Modelling and simulation of surface topography machined by peripheral milling considering tool radial runout and axial drift

2019 ◽  
Vol 233 (12) ◽  
pp. 2227-2240 ◽  
Author(s):  
Hui-Qun Chen ◽  
Qing-Hui Wang
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Surface Finish ◽  
Dominant Frequency ◽  
Peripheral Milling ◽  
Stability Lobe Diagram ◽  
Vector Operation ◽  
Good Surface ◽  
Stability Lobe ◽  
Feed Mark

Based on the Z-map model of a workpiece and the dynamic cutting forces model of peripheral milling in which the regenerative effect of tool radial runout and axial drift are considered, a model for the prediction of surface topography in peripheral milling operations is presented. According to the stability lobe diagram obtained by the zero-order analytical method, the relationship between spindle speed and surface topography, the tool radial runout, and the axial drift following the chatter are studied. The results show that a stable cutting status but a poor surface finish is obtained at the spindle speeds at which the dominant frequency of the milling system is integral multiples of the selected machining frequency, and a stable cutting status with a good surface finish can be obtained near and on the left side of the resonant spindle speeds determined by the predicted stability lobe diagram. The motion equations of any tooth end mill for peripheral milling are established, and these equations are based on the transformation matrix and the vector operation principle of motion-homogeneous coordinates. In addition, the simulation algorithm and the system of surface topography generated in peripheral milling are given based on the Z-map model. Cutting tests are carried out, and good agreement between the measured surface topographies and the topographies predicted by the model in this study is found in terms of their shape, magnitude, feed mark, profile height of cross-section, and surface roughness. The simulation results show that the milling surface roughness increases with the increase in feed per tooth, which further shows that this simulation system has high credibility. Thus, the simulation and experimental results can provide some practical instructions for the actual peripheral milling in determining the optimal machining conditions.

scholarly journals An Investigation To Achieve a Good Surface Integrity in WEDM of Ti-6242 Super Alloy

2021 ◽  
Author(s):  
Sonia Ezeddini ◽  
Wajdi Rajhi ◽  
Mohamed Boujelbene ◽  
Emin Bayraktar ◽  
Sahbi Ben Salem
Keyword(s):  
Surface Roughness ◽  
Pulse Duration ◽  
Surface Integrity ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Good Surface ◽  
Pulse On Time ◽  
Super Alloy

Abstract Ti-6242 is a super alloy which exhibits the best creep resistance among available titanium alloys and is widely used in the manufacture by WEDM of aircraft engine turbomachinery components. However, the final quality of wire EDMed surface is a great challenge as it is affected by various factors that need optimization for surface integrity and machine efficiency improvement. The aim of this study is to investigate the effect of a set of cutting process parameters such as pulse on time (Ton), servo voltage (U), feed rate (S) and flushing pressure (p) on surface roughness (SR) when machining Ti-6242 super alloy by WEDM process using a brass tool electrode and deionized water as a dielectric fluid. WEDM experiments were conducted, and SR (Ra) measurement was carried out using a 3D optical surface roughness-meter (3D–SurfaScan). As a tool to optimize cutting parameters for SR improvement, Taguchi's signal‐to‐noise ratio (S/N) approach was applied using L9 (3^4) orthogonal array and Lower-The-Better (LTB) criteria. Substantially, the findings from current investigation suggest the application of the values 0.9 µs, 100V, 29 mm/min, and 60 bar for Ton, U, S and p cutting parameters, respectively, for producing a good surface finish quality. Percent contributions of the machining parameters on SR (Ra) assessed based on ANOVA analysis are 62.94%, 20.84%, 11.46% and 4.74% for U, S, Ton and p, respectively. Subsequently, accurate predictive model for SR (Ra) is established based on response surface analysis (RSA). The contour plots for SR (Ra) indicate that when flushing pressure p converges to a critical value (80 bar), a poor-quality surface finish is highly expected with the excessive increase in U and S. Electron microscope scanning (SEM) observations have been performed on machined surface for a wide range of cutting parameters to characterize wire EDMed surface of Ti-6242. SEM micrographs indicate that the machined surface acquires a foamy structure and shows white layer and machining-induced damage that the characteristics are highly dependent on cutting parameters. At high servo-voltage, the decrease in pulse on time Ton and feed rate S results in a large decrease in overall machining-induced surface damage. Moreover, for high servo-voltage and feed rate levels, it has been observed that pulse on time could play a role of controlling the surface microcracks density. In fact, the use of a low pulse duration of cut combined with high servo-voltage and feed rate has been shown to inhibit surface microcracks formation giving the material surface a better resistance to cracking than at high pulse duration.

An Experimental Investigation of the Laser Milling Process for Polycrystalline Diamonds

2011 ◽  
Vol 291-294 ◽  
pp. 810-815 ◽  
Author(s):  
Qi Wu ◽  
Jun Wang
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Polycrystalline Diamond ◽  
Milling Process ◽  
Depth Of Cut ◽  
Good Surface ◽  
Laser Milling ◽  
Cavity Profile ◽  
Profile Depth ◽  
Good Surface Finish

An experimental study of the pulsed laser milling process for a sintered polycrystalline diamond is presented. The characteristics and quality of the cavities machined with a Yd laser under different pulse energies, pulse overlaps, scan overlaps and numbers of passes are discussed, together with the effects of these parameters on the cavity profile, depth of cut and surface roughness. A statistical analysis is also presented to study the relationship between the process parameters and surface roughness. It shows that the optimum pulse overlap and pulse energy may be used to achieve good surface finish, whereas scan overlap and number of passes can be selected to improve the depth of cut without much effect on the surface finish.

scholarly journals Surface topography and bacterial adhesion of CAD/CAM resin based materials after application of different surface finishing techniques

2018 ◽  
Vol 17 ◽  
pp. 1-11
Author(s):  
Raphael Meneghetti Hamerschmitt ◽  
Paulo Henrique Tomazinho ◽  
Kaíke Lessa Camporês ◽  
Carla Castiglia Gonzaga ◽  
Leonardo Fernandes da Cunha ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Surface Finish ◽  
Bacterial Adhesion ◽  
Resin Composite ◽  
The Other ◽  
Surface Finishing ◽  
Roughness Parameters ◽  
Surface Finishes ◽  
Hybrid Ceramic

Aim: This study evaluated the surface topography and bacterial adhesion of a hybrid ceramic and a nano ceramic resin composite after different surface finishes. Methods: Hybrid ceramic (Vita Enamic, VITA - EN) and nano ceramic resin composite (Lava Ultimate, 3M/ESPE - LV) blocks of 12 x 14 x 18 mm were cut into 1 mm slices. Each slice was divided into four specimens (6 x 7 mm) that were randomly allocated into 4 groups (n=8) according to the surface finishing: CTL - without surface finish (control); DB - wear with a diamond bur; VT - polishing system for hybrid ceramic (VITA); and DD - polishing system for ceramics (Dedeco). The specimens were analyzed regarding surface roughness parameters (Ra, Rz, Rq), sterilized and subjected to bacterial adhesion. Representative specimens from each group were observed by SEM and Confocal Laser Scanning Microscopy. Data were submitted to two-way ANOVA and Tukey's test (α=0.05). Results: EN had lower surface roughness and bacterial adhesion than LV (p<0.05), regardless of the surface finish. The highest values for all roughness parameters was observed in LVDB group, differing from the other groups, which were not significantly different. Smaller bacterial adhesion values (CFU/mL) were observed for ENDD and ENVT, which differed significantly from the other groups, except ENCTL. For LV groups there was no significant difference between the different surface finishes (p>0.05). The type of material and surface finish system significantly interfered with surface roughness parameters and bacterial adhesion. The hybrid ceramic performed better after polishing than the nano-ceramic resin. Conclusion: An adequate finishing/polishing technique should always be performed after any kind of adjustment to indirect restorations made with these materials tested.

Surface Roughness and Topography Analysis in Precision Milling of 3J33 Maraging Steel

2016 ◽  
Vol 874 ◽  
pp. 497-502 ◽  
Author(s):  
Yang Yao ◽  
Hong Tao Zhu ◽  
Chuan Zhen Huang ◽  
Dian Cong Zhang ◽  
Jun Wang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Surface Topography ◽  
Maraging Steel ◽  
Surface Finish ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Milling Parameters ◽  
Optimization Of Cutting Parameters

In precision milling, the quality of surface finish is an important requirement for workpiece machined. Thus, optimization of cutting parameters is important for controlling the surface quality. In this study, the Taguchi method is used to find the effects of milling parameters on surface roughness in precision milling of 3J33 maraging steel. A model, which is based on the milling parameters and tool geometry, is also proposed in order to predict the surface topography. The experimental results show that milling speed has significant effect on the surface roughness among the milling parameters. Besides, tool geometry and material deformation play important roles in the surface topography.

Experimental Investigation of Electrochemical Micro Turning of Ti6Al4V With NaOH Solution

2020 ◽  
Author(s):  
Arnab Das ◽  
Deepak Kumar ◽  
Mohan Kumar ◽  
Vivek Bajpai
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Material Removal ◽  
Electrochemical Machining ◽  
Electrode Gap ◽  
Machining Time ◽  
Good Surface ◽  
Naoh Solution ◽  
Micro Turning ◽  
Good Surface Finish

Abstract Ti6Al4V is a highly favorable material in biomedical, aerospace and many other industries. However, rapid tool wear during machining has made Ti6Al4V into a difficult-to-machine material. Electrochemical machining may be a solution to that challenge. Moreover, high chemical affinity and formation of oxide layer over the surface have limited the application electrochemical machining for Ti6Al4V. In this paper, an experimental approach of electrochemical micro turning of Ti6Al4V has been described. The electrolyte was 10% aqueous solution of NaOH and the tool was SS 310. For each and every experiment workpiece rotational speed and machining time were kept constant. Constant DC voltage was applied and the inter-electrode gap between tool and workpiece was kept constant for each experiment. Experiments were performed using two different levels of applied voltage, axial feed rate and inter-electrode gap. Their effects over MRR and surface roughness have been determined. Additionally, the optimum working condition was determined in order to maximize MRR and minimize surface roughness. For each experiment, acceptable material removal and good surface finish have been achieved. The maximum surface roughness (Ra) was found 1.128 μm in experiment 1. The utilization of NaOH solution has resulted in controlled electrolyzing current, controlled material removal and therefore, good surface finish.

Investigation on Precision Finishing of Helical Gears Using Newly Developed Silicon Carbide Mixed Styrene Butadiene Media and Abrasive Flow Finishing Process

2021 ◽  
Vol 06 ◽  
Author(s):  
Irfan Ahmad Ansari ◽  
Dipti Sharma ◽  
Kamal K. Kar ◽  
Janakarajan Ramkumar
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Surface Finish ◽  
Helix Angle ◽  
Helical Gears ◽  
Good Surface ◽  
Finishing Process ◽  
Good Surface Finish ◽  
Styrene Butadiene ◽  
Abrasive Flow Finishing

The good surface finish of gears is one of the critical parameters which leads to its noise-free operation, efficient power transmission, and longer service life. However, most of the gear manufacturing processes do not produce a good surface finish. Therefore, gears need post-processing to finish their surface. Out of several methods of gear finishing like gear grinding, lapping, and honing, the abrasive flow finishing process offers more flexibility due to its self-deformable abrasive medium which can easily flow across complex internal or external geometry. The present study aims to improve the surface finish of helical gear by abrasive flow finishing (AFF) by experimentally identifying the optimum range of the potential input process parameters. An AFF set up was used for gear finishing by using a medium of styrene-butadiene and soft silicone polymer, Silicon carbide abrasive, and silicone oil as a blending agent. A special fixture was developed comprising of five parts namely spider, mandrel, upper, middle, and bottom cylinder with a circumferential hole, which allows the back and forth movement of AFF medium through the annular volume between fixture and gear. Further, an experimental investigation of process parameters like viscosity, effect of percentage of various components in medium, operating pressure, and helix angle of helical gears have been studied on percentage improvement of surface roughness (Ra) value of the gear. It is found that the concentration of abrasives in media and extrusion pressure were the two most significant parameters that have a maximum effect on the percentage reduction in surface roughness and finishing rate. Results show that the optimum combination of the extrusion pressure and abrasive weight percentage is 38 bar and 40 % that produces best results of around 76 and 69 % improvement in Ra for gear of helix angle 30 degree and 45 degree respectively.

Tribological performance of non-asbestos brake friction material in contact with brake disc of varying topography

2020 ◽  
Vol 72 (10) ◽  
pp. 1277-1283
Author(s):  
Dinesh Shinde ◽  
Mukesh Bulsara ◽  
K.N. Mistry
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Peer Review ◽  
Surface Finish ◽  
Friction Material ◽  
Tribological Performance ◽  
Brake Disc ◽  
Content Type ◽  
Disc Surface ◽  
Brake Friction Material

Purpose The purpose of this paper is to evaluate experimentally the influence of different surface roughness of the contacting disc on tribological performance of the non-asbestos brake friction material (BFM). Design/methodology/approach Taguchi method was applied to design an experiment using three different discs of gray cast iron with different surface roughness, which is measured using optical profilometer. These discs were subjected to sliding against pins prepared with the developed non-asbestos BFM, using pin on disc friction and wear monitor. Findings The experimental results shows that the disc 2 (Ra = 3.77 µm) gives wear of 22.78 µm and coefficient of friction of 0.462, which is recommended for extreme brake performance. Analysis of Taguchi design revealed that the disc surface was most significant parameter among the parameters under study. Practical implications During braking, continuous sliding between the BFM and brake disc or drum not only results into wear of BFM but also changes the surface finish of the brake drum or disc. This leads to variation in surface topography of the drum or disc surface with application of brakes, which further affects the characteristics of the BFM. Originality/value The tribological performance of BFM depends upon the topography of the surface on which it was sliding. To get best performance of the non-asbestos friction materials, disc having moderate surface finish is recommended. Scanning electron microscope micrographs had shown the different plateaus formed and energy-dispersive X-ray spectroscopy spectra identified presence of different chemical elements prior to sliding of the pins surface over different discs surface topography. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2020-0120/

scholarly journals Research of Chatter Suppression in Turning Operation with Process Damping using Stability Lobe Diagram

2019 ◽  
Vol 8 (12S2) ◽  
pp. 539-543
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Modal Testing ◽  
Stability Lobe Diagram ◽  
Diagram Method ◽  
Process Damping ◽  
Chatter Suppression ◽  
Stability Lobe ◽  
The Stability ◽  
The Impact

This paper presents a chatter detection technique based on the stability of the measured Ra and Rz values of process damping and surface roughness in low cutting speed activities. In practice, process damping during machining procedures is hard to predict and identify due to the model and technique of limitation. The impact of cutting conditions on process damping in turning with P20 steel pre-hardened metal in terms of cutting velocity, feed rate and cutting depth was explored by the Stability Lobe Diagram method. A CNC turning machine was used in dry turning procedures with carbide insert. The highest and minimum value of natural frequencies and damping ratios were evaluated by modal testing and the stability lobe diagram analysis was applied. It is concluded that in the same region of the Stability Lobe Diagram, the chatter and measured surface roughness values were correlated and shown to have strong consensus.

Optimization of Precision Grinding Parameters of Silicon for Surface Roughness Based on Taguchi Method

2011 ◽  
Vol 264-265 ◽  
pp. 997-1002 ◽  
Author(s):  
Alao Abdur-Rasheed ◽  
Mohamed Konneh
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Surface Finish ◽  
Machine Tools ◽  
Optimization Technique ◽  
Experimental Studies ◽  
Precision Grinding ◽  
Taguchi Optimization ◽  
Good Surface ◽  
Grinding Parameters

Silicon being a typical hard-brittle material is difficult to machine to a good surface finish. Although ductile-mode machining (DMM) is often employed to machine this advanced material but this technique requires the use of expensive ultra-precision machine tools therefore limiting its applicability. However, by proper selection of grinding parameters, precision grinding which can be performed on conventional machine tools can be used to generate massive ductile surfaces thereby reducing the polishing time and improving the surface quality. Precision grinding should be planned with reliability in advance and the process has to be performed with high rates of reproducibility. Therefore, this study investigated the effect and optimization of grinding parameters using Taguchi optimization technique during precision grinding of silicon. Experimental studies were conducted under varying depths of cut, feed rates and spindle speeds. An orthogonal array (OA), signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) were employed to find the minimum surface roughness value and to analyze the effect of the grinding parameters on the surface roughness. Confirmation tests were carried out in order to illustrate the effectiveness of the Taguchi method. The results show that feed rate mostly affected the surface roughness. The predicted roughness (Ra) of 34 nm was in agreement with the confirmation tests. Massive ductilestreaked surface was also found corresponding to the minimal surface finish determined from the optimal levels.

Surface roughness and substrate induced symmetry-breaking: influence on the plasmonic properties of aluminum nanostructure arrays

Nanoscale ◽  
2020 ◽  
Author(s):  
Feifei ZHANG ◽  
Jérôme Plain ◽  
Davy Gerard ◽  
Jérôme Martin
Keyword(s):  
Surface Roughness ◽  
Optical Properties ◽  
Symmetry Breaking ◽  
Surface Topography ◽  
Metallic Nanoparticles ◽  
Far Field ◽  
Al Nanoparticles ◽  
Nanostructure Arrays

The surface topography is known to play an important role on the near- and far- field optical properties of metallic nanoparticles. In particular, aluminum (Al) nanoparticles are commonly fabricated through...

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