scholarly journals Study on Alloy Steel TEW 6582 Machined Surface Rougness Under Dry Machining

2018 ◽  
Vol 7 (2.13) ◽  
pp. 398
Author(s):  
Suhardi Napid ◽  
Muhammad Rafiq Yanhar ◽  
Ahmad Bakhori ◽  
Abdurrozzaq Hasibuan ◽  
Oris Krianto Sulaiman ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Alloy Steel ◽  
Optical Microscope ◽  
Work Piece ◽  
Cutting Condition ◽  
Dry Machining ◽  
Cnc Machine ◽  
Machined Surface ◽  
Significant Difference ◽  
Optimum Cutting

The purpose of research is to study the surface roughness of machining results obtained to give consideration that the possibility of dry machining can be realized at alloy steel machining of TEW 6582. In the field of surface texture only discuss the machined surface roughness with some testing that is processing and data analysis can be done statistically. The TEW 6582 alloy steel samples were produced from dry machining operations with 9 cutting forms using standard L 9 (34). In this case 3 variations of tool wear are determined by tool edge wear (VB) = 0.1 mm, 0.3 mm and 0.6 mm including also in wet machining. To cut the work piece used CNC machine, optical microscope and surface test . The roughness test was obtained the roughness value with dry machining for optimum cutting conditions ie HPK1.0.1 = 1,467 μm, HPK8,0.3  = 2,133 μm and HPK8,0.6 = 2,8 μm whereas value in wet machining was found with HPB1,0.1 = 1,581 μm, HPB8.0.3 = 2,304 μm and HPB8,0.6 = 2,906 μm. From the above machining results data, HPK8.06 can be determined as the most optimum cutting condition which can be concluded that dry machining gives better machining results  roughness through Ravg value and no significant difference is obtained when compared to wet machining after statistically analyzed, so that dry machining is a good chance that can be realized in manufacturing and automotive industries.  

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

scholarly journals Study of Optimum Cutting While Lathing Carbonate Steel VCN-150 Uses a Layered Carbide Chisel PVD on Dry and Wet Condition

2018 ◽  
Vol 7 (2.13) ◽  
pp. 389
Author(s):  
Muksin R. Harahap ◽  
Ahmad Bakhori ◽  
Suhardi Napid ◽  
Muhammad Rafiq Yanhar ◽  
Abdurrozzaq Hasibuan
Keyword(s):  
Surface Roughness ◽  
High Temperature ◽  
Carbon Steel ◽  
Dry Cutting ◽  
Surface Method ◽  
Significant Difference ◽  
Optimum Cutting ◽  
Wet Condition

To improve the productivity of this machining perhaps it may be recommended in a dry cutting but a dry cutting is recognized very sensitive to a high temperature. In this case, in order to overcome is perhaps required by using a tool carbide either in layers or without any layers whereby each layer has certain superior. There was conducted an experiment to have an optimum cutting on a carbon steel VCN-150 using a layers tool carbide  and Respond Surface Method (RSM) with a CCD operation. The result of study recommended that condition optimum cutting shall be achieved (When cutting tc ) on a medium machining refers to ISO 3685 and medium surface roughness (Ra ) ISO 1320. Statistically, there is no found significant difference between a dry and wet cutting on optimum dry condition.  

EFFECT OF CUTTING PARAMETERS ON CUTTING ZONE IN CRYOGENIC HIGH SPEED MILLING OF INCONEL 718 ALLOY

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
A. H. Musfirah ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Part Quality ◽  
Cutting Zone ◽  
Coated Carbide

In tribology phenomenon, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in ball end milling process. Experiments were performed using a multi-layer TiAlN/AlCrN-coated carbide inserts under cryogenic and dry cutting condition. A transient milling simulation model using Third Wave Advantedge has been done in order to gain in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can  decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining. Furthermore, the microstructure of machined workpiece revealed that cryogenic cooling also can reduce a plastic deformation at the cutting surface as compared with the dry machining. 

scholarly journals Experimental Study on the Effects of Coolants on Surface Quality and Mechanical Properties of Micromilled Thin-Walled Elgiloy

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1497 ◽  
Author(s):  
Da Qu ◽  
Peng Zhang ◽  
Jiadai Xue ◽  
Yun Fan ◽  
Zuhui Chen ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Surface Quality ◽  
Lower Surface ◽  
Work Piece ◽  
Dry Machining ◽  
Core Component ◽  
The Core ◽  
Thin Walled ◽  
The One

In this study, minimum quantity coolant/lubrication (MQCL) is found to have significant impact on the surface quality and mechanical properties of the micromilled thin-walled work piece that is the core component of an aeroaccelerometer. Three kinds of coolants were used in the micromilling process to analyze their effects on surface quality and mechanical properties of the component. The experiment results show that an appropriate dynamic viscosity of coolant helps to improve surface roughness. The high evaporation rate of the coolants can enhance the cooling performance. Comparing with the dry machining case, MQCL has better performance on improving tool wear, surface quality, and mechanical properties of the micromilled work piece. It yielded up to 1.4–10.4% lower surface roughness compared with the dry machining case in this experiment. The machined work piece with the best mechanical properties and the one with the worst mechanical properties appeared in the ethyl alcohol and the dry machining case, respectively. The reasons for deteriorating surface quality and mechanical properties in dry machining cases are also analyzed. For improving the micromilling process, the penetration and cooling effect of the coolants are more important. This paper gives references to obtain better service performance of the component by improving the micromilling process.

Evaluation of Cutting Rate for Ultrasonic Work Piece Vibration Assisted Wire-EDM under Varying Amplitude of Vibration

2020 ◽  
Vol 979 ◽  
pp. 149-156
Author(s):  
Sanjay Kumar ◽  
Sandeep Grover ◽  
Ravinder S. Walia
Keyword(s):  
Cutting Speed ◽  
Work Piece ◽  
Cutting Condition ◽  
Time Level ◽  
Peak Current ◽  
Optimum Cutting ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Level 2

This paper present an investigation on cutting speed of ultrasonic vibration assisted wire electrical discharge machining (US-WEDM) for High carbon high chromium D3 Steel. An extensive research study was carried out with an aim to select the optimum cutting condition with the varying amplitude of vibration in order to get the optimum cutting speed for the proposed set-up. The process was mathematically modeled using the response parameters, i.e. cutting speed under a range of control parameters and the main influencing factors were determined for cutting speed criteria Taguchi’s experimentation methodology indicated the contribution of amplitude of vibration (P=6.16%), pulse on time (P=14.54%), pulse off time (P=73.16%) and peak current (P=5.94%). Finally, the optimum parametric setting for different cutting speed arising out of study has synthesized as amplitude of vibration at level 3 (18μm), peak current level 1 (100 units), pulse on time level 2 (118 μ sec) and pulse off time level 2 (46 μ sec) and analyses in this study.

Dry Machining of Brass Using Titanium Carbonitride (TiCN) Coated Tool

2013 ◽  
Vol 372 ◽  
pp. 495-500
Author(s):  
Tasnim Firdaus Ariff ◽  
Mohd Syahidan Kamarudin ◽  
Mohd Amiruddin Haron
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Cutting Parameters ◽  
Titanium Carbonitride ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Machining ◽  
Wear Rates ◽  
Optimum Cutting ◽  
The Cost

Dry machining is environmentally friendly, clean and safe to be performed. Regardless of decreasing tool life due to lack of lubricants, choosing dry machining over wet machining may be a wiser choice since the cost of purchasing and disposing the cutting fluids can contribute to a higher cost. Wear rates, tool wear intensities and material removal rates (MRR) of TiCN coated tools using both dry and traditional wet machining on brass were studied with the aim in finding the optimum cutting condition from four different cutting speeds (207, 279, 372 and 498 m/min) with two sets of cutting parameters; depth of cut and feed rate (d = 0.1 mm, f = 0.2 mm/rev and d = 0.2 mm, f = 0.4 mm/rev). Temperatures at the tool-chip interface were measured to analyze the effects of temperature rise during dry machining. Cost analysis on machining cost per piece between dry and wet machining was performed. The optimum cutting condition for wet and dry machining of brass using TiCN coated cutting tool was found to be 498 m/min at d = 0.2 mm, f = 0.4 mm/rev. The tool tip temperature obtained from dry machining did not influence tool wear since the temperature rise is quite similar to the wet machining temperatures. The machining for the dry machining reduced to about 25-76% per piece when compared with wet machining.

Machining characteristics of Inconel 718 under several cutting conditions based on Taguchi method

2012 ◽  
Vol 227 (9) ◽  
pp. 1889-1897 ◽  
Author(s):  
R Thirumalai ◽  
JS Senthilkumaar ◽  
P Selvarani ◽  
S Ramesh
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Flank Wear ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Parameters ◽  
Dry Machining ◽  
Noise Factors

Extensive researchers have conducted several experiments in the past for selecting the optimum parameters in machining nickel based alloy – Inconel 718. These experiments conducted so far are dealt with dry machining and flooded coolant machining of nickel alloy Inconel 718. In this research study, the usage of refrigerated coolant is also dealt with and it is compared with dry machining and flooded coolant machining. Cutting speed, feed and depth of cut are considered as the machining parameters. The effectiveness of the refrigerated coolant in machining the heat resistant super alloy material Inconel 718 with respect to these machining parameters are described in this article. The machinability studies parameters were generated with surface roughness and flank wear. The performance of uncoated carbide cutting tool was investigated at various cutting condition under dry, flooded coolant and refrigerated coolant machining. The relationship between the machining parameters and the performance measures were established and using analysis of variance significant machining parameters determined. This article made an attempt to Taguchi optimization technique to study the machinability performances of Inconel 718. Taguchi approach is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer experiments than a factorial design. Taguchi’s optimization analysis indicates that the factors level, its significance to influence the surface roughness and flank wear for the machining processes. Confirmation tests were conducted at an optimal condition to make a comparison between the experimental results foreseen from the mentioned correlations.

A Study of Surface Integrity when Machining Refractory Titanium Alloys

2009 ◽  
Vol 83-86 ◽  
pp. 1059-1068 ◽  
Author(s):  
Armansyah Ginting ◽  
Mohammed Nouari ◽  
Nadhir Lebaal
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Surface Integrity ◽  
Bulk Material ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Feed Speed ◽  
Machined Surface ◽  
Feed Mark ◽  
Coated Carbide

In this paper, the surface integrity is studied when machining the aeronautical titanium alloys. Surface roughness, lay, defects, microhardness and microstructure alterations are studied. The result of surface roughness judges that the CVD-coated carbide fails to produce better Ra value than the uncoated. Lay is characterized by cutting speed and feed speed directions. Feed mark, tearing surface, chip layer formation as built up layer (BUL), and deposited microchip are the defects. Microhardness is altered down to 350 microns beneath the machined surface. The first 50 microns is the soft sub-surface caused by thermal softening in ageing process. Microstructure alteration is observed in this sub-surface. Down to 200 microns is the hard sub-surface caused by the cyclic internal work hardening and then it is gradually decreasing to the bulk material hardness. It is concluded that dry machining titanium alloy is possible using uncoated carbide with cutting condition limited to finish or semi-finish for minimizing surface integrity alteration.

scholarly journals FEASIBILITY STUDY OF ULTRASONIC FREQUENCY APPLICATION ON FDM TO IMPROVE PARTS SURFACE FINISH

2015 ◽  
Vol 77 (32) ◽  
Author(s):  
Maidin, S. ◽  
Muhamad, M.K. ◽  
Pei, E.
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Surface Defects ◽  
Complex Geometry ◽  
Acrylonitrile Butadiene Styrene ◽  
Optical Microscope ◽  
Machining Process ◽  
Ultrasonic Frequency ◽  
Machined Surface ◽  
Machining Parameter

Fuse Deposition Modeling (FDM) offer several advantages such as less expensive material, lack of expensive lasers and allows complex geometry to be built. However, FDM have limitations such as seam lines appear between layers and excess material residue, leading to surface roughness and poor finish. Ultrasound has been applied in various conventional machining process and shows good machined surface finish. However, from the literature review, it was found there is no investigation made on the application of ultrasound for Additive Manufacturing (AM) especially for FDM. This paper presents an adaptive approach to improve surface finish of FDM sample by applying ultrasonic vibration. The papers discuss the result of the surface finish of test piece printed via a desktop FDM system whereby an ultrasound device that was securely mounted onto the platform during printing process. Frequency that was used in the experiment is 11, 16 and 21 kHz with acrylonitrile butadiene styrene (ABS) material. Optical microscope with the aid of pro VIS software version 2.90 was used to measure the surface roughness of the four samples printed with a vibration in the above specified frequency. It was found that a 21 kHz frequency applied to the FDM process achieved the best surface finish due to less surface defects found and thickness had finer layers being produced. The results from this study could potentially be applied to other AM system such as the selective laser sintering, electron beam machining and stereolithography. The new data on effects of ultrasonic FDM technique and machining parameter for achieving improved surface finish has potential benefit to be used in various industries such as automotive, consumer, medical, sports, etc to produce prototypes or customized end used product or part. The data will benefit in term of product design and development elimination of manual post processing. Further study that could be done is to use different types of material such as polyactic acid (PLA) or composite material.

Research on Cutting Force Spectrum Character and Tools Vibration Character under Titanium Alloy End-Surface Turning

2013 ◽  
Vol 274 ◽  
pp. 196-199
Author(s):  
Wei Zhang ◽  
Min Li Zheng ◽  
Ying Bin Li
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Parameters ◽  
Work Piece ◽  
Characteristic Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Testing Experiment ◽  
The Relationship

titanium alloy cutting force testing experiment of end-surface turning is made, and spectrum character is analyzed by obtained data of cutting force experiment, and ten the influencing rule of cutting parameter on cutting force character is discovered; using the similarity between tools vibration character and cutting force spectrum character, and based on obtained data of machined surface roughness testing experiment, the two characteristic parameters of vibration frequency and amplitude value relative to work piece is calculated, and the relationship curve between cutting parameters and tools vibration character parameter is established is this paper.

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