cutting condition by optimizing the cutting parameters to contribute to those issues. An analysis of variance (ANOVA) was employed to analyze the effects and contribution of depth of cut, feed, and cutting speed on the response variable, specific cutting energy. The result of this experiment showed that the feed was the most significant factor for minimizing energy consumption followed by the cutting speed and the depth of cut. The minimum energy consumption was obtained when the highest level of cutting parameters have been used.

Study on Wear Properties and Mechanisms of Coated Carbide Tools in Dry Turning of 300M Steel

2011 ◽  
Vol 314-316 ◽  
pp. 1142-1145
Author(s):  
Zong Yang Zhang ◽  
Xing Ai ◽  
Zhan Qiang Liu ◽  
Min Wang
Keyword(s):  
Cutting Speed ◽  
No Oxidation ◽  
Depth Of Cut ◽  
Wear Properties ◽  
Workpiece Material ◽  
Dry Turning ◽  
300M Steel ◽  
Coated Carbide ◽  
Oxidation Wear ◽  
Coated Carbide Tools

This paper deals with an experimental research on wear properties and mechanisms of coated carbide tools in dry turning of 300M steel which are widely used to manufacture the central spindle, wheel gear, aerofoil fastener and so on. Based on Makarow’s theory, the minimum surface wear rate hs = 2.88 μm and the optimal cutting speed v = 200 m/mim were attained under the condition of the feed rate f = 0.1 mm/r and the depth of cut ap = 0.15 mm. Analysis carried out with the SEM suggests that adhesion of workpiece material and chipping are dominant wear mechanisms. There was no observation of oxygen existing based on the analysis of EDS which indicated no oxidation wear generated during the turning machining.

scholarly journals The Experimental Investigation of Surface Roughness After Dry Turning of Steel S235

2019 ◽  
Vol 26 (4) ◽  
pp. 179-184
Author(s):  
Justyna Molenda
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Scientific Work ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Important Indicator

AbstractNowadays lot of scientific work inspired by industry companies was done with the aim to avoid the use of cutting fluids in machining operations. The reasons were ecological and human health problems caused by the cutting fluid. The most logical solution, which can be taken to eliminate all of the problems associated with the use of cooling lubricant, is dry machining. In most cases, however, a machining operation without lubricant finds acceptance only when it is possible to guarantee that the part quality and machining times achieved in wet machining are equalled or surpassed. Surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered as one of the most important parameter in industry. Today the quality of surface finish is a significant requirement for many workpieces. Thus, the choice of optimized cutting parameters is very important for controlling the required surface quality. In the present study, the influence of different machining parameters on surface roughness has been analysed. Experiments were conducted for turning, as it is the most frequently used machining process in machine industry. All these parameters have been studied in terms of depth of cut (ap), feed rate (f) and cutting speed (vc). As workpiece, material steel S235 has been selected. This work presents results of research done during turning realised on conventional lathe CDS 6250 BX-1000 with severe parameters. These demonstrate the necessity of further, more detailed research on turning process results.

scholarly journals Scalogram-Based Instantaneous Features of Acoustic Emission in Grinding Burn Detection

2021 ◽  
Author(s):  
Isa Yesilyurt ◽  
◽  
Abdullah Dalkiran ◽  
Onder Yesil ◽  
Ozan Mustak ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
Cutting Speed ◽  
Operating Conditions ◽  
Depth Of Cut ◽  
Signal Phase ◽  
Time Frequency ◽  
Grinding Burn ◽  
Frequency Moments ◽  
Phase Deviation ◽  
Instantaneous Energy

Time-frequency methods are effective tools in identifying the frequency content of a signal and revealing its time-variant features. This paper presents the use of instantaneous features (i.e. instantaneous energy and signal phase) of acoustic emission (AE) in the detection of thermal damage to the workpiece in grinding. Both the instantaneous energy and mean frequency are obtained using the low-order frequency moments of a scalogram. While the zero-order frequency moment yields the instantaneous energy, the first-order frequency moment gives the instantaneous frequency by which the signal phase is recovered. The grinding process is monitored using acoustic emission for various operating conditions, including the regular grinding, grinding at a higher cutting speed and larger infeed, and small dressing depth of cut. It has been found that both the instantaneous energy and phase deviation indicate the presence of burn damage and serve as robust and reliable indicators, providing a basis for detecting the grinding burn.

scholarly journals Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions

2019 ◽  
Vol 10 (2) ◽  
pp. 561-573 ◽  
Author(s):  
Muhammad Ali Khan ◽  
Syed Husain Imran Jaffery ◽  
Mushtaq Khan ◽  
Muhammad Younas ◽  
Shahid Ikramullah Butt ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Effective Means ◽  
Sustainable Manufacturing ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Positive Effect

Abstract. Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33 % whereas specific cutting energy and surface roughness were improved by 10 % and 9 % respectively by adapting the optimum machining conditions.

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