Effect of machining parameters and vibration on polymethylmethacrylate curved surface in single-point diamond turning

2020 ◽  
pp. 251659842094172
Author(s):  
Kuldeep A. Mahajan ◽  
Raju Pawade
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Single Point ◽  
Optical Devices ◽  
Diamond Turning ◽  
Curved Surface ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material

Single-point diamond turning (SPDT) is an emerging process for achieving nanometric surface finish, required in various optical devices made from metals like aluminum, copper, and nonmetals like polymers. The optical devices are manufactured in different shapes and profiles, preferably flat and curved surfaces. During the manufacturing of optical devices, controllable and noncontrollable parameters affect the desired surface finish. In this article, controllable machining parameters such as the incremental distance of X slide, feed rate, spindle speed, and depth of cut are selected to study their effect on surface finish and vibration generation of the curved surface. The chosen workpiece material is polymethylmethacrylate (PMMA). Design of experiment (DoE) is used to find out the optimum parameters of surface finish and infeed vibration responses. According to the Taguchi and analysis of Variance (ANOVA) analysis, the feed rate is the most influencing parameter for surface roughness, and incremental distance is for infeed vibration. A confirmation test is carried out to verify the experimental responses with a mathematical regression model, and it shows a close difference within 2.7 percent. Further, minimum surface roughness is perceived as 12.4 nm, corresponding to an infeed vibration amplitude of 4.9 µm/s2, which is signified at a lower frequency.

scholarly journals Effect of Nose Radius on Surface Roughness of Diamond Turned Germanium Lenses

2021 ◽  
Author(s):  
Adeniyi Adeleke ◽  
Abou-El-Hossein Khaled ◽  
Odedeyi Peter
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Single Point ◽  
Absolute Error ◽  
Diamond Turning ◽  
Machining Process ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Machining Parameters ◽  
Nose Radius

Abstract The desire for quality infrared lens with better surface finish has brought about the usage of brittle materials like germanium to be machined via a single point diamond turning machining process. However, achieving the required surface finish is complex if special machining techniques and approaches are not employed. In this paper, the effect of two different tool nose radius parameters on surface roughness of single point diamond turned germanium workpiece were studied and analyzed. The machining parameters selected for this experiment were feed, speed and depth of cut. Box-Behnken design was adopted to optimally create a combination of cutting parameters. Measurement of surface roughness after each run in both experiments was achieved using a Taylor Hobson PGI Dimension XL surface Profilometer. The resulting outcomes show that at most experimental runs, the surface roughness value decreased with an increase in nose radius. Mean absolute error was also used to compare the accuracy validation of the two models.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

scholarly journals The Experimental Investigation of Surface Roughness After Dry Turning of Steel S235

2019 ◽  
Vol 26 (4) ◽  
pp. 179-184
Author(s):  
Justyna Molenda
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Scientific Work ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Important Indicator

AbstractNowadays lot of scientific work inspired by industry companies was done with the aim to avoid the use of cutting fluids in machining operations. The reasons were ecological and human health problems caused by the cutting fluid. The most logical solution, which can be taken to eliminate all of the problems associated with the use of cooling lubricant, is dry machining. In most cases, however, a machining operation without lubricant finds acceptance only when it is possible to guarantee that the part quality and machining times achieved in wet machining are equalled or surpassed. Surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered as one of the most important parameter in industry. Today the quality of surface finish is a significant requirement for many workpieces. Thus, the choice of optimized cutting parameters is very important for controlling the required surface quality. In the present study, the influence of different machining parameters on surface roughness has been analysed. Experiments were conducted for turning, as it is the most frequently used machining process in machine industry. All these parameters have been studied in terms of depth of cut (ap), feed rate (f) and cutting speed (vc). As workpiece, material steel S235 has been selected. This work presents results of research done during turning realised on conventional lathe CDS 6250 BX-1000 with severe parameters. These demonstrate the necessity of further, more detailed research on turning process results.

Optimization of Cutting Parameters for Turning Operation of Titanium Alloy Ti-6Al-4V Material Workpiece Using the Taguchi Method

2013 ◽  
Vol 685 ◽  
pp. 57-62
Author(s):  
Seyyed Pedram Shahebrahimi ◽  
Abdolrahman Dadvand
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Taguchi Method ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Material Tool

One of the most important issues in turning operations is to choose suitable parameters in order to achieve a desired surface finish. The surface finish in machining operation depends on many parameters such as workpiece material, tool material, tool coating, machining parameters, etc. The purpose of this research is to focus on the analysis of optimum cutting parameters to get the lowest surface roughness in turning Titanium alloy Ti-6Al-4V with the insert with the standard code DNMG 110404 under dry cutting condition, by the Taguchi method. The turning parameters are evaluated as cutting speed of 14, 20 and 28 m/min, feed rate of 0.12, 0.14 and 0.16 mm/rev, depth of cut of 0.3, 0.6 and 1 mm, each at three levels. The Experiment was designed using the Taguchi method and 9 experiments were conducted by this process. The results are analyzed using analysis of variance method (ANOVA). The results of analysis show that the depth of cut has a significant role to play in producing lower surface roughness that is about 63.33% followed by feed rate about 30.25%, and cutting speed has less contribution on the surface roughness. Also it was realized that with the use of the confirmation test, the surface roughness improved by 227% from its initial state.

Modeling and Prediction of Surface Roughness in Ultra-High Precision Diamond Turning of Contact Lens Polymer Using RSM and ANN Methods

2018 ◽  
Vol 928 ◽  
pp. 139-143 ◽  
Author(s):  
Muhammad Mukhtar Liman ◽  
K. Abou-El-Hossein ◽  
Peter Babatunde Odedeyi
Keyword(s):  
Surface Roughness ◽  
Contact Lens ◽  
Predictive Models ◽  
Feed Rate ◽  
Single Point ◽  
Computational Cost ◽  
Cutting Speed ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Statistical Experimental Design

In this paper, Single point diamond turning tests were carried out on rigid gas permeable contact lens (ONSI-56), using monocrystalline diamond cutting tools. During the tests, the depth of cut, feed rate, and cutting speed were varied. Turning experiments were designed based on Box-Behnken statistical experimental design technique. An artificial neural network (ANN) and response surface (RS) model were developed to predict surface roughness on the contact lens turned part surface. In the development of predictive models, cutting parameters of cutting speed, depth of cut and feed rate were considered as model variables. The required data for predictive models are obtained by conducting a series of turning test and measuring the surface roughness data. Good agreement is observed between the predictive models results and the experimental measurements. The ANN and RSM models for ONSI-56 contact lens turned part surfaces are compared with each other for accuracy and computational cost.

scholarly journals Optimisation of Cutting Parameters for Minimal Surface Roughness in Single Point Diamond Turning of TI6AL4VELI

2019 ◽  
Vol 8 (12) ◽  
pp. 3222-3226
Keyword(s):  
Surface Roughness ◽  
Minimal Surface ◽  
Feed Rate ◽  
Single Point ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Influential Factors ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Diamond Cutting Tool

In this study the effect and optimisation of machining parameters on surface roughness in a facing operation of Ti6Al4VELI by single point diamond machining have been investigated. The experimental studies carried under varying cutting speeds, feed rates, different tool nose radius and depths of cut. The orthogonal array, signal-to-noise ratio (S / N) and variance analysis (ANOVA) were used to examine the performance characteristics of the Ti6Al4VELI alloy turning by using single-point diamond cutting tool. The influential factors on the surface roughness after machining are feed rate and cutting speed after the conclusions revealed. Whereas the feed rate had the most significant effect on tool life. Minimal surface roughness achieved after machining is in nano-level which is better than other conventional precision machining.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Application of Taguchi Technique to Surface-Grinding of Mold Steel

2016 ◽  
Vol 689 ◽  
pp. 7-11 ◽  
Author(s):  
Y. Şahin ◽  
Senai Yalcinkaya
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Quality Characteristics ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Fluid Environment ◽  
Selection Of

The selection of optimum machining parameters plays a significant role for the quality characteristics of products and its costs for grinding. This study describes the optimization of the grinding process for an optimal parametric combination to yield a surface roughness using the Taguchi method. An orthogonal array and analysis of variance are employed to investigate the effects of cutting environment (A), depth of cut (B) and feed rate (C) on the surface roughness characteristics of mold steels. Confirmation experiments were conducted to verify the optimal testing parameters. The experimental results indicated that the surface finish decreased with cutting-fluid and depth of cut, but decreased with increasing feed rate. It is revealed that the cutting fluid environment had highest physical as well as statistical influence on the surface roughness (71.38%), followed by depth of cut (25.54%), but the least effect was exhibited by feed rate (1.62%).

Form Accuracy of Optical Mould Inserts Made from Rapidly Solidified Aluminium Alloys

2015 ◽  
Vol 828-829 ◽  
pp. 62-68
Author(s):  
Khaled Abou-El-Hossein
Keyword(s):  
High Precision ◽  
Surface Finish ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Optical Surface ◽  
Form Accuracy ◽  
Optical Surfaces ◽  
Rapidly Solidified

Plastic optical components and lenses produced in mass quantities are usually manufactured using high-precision plastic injection technology. For that, high-precision plastic moulds with aluminium optical inserts made with extremely high dimension accuracy and high optical surface quality are used. Ultra-high precision single-point diamond turning have been successfully used in shaping optical mould inserts from various aluminium grades such as traditional 6061. However, extreme care should be taking when selecting machining parameters in order to produce optically valid surfaces before premature tool wear takes place especially when the machined optical materials has inadequate machining database. The current experimental study looks at the effect of cutting conditions on optical surfaces made from aluminium. The study embarks on helping establish some diamond machining database that helps engineers select the most favourable cutting parameters. The papers reports on the accuracy and surface finish quality received on an optical surface made on mould inserts from a newly developed aluminium alloy. Rapidly solidified aluminium (RSA) grades have been developed recently to address the various problems encountered when being cut by single-point diamond turning operation. The material is characterised by its extremely fine grained microstructure which helps extend the tool life and produce optical surfaces with nanometric surface finish. It is found the RSA grades can be successfully used to replace traditional optical aluminium grades when making optical surfaces. Surface finishes of as low as 10 nanometres and form accuracy of less than one micron can be achieved on RSA.

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