Influence of process variables on machining characteristics in turning of novel AM alloy

2020 ◽  
pp. 095440542097809
Author(s):  
Sunil Dutta ◽  
Suresh Kumar Reddy Narala
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Flank Wear ◽  
Surface Condition ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Input Parameters ◽  
Response Variables

In this paper, the machinability of a fabricated AM alloy (Mg-7 wt%Al-0.9 wt%Mn) has been examined. The novel AM alloy was subjected to turning using a systemized CNC setup. The input turning variables: feed ( f), cutting speed ( v), and depth of cut (DOC) were suitably altered to analyze effects on response variables such as cutting force ( Fc), cutting temperature ( T), and tool life ( TL). Subsequently, the microstructure characterization of the machined surface was done for validating the experimental results. The experimental results established the influence of input parameters on response variables. The cutting force was mostly dominated by DOC, and the cutting temperature was predominantly influenced by cutting speed. The SEM images exhibited the adverse effect of higher values of input parameters on the surface condition. The finest surface was observed at f: 0.1 mm/rev, DOC: 0.5 mm, and v: 115 m/min. Further, the analysis of tool life was done by assessing the flank wear; the measured data showed the significant influence of cutting speed on flank wear. The maximum tool life of 51 min was achieved at the lowest levels of three input parameters.

scholarly journals Optimizing Multi-Response Parameters in Turning of AISI1040 Steel Using Desirability Approach

2019 ◽  
Vol 4 (4) ◽  
pp. 905-921
Author(s):  
Srinu Gugulothu ◽  
Vamsi Krishna Pasam
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Multi Objective ◽  
Single Objective

In this study, an attempt is made to examine the machining response parameters in turning of AISI 1040 steel under different lubrication environment. Subsequently, design of experiment technique Response surface methodology (RSM) is used for analyzing machining performance by varying cutting conditions with the use of 2wt% of CNT/MoS2(1:2) HNCF. Regression models are developed for multiple machining responses. Optimization is performed for these models by using desirability function, which converts multi-objective into single objective. Then the optimal setting parameters for single objective is found. Significant reduction in main cutting force (Fz), cutting temperature (T), surface roughness(Ra) and tool flank wear (Vb) are found with the use of 2wt% of CNT/MoS2(1:2) HNCF compared to other lubrication environment. Significant factors that affect the main cutting force (Fz), the temperature in the cutting zone are cutting speed, feed rate and depth of cut. Parameter depth of cut has an insignificant effect on tool flank wear and surface roughness (Ra). The optimal cutting conditions for four multi-objective optimization of main cutting force (Fz), cutting temperature, surface roughness (Ra) and tool flank wear are found to be cutting speed 70.25 m/min, feed 0.13 mm/rev and doc 0.5mm at desirability value of 0.907.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Tool Life Analysis when Turning Ti-6Al-4V Using Vegetable Oil-Based Cutting Fluid

2017 ◽  
Vol 882 ◽  
pp. 36-40
Author(s):  
Salah Gariani ◽  
Islam Shyha ◽  
Connor Jackson ◽  
Fawad Inam
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Vegetable Oil ◽  
Flank Wear ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Fluid Concentration

This paper details experimental results when turning Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. The effects of coolant concentration and working conditions on tool flank wear and tool life were evaluated. L27 fractional factorial Taguchi array was employed. Tool wear (VBB) ranged between 28.8 and 110 µm. The study concluded that a combination of VOs based cutting fluid concentration (10%), low cutting speed (58 m/min), feed rate (0.1mm/rev) and depth of cut (0.75mm) is necessary to minimise VBB. Additionally, it is noted that tool wear was significantly affected by cutting speeds. ANOVA results showed that the cutting fluid concentration is statistically insignificant on tool flank wear. A notable increase in tool life (TL) was recorded when a lower cutting speed was used.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Technological Investigation of Effect of Machining Parameter on Tool Life

2020 ◽  
Vol 22 (4) ◽  
pp. 41-53
Author(s):  
Manojkumar Sheladiya ◽  
◽  
Shailee Acharya ◽  
Ghanshyam Acharya ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Time ◽  
Machining Parameter

Introduction. The machinability is typical criteria to be investigated and different authors suggested different parameters describing its quantification. Different parameters i. e. speed, feed, depth of cut, tool work-piece combination, machine types and its condition, cutting fluid, machinist expertise, etc. are contributing directly to the tool life. The selection of the tool for the machining impacts greatly on the economic viability of the machining in terms of energy usage and tooling costs. The method of investigation. The current research emphasis mainly on tool life investigation when machining the mild steel specimens ISRO 50, BIS 1732:1989 at constant cutting speed i.e. 200 m / min. In the industries the mild steel material is commonly used for various products manufacturing. Considering the high demands on productivity and surface finish, machining at 200 m / min is the preferred. The computerized numerical control machine (CNC DX-150) is used for the turning. The four corner insert (TNMG 120408) is used for different machining times i.e. 10, 15, 20 and 25 minutes respectively. The flank wear of the tool is measured with calibrated optical microscope. The temperature of the tool corner during machining is continuously measured for possible impact of temperature on bonding properties of the tool insert and impact on red hardness. Results and discussion. The plot of flank wear vs. machining time will give the value of tool life. The other quality output parameter, such as surface roughness, is measured after machining, indicating surface irregularities in root means square value. Efforts have been made to identify the relationship of tool life, machining time, the quantity of metal removed, surface roughness, and tool bit temperature.

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

scholarly journals Performance of Near Dry Hard Machining Through Pressurised Air Water Mixture Spray Impingement Cooling Environment

2019 ◽  
Vol 16 (1) ◽  
pp. 6108-6133
Author(s):  
R. Kumar ◽  
A.K. Sahoo ◽  
P.C. Mishra ◽  
R.K. Das
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Water Mixture ◽  
Impingement Cooling ◽  
Aisi D2 ◽  
Spray Impingement

The present paper emphasizes on experimental investigation, mathematical modelling, optimisation, tool life and cost analysis during machining of AISI D2 (heat treated) (55±1 HRC) steel using uncoated carbide tool through a novel method under spray impingement cooling environment. Taguchi based L16 orthogonal array was utilised to conduct the experiments. Analysis of variance with 95% confidence level shows that the feed and depth of cut, are the most compelling factor towards surface roughness as well as chip reduction coefficient whereas cutting speed is the utmost compelling feature associated to flank wear as well as chip-tool interface temperature. Optimised result is identified as v1-f1-d1 (machining speed of 63 m/min; cutting feed of 0.04 mm/rev and depth of cut of 0.1 mm) based on grey relational analysis and tool life is found to be 15 minutes at optimised cutting conditions. Flank wear due to abrasion, catastrophic failure due to diffusion, chipping and notch wear are noticed as the major tool wear mechanisms in hard turning. Mathematical machinability models show statistically significance because due to the superior coefficient of correlations. As the global machining cost for each part is less, uncoated carbide tools can machine effectively, efficiently and economically at optimum cutting conditions under spray environment.

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

scholarly journals Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 840 ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Mozammel Mia
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Desirability Function ◽  
Interactive Effect ◽  
Cutting Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

Machinability Investigation of HSLA Steel in Hard Turning with Coated Ceramic Tool: Assessment, Modeling, Optimization and Economic Aspects

2019 ◽  
Vol 18 (04) ◽  
pp. 625-655 ◽  
Author(s):  
Asutosh Panda ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ceramic Tool ◽  
Life Estimation

The present study addresses the machinability investigation in finish dry hard turning of high strength low alloy steel with coated ceramic tool by considering cutting speed, feed and depth of cut as machining parameters. The technological parameters like surface roughness, flank wear, chip morphology and economical feasibility have been considered to investigate the machinability performances. Twenty seven set of trials according to full factorial design of experiments are performed and analysis of variance, multiple regression method, Taguchi method, desirability function approach and finally Gilbert’s approach are subsequently applied for parametric influence study, mathematical modeling, multi-response optimization, tool life estimation and economic analysis. Results indicated that feed and cutting speed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness and tool flank wear is considered. Abrasions, adhesion followed by plastic deformation have been observed to be the principal wear mechanism for tool life estimation and observed tool life for coated ceramic insert is 47[Formula: see text]min under optimum cutting conditions. The total machining cost per part is ensued to be lower ($0.29 only) as a consequence of higher tool life, reduction in downtime and enhancement in savings, which finds economical benefits in hard turning. The current work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process considering techno-economical and ecological aspects.

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