The Effect of Machining Parameters on the Cutting Forces, Tool Wear, and Machined Surface Roughness of Metal Matrix Nano Composite Material

The article compares two cutting edge preparation methods and their influence on the machined surface roughness of the difficult to cut nickel alloy Inconel 718 and the tool wear of cutting inserts made of cemented carbide. The manufacturing and preparation process of cutting inserts used in the experiment were made by Dormer Pramet. The preparation methods used in the experiment were drag finishing and brushing. Cutting parameters did not change during the whole turning process to maintain the same conditions in each step of the process and were determined based on tests for a semi-finishing operation of the turning process. To obtain durability of 25 to 30 minutes with controlled development of the tool wear the cutting parameters were determined with cooperation with the cutting inserts manufacturer.

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Machinability Investigation in Dry Turning of Ti–6al–4v With a Novel Tib2-based Cermet Tool Using Response Surface Methodology

10.21203/rs.3.rs-28787/v1 ◽

2020 ◽

Author(s):

Yikun Yuan ◽

Wenbin Ji ◽

Shijie Dai ◽

Huibo Zhang

Keyword(s):

Surface Roughness ◽

Cutting Temperature ◽

Cutting Parameters ◽

Machining Parameters ◽

Processing Efficiency ◽

Machined Surface ◽

Dry Turning ◽

Diffusion Wear ◽

Cutting Length ◽

Machined Surface Roughness

Abstract To ensure accuracy and improve the processing efficiency of Ti–6Al–4V alloys, dry turning experiment of Ti–6Al–4V was carried out using a novel TiB2-based cermet tool. The tool was reinforced by nanoscale VC additive and exhibited excellent hardness and fracture toughness.Response Surface Methodology (RSM) was used in the experiment to verify andevaluatethe cutting performance ofTiB2-based cermet tool.The cutting forces and machined surface roughness (Ra) were selected as the optimization objective. An analysis of variance (ANOVA) was used to find out the effective machining parameters on response factorsand demonstrate correctness of the models. It was found that theeffective factor on surface roughness was feed rate, while cutting depth significantly affected cutting forces.And the confirmation experiments showedthat the predicted values were in good agreement with experimental values. Based on the optimized cutting parameters, the tool life was measured and tool wear mechanismwasinvestigated. When the vc, apandfwere 100 mm/min, 0.16 mm, 0.1 mm/rev respectively for Ra optimization, the cutting length and tool lifecould reach to 3233 m and 29.4 min, respectively, due to the excellentwear resistance and stability of TiB2-based cermet tool at high cutting temperature. In this case, the main wear mechanism was adhesive wear and diffusion wear.

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Experimental Investigation of Cutting Parameters Effects on the Surface Roughness and Tools Wear during the Drilling of Fiber Reinforced Composite Materials

Mehran University Research Journal of Engineering and Technology ◽

10.22581/muet1982.1903.15 ◽

2019 ◽

Vol 38 (3) ◽

pp. 717-728 ◽

Cited By ~ 1

Keyword(s):

Surface Roughness ◽

Composite Material ◽

Tool Wear ◽

Cutting Speed ◽

Fiber Reinforced Polymer ◽

Machining Parameters ◽

Fiber Reinforced ◽

Minimum Surface ◽

Reinforced Polymer ◽

Tools Wear

Optimization of the drilling parameters of the composite material is the key objective of this research, enhancing the surface roughness and minimizing the tool wear. In contrary to the other research, optimizing the machining parameters for a specific composite material for the mass productions, machining parameters are optimized for GFRP (Glass Fiber Reinforced Polymer), CFRP (Carbon Fiber Reinforced Polymer) and KFRP (Kevlar Fiber Reinforced Polymer) for the job shop production. In this research, the machining parameters are optimized for the enhanced surface roughness and minimum tool wear by varying the three types of composite material and three levels of the cutting speed. Nine experiments were performed, which were repeated twice in random manner to eliminate the biasness of the results. In these experiments, PVD (Physical Vapor Deposition) coated carbide inserts are used with the same geometry. Seventeen holes were machined in a single experiment, which surface roughness is measured by cutting the composite plate from middle of the hole and using the Countermatic surface roughness meter at different locations. Average surface roughness is determining for each set of varying parameters and plotted to observe the set of parameters for the minimum surface roughness. It has been observed that the minimum surface roughness are observed at; 1500 rpm in GFRP, 2000 rpm in CFRP and at 2500 rpm in KFRP. Finally, the wear patterns are also observed on the drill inserts using SEM (Scanning Electron Microscope) and it has been found that no prominent wear has been observed in the drill inserts, whereas, prominent depletion of coating are found at the higher cutting speed.

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Roughness of Metal Surface After Finishing Using Ceramic Brush Tools

Advances in Materials Science ◽

10.1515/adms-2017-0024 ◽

2018 ◽

Vol 18 (1) ◽

pp. 20-27 ◽

Cited By ~ 7

Author(s):

T. Salacinski ◽

T. Chmielewski ◽

M. Winiarski ◽

R. Cacko ◽

R. Świercz

Keyword(s):

Surface Roughness ◽

Inconel 718 ◽

Construction Materials ◽

Industrial Applications ◽

Machining Parameters ◽

Machined Surface ◽

Ceramic Tools ◽

Metal Parts ◽

Internal Surfaces ◽

Machined Surface Roughness

AbstractThe paper describes processes of metal parts edges deburring and surface of metal samples polishing with ceramic tools based on fibre aluminium oxide. It presents the construction of basic types of tools and their practical industrial applications, and evaluates the influence of machining parameters on surface roughness. An important advantage of the used tools is the possibility of deburring and machining of external flat and shaped surfaces as well as internal surfaces and even deep drilled holes. These tools can be practically used for machining all construction materials. The results of machining of selected engineering materials, such as aluminium 5052 and 2017A, Inconel 718, non-alloy steel, in various variants of machining parameters are presented. The influence of machining parameters on machined surface roughness was described.

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The Effect of the Cutting Parameters on the Machined Surface Roughness

Solid State Phenomena ◽

10.4028/www.scientific.net/ssp.260.219 ◽

2017 ◽

Vol 260 ◽

pp. 219-226 ◽

Cited By ~ 1

Author(s):

Viktors Gutakovskis ◽

Eriks Gerins ◽

Janis Rudzitis ◽

Artis Kromanis

Keyword(s):

Surface Roughness ◽

Metal Cutting ◽

Cutting Tool ◽

Cutting Tools ◽

Cutting Parameters ◽

Cutting Process ◽

Tool Geometry ◽

Machining Parameters ◽

Machined Surface ◽

Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

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Machinability, Modelling and Statistical Analysis of In-Situ Al–Si–TiB2 Composites

Journal of Composites Science ◽

10.3390/jcs3010028 ◽

2019 ◽

Vol 3 (1) ◽

pp. 28 ◽

Cited By ~ 4

Author(s):

Jimmy Karloopia ◽

Shaik Mozammil ◽

Pradeep Jha

Keyword(s):

Surface Roughness ◽

Statistical Analysis ◽

Tool Wear ◽

Cutting Forces ◽

Elevated Temperatures ◽

Optimization Technique ◽

Cutting Speed ◽

Depth Of Cut ◽

Machining Parameters ◽

Conventional Machining

Aluminum and its alloys have numerous applications in manufacturing, aerospace, and automotive industries. At elevated temperatures, they start to fail in fulfilling their roles and functions. Aluminum-based metal matrix composites (MMCs) are good alternatives for metal and alloys due to their excellent properties. However, the conventional machining of several composites shows complications for a number of reasons, such as high tool wear, poor surface roughness, high machining cost, cutting forces, etc. Numerous studies have already been conducted on the machinability of various MMCs, but the machinability of Al–Si–TiB2 composite is still not well studied. It is of utmost importance that several process parameters of conventional machining are precisely controlled as well as optimized. In this study an effort was made to optimize input parameters such as cutting speed, depth of cut, and feed to obtain well-finished final components with the minimum cutting force and tool wear. These progressions are involved with multiple response characteristics, therefore the exploration of an appropriate multi-objective optimization technique was indeed essential. The performance characteristics of cutting forces and surface roughness were considered for optimization of the machining parameters. Analysis of variance (ANOVA) was employed for the optimization and statistical analysis.

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Study on Effect of Ultrasonic Vibration in Machining of Alumina Ceramic

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.516.311 ◽

2012 ◽

Vol 516 ◽

pp. 311-316 ◽

Cited By ~ 2

Author(s):

Kyung Hee Park ◽

Kyeong Tae Kim ◽

Yun Hyuck Hong ◽

Hon Jong Choi ◽

Young Jae Choi

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Ultrasonic Vibration ◽

Cutting Forces ◽

Cutting Temperature ◽

Cutting Speed ◽

Ultrasonic Machining ◽

Machining Performance ◽

Machined Surface ◽

Combination Technique

Ultrasonic machining can be applied for the machining of difficult-to-cut materials using ultrasonical oscillation in an axial direction on top of tool rotation, which can cause reduction of cutting temperature and tool wear. In this study, the experiments were performed on a DMG ULTRASONIC 20 linear machine tool using diamond tools in both conventional and ultrasonic vibration assisted machining. The machining performance was evaluated and compared for both cases in terms of cutting forces, machined surface roughness and tool wear. And the combination technique of 3D surface topography measurement and image processing was applied for the tool wear progress. Overall, the experimental results showed that ultrasonic machining had less tool wear and lower cutting forces at low cutting speed compared to conventional machining. Also surface roughness was slightly lower in ultrasonic machining than that without ultrasonic vibration.

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Forward and Inverse Relational Models between Machined Surface Roughness and Key Parameters of Machining Process

10.21203/rs.3.rs-300729/v1 ◽

2021 ◽

Author(s):

Ri Pan ◽

Ren Xingfei ◽

Zhenzhong Wang ◽

Dongju Chen ◽

Jinwei Fan

Keyword(s):

Surface Roughness ◽

Inverse Model ◽

Forward Model ◽

Machining Process ◽

Relational Model ◽

Universal Method ◽

Machining Parameters ◽

Machined Surface ◽

Average Deviation ◽

Machined Surface Roughness

Abstract The relational model between machined surface roughness (MSR) and the adopted key machining parameters (KMPs) significantly influences the predictability and controllability of the machining process; therefore, it has attracted considerable attention. However, two critical problems still persist in this field. First, although most existing studies focus on the prediction model for MSR (forward model), wherein the MSR is dependent on input KMPs values, the inverse model that can calculate the KMP based on input MSR value is equally important; however, the inverse model has not been investigated as extensively as the forward model. The second issue is that most of the existing forward models are mainly established based on mechanism analysis; however, due to the complexity of most machining processes, the accuracy and generality of the model are not optimal. Therefore, this paper proposes a universal method for mathematically establishing the inverse model of the relation between the MSR and KMP. Initially, based on the response surface methodology, orthogonal experiments were designed and conducted, and the results were used to establish the forward model between the MSR and KMP. Subsequently, by combining the forward model with a self-developed genetic algorithm-based multi-objective optimization algorithm, an establishing method for inverse model between MSR and KMPs was proposed. Finally, experiments were conducted to validate the developed models. The experimental results show that for the forward model, all the 10 experimental MSR values approach the MSR values predicted by the forward model, and the average deviation was only approximately 7%. Contrarily, for the inverse model, the average deviation was only approximately 7.64%. Both these results verify the accuracy and effectiveness of the proposed models. With this method, as long as the desired processing results and constraints are given, the process parameters can be accurately derived.

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Turning particulate metal matrix composites: Experimental study of the evolution of the cutting forces, tool wear and workpiece surface roughness with the cutting time

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/0954405011515433 ◽

2001 ◽

Vol 215 (3) ◽

pp. 371-376 ◽

Cited By ~ 31

Author(s):

J P Davim

Keyword(s):

Experimental Study ◽

Surface Roughness ◽

Tool Wear ◽

Metal Matrix Composites ◽

Cutting Forces ◽

Metal Matrix ◽

Matrix Composites ◽

Workpiece Surface ◽

Particulate Metal

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Ultraprecision Cutting of Nickel Plated Mold for X-Ray Mirror

International Journal of Automation Technology ◽

10.20965/ijat.2016.p0624 ◽

2016 ◽

Vol 10 (4) ◽

pp. 624-631 ◽

Cited By ~ 3

Author(s):

Hirofumi Suzuki ◽

◽

Mutsumi Okada ◽

Yuki Masuda ◽

Yoshiharu Namba ◽

...

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Electroless Nickel ◽

Cutting Conditions ◽

Machining Accuracy ◽

Machined Surface ◽

Form Accuracy ◽

X Ray ◽

Machined Surface Roughness ◽

Telescope Mirrors

To improve the machining preciseness of X-ray telescope mirrors for astronomical use, the molds of electroless nickel and electro nickel are diamond-turned, and the tool wear and machining accuracy are then quantitatively evaluated. The machined surface roughness is measured and discussed in terms of the effects of cutting conditions on the resulting quality. Finally, the actual nickel-plated molds of X-ray mirrors are test cut, and their form accuracy and surface roughness are measured and evaluated. These experiments reveal that a surface roughness of 0.5 nm Ra and a form accuracy of 0.1 μm P-V can be obtained under the optimized cutting conditions.

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