Influence of flow parameters in the dual nozzle CO2-based vortex tube cooling system during turning of Ti-6Al-4V

2021 ◽  
pp. 095440622110574
Author(s):  
Khirod Mahapatro ◽  
P Vamsi Krishna
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Vortex Tube ◽  
Cooling System ◽  
Cutting Temperature ◽  
Nozzle Diameter ◽  
Energy Separation ◽  
Optimum Conditions ◽  
Dry Cutting ◽  
Input Variables

Dual nozzle vortex tube cooling system (VTCS) is developed to improve the machinability of Ti-6Al-4V where cold-compressed CO2 gas is used as a coolant. The cooling effect is produced by the process of energy separation in the vortex tube and the coolant is supplied into the machining zone to remove the generated heat in machining. In this study, the responses such as cutting force (Fz), cutting temperature (Tm), and surface roughness (Ra) are analyzed by considering coolant inlet pressure, cold fraction, and nozzle diameter as input variables. Further optimization is performed for the input variables using the genetic algorithm technique, and the results at optimum conditions are compared with those of dry cutting. From the results, lower cutting force is observed at lower coolant pressure and cold fraction and higher nozzle diameter. The cutting temperature is minimized by increasing coolant pressure and cold fraction and by decreasing nozzle diameter. A better surface finish is observed at high coolant pressure and cold fraction and lower nozzle diameters. It is observed from the response surface method (RSM) that the coolant pressure is most significantly affecting all the responses. At optimum conditions, the cutting temperature and surface roughness are 35.6% and 66.14%, respectively, lower than dry cutting due to the effective cooling and lubricating action of the CO2 gas, whereas cutting force observed under the VTCS is 18.6% higher than that of dry cutting because of the impulse force of the coolant VTCS and thermal softening of the workpiece in dry cutting.

Effect of Air Cooling on the Process of High Speed Hard Cutting GCr15

2006 ◽  
Vol 532-533 ◽  
pp. 369-372
Author(s):  
Jing Shu Hu ◽  
Hong Min Pen ◽  
Yu Wang ◽  
Tao Chen ◽  
Zhen Chang ◽  
...  
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Vortex Tube ◽  
Cooling System ◽  
Cutting Temperature ◽  
Reference Value ◽  
High Hardness ◽  
Chemical Pollution ◽  
Air Cooling ◽  
Air Cooling System

Air cooling is a near dry machining method, which cools cutting area and evacuates chip using low temperature wind instead of cutting liquid. It can decrease tool wear, improve tool life, reduce cost and produce no chemical pollution. In this paper, air cooling system is established, in which vortex tube is used for cooling. Air cooling test was carried on, in which high hardness bear steel GCr15 is machined by PCBN tool. Experiment results indicated that cold air from vortex tube has a significant effect on cutting force, cutting temperature and chip formation process. Cutting force and cutting temperature were simulated using Marc. Change rules that analysis results indicated are in accordance with experiment results. This paper’s conclusions have a great reference value for the practical application of air cooling technology.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

scholarly journals Influence of Ultrasonic Vibration-Assisted Ball-End Milling on the Cutting Performance of AZ31B Magnesium Alloy

2020 ◽  
Vol 9 (4) ◽  
pp. 271-276
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Biomedical Applications ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Machining Process ◽  
Dry Conditions ◽  
Good Biocompatibility

Magnesium alloys have a tremendous possibility for biomedical applications due to their good biocompatibility, integrity and degradability, but their low ignition temperature and easy corrosive property restrict the machining process for potential biomedical applications. In this research, ultrasonic vibration-assisted ball milling (UVABM) for AZ31B is investigated to improve the cutting performance and get specific surface morphology in dry conditions. Cutting force and cutting temperatures are measured during UVABM. Surface roughness is measured with a white light interferometer after UVABM. The experimental results show cutting force and cutting temperature reduce due to ultrasonic vibration, and surface roughness decreases by 34.92%, compared with that got from traditional milling, which indicates UVABM is suitable to process AZ31B for potential biomedical applications.

Comparison of Superabrasive Tools in Rotary Ultrasonic Machining of Stainless Steel

2010 ◽  
Author(s):  
Weilong Cong ◽  
Qiang Feng ◽  
Z. J. Pei ◽  
Clyde Treadwell
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Force ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Time In Literature ◽  
Reported Study ◽  
Input Variables ◽  
Superabrasive Materials

Many experiments on rotary ultrasonic machining (RUM) have been conducted to study how input variables (including tool rotation speed, ultrasonic power, feedrate, and abrasive size) affect output variables (such as cutting force, torque, surface roughness, and edge chipping) by using diamond tools. However, a literature review has revealed that there is no reported study on CBN tools in RUM. This paper, for the first time in literature, presents an investigation of RUM of stainless steel using CBN tools. Firstly, an introduction of superabrasive materials and RUM principle was provided. After presenting the experiment procedures and workpiece properties, it reports the results on tool wear, cutting force, torque, surface roughness in RUM of stainless. Finally, it discusses and compares the performances of diamond and CBN tools in RUM of stainless steel under certain conditions.

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.

MULTI-PARAMETER ANN MODEL FOR FLAT-END MILLING

2008 ◽  
Vol 32 (3-4) ◽  
pp. 523-536 ◽  
Author(s):  
Hazim El Mounayri ◽  
M. Affan Badar ◽  
Gustavo A. Rengifo
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Predictive Ability ◽  
Ann Model ◽  
Network Output ◽  
Input Variables ◽  
Artificial Neural Network Ann

The quality, productivity and safety of machining can be significantly improved through the optimization of cutting conditions. The first step in achieving such an objective is the development of accurate and reliable models for predicting the critical process parameters. In this paper, an innovative Artificial Neural Network (ANN) model that predicts both cutting force and surface roughness in end milling is developed and validated. A set of five input variables is selected to represent the machining conditions while twelve quantities representing two key process parameters, namely, cutting force and surface roughness, form the variables of the network output. Full factorial design of experiments is used to generate data for both training and validation. Successful training of the neural network is demonstrated through comparison of simulated and experimental results for four different output variables, namely cutting force, surface roughness, feed marks, and tooth passing frequency. The predictive ability of the model is verified experimentally by comparing simulated output variables with their experimental counterparts. A good agreement is observed.

scholarly journals Analysis and Optimization of Cutting Tool Coating Effects on Surface Roughness and Cutting Forces on Turning of AA 6061 Alloy

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
Mahir Akgün ◽  
Fuat Kara
Keyword(s):  
Surface Roughness ◽  
Mathematical Models ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Machined Surface ◽  
Tool Coating ◽  
Cutting Inserts

The present work has been focused on cutting force (Fc) and analysis of machined surface in turning of AA 6061 alloy with uncoated and PVD-TiB2 coated cutting inserts. Turning tests have been conducted on a CNC turning under dry cutting conditions based on Taguchi L18 (21 × 33) array. Kistler 9257A type dynamometer and equipment have been used in measuring the main cutting force (Fc) in turning experiments. Analysis of variance (ANOVA) has been applied to define the effect levels of the turning parameters on Fc and Ra. Moreover, the mathematical models for Fc and Ra have been developed via linear and quadratic regression models. The results indicated that the best performance in terms of Fc and Ra was obtained at an uncoated insert, cutting speed of 350 m/min, feed rate of 0.1 mm/rev, and depth of cut of 1 mm. Moreover, the feed rate is the most influential parameter on Ra and Fc, with 64.28% and 54.9%, respectively. The developed mathematical models for cutting force (Fc) and surface roughness (Ra) present reliable results with coefficients of determination (R2) of 96.04% and 92.15%, respectively.

Cutting Behavior of Self-Lubricating Ceramic Tool in Dry Machining of 40Cr Quenched Steel

2021 ◽  
Vol 871 ◽  
pp. 176-188
Author(s):  
Ben Yuan Wang ◽  
Guang Chun Xiao ◽  
Zhao Qiang Chen ◽  
Ming Dong Yi ◽  
Jing Jie Zhang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Friction Coefficient ◽  
Cutting Force ◽  
Solid Lubricant ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Ceramic Composites ◽  
Ceramic Tool ◽  
Cutting Depth ◽  
Ceramic Tools

In this paper, the dry cutting performance of Al2O3/TiC-based ceramic composites with nanoCaF2 was studied. Compared with the Al2O3/TiC ceramic tool, the Al2O3/TiC/CaF2 ceramic tool has lower cutting force, cutting temperature and surface roughness when milling 40Cr hardened steel. Three cutting parameters of cutting speed, feed per tooth, and cutting depth were used to conduct orthogonal experiments to study its changing trend. Through testing of cutting force, cutting temperature and surface roughness, and by comparison with ceramic tools without nanosolid lubricant added, the order of influence of three cutting parameters on cutting force, cutting temperature and surface roughness was obtained. The experimental results showed that the cutting force, cutting temperature and surface roughness of Al2O3/TiC/CaF2 ceramic tools containing nanoCaF2 werebetter than those of Al2O3/TiC ceramic tools. The cutting force, the cutting temperature, and the surface roughness were respectively reduced by 16.5%, 25.8% and 43% compared to when no solid lubricant was added. In addition, after adding solid lubricant, the effect of cutting depth on cutting force was significantly reduced. The average friction coefficient of the tool rake surface was 31.1% lower than that of ceramic tools without solid lubricant. In order to explain this phenomenon, through scanning electron microscopy (SEM) scanning and energy spectroscopy (EDS) elemental analysis, the wear reduction mechanism of solid lubricants was analyzed, that is, during the cutting process, nanosolid lubricants precipitated and formed lubricating film on the rake surface of the tool to reduce the friction coefficient. This was also the main reason for reducing the cutting temperature.

A Study of Minimal Quantity Lubrication with MWCNTs in Turning of AISI 304L Steel

2014 ◽  
Vol 625 ◽  
pp. 108-114 ◽  
Author(s):  
Wei Tai Huang ◽  
Hsun Heng Tsai ◽  
Der Ho Wu ◽  
Wei Tai Lee
Keyword(s):  
Surface Roughness ◽  
Cutting Temperature ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Aisi 304L ◽  
Thermal Wear ◽  
Minimal Quantity Lubrication ◽  
Minimal Quantity ◽  
304L Steel

This paper proposes a new lubricant environment when MWCNTs was used in MQL for AISI 304L in the turning machine. The effects of dry cutting, MQL cutting, and MWCNTs/MQL were compared to the surface roughness of work pieces, cutting temperature and the tool wear. In the past, the studies have shown that the MQL process can prolong tool life and improve surface accuracy in machining. The purpose of using MWCNTs suspensions is to increase the thermal conductivity of cutting fluid and to reduce the temperature during the cutting and decrease the thermal wear of tool simultaneously. The present study investigated the characterization of the MWCNTs was applied into MQL during the turning process of AISI 304L experimentally. The results showed that the MWCNTs will be a very good additive to MQL, not only with the benefits of improving surface roughness but also with ability of prolonging life of tool by reducing the cutting temperature in turning AISI 304L.

Sign in / Sign up

Export Citation Format

Share Document