Effect of cutting parameters on surface quality during diamond turning of micro-prism array

2016 ◽  
Vol 231 (3) ◽  
pp. 555-561 ◽  
Author(s):  
Dongxu Wu ◽  
Peng Zhang ◽  
Huiming Wang ◽  
Zheng Qiao ◽  
Bo Wang
Keyword(s):  
Surface Quality ◽  
Surface Defects ◽  
Cutting Speed ◽  
Side Surface ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Dominant Factor ◽  
Controlled Cooling ◽  
Cutting Depth ◽  
Ultra Precision

In order to achieve the high-quality roller mold used in roll-to-roll fabrication of optical prism films, this article investigates the effects of cutting parameters on surface quality during diamond turning of micro-prism array, and some cutting experiments are carried out on home-made ultra-precision drum roll lathe. The surface defects such as micro pits and burrs are presented and discussed at different cutting parameters. The experimental results show that, when the cutting depth is more than 4 µm, the plowing force becomes the dominant factor to remove material, which may cause the generation of micro pits on the side surface of micro prism. During multiple-step diamond turning of micro-prism array, the final cutting depth is recommended not to exceed 2 µm; in this case, there is no generation of micro pits and the height of burr is less than 13.6 nm. Moreover, the well-controlled cooling and chip evacuation can effectively improve the influence of cutting speed on surface quality. Finally, micro-prism array with pitch of 40 µm is successfully machined without apparent surface defects.

Study on Surface Roughness of Milling In-Situ TiB2 Particle Reinforced Al Matrix Composites

2019 ◽  
Author(s):  
Xiao-fen Liu ◽  
Wen-hu Wang ◽  
Rui-song Jiang ◽  
Yi-feng Xiong ◽  
Kun-yang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Matrix Composites ◽  
Cutting Depth

Abstract The current state of surface roughness focuses on the 2D roughness. However, there are shortcomings in evaluating surface quality of particle reinforced metal matrix composites using 2D roughness due to the fact that the measuring direction has a vital impact on the 2D roughness value. It is therefore of great importance and significance to develop a proper criterion for measuring and evaluating the surface roughness of cutting particle reinforced metal matrix composites. In this paper, an experimental investigation was performed on the effect of cutting parameters on the surface roughness in cutting in-situ TiB2/7050Al MMCs. The 2D roughness Ra, 3D roughness Sa and Sq were comparatively studied for evaluating the machined surface quality of in-situ TiB2/7050Al MMCs. The influence of cutting parameters on the surface roughness was also analyzed. The big difference between roughness Ra measured along cutting and feed directions showed the great impact of measuring direction. Besides, surface defects such as pits, grooves, protuberances and voids were observed, which would influence 2D roughness value greatly, indicating that 3D roughness was more suitable for evaluating surface quality of cutting in-situ TiB2/7050Al MMCs. The cutting depth and feed rate were found to have the highest influence on 3D roughness while the effect of cutting speed was minimal. With increasing feed rate, cutting depth or width, the 3D roughness increased accordingly. But it decreased as cutting speed increased.

Influence of Tool Geometry and Machining Parameters on the Surface Quality and the Effect of Surface Quality on Compressive Strength of Carbon Fibre Reinforced Plastic

2013 ◽  
Vol 763 ◽  
pp. 107-125 ◽  
Author(s):  
Madjid Haddad ◽  
Redouane Zitoune ◽  
Florent Eyma ◽  
Bruno Castanié
Keyword(s):  
Surface Quality ◽  
Surface Defects ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Cutting Condition ◽  
Machining Parameters ◽  
High Cutting Speed ◽  
Carbon Fibre Reinforced Plastic

In this chapter the influence of tool geometry and cutting conditions on cutting forces, surface defects and the percetage of dust generated durring trimming and reaching the pulmonary alveoli is investigated. The surface defects were analysed using a scanning electron microscope and diferent surface roughness measurement devices. It was observed that these leters were highly depend on the cutting condition and the tool geometry, and more important that the effect of cutting parameters can be completely diferent from a tool to an other or even when considering different ranges of cutting parameters (standard cutting speed and high cutting speed). The compressive strenght after machining is also investigated. It is observed that whatever tool geometry, cutting conditions, surface roughnesses (defects) are, the response still the same for all the composite samples except for those machined at cutting temperatures higher than the glass fiber transition.

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.

An Experimental Study of Cutting Force on Large Cutting Depth Turning Titanium Alloy with CBN Tool

2014 ◽  
Vol 800-801 ◽  
pp. 237-240
Author(s):  
Li Fu Xu ◽  
Ze Liang Wang ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Cbn Tool ◽  
Cutting Experiment ◽  
Rough Turning

In this paper, the cutting experiment was used to study the influence of various cutting parameters on cutting force when rough turning titanium alloy (TC4) with the whole CBN tool. The results indicate that among the cutting speed, feed rate and cutting depth, the influence of the cutting depth is the most significant on cutting force; the next is the feed rate and the cutting speed is at least.

Nano-Process of SiC Ceramics by Molecular Simulation

2011 ◽  
Vol 189-193 ◽  
pp. 3097-3102 ◽  
Author(s):  
Guo Zhi Liu ◽  
Ke Zhang ◽  
Yu Lan Tang ◽  
Hong Sun ◽  
Hai Yan Gao
Keyword(s):  
Kinetic Energy ◽  
Molecular Simulation ◽  
Molecular Model ◽  
Cutting Speed ◽  
Chemical Properties ◽  
Cutting Depth ◽  
Sic Ceramics ◽  
Ultra Precision ◽  
Physical And Chemical ◽  
And Chemical Properties

SiC ceramics have been widely used in a variety of areas due to the excellent physical and chemical properties. However, the process of SiC ceramics is difficult and high-cost, molecular simulation is an effective and feasible method to study the nano-process of SiC ceramics. In this paper, a molecular model is presented to simulate the stress and energy in the nano-cutting of SiC ceramics. The influences of the cutting depth and cutting speed on the kinetic energy and potential are analyzed. The results show that potential energy increases with the decrease of the cutting depth. Kinetic energy increases with the increase of the cutting speed. The results are very helpful for improvement the level of ultra-precision processing and nano-processing of brittle ceramics.

Effects of Cutting Parameters on Residual Stresses in High-Speed Milling of Ti-17

2013 ◽  
Vol 834-836 ◽  
pp. 861-865 ◽  
Author(s):  
Yong Shou Liang ◽  
Jun Xue Ren ◽  
Yuan Feng Luo ◽  
Ding Hua Zhang
Keyword(s):  
Experimental Study ◽  
Residual Stresses ◽  
High Speed ◽  
Experimental Parameter ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Single Factor ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Parameter Ranges

An experimental study was conducted to determine cutting parameters of high-speed milling of Ti-17 according to their effects on residual stresses. First, three groups of single factor experiments were carried out to reveal the effects of cutting parameters on residual stresses. Then sensitivity models were established to evaluate the influence degrees of cutting parameters on residual stresses. After that, three criteria were proposed to determine cutting parameters from experimental parameter ranges. In the experiments, the cutting parameter ranges are recommended as [371.8, 406.8] m/min, [0.363, 0.412] mm and [0, 0.018] mm/z for cutting speed, cutting depth and feed per tooth, respectively.

A study of conditions of surface defects formation when bar rolling at a bar and wire mill and methods of their elimination

2021 ◽  
Vol 77 (10) ◽  
pp. 1053-1059
Author(s):  
I. A. Pankovets ◽  
V. I. Voznaya ◽  
A. V. Vedeneev ◽  
M. N. Vereshchagin
Keyword(s):  
Temperature Gradient ◽  
Surface Quality ◽  
Surface Defects ◽  
Temperature Deformation ◽  
Controlled Cooling ◽  
Wire Mill ◽  
The Core ◽  
Local Overheating ◽  
Rolling Production

Quality of long products surface is an important consumer property of it. In the process of measures elaboration aimed at the increase of long products surface quality, in particular of bars produced at the mill 370/150 of ОJSC “BMZ – managing company of holding “BMK”, studies were accomplished by metallographic laboratory. It was established that defects being revealed at the bars finishing, don’t relate to the quality of continuously casted billet (CCB), but formed in the process of deformation. Studies of the mechanism of surface defects formation on hot-rolled bar of rolling origin – deformation fissure and wrinkles were carried out. Results of numerical simulation of rolling in roughing group of stands at various temperature-deformation parameters presented. Regularities of formation of surface defects on the bar in the finished product were revealed. It was shown that the reason of the surface defects of rolling origin – deformation fissure and wrinkles was a high temperature gradient between the core and the surface of billet, originated from local overheating of surface in the angles zone of CCB resulted in nonuniformity of drawing out of different layers of the billet being deformed. To eliminate the defects, minimum possible temperature gradient between the surface and the core of a billet by controlled rolls cooling should be provided. By calculation, the maximum permissible temperature of the working surface of the rolls of the rough group of stands was established, and empirically the actual temperatures of the rolls with the current production technology, as well as the temperature of the rolls support bearings seats of the rolls were measured. The technical and technological possibilities for improving of rolling technology on a bar and wire mill in order to improve the surface quality of rolled bars were demonstrated. The existing technology was adjusted and new technological modes of rolling with controlled cooling of the rolls were established, which made it possible to significantly reduce the rejection of the finished product due to defects in rolling production. A device was proposed for the roughing group of stands, which enables to minimize the ingress of coolant onto the bar rolled.

Modelling of Electrostatic Charge in Ultra-High Precision Diamond Turning of Contact Lens Polymer

2019 ◽  
Vol 298 ◽  
pp. 135-140
Author(s):  
Muhammad Mukhtar Liman ◽  
Khaled Abou El Hossein
Keyword(s):  
High Precision ◽  
Contact Lens ◽  
Feed Rate ◽  
Contact Lenses ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Electrostatic Charge ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Electrostatic Charges

The electrostatic charges encountered by a cutting tool when turning advanced contact lenses are important as they reflect the quality and condition of the tool, machine, fixture, and sometimes even the surface finished which is responsible for tool wear and poor surface quality. This study investigates the influence of cutting parameters namely cutting speed, feed rate and depth of cut on electrostatic charge (ESC) which play the leading role in determining the machine economics and quality of machining contact lens polymers. An electrostatic charge model based on response surface statistical method is developed for reliably predicting the values of static charging based on its relationship to cutting parameters in ultra-high precision diamond turning of contact lenses. It is clearly seen that all the model terms are significant with cutting speed having the highest degree of significance followed by feed rate and the interaction of speed and feed. However, depth of cut has the lowest degree of significance on the electrostatics charge.

Effects of Machining Parameters on Surface Roughness when Ultra-High Precision Diamond Turning RSA443 Optical Aluminum

2019 ◽  
Vol 287 ◽  
pp. 30-34
Author(s):  
Zwelinzima Mkoko ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Silicon Content ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Turning Process ◽  
Optical Components ◽  
Box Behnken Design ◽  
Factors Influencing

In the globally competitive environment, surface roughness and finer tolerances are becoming stringent and certainly most critical for optical components. The aim of this study is to determine the effects of diamond turning process parameters on surface finish when diamond turning RSA 443 alloy having high silicon content. This alloy is a new grade of aluminum that has a potential to be used for production of various optical components. The experiments were conducted based on the Box-Behnken design with three diamond-turning parameters varied at three levels. A mathematical regression model was developed for predicting surface roughness. Further, the analysis of variance was used to analyze the influence of cutting parameters and their interaction in machining. The developed prediction model reveals that cutting speed and feed rate are the most dominant diamond turning factors influencing surface roughness.

Analysis and Experimental Design of Damper System and Cutting Parameters of CNC Router

2019 ◽  
Vol 894 ◽  
pp. 82-89
Author(s):  
Van Thuy Tran ◽  
Huu Loc Nguyen ◽  
Hoang Hiep Nguyen
Keyword(s):  
Dynamic Behavior ◽  
Feed Rate ◽  
Vibration Amplitude ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cnc Machine ◽  
Cutting Depth ◽  
System Effect ◽  
Comparison Results ◽  
Spindle Vibration

. An understanding of the dynamic characteristics of a CNC machine is a vital element in the control of the machine which has a direct effect on the machining precision. The ways in which energy is dissipated, such as friction and damping, have a significant effect on the dynamic behavior and spindle vibration of a CNC machine. The paper presents kinetic analysis of the CNC machine damper system, effect of the damper and the cutting parameters such as feed rate, cutting speed, and cutting depth on the dynamic behavior and spindle vibration of a CNC machine. Experimental results have established a second-order regression equation that demonstrates the effect of three parameters such as feed rate, cutting speed, and cutting depth on the vibration amplitude of the spindle. In addition, the comparison results show that the spindle head vibration amplitude of the machine using the damper is smaller than the spindle head vibration amplitude of the machine not using the damper.

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