scholarly journals Burr edge occupancy: edge finishing index for milling machined parts

2019 ◽  
Vol 43 (2) ◽  
pp. 248-255 ◽  
Author(s):  
Seyed Ali Niknam ◽  
Azziz Tiabi ◽  
Victor Songmene
Keyword(s):  
Aluminium Alloys ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Time ◽  
Slot Milling ◽  
Burr Size ◽  
Machined Parts ◽  
Edge Finishing ◽  
Selection Of

Machining burrs are formed at all machined workpiece edges. One useful solution to decrease machining time and cost, in particular for milling parts, is to generate machined parts edges with minimum burr. This article proposes burr edge occupancy ηs as an index to evaluate deburring difficulty and, consequently, adequate selection of suitable deburring methods. Initially the sensitivity of ηs to cutting parameters must be evaluated. We investigated the main governing factors on ηs when slot milling two types of aluminium alloys (from different families) that are used in the automotive and aerospace industries. The cutting parameters that led to edges with minimum ηs are presented. It was found that, unlike most burr size attributes, ηs is sensitive to variation of the cutting parameters used: cutting speed, family of material, and cutting tools. Lower ηs means less time and effort for deburring and edge finishing of machined parts. Furthermore, ηs measurement is more convenient than the procedures used to measure other burr size attributes, including burr height (bh) and burr thickness (bt).

scholarly journals Infrared Thermography for Investigation of Surface Quality in Dry Finish Turning of Ti6Al4V

Metals ◽  
2022 ◽  
Vol 12 (1) ◽  
pp. 154
Author(s):  
Manuela De Maddis ◽  
Vincenzo Lunetto ◽  
Valentino Razza ◽  
Pasquale Russo Spena
Keyword(s):  
Surface Roughness ◽  
Infrared Thermography ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Finish Turning ◽  
Machined Parts ◽  
Cutting Operation ◽  
Selection Of

The machining of titanium alloys always raises issues because of their peculiar chemical and physical characteristics as compared to traditional steel or aluminum alloys. A proper selection of parameters and their monitoring during the cutting operation makes it possible to minimize the surface roughness and cutting force. In this experimental study, infrared thermography was used as a control parameter of the surface roughness of Ti6A4V in dry finish turning. An analysis of variance was carried out to determine the effect of the main cutting parameters (cutting speed and feed rate) on the surface roughness and cutting temperature. In the examined range of the machining parameters, cutting speed and feed were found to have a primary effect on the surface roughness of the machined parts. Cutting speed also significantly affected the temperature of the cutting region, while feed was of second order. Higher cutting speeds and intermediate feed values gave the best surface roughness. A regression analysis defined some models to relate the cutting temperature and surface roughness to the machining parameters. Infrared thermography demonstrated that the cutting temperature could be related to roughness.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

Analysis of tool vibration and surface roughness during turning process of tempered steel samples using Taguchi method

2021 ◽  
pp. 095440892110019
Author(s):  
Menderes Kam ◽  
Mustafa Demirtaş
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Turning Process ◽  
Machining Time ◽  
Tool Vibration ◽  
Control Factors ◽  
Tempered Steel

This study analyzed the tool vibration (Vib) and surface roughness (Ra) during turning of AISI 4340 (34CrNiMo6) tempered steel samples using Taguchi Method. In this context, Taguchi design L18 (21 × 32) was used to analyze the experimental results. The vibration amplitude values from cutting tools were recorded for different machining parameters, control factors; two different sample hardness (46 and 53 HRc), three different cutting speeds (180, 220, 260 m.min−1), and feed rates (0.08, 0.14, 0.20 mm.rev−1) were selected. The machining parameters giving optimum Vib and Ra values were determined. Regression analysis is applied to predict values of Vib and Ra. Analysis of variance was used to determine the effects of machining parameters on the Vib and Ra values. The most important machining parameters were found to be the feed rate, sample hardness, and cutting speed for Vib and Ra, respectively. The lowest Vib and Ra values were obtained in 46 HRc sample as 0.0022 gRMS and 0.255 µm, respectively. The surface quality can be improved by reducing the sources of vibration by using appropriate machining parameters. As a result, there is a significant relationship between Ra and Vib. The lower Ra values were found during turning process of tempered steel samples according to the literature studies. It is suggested that the process can be preferred as an alternative process to grinding process due to lower cost and machining time. In application of the turning of experiment samples by ceramic cutting tool, a substantial technological and economical benefit has been observed.

Process Planning Strategies to Reduce Energy Consumption in Machining

2018 ◽  
Author(s):  
Arun Unnikrishnan ◽  
P. V. M. Rao
Keyword(s):  
Energy Consumption ◽  
Process Planning ◽  
High Performance ◽  
Cutting Parameters ◽  
High Energy ◽  
Point Of View ◽  
Energy Estimation ◽  
Tool Paths ◽  
Machined Parts ◽  
Selection Of

Continuous need to increase productivity and reliability in machining has led to high-performance machines that are often characterized by high energy demands. As a result, energy minimization is identified as one of the key goals in machining. With the availability of improved predictive models for energy estimation in machining, energy-conscious process planning for machining is now possible. The present work focuses on the assessment of process plans of machined parts from energy consumption point of view. An experimentally validated model for energy estimation is first presented. Using this model two important process planning variables on energy consumption in machining has been studied. Firstly selection of tool paths including curvilinear tool paths has been considered from energy consumption point of view. Secondly, strategies for the selection of cutting parameters for roughing, semi-finishing and finishing from energy consumption perspective are discussed.

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.

scholarly journals STUDY OF THE INFLUENCE OF CUTTING FLUID AMOUNT IN STEEL TURNING OF AISI 52100

2020 ◽  
Vol 5 (7) ◽  
pp. 49-56
Author(s):  
Ítalo de Abreu Gonçalves ◽  
Leonardo Leite ◽  
Tarcísio G. De Brito ◽  
Emerson J. De Paiva ◽  
Carlos H. De Oliveira ◽  
...  
Keyword(s):  
Cutting Tools ◽  
Roughness Parameter ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Machined Surface ◽  
Aisi 52100 ◽  
Machined Parts ◽  
Steel Turning ◽  
Good Productivity

The steel turning AISI 52100 has been gaining prominence in industry in recent years, as it allows machined parts to have better quality without the need for furthers processes. However, to ensure the final product quality, it is important that the turning for machining procedure is well planned and prepared, so that the cutting tools have their wear minimized in the process, while putting good productivity rates and zero occurrences of reworked parts. Thus, this article will study the quality of the machined surface in the turning process using interchangeable PCBN inserts. The aim is to identify the optimal combination of the input parameters that are cutting speed (Vc), feed (f) and machining depth (ap). The response measured is the roughness parameter Ra, under the influence of cutting fluid and tool wear.

scholarly journals Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Harun Gokce
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Taguchi Method ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Tool Wear ◽  
Wide Range

Stainless steels with unique corrosion resistance are used in applications with a wide range of fields, especially in the medical, food, and chemical sectors, to maritime and nuclear power plants. The low heat conduction coefficient and the high mechanical properties make the workability of stainless steel materials difficult and cause these materials to be in the class of hard-to-process materials. In this study, suitable cutting tools and cutting parameters were determined by the Taguchi method taking surface roughness and cutting tool wear into milling of Custom 450 martensitic stainless steel. Four different carbide cutting tools, with 40, 80, 120, and 160 m/min cutting speeds and 0.05, 0.1, 0.15, and 0.2 mm/rev feed rates, were selected as cutting parameters for the experiments. Surface roughness values and cutting tool wear amount were determined as a result of the empirical studies. ANOVA was performed to determine the significance levels of the cutting parameters on the measured values. According to ANOVA, while the most effective cutting parameter on surface roughness was the feed rate (% 50.38), the cutting speed (% 81.15) for tool wear was calculated.

scholarly journals Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 927 ◽  
Author(s):  
Irene Del Sol ◽  
Asuncion Rivero ◽  
Antonio J. Gamez
Keyword(s):  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Thin Plates ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Final Thickness ◽  
Machined Parts ◽  
Chemical Milling ◽  
Skin Panels

Nowadays, the industry looks for sustainable processes to ensure a more environmentally friendly production. For that reason, more and more aeronautical companies are replacing chemical milling in the manufacture of skin panels and thin plates components. This is a challenging operation that requires meeting tight dimensional tolerances and differs from a rigid body machining due to the low stiffness of the part. In order to fill the gap of literature research on this field, this work proposes an experimental study of the effect of the depth of cut, the feed rate and the cutting speed on the quality characteristics of the machined parts and on the cutting forces produced during the process. Whereas surface roughness values meet the specifications for all the machining conditions, an appropriate cutting parameters selection is likely to lead to a reduction of the final thickness deviation by up to 40% and the average cutting forces by up to a 20%, which consequently eases the clamping system and reduces machine consumption. Finally, an experimental model to control the process quality based on monitoring the machine power consumption is proposed.

Experimental Prediction Model for Roughness in the Turning of UNS A97075 Alloys

2014 ◽  
Vol 797 ◽  
pp. 59-64 ◽  
Author(s):  
F.J. Trujillo ◽  
Mariano Marcos Bárcena ◽  
L. Sevilla
Keyword(s):  
Prediction Model ◽  
Cutting Speed ◽  
High Sensitivity ◽  
Cutting Parameters ◽  
The Other ◽  
Sensitivity To Change ◽  
Average Roughness ◽  
Machining Time ◽  
Experimental Prediction

In this work, a study of the influence of the cutting parameters on superficial quality of dry-turned UNS A97075 test bars has been carried out. The superficial quality has been evaluated trough the arithmetical average roughness,Ra. In addition, the evolution ofRaas a function of the axial machining length has been analyzed. In order to do this, a set of machining tests has been performed under different combinations of cutting speed and feed. The experimental data have revealed a high sensitivity to change ofRawith feed, whereas this sensitivity is lower with cutting speed. On the other hand, a tendency to decreaseRawith the axial machining length has been found. Finally, an experimental prediction model forRahas been developed. This model allows predicting the value ofRaas a function of the cutting parameters and the machining time.

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