Burn threshold of high-carbon steel in high-efficiency deep grinding

2002 ◽  
Vol 216 (3) ◽  
pp. 357-364 ◽  
Author(s):  
T Jin ◽  
D J Stephenson ◽  
J Corbett
Keyword(s):  
Carbon Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
High Carbon Steel ◽  
Numerical Control ◽  
Theoretical Expression ◽  
High Carbon ◽  
Five Axis

The burn-threshold of high-carbon steel (51CrV4) in the high-efficiency deep-grinding (HEDG) process is investigated. It is found that the burn threshold in HEDG is determined by the wheel-workpiece contact length, material removal rate and wheel speed. A theoretical expression for the burn threshold has been derived, which is based on the thermal modelling for deep grinding and takes account of the grinding parameters, wheel conditions, thermal properties of the workpiece and abrasive grain, and the heat convected away by the coolant and chips. The predicted upper and lower boundaries for occurrence of workpiece burn show good agreements with the experimental observations. It is shown that burn threshold in HEDG is related to the film boiling of process coolant and the critical heat flux increases as the specific material removal rate increases. The experiments were carried out on an Edgetek five-axis computer numerical control (CNC) grinding machine, which is capable of HEDG in a relatively wide range of process parameters.

INVESTIGATION ON CR, MRR AND SR OF WIRE ELECTRICAL DISCHARGE MACHINING (WEDM) ON HIGH CARBON STEEL S50C

2015 ◽  
Vol 76 (6) ◽  
Author(s):  
Bulan Abdullah ◽  
Mohammad Faezeen Mad Nordin ◽  
Muhamad Hafizuddin Mohamad Basir
Keyword(s):  
Surface Roughness ◽  
Carbon Steel ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
High Carbon Steel ◽  
Machining Parameters ◽  
High Carbon ◽  
Brass Wire

The purpose of this project is to study the encouragement of three machining parameters on wire electrical discharge machining that consist of peak current (IP), pulse OFF time (OFF) and wire tension (WT) to three machining responses which are cutting rate (CR), material removal rate (MRR) and surface roughness (SR) on high carbon steel (S50C). Brass wire with diameter 0.25 mm was used as the cutting tool for machining a high carbon steel (S50C) using Mitsubishi FX Wire Electrical Discharge Machine (WEDM). The machining parameters such as pulse off time, wire tension and peak current were determined by referring from the guideline in the manual book for Mitsubishi FX Wire Electrical Discharge Machine (WEDM). The calculation of material removal rate and cutting rate were obtained using mathematical equation. The surface roughness was measured using optical measurement “Alicona Infinite Focus” machine. The relationship between material removal rate and surface roughness shows that the optimum machine parameter using brass wire as the electrode is C1. From the spark analysis using brass wire as the machine’s electrode, the deeper the spark occurred, the higher value of the surface roughness. 

Experimental Investigation and Study the Effect of Hydro Fluoric Acid in Ultrasonic Machining of Polycarbonate Bullet Proof UL-752 and Acrylic Heat Resistant BS-476 Glass

2017 ◽  
Vol 24 ◽  
pp. 24-39 ◽  
Author(s):  
Kanwal Jeet Singh ◽  
Inderpreet Singh Ahuja ◽  
Jatinder Kapoor
Keyword(s):  
Tool Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
High Carbon Steel ◽  
Ultrasonic Machining ◽  
High Carbon ◽  
Heat Resistant ◽  
Machining Parameter

The main objective of this experimental work is to study the effect of Hydro Fluoric acid in ultrasonic machining of polycarbonate bullet proof UL-752 and Acrylic Heat resistant BS 476 Glass. In which, mixture of abrasive particle are also used as the input machining parameter. Three types of abrasive; Alumina, Silicon Carbide and Boron Carbide are used for machining. Experiment has been performed with 8mm of high carbon high chromium tool steel (D2), high carbon steel (HCS) and high speed tool steel (HSS) tools. The material removal rate was father enhanced by HF acid. The experimentation date represent the main effect plots for tool wear rate and material removal rate. After analysis, results reveals that Al2O3+SiC+B2C mixed slurry (1:1:1), Hydro Fluoric acid with 1% concentration and High Speed tool Steel material produce the higher material removal affect.

Wear Characteristics of the Sub-Aperture Tools and Material Removal Rate in Precision Grinding with Loose Abrasives

2007 ◽  
Vol 329 ◽  
pp. 69-74
Author(s):  
H. Cheng ◽  
H.Y. Tam ◽  
Y. Gao ◽  
Yong Bo Wu ◽  
Y. Wang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Process Analysis ◽  
Actual Process ◽  
Correlative Function ◽  
Glass Specimen ◽  
Grinding Tool ◽  
The Relationship

This paper proposes a sub-aperture grinding tool for loose abrasive computer controlled surfacing, which is designed to perform epicyclic motion and rotate around its centre at a rapid rate, whilst the entire mechanism revolves around a secondary centre at a slower rate. In actual process, the wear of the tool could affect the material removal function, and make the process unstable, thus in fact, it is difficult to make a deterministic manufacturing. The focus of the present paper is on wearing characteristics of sub-aperture tools and the wear evenness as the main objectives. To make a further study, material removal function of the tool is firstly established through theoretically modelling, next, a correlative function with weighted factors is built, which is suitable for specifying the wearing degree of the tool. Finally, to discover the relationship between the material removal rate and the tool wearing characteristics, and to optimize the grinding process, analysis and experiments are then carried out on a K9 glass specimen by means of three kinds of tool materials, i.e., polyurethane pad, aluminum plate and pitch based on the proposed technique and model. The results indicated that the required high efficiency and precision could be achieved by choosing proper processes.

scholarly journals Pengaruh Kecepatan Potong, Kecepatan Pemakanan Dan Sudut Potong Utama Terhadap Kekasaran Permukaan Pada Proses Bubut Medium Carbon Steel

2020 ◽  
Vol 11 (2) ◽  
pp. 13-18
Author(s):  
P. I. Gultom ◽  
Kiswandono
Keyword(s):  
Carbon Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Medium Carbon Steel ◽  
Medium Carbon

Persaingan di industri manufaktur menuntut produk dengan kualitas tinggi dan produktivitas tinggi juga.Parameter pemesinan seperti sudut potong, kecepatan potong dan kecepatan pemakanan menentukan besarnya laju pengerjaan material atau material removal rate (MRR) dari proses bubut. Penentuan parameter pemesinan secara berlebihan justru akan menurunkan produktivitas karena adanya suatu produk yang harus dikerjakan ulang (reworked). Penelitian ini khususnya akan ditekankan pada proses bubut dengan benda kerja medium carbon steel.Permasalahan yang timbul adalah bagaimana menentukan kecepatan potong, kecepatanpemakanan, dan sudut potong utama pada proses bubut dengan benda kerja medium carbon steel yang akan menghasilkankehalusan permukaan hasil bubut pada produk. Hasil dari penelitian menunjukkan bahwa proses bubut baja ST-60 tanpa follower rest, dengan parameter pemesinan sudut potong utama Kr = 45°,  kecepatan potong 60,5 m/menit, kecepatan pemakanan 44,66 mm/menit dan pada kedalaman potong 0,2 mm diperoleh nilai kekasaran permukaan 3,72 µm atau tingkat kekasaran N8. Sedangkan untuk parameter pemesinan sudut potong utama Kr = 90°,  kecepatan potong 60,5 m/menit, kecepatan pemakanan 22,33 mm/menit dan pada kedalaman potong 0,2 mm diperoleh nilai kekasaran permukaan 3,69 µm atau tingkat kekasaran N8.

scholarly journals Influence of different tool polarity on short electric arc machining of GH4169

2019 ◽  
Vol 234 (1-2) ◽  
pp. 108-117 ◽  
Author(s):  
Xiaokang Chen ◽  
Jianping Zhou ◽  
Kedian Wang ◽  
Yan Xu
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electric Arc ◽  
Positive Polarity ◽  
Machining Performance ◽  
Workpiece Surface ◽  
Nickel Based Superalloy

Short electric arc machining is a recently developed high-efficiency electrical discharge machining technology. Material removal rate, tool mass wear ratio ([Formula: see text]), and workpiece surface roughness ( Ra) are important indexes used to evaluate the machining performance of short electric arc machining. In order to obtain better machining effect, the nickel-based superalloy GH4169 is machined by graphite in this article. The influence of voltage, duty cycle, and flushing pressure on short electric arc machining performance is then investigated under different tool polarity conditions. Experimental results show that higher material removal rate and lower [Formula: see text] can be obtained by negative polarity machining, while positive polarity machining can produce better surface quality. To investigate the cause of this difference, the surface integrity of GH4169 machined by different tool polarity is studied from macro and micro perspectives.

Modeling Material Removal Rate of Heavy Belt-Grinding in Manufacturing of U71Mn Material

2016 ◽  
Vol 693 ◽  
pp. 1082-1089 ◽  
Author(s):  
Rong Quan Wang ◽  
Jian Yong Li ◽  
Yue Ming Liu ◽  
Wen Xi Wang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Low Cost ◽  
Belt Grinding ◽  
Abrasive Particles ◽  
Grinding Conditions ◽  
Modeling Material ◽  
Abrasive Cutting

The heavy belt-grinding is a new machining method, which combined the characters of heavy-duty grinding and belt-grinding together, with high efficiency and low cost. In the present paper the removal rate model of heavy belt-grinding in manufacturing of U71Mn steel is established. It is assumed that the distribution of the abrasive particles protrusion height of the abrasive belt surface closes to Gaussian distribution. The model is presented by calculating the removal volumes of all abrasive grains contributing to cutting action based on the probability theory, elastic-plastic mechanics and abrasive cutting theory. It is analysis that the material removal rate depends essentially on the mechanical properties of the workpiece and the belt and the grinding conditions. It is proportional to the average pressure, belt velocity and the indentation depth and is inverse proportion to the grain size.

Optimizing of Integral Impeller NC Program Based on the Material Removal Rate

2014 ◽  
Vol 1030-1032 ◽  
pp. 1305-1308
Author(s):  
Shi Chao Li ◽  
Song Lin Wu ◽  
Yan Kun Liang
Keyword(s):  
Material Removal Rate ◽  
Machine Tools ◽  
Material Removal ◽  
Removal Rate ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Nc Machine ◽  
Nc Machine Tools ◽  
Five Axis

It is a general processing technology that multi-axis NC machine tools is used for machining impeller at present. In order to improve the machining accuracy of the five-axis NC machine tools, the paper analyzes the computing interpolation error of the Multi-axis CNC system in detail. Some of the measures of tools selection have been proposed in purpose of diminishing the accumulative error of the system. The paper also establishes the optimized objective function to optimize the process parameters of the CNC machining based on the material removal rate. All these measures will improve the machining efficiency significantly and increase the stationary of the machining process.

Specific Material Removal Rate Calculation in Five-Axis Grinding

2017 ◽  
Vol 139 (12) ◽  
Author(s):  
Raja Kountanya ◽  
Changsheng Guo
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Tool Path ◽  
Removal Rate ◽  
Unit Length ◽  
Chip Thickness ◽  
Impeller Blade ◽  
Tool Profile ◽  
Specific Material ◽  
Five Axis

Specific material removal rate (MRR) q′ was calculated for five-axis grinding in a virtual machining simulation environment (VMSE). The axis-symmetric tool rotational profile was arc-length parameterized. The twisted grazing curve due to the concurrent translation and rotation in every move was modeled through an exact velocity field and areal MRR density q″, positive in the front of the grazing curve on the tool surface. Variation of q′ and equivalent chip thickness h within the instantaneous engagement contour were deduced from q″. Illustrative results with a five-axis impeller blade finishing simulation are shown. The results were benchmarked against an average q′ calculated from the instantaneous MRR from the VMSE. As a function of time, maximum chip thickness hmax within the extents of contact along the tool profile in every move showed more isolated peaks than corresponding qmax′. Maximum cumulative material removed per unit length Qmax′ along the tool profile from all the moves was calculated to predict axial location of maximum risk of cutter degradation.  Qmax′ and hmax are useful metrics for tool path diagnosis and tool wear analysis.

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