Parametric optimization of laser drilling of microwave-processed kenaf/HDPE composite

2020 ◽  
pp. 096739112090570
Author(s):  
Renu Tewari ◽  
Manoj Kumar Singh ◽  
Sunny Zafar ◽  
Satvasheel Powar
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Laser Drilling ◽  
Scanning Electron Micrographs ◽  
Taper Angle ◽  
Kenaf Fiber ◽  
Variable Parameters ◽  
Kerf Taper ◽  
Central Composite ◽  
Good Agreement

The present work focused on the investigation of hole quality characteristics in laser-drilled kenaf/high-density polyethylene (HDPE) composites. Microwave-assisted compression molding was used to fabricate kenaf/HDPE composite with 20 wt% of the kenaf fiber reinforcement. The two input parameters pertaining to the experimentation were laser power and cutting speed. Kerf taper angle, heat-affected zone (HAZ), and surface roughness were investigated to evaluate the surface quality and accuracy of the holes generated through laser drilling on composite specimens. The assessment of HAZ was performed qualitatively through image analysis on scanning electron micrographs. Additionally, the effect of composite thickness on laser drilling was also investigated for 3-, 6.7-, and 10-mm composite specimens. The central composite design was used to plan the experiments. The kenaf/HDPE composite drilled at power 120 W and speed 2 mm/s shows a minimum kerf taper angle and surface roughness of 0.056° and 3.83 ± 0.19 µm, respectively. Regression model was obtained for the establishment of relation between input variable parameters and responses. Experimental results and predicted model results exhibited good agreement with each other as they provide error less than 5.35%. The analysis of variance was carried out to obtain the significance of the model chosen for optimization of the output values, that is, surface roughness and kerf taper.

Predicting Surface Roughness with Respect to Process Parameters Using Regression Analysis Models in End Milling

2012 ◽  
Vol 576 ◽  
pp. 99-102 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz H.F. Al Hazza ◽  
M.Y. Suprianto ◽  
Muhammad Riza
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Functional Attributes ◽  
Aisi H13 ◽  
Analysis Models ◽  
End Milling Process ◽  
Required Quality ◽  
Central Composite

Surface roughness affects the functional attributes of finished parts. Therefore, predicting the finish surface is important to select the cutting levels in order to reach the required quality. In this research an experimental investigation was conducted to predict the surface roughness in the finish end milling process with higher cutting speed. Twenty sets of data for finish end milling on AISI H13 at hardness of 48 HRC have been collected based on five-level of Central Composite Design (CCD). All the experiments done by using indexable tool holder Sandvick Coromill R490 and the insert was PVD coated TiAlN carbide. The experimental work performed to predict four different roughness parameters; arithmetic mean roughness (Ra), total roughness (Rt), mean depth of roughness (Rz) and the root mean square (Rq).

scholarly journals Optimization of CNC Turning Parameters in Machining EN19 using Face Centered Central Composite Design Based RSM

2020 ◽  
Vol 9 (2) ◽  
pp. 889-896
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Removal Rate ◽  
Cutting Speed ◽  
Vital Role ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Turning ◽  
Software Analysis ◽  
Central Composite

Manufacturing a defect free (quality) product is playing a vital role in today’s globally competitive, customer oriented era. Meeting the demand of the market by producing sufficient quantity is another challenge. Achieving greater production rates without compromising on quality, increases the complexity of the task. Adopting modern manufacturing methods like CNC turning are essential to meet the above requirements. EN19 is an important member in the family of alloy steels, which has a wide variety of applications in automobile and machine tool industries. Optimization of machining parameters is crucial in obtaining the required outputs such as quality and productivity. In this work, optimization of CNC turning parameters for machining EN19 alloy steel is performed. The number of experiments was designed using face centred central composite based response surface methodology with varied independent process parameters namely cutting speed, feed and depth of cut. After designing the experiments, the performance measures such as surface roughness of the test samples and Material Removal Rate (MRR) is calculated using the existing formulae. The influence of parameters on MRR and surface roughness are determined by analysis of variance (ANOVA) and for significance interactions of the process parameters are also considered. Using MINITAB 17 software analysis is performed. Further, regression analysis has been done and second order mathematical model is obtained. Using desirability approach, optimization is carried out.

Optimization of Surface Roughness in End Milling of Titanium Alloy Ti-6Al-4V under the Influence of Magnetic Field from Permanents Magnets

2012 ◽  
Vol 576 ◽  
pp. 51-55 ◽  
Author(s):  
Syidatul Akma Sulaiman ◽  
A.K.M. Nurul Amin ◽  
M.D. Arif
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Permanent Magnets ◽  
End Milling ◽  
Desirability Function ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Central Composite

This paper presents the effect of cutting parameters on surface roughness in end milling of Titanium alloy Ti-6Al-4V under the influence of magnetic field from permanent magnets. Response Surface Methodology (RSM) with a small central composite design was used in developing the relationship between cutting speed, feed, and depth of cut, with surface roughness. In this experiment, three factors and five levels of central composite with 0.16817 alpha value was used as an approach to predict the surface roughness, in end milling of titanium alloy, with reasonable accuracy. The Design-Expert 6.0 software was applied to develop the surface roughness equation for the predictive model. The adequacy of the surface roughness model was validated to 95% by using ANOVA analysis. Finally, desirability function approach was used to determine the optimum possible surface roughness given the capabilities of the end machine.

A study on magnetic field assisted laser percussion drilling and its effect on surface integrity

2018 ◽  
Vol 1 (94) ◽  
pp. 35-40
Author(s):  
S. Balamurugan ◽  
C. Bala Manikandan ◽  
P. Balamurugan
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Aluminium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Laser Drilling ◽  
Machining Process ◽  
Profile Error ◽  
Taper Angle

Purpose: of this paper is to reduce the taper angle and surface roughness of the laser drilled hole on Aluminium alloy with the assistance of magnetic field. At lower laser powers, able to achieve higher material removal rate in drilling with reduced taper angle and roughness. Design/methodology/approach: Aluminium alloy is a highly reflective material, while laser drilling it ejects plumes, which makes the drilling unreliable. The plume generated due to this action causes deteriorating effects over the work piece as such affecting surface textures. Removal of plume is the major consideration in laser machining process, especially in laser assisted drilling. The plume is a form of cluster of ions having charges in it. Due to the magnetic field input, the ions line the path along the lines of force of magnets. Thus, the ion cloud can be cleared at the localized plane, where the subsequent laser drilling going to be happens, leads to reduced plume thereby reduces the taper angle and surface roughness. Findings: The defect of percussion laser drilling that is barrelling effect in the drilled hole was reduced with the assistance of magnetic field setup. For the laser energy of 90 mJ, the magnetic assisted laser drilling shows better improvement in the material removal rate of 64.5%, the profile error (spatter height) was reduced to 45% and the taper angle of the drilled hole also reduced by 16.3%. The results confirmed the fact that, the Lorentz force confined the plume particle to be raised upwards and circulated outwards to the sidewall from the centre of the laser beam. This expansion of laser induced plasma plume, improved the material removal rate of the hole. Research limitations/implications: Laser drilling was carried out by a constant magnetic field and the parameters like material removal rate, taper angle, profile error, surface roughness were studied. In the future work, these parameters were studied with the application of varying magnetic field. Practical implications: As a result of the work, laser drilling was carried out on turbine blades or complex shapes for retention properties, with reduced taper hole and surface roughness, thereby improving the efficiency of the systems. Originality/value: The novelty of the work is providing magnetic flux for the laser drilling process, which improves the process parameters. The incorporation of magnetic field to the laser drill needs a cost less setup, which can ensure reliable improvement in the material removal rate, reduction in taper angle and profile error.

scholarly journals Cutting Force and Cutting Quality during Tapered Milling of Glass Magnesium Board

2019 ◽  
Vol 9 (12) ◽  
pp. 2533
Author(s):  
Pingxiang Cao ◽  
Zhaolong Zhu ◽  
Xiaolei Guo ◽  
Xiaodong (Alice) Wang ◽  
Chunchao Fu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Tool Geometry ◽  
Cutting Condition ◽  
Cutting Depth ◽  
Machined Surface ◽  
Taper Angle

In this paper, the effects of tool geometry and cutting parameters on cutting force and quality were investigated during the tapered milling of glass magnesium (MGO) board with diamond cutters. The results were as follows: firstly, both the cutting force and roughness of the machined surface were positively correlated with the taper angle of the cutters and the cutting depth, but negatively related to the spindle speed. Then, the cutting depth had the largest influence on the cutting force and surface roughness, followed by the taper angle and spindle speed. Thirdly, the taper angle had a significant influence on the cutting force, but not on the surface roughness. The contribution of the spindle speed to both the cutting force and the surface roughness were significant, while the cutting depth had an insignificant effect on the cutting force and the surface roughness. Finally, the optimal cutting condition for the tapered milling of glass magnesium board was found to be a taper angle of 15°, a spindle speed of 5000 rpm (cutting speed of 36.63 m/s), and a cutting depth of 0.5 mm, which are proposed for industrial production in order to achieve greater cutting quality and economic benefit.

Performance of Cutting Parameters for Surface Excellence on 304 Stainless Steel Using Abrasive Water Jet Technique

2021 ◽  
Author(s):  
Isam Qasem ◽  
Ahmed Hussien ◽  
Pramodkumar S. Kataraki ◽  
Ayub Ahmed Janvekar
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
High Precision ◽  
Flow Rate ◽  
Work Hardening ◽  
Water Pressure ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Abrasive Water Jet ◽  
Kerf Taper

Abstract Advanced machining techniques are extensively being adopted for machining of high strength materials such as stainless steels. However, these materials are difficult to be machined out due to properties such as high work hardening rate and low thermal conductivity, work hardening and poor machinability. The manufacturing requirements such as production of high precision and surface finished components has led the researchers to study abrasive water jet (AWJ) machining and its applications in industrial sectors. As the AWJ is multi-operational and can produce high precision components. The carried-out work mainly intended to involve technical parameters such as water pressure, cutting speed, abrasive flow. These parameters were analyzed with respect to kerf taper and surface roughness on 304 stainless steel. Two critical variables namely cutting speed and outlet pressure were varied from 100 to 200 mm /min and 100 to 200 MPa, respectively. In additional based on the setup flow rate was altered from 360 to 540 g/min. The experimental results indicate kerf taper and surface roughness were strongly deflect by varying cutting rate, water pressure, and flow rate. Optimization of process parameter was performed by adopting response surface methodology as well as central composite design method. Finally, mathematical models and set of contour graphs for tested surface quality along the kerf taper angle was carried out using ANOVA analysis.

Parametric investigation and modelling of hardness and surface quality in CO2 laser cutting process of AISI 314 Stainless steel

2017 ◽  
Vol 20 (3) ◽  
pp. 101-107 ◽  
Author(s):  
V. Senthilkumar ◽  
G. Jayaprakash
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Quality ◽  
Co2 Laser ◽  
Laser Power ◽  
Laser Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Manufacturing Method ◽  
Kerf Taper

Laser cutting is the popular unconventional manufacturing method widely used to cut various engineering materials. In this work CO2 laser cutting of AISI 314 satinless steel has been investigated. This paper focus on the investigation into the effect of laser cutting parameters like laser power, assist gas pressure, cutting speed and stand-off distance on surface roughness, hardness and kerf dimensions like kerf width, kerf ratio and kerf taper in CO2 laser cutting of AISI 314 stainless steel.

scholarly journals Surface Roughness Characterization of Inconel 718 after Laser Assisted Turning

2018 ◽  
Vol 237 ◽  
pp. 01004 ◽  
Author(s):  
Agata Felusiak ◽  
Tadeusz Chwalczuk ◽  
Martyna Wiciak
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Laser Power ◽  
Cutting Speed ◽  
Complex Interaction ◽  
Laser Power Density ◽  
Roughness Parameters ◽  
Laser Assisted Turning ◽  
Central Composite

This paper describes the surface roughness parameters evaluation of Inconel 718 (43 HRC) after turning under laser assisted conditions. The experiment was conducted for cemented carbides inserts under various cutting and laser heating parameters. Tesets based on central composite research program allows to describe an interaction between input (cutting speed vc, laser power P, feed f) and output (roughness parameters according to PN-ISO 4288: Ra, Rz, Rt, Rsk, RSm, Rdq) parameters. The results showed that laser power density decrease values of amplitude type of roughness parameters. Such occurrence is not observed for horizonal and hybrid parameters of surface. The function is not described by monotonic projection. Therefore optimization by usability function was performed to observe complex interaction between input and output values. The findings of this work define which one of values from cutting speed, laser power and feed values have crucial impact on surface roughness constitution.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

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