Experimental analysis of the process parameters affecting bone burring operations

2017 ◽  
Vol 232 (1) ◽  
pp. 33-44 ◽  
Author(s):  
Jonathan R Kusins ◽  
O Remus Tutunea-Fatan ◽  
Louis M Ferreira
Keyword(s):  
Process Parameters ◽  
Cutting Forces ◽  
Depth Of Cut ◽  
Tool Vibration ◽  
Tool Paths ◽  
Bone Removal ◽  
Desirable Outcome ◽  
Process Outcomes ◽  
Experimental Apparatus ◽  
Process Trends

The experimental quantification of the process parameters associated with bone burring represents a desirable outcome both from the perspective of an optimized surgical procedure as well as that of a future implementation into the design of closed-loop controllers used in robot-assisted bone removal operations. Along these lines, the present study presents an experimental investigation of the effects that tool type, rotational speed of the tool, depth of cut, feed rate, cutting track overlap, and tool angle (to a total of 864 total unique combinations) have on bone temperature, tool vibration, and cutting forces associated with superficial bone removal operations. The experimental apparatus developed for this purpose allowed a concurrent measurement of bone temperature, tool vibration, and cutting forces as a function of various process parameter combinations. A fully balanced experimental design involving burring trials performed on a sawbone analog was carried out to establish process trends and subsets leading to local maximums and minimums in temperature and vibration were further investigated. Among the parameters tested, a spherical burr of 6 mm turning at 15,000 r/min and advancing at 2 mm/s with a 50% overlap between adjacent tool paths was found to yield both low temperatures at the bone/tool interface and minimal vibrations. This optimal set of parameters enables a versatile engagement between tool and bone without sacrificing the optimal process outcomes.

scholarly journals Investigation of the Subsurface Temperature Effects on Nanocutting Processes via Molecular Dynamics Simulations

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1220
Author(s):  
Michail Papanikolaou ◽  
Francisco Rodriguez Hernandez ◽  
Konstantinos Salonitis
Keyword(s):  
Molecular Dynamics ◽  
Molecular Dynamics Simulations ◽  
Process Parameters ◽  
Cutting Forces ◽  
Rake Angle ◽  
Von Mises Stress ◽  
Depth Of Cut ◽  
Subsurface Temperature ◽  
Workpiece Material ◽  
Dynamics Simulations

In this investigation, three-dimensional molecular dynamics simulations have been performed in order to investigate the effects of the workpiece subsurface temperature on various nanocutting process parameters including cutting forces, friction coefficient, as well as the distribution of temperature and equivalent Von Mises stress at the subsurface. The simulation domain consists of a tool with a negative rake angle made of diamond and a workpiece made of copper. The grinding speed was considered equal to 100 m/s, while the depth of cut was set to 2 nm. The obtained results suggest that the subsurface temperature significantly affects all of the aforementioned nanocutting process parameters. More specifically, it has been numerically validated that, for high subsurface temperature values, thermal softening becomes dominant and this results in the reduction of the cutting forces. Finally, the dependency of local properties of the workpiece material, such as thermal conductivity and residual stresses on the subsurface temperature has been captured using numerical simulations for the first time to the authors’ best knowledge.

scholarly journals Effects of Process Parameters On Tool Vibration And Force Transmissibility In High-Speed Micro-Milling Machine

2021 ◽  
Author(s):  
Chitransh Singh ◽  
Arnab Das ◽  
Vivek Bajpai ◽  
Madan Lal Chandravanshi
Keyword(s):  
Process Parameters ◽  
High Speed ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Commercially Pure Titanium ◽  
Axial Thrust ◽  
Tool Vibration ◽  
Radial Thrust

Abstract High-speed micro-milling is an emerging technology used to produce micro and miniaturized products with smooth surface finish and high dimensional precision. However, tool vibration is a major problem in micro-milling as it directly affects the product accuracy, surface quality and tool life. Inappropriate selection of process parameters increases radial and axial thrust as well as force transmitted to structure during micro-machining which results in rapid tool vibration. This work focuses on the experimental investigation of process parameters (cutting speed and depth of cut) in order to reduce tool vibration due to axial and radial thrust in high-speed micro-milling. The tool used in this experiment is a 2-flute end mill cutter (1 mm cutter diameter) and workpiece is a commercially pure titanium (CpTi) plate. The operation was performed at different depth of cut and varying cutting speeds keeping the chip load constant. Vibration signals were acquired and processed to obtain the vibration thrust of the tool and the force transmitted to the structure. The results indicated that as the depth of cut and cutting speed increases, both axial as well as radial thrust decreases leading to lower vibration amplitude of the cutting tool and reduction in force transmitted to the machine structure.

In vivo evaluation of machining forces, torque, and bone quality during skull bone grinding

2020 ◽  
Vol 234 (6) ◽  
pp. 626-638 ◽  
Author(s):  
Atul Babbar ◽  
Vivek Jain ◽  
Dheeraj Gupta
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Rotational Speed ◽  
Cutting Forces ◽  
Tangential Force ◽  
Depth Of Cut ◽  
Regeneration Ability ◽  
Skull Bone ◽  
In Vivo Evaluation

This study investigates neurosurgical bone grinding with varying parameters on skull bone using a miniature grinding burr. Three process parameters, namely, rotational speed, feed rate, and depth of cut, have been investigated at three different levels in the terms of tangential force, thrust force, and torque generated during grinding. The results revealed that as the rotational speed is increased, the cutting forces and torque showed a decreasing trend. Nevertheless, the increase in feed rate and depth of cut leads to the escalation in response characteristics. The best parametric combination for minimum cutting forces and torque is as follows: rotational speed = 55,000 r/min, feed rate = 20 mm/min, and depth of cut = 0.50 mm. Morphological analysis reveals cracks in the bone’s surface at a higher feed rate. Furthermore, delamination and cutting streaks are also visible on the surface of the bone after grinding. Energy-dispersive spectroscopy and elemental mapping of the tool after bone grinding indicate the accumulation of the bone chips in the successive diamond abrasives. The outcomes of the study will be beneficial for the neurosurgeons in understanding the effect of various process parameters on cutting force, toque, microcracks, and bone’s regeneration ability during surgical bone grinding.

Effect of Process Parameters on Cutting Forces and Surface Roughness in Machining of DSS 2205 Using Taguchi’s Approach

2019 ◽  
Vol 895 ◽  
pp. 26-31
Author(s):  
R. Suresh ◽  
L. Shivaramu ◽  
N.G. Siddesh Kumar ◽  
T.N. Srikantha Dath
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Material Behavior ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Coated Carbide ◽  
Side Flow

In the present study an attempt has been made to investigate the effect of process parameters on surface roughness and cutting forces generation in machining of Duplex Stainless Steel (DSS 2205) grade material with TiN coated carbide tool. Taguchi technique is used for optimizing the process parameters. L27 orthogonal array was used to conduct the experimental trials. Cutting forces recorded using piezo-electric based mill tool dynamometer and surface roughness measured using surface roughness measuring instrument. The obtained results indicated that the cutting force increases with increase in feed rate and depth of cut whereas cutting forces decreases with increase in cutting speed. Surface roughness decreases with increase in cutting speed and low feed rate. Scanning Electroscope Microscopic (SEM) images indicates the feed marks, undeformed material and patches on the machined surface. The formation of material side flow and burrs on the feed marks ridges observed at higher cutting speed, low feed rate and depth of cut. It is mainly due to the material behavior like elastic-plastic deformation of the surface layer. The material side flow causes the considerable deterioration of surface quality of the DSS 2205 steel.

Application of Taguchi Method for Optimization of Parameters in Turning Operation

2016 ◽  
Vol 16 (3) ◽  
pp. 183-187 ◽  
Author(s):  
B. Singaravel ◽  
T. Selvaraj
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Cutting Tool ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Optimum Level ◽  
Turning Process ◽  
Tool Vibration ◽  
Machining Characteristics

AbstractCutting tool vibration analysis is the effective way to understand the machining characteristics of any material. In the present work, the effect of process parameters on cutting tool vibration is estimated using Taguchi method in turning of EN25 steel. Taguchi method uses Signal-to-Noise ratio (S/N) and Analysis of Variance (ANOVA) to determine the optimum level of process parameters and significant parameters. The results showed that cutting speed of 215 m/min, feed rate of 0.07 mm/rev and depth of cut of 0.5 mm are the optimum combination of process parameters. Cutting speed and depth of cut are the influencing parameters on cutting tool vibration. The results are experimentally verified and the results based on turning process response can be effectively improved.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

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%.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

Evaluation of Process Parameters in Machining of AA6063 Alloy

2018 ◽  
Vol 1148 ◽  
pp. 109-114
Author(s):  
M. Balaji ◽  
C.H. Nagaraju ◽  
V.U.S. Vara Prasad ◽  
R. Kalyani ◽  
B. Avinash
Keyword(s):  
Surface Roughness ◽  
Regression Analysis ◽  
Process Parameters ◽  
Single Channel ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Aa6063 Alloy

The main aim of this work is to analyse the significance of cutting parameters on surface roughness and spindle vibrations while machining the AA6063 alloy. The turning experiments were carried out on a CNC lathe with a constant spindle speed of 1000rpm using carbide tool inserts coated with Tic. The cutting speed, feed rate and depth of cut are chosen as process parameters whose values are varied in between 73.51m/min to 94.24m/min, 0.02 to 0.04 mm/rev and 0.25 to 0.45 mm respectively. For each experiment, the surface roughness parameters and the amplitude plots have been noted for analysis. The output data include surface roughness parameters (Ra,Rq,Rz) measured using Talysurf and vibration parameter as vibration amplitude (mm/sec) at the front end of the spindle in transverse direction using single channel spectrum analyzer (FFT).With the collected data Regression analysis is also performed for finding the optimum parameters. The results show that significant variation of surface irregularities and vibration amplitudes were observed with cutting speed and feed. The optimum cutting speed and feed from the regression analysis were 77.0697m/min and 0.0253mm/rev. for the minimum output parameters. No significant effect of depth of cut on output parameters is identified.

Optimal Rough Machining of Sculptured Parts on a CNC Milling Machine

1993 ◽  
Vol 115 (4) ◽  
pp. 424-431 ◽  
Author(s):  
Z. Dong ◽  
H. Li ◽  
G. W. Vickers
Keyword(s):  
Production Costs ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Rough Machining ◽  
Machining Time ◽  
Tool Paths ◽  
Cnc Milling Machine ◽  
Cnc Programming ◽  
Sculptured Parts ◽  
Optimal Approach

An optimal approach to the rough machining of sculptured parts with least machining time is presented. The contour map cutting method is used to generate CNC tool paths based on the CAD model of sculptured parts. The part and stock geometry related parameters, including the number of cutting layers and the distributions of cutting depth, and the process parameters of feed rate and depth of cut, are optimized. The method can automate CNC programming for sculptured part rough machining, considerably improve productivity, and lower production costs. Two examples are used to illustrate the approach and its advantages.

Sign in / Sign up

Export Citation Format

Share Document