scholarly journals Intensity increase in metal removal at vibration treatment based on use of “slot” effect in working chamber

2017 ◽  
Vol 2 (9) ◽  
pp. 33-38 ◽  
Author(s):  
Анатолий Бабичев ◽  
Anatoly Babichev ◽  
Филипп Пастухов ◽  
Philip Pastukhov ◽  
Амбогему Вобу ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Intensity Increase ◽  
Vibration Treatment ◽  
Working Chamber ◽  
Section Dimension ◽  
Slot Effect

The results of the investigations on metal removal intensity increase during the vibration treatment on the basis of the “slot” effect use in a working chamber are presented. The investigation results presented show that with the decrease of a section dimension in the working chamber metal removal increases and surface roughness is getting better.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

Optimization of MRR and Surface Roughness of AlMg3 (AA5754) Alloy in CNC Lathe Machine by Using Taguchi Method

2018 ◽  
Vol 877 ◽  
pp. 110-117 ◽  
Author(s):  
Poornesh Kumar Chaturvedi ◽  
Harendra Kumar Narang ◽  
Atul Kumar Sahu
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Metal Removal ◽  
Removal Rate ◽  
Surface Condition ◽  
Point Of View ◽  
Depth Of Cut ◽  
Metal Removal Rate ◽  
Cnc Lathe ◽  
Lathe Machine

Quality of the product is the major concern in manufacturing industries from customers as well as producers point of view. There are number of factors in the product such as surface condition, height, weight, length, width etc., which may be consider for the measurement of the quality. Surface roughness and Metal Removal Rate (MRR) are the two main outcomes on which numerous researchers have applied different approaches for several years to get optimum results. In this study, Taguchi Method is applied for getting optimum parameters settings for Surface roughness and Metal Removal Rate (MRR) in case of turning AlMg3 (AA5754) in CNC Lathe machine, which is an aluminum alloy having diameter 20 mm and length 100 mm. The three parameters i.e. spindle speed, feed rate and depth of cut with 3 levels are taken as the process variables and the working ranges of these parameters for conducting experiments are selected based on Taguchi’s L9 Orthogonal Array (OA) design. To analyze the significant process parameters; main effect plots for data means and for S/N ratio are generated using Minitab statistical software.

scholarly journals Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

2021 ◽  
Author(s):  
Dragan Rodic ◽  
Marin Gostimirovic ◽  
Milenko Sekulic ◽  
Borislav Savkovic ◽  
Branko Strbac
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Positive Effects ◽  
Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

Metal Removal and Surface Roughness Formation in Robotic Finishing

2021 ◽  
pp. 395-405
Author(s):  
Aleksei Aleksandrov ◽  
Michail Vartanov ◽  
Dmitry Mironov
Keyword(s):  
Surface Roughness ◽  
Metal Removal

Effect of the Al2O3 powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining

2020 ◽  
Vol 234 (12) ◽  
pp. 1538-1548 ◽  
Author(s):  
Hossam M Yehia ◽  
Mohamed Hakim ◽  
Ahmed El-Assal
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Lower Surface ◽  
Maximum Effect ◽  
Metal Removal Rate ◽  
Powder Addition ◽  
Different Depths ◽  
Electrochemical Grinding ◽  
Better Than

The integrated electrochemical grinding machining has received wide acceptance in the aircraft turbine industry for the machining of blades, vanes, and honeycomb seal rings. Also, medical devices, instruments and forceps, shells, precision nozzles, instrument coupling, and air rotor motors that produced from stainless steel and new materials have all successfully been accomplished with electrochemical grinding. To improve the metal removal rate and to reduce the surface roughness ( Ra) of the electrochemical grinding at high voltages, an integration between the alumina abrasive jet and the electrochemical grinding machining has been performed. The effect of the Al2O3 abrasive content on the metal removal rate and the Ra of the K110 alloy steel using Everite electrochemical grinding 618 at different voltages, different feed rates, different electrolyte NaCl concentrations, and different depths of the cut were successfully investigated. The results revealed that the abrasive electrochemical grinding was better than the electrochemical grinding results. The maximum effect of the Al2O3 on the metal removal rate was achieved at 5 wt.%. The current density in the machining gap was affected by the addition of the Al2O3, where it was decreased at percentages over 5-wt.% Al2O3. The abrasive electrochemical grinding resulted in lower surface roughness than the electrochemical grinding process.

EXPERIMENTAL INVESTIGATIONS INTO THE INFLUENCING PARAMETERS OF ELECTROCHEMICAL MACHINING OF AISI 202

2008 ◽  
Vol 07 (02) ◽  
pp. 337-343 ◽  
Author(s):  
T. SEKAR ◽  
R. MARAPPAN
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
High Energy ◽  
Experimental Investigations ◽  
Metal Removal Rate ◽  
Hard Materials ◽  
Influencing Parameters ◽  
Traditional Process

Electrochemical machining (ECM) is a non-traditional process used mainly to cut hard or difficult to cut metals, where the application of a more traditional process is not convenient. Those difficult to cut metals demand high energy to form chips, which can result in thermal effects due to the high temperatures inherent to the process in the chip–tool interface. In traditional processes, the heat generated during the cut is dissipated to the tool, chip, workpiece and environment, affecting the surface integrity of the workpiece, mainly for those hard materials. In this work, experimental investigations have been made on the various influencing parameters involved in the Metal removal rate (MRR) and Surface roughness using ECM on AISI 202 steel. The major intervening parameters are studied and the relationship between the parameters has been determined to achieve maximum metal removal rate and minimum surface roughness by using NaNO 3-Aqua solution.

Optimization of Machining Parameters During Turning of Tungsten Heavy Alloys Using Taguchi Analysis

2019 ◽  
Author(s):  
Chithajalu Kiran Sagar ◽  
Amrita Priyadarshini ◽  
Amit Kumar Gupta
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
Metal Removal ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Taguchi Analysis ◽  
Heavy Alloys ◽  
Wide Range ◽  
Tungsten Heavy Alloys ◽  
Machining Parameter

Abstract Tungsten heavy alloys (WHAs) are ideally suited to a wide range of density applications such as counterweights, inertial masses, radiation shielding, sporting goods and ordnance products. Manufacturing of these components essentially require machining to achieve desired finish, dimensions and tolerances However, machining of WHAs are extremely challenging because of higher values of elastic stiffness and hardness. Hence, there is a need to find the right combination of cutting parameters to carry out the machining operations efficiently. In the present work, turning tests are conducted on three different grades of WHAs, namely, 90WHA, 95WHA and 97WHA. Taguchi analysis is carried out to find out the most contributing factor as well as optimum cutting parameters that can give higher metal removal rate (MRR), lower surface roughness and lower cutting forces. It is observed that feed rate is the most prominent factor with percentage contribution varying in the range of 46–61%; whereas cutting speed has least effect on cutting forces, especially for 95WHA and 97WHA. Optimum values of forces, surface roughness and MRR and the corresponding machining parameters to be taken are presented. It is observed that 95W WHA has slightly better machinability as compared to other two grades since it gives highest MRR with lowest cutting forces and surface roughness values. The optimum machining parameter settings, so predicted, can be utilized to machine WHAs efficiently for manufacture of counter weights and inertial masses used in aerospace applications.

scholarly journals Evaluation of surface roughness in drilling particle-reinforced composites

2020 ◽  
Vol 29 ◽  
pp. 2633366X2093771
Author(s):  
Ferit Ficici
Keyword(s):  
Surface Roughness ◽  
Composite Materials ◽  
Feed Rate ◽  
Metal Removal ◽  
Cutting Speed ◽  
Weight Fraction ◽  
Matrix Alloy ◽  
Reinforced Composites ◽  
Structural Applications ◽  
Drilling Operations

Aluminum matrix composite materials being used in different sectors including automobile, aerospace, defense, and medical and are currently displacing unreinforced materials with their superior mechanical properties. The metal removal process of drilling is widely used in many structural applications. This study experimentally investigates the drilling characteristics of silicon carbide (SiCp)-reinforced Al 7075 composites produced by stir casting method. Also, two different drill materials with high-speed steel (HSS) and titanium nitride (TiN)-coated HSS carry out in drilling operation. The effect of operational parameters such as cutting speed and feed rate and materials parameters such as weight fraction of reinforcement and cutting tools on the surface roughness of drilled holes were evaluated in the drilling operations. The results of the drilling test indicate that the feed rate and cutting speed have a very strong effect on the surface roughness of matrix alloy and composite materials. The surface roughness ( Ra) values increased with increasing the feed rate and decreased with increasing the cutting speed. Under 0.10 mm/rev and 20 m/min drilling conditions and using HSS drill, surface roughness values for matrix, 5% SiC-, 10% SiC-, and 15% SiC-reinforced composites, were obtained 2.57, 2.59, 2.61, and 2.64 µm, respectively; besides, using TiN-coated HSS drill, surface roughness values were obtained 1.60, 1.63, 1.64, and 1.66 µm, respectively. An increase in the weight fraction of the abrasive SiC particle resulted in a very crucial deterioration quality of the drilled hole. TiN-coated HSS drills better performance exhibits than uncoated HSS drills for all the drilling operations about surface roughness properties. Short chip formations observed both the matrix alloy and the composite materials for two different drills in the drilling operations.

scholarly journals An overview of conventional and non-conventional techniques for machining of titanium alloys

2020 ◽  
Vol 7 ◽  
pp. 34 ◽  
Author(s):  
Samuel Ranti Oke ◽  
Gabriel Seun Ogunwande ◽  
Moshood Onifade ◽  
Emmanuel Aikulola ◽  
Esther Dolapo Adewale ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Metal Removal ◽  
Removal Rate ◽  
High Volume ◽  
Future Research ◽  
Tool Wear Rate ◽  
The Common

Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

Experimental Investigation of Vibratory Finishing Process

2014 ◽  
Author(s):  
Xiaozhong Song ◽  
Rahul Chaudhari ◽  
Fukuo Hashimoto
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Metal Removal ◽  
Contact Forces ◽  
Chemical Solution ◽  
Impact Frequency ◽  
Vibratory Finishing ◽  
Factors Affecting ◽  
Finishing Process ◽  
Chemical Solutions

The vibratory finishing process is widely used for finishing metal components. An experimental investigation is reported on the factors affecting the metal removal and resultant surface roughness during vibratory finishing including the influence of chemical solutions. The effect of process parameters such as media size and impact frequency is studied by measuring the contact forces. A method to investigate the effect of chemical solution and to optimize the processing time to achieve desired resultant surface roughness is presented.

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