Stability-based selection of cutting parameters to increase material removal rate in high-speed machining process

2015 ◽  
Vol 230 (2) ◽  
pp. 227-240 ◽  
Author(s):  
Hongrui Cao ◽  
Kai Zhou ◽  
Xuefeng Chen
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Machining Process ◽  
High Speed Machining ◽  
Selection Of

Reduction of Vibrations due to Unbalance with Anti-Vibration Clearance Angle in High Speed Milling

2016 ◽  
Vol 836-837 ◽  
pp. 161-167
Author(s):  
Anna Thouvenin ◽  
Xin Li ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Machining Process ◽  
High Speed Machining ◽  
Machining Processes ◽  
High Speed Milling ◽  
Clearance Angle ◽  
Fast Solution ◽  
Considerable Problem

High speed milling is one of the most commonly used machining processes in many fields of the industry. It is regarded as a simple and fast solution to achieve a high material removal rate, which allows an important production of parts. Unbalance is a problem in any machining process but becomes a considerable problem when reaching high speed machining. The vibrations due to an unbalanced tool or tool holder can result in a poor surface quality and a damaged tool. The damping of the vibrations can be achieved with a specially designed tool showing an anti-vibration clearance angle. This paper shows the influence of the anti-vibration clearance angle by a computational model and a set of experiments to see if it can reduce or suppress the vibrations due to unbalance in high speed milling.

scholarly journals Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3749 ◽  
Author(s):  
Adel T. Abbas ◽  
Neeraj Sharma ◽  
Saqib Anwar ◽  
Faraz H. Hashmi ◽  
Muhammad Jamil ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

Effects of Non-Electrical Parameters on Material Removal Rate of High-Speed Small Hole EDM Drilling

2008 ◽  
Vol 53-54 ◽  
pp. 403-407 ◽  
Author(s):  
Ming Rang Cao ◽  
Y.Q. Wang ◽  
Shi Chun Yang ◽  
Sheng Qiang Yang ◽  
Wen Hui Li
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Small Hole ◽  
Manufacturing Processes ◽  
Electrical Parameters ◽  
Drilling System ◽  
Edm Drilling ◽  
Selection Of

The selection of manufacturing conditions is very important in manufacturing processes as these ones determine the material removal rate (MRR) of the so-obtained parts. So in this paper, based on the brief introduction of the experimental principle and the high-speed small hole EDM drilling system, effects of non-electrical parameters on MRR are discussed in detail. The relationships between MRR and these factors are also analyzed. The conclusion can provide an important reference for production in practice.

scholarly journals ANALISIS KONDISI PEMESINAN IDEAL UNTUK MENCAPAI UMUR OPTIMAL DARI ROUTING CUTTER DIAMETER 32 mm DAN SLOT DRILL 25 mm PADA MESIN CNC DMC 210 U

2018 ◽  
Vol 14 (2) ◽  
Author(s):  
Deni Fajar Fitriyana ◽  
Sulardjaka Sulardjaka ◽  
Norman Iskandar ◽  
Pratama Eka P. S ◽  
Muhammad Dzulfikar
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Machining

Teknologi pemesinan kecepatan tinggi (high speed machining) merupakan salah satu alternatif untuk meningkatkan produktivitas disuatu proses pemesinan. Mesin kecepatan tinggi yang digunakan di PT X adalah mesin CNC DMG Mori DMC 210U yang merupakan mesin CNC 5 axis. Namun dalam aplikasinya, mesin DMG Mori DMC 210 U ini masih belum dapat bekerja secara maksimal. Salah satu penyebabnya adalah umur pahat yang belum optimal. Tujuan dari penelitian ini adalah untuk mengetahui kondisi pemesinan yang sesuai untuk pahat routing cutter (T02) dan pahat slot drill (T31) agar mencapai umur pahat yang optimal berdasarkan data perbandingan nilai teoritis dengan nilai aktual pada mesin CNC DMC 210U. Hasil dari penelitian ini menunjukkan bahwa pada pahat routing cutter (T02), umur optimalnya adalah 300 menit sedangkan umur aktualnya adalah 196,41 menit. Pada pahat slot drill (T31), umur optimalnya adalah 350 menit sedangkan umur aktualnya adalah 330,48 menit. Maka dari itu perlu dilakukan penyesuaian kondisi pemesinan agar umur pahat menjadi optimal, dimana kondisi pemesinan yang sesuai untuk pahat routing cutter (T02) yaitu : kecepatan potong (Vc)=1225,31 mm/min, kecepatan spindle (N)= 12200 rpm , feed rate (f)=3660 mm/min , material removal rate= 351,36 cc/min, sedangkan untuk pahat slot drill (T31) yaitu : kecepatan potong (Vc)=1245,14 mm/min , kecepatan spindle (N)= 15862 rpm , feed rate (f)=4758,6 mm/min , material removal rate= 237,93 cc/min .Kata kunci: high speed machining, routing cutter, slot drill, umur pahat

Optimization of Process Parameters Using Taguchi Coupled Genetic Algorithm

2017 ◽  
pp. 67-93 ◽  
Author(s):  
Supriyo Roy ◽  
J. Paulo Davim ◽  
Kaushik Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Nsga Ii ◽  
Optimization Of Process Parameters ◽  
Cnc Lathe

In the era of mass manufacturing, Material removal rate and Surface Roughness are of primary concern even in manufacturing using contemporary CNC machines. In this work, L27 Orthogonal Array of Taguchi method is selected for three parameters (Depth of cut, Feed and Speed) with three different levels to optimize the turning parameters for Material Removal Rate and Surface Roughness on an EMCO Concept Turn 105 CNC lathe for machining SAE 1020 material with carbide tool. The MRR and SR are observed as the objective to develop the combination of optimum cutting parameters. The objectives were optimized using Taguchi, Grey Taguchi and NSGA-II. The result from these techniques was compared to identify the optimal values of cutting parameters for maximum MRR, minimum SR and best combination of both. This study also produced a predictive equation for determining MRR and SR for a given set of parameters outside the considered values. Thus, with the proposed optimal parameters it is possible to increase the efficiency of machining process and decrease production cost in CNC Lathe.

scholarly journals Optimization of Input Parameters with Carbide Inserts and HSS Tool on CNC Turning of EN19 Steel

2019 ◽  
Vol 8 (12) ◽  
pp. 3869-3875
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Cutting Tool ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Process ◽  
Steel Tool ◽  
Carbide Inserts

This paper deals with the experimental investigation and testing on a single point cutting tool with carbide inserts and high speed steel tool. Cutting tool has to be strong enough to withstand the wear resistance. It is to be proved that carbide inserts have better performance than HSS tools on machining operation. Components with higher surface quality, higher material removal rate in less time and lower tool wear is only possible by carbide insert tools. The tool material selected for this experiment are cemented & tungsten carbide inserts along with high speed steel tool on machining medium carbon steel EN19. The complete machining process is performed on cnc lathe machine Hence the intention of this project is to minimize the surface roughness, tool wear, machining time and increasing the material removal rate. Taguchi’s L9 orthogonal array is favor for this investigation work. The result obtained in this project can be further used for optimizing the process parameters there by optimized results helps the operator to improve the quality as well as production rate.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

scholarly journals A surrogate-assisted optimization approach for multi-response end milling of aluminum alloy AA3105

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2419-2439
Author(s):  
Tamal Ghosh ◽  
Yi Wang ◽  
Kristian Martinsen ◽  
Kesheng Wang
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Cutting Forces ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Data Driven ◽  
Optimal Cutting Parameters

Abstract Optimization of the end milling process is a combinatorial task due to the involvement of a large number of process variables and performance characteristics. Process-specific numerical models or mathematical functions are required for the evaluation of parametric combinations in order to improve the quality of the machined parts and machining time. This problem could be categorized as the offline data-driven optimization problem. For such problems, the surrogate or predictive models are useful, which could be employed to approximate the objective functions for the optimization algorithms. This paper presents a data-driven surrogate-assisted optimizer to model the end mill cutting of aluminum alloy on a desktop milling machine. To facilitate that, material removal rate (MRR), surface roughness (Ra), and cutting forces are considered as the functions of tool diameter, spindle speed, feed rate, and depth of cut. The principal methodology is developed using a Bayesian regularized neural network (surrogate) and a beetle antennae search algorithm (optimizer) to perform the process optimization. The relationships among the process responses are studied using Kohonen’s self-organizing map. The proposed methodology is successfully compared with three different optimization techniques and shown to outperform them with improvements of 40.98% for MRR and 10.56% for Ra. The proposed surrogate-assisted optimization method is prompt and efficient in handling the offline machining data. Finally, the validation has been done using the experimental end milling cutting carried out on aluminum alloy to measure the surface roughness, material removal rate, and cutting forces using dynamometer for the optimal cutting parameters on desktop milling center. From the estimated surface roughness value of 0.4651 μm, the optimal cutting parameters have given a maximum material removal rate of 44.027 mm3/s with less amplitude of cutting force on the workpiece. The obtained test results show that more optimal surface quality and material removal can be achieved with the optimal set of parameters.

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