scholarly journals Characteristics of Surface Roughness According to Wire Vibration Wire-cut Electric Discharge Machining of Aluminum Alloy 6061(II)

2015 ◽  
Vol 14 (4) ◽  
pp. 100-107
Author(s):  
Cheong-Won Ryu ◽  
Seong-Dae Choi
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Electric Discharge ◽  
Electric Discharge Machining ◽  
Aluminum Alloy 6061 ◽  
Wire Vibration ◽  
Alloy 6061

Tool Wear of Diamond-Like Carbon-Coated High-Speed Steel with a Cr-Based Interlayer in Cutting of Aluminum Alloys

2012 ◽  
Vol 152-154 ◽  
pp. 74-79
Author(s):  
Tadahiro Wada ◽  
Koji Iwamoto ◽  
Hiroaki Sugita
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Diamond Like Carbon ◽  
Aluminum Alloy 6061 ◽  
Coated Tool ◽  
Alloy 6061

In cutting aluminum alloy 6061, continuous chips have a negative influence on the machining operation. Usually, Pb is added in order to break continuous chips. However, from the standpoint of environmental protection, it is necessary to improve chip breakability without adding Pb. One effective measure to improve chip breakability is by adding Si to aluminum alloy 6061. However, the influence of Si content on tool wear has not been fully examined. In this study, in order to clarify the influence of a diamond-like carbon (DLC) coating layer with a Cr-based interlayer, namely (Al,Cr)N, on cutting performance, aluminum alloys having different Si contents were turned. The substrate of the tool material was high-speed steel (1.4%C). The tool wear and the surface roughness were experimentally investigated. The following results were obtained: (1) In cutting two kinds of Al-Si alloys, namely the Al-2%Si alloy and Al-4%Si alloy, the progress of wear of the DLC/(Al,Cr)N-coated tool was slower than that of the DLC-coated tool. Therefore, the (Al,Cr)N interlayer was effective for decreasing the tool wear of the DLC-coated tool. (2) The wear progress of the two kinds of DLC-coated tools in cutting of Al-4%Si alloy was faster than that in cutting of Al-2%Si alloy. (3) In cutting of Al-2%Si alloy with the (Al,Cr)N/DLC-coated tool, the surface roughness was almost constant in the range of a cutting distance from 0.1 km to 9.5 km.

scholarly journals Effect of extrusion temperature on the surface roughness of solid state recycled aluminum alloy 6061 chips during turning operation

2017 ◽  
Vol 9 (10) ◽  
pp. 168781401773415 ◽  
Author(s):  
Adham Ezzat Ragab ◽  
Mohamed Adel Taha ◽  
Adel Taha Abbas ◽  
Essam Ali Al Bahkali ◽  
Ehab Adel El-Danaf ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Solid State ◽  
Extrusion Temperature ◽  
Turning Operation ◽  
Aluminum Alloy 6061 ◽  
Alloy 6061

Impact of Cutting Parameters on Surface Roughness in Milling Aluminum Alloy 6061 Using ANN Models

2011 ◽  
Vol 63-64 ◽  
pp. 412-415 ◽  
Author(s):  
Yu Mei Liu ◽  
Zhao Liang Jiang ◽  
Zhi Li
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ann Model ◽  
Aluminum Alloy 6061 ◽  
Radial Depth ◽  
Four Levels ◽  
Alloy 6061

The surface roughness is difficult to estimate in machining, especially for weak stiffness workpiece. So, prediction model of surface roughness using artificial neural network (ANN) is developed. This model investigates the effects of cutting parameters during milling Aluminum alloy 6061. The experiments are planned with four factors and four levels for developing the knowledge base for ANN training. Three-dimensional surface plots are generated using ANN model to study the effects of cutting parameters on surface roughness. The analysis reveals that cutting speed and feed rate have significant effects in reducing the surface roughness, while the axial and radial depth of cut has less effect. And the variations of surface roughness are highly non-linear with the cutting parameters.

scholarly journals Effect of Equal Channel Angular Pressing on the Surface Roughness of Solid State Recycled Aluminum Alloy 6061 Chips

2017 ◽  
Vol 2017 ◽  
pp. 1-11 ◽  
Author(s):  
Adel Taha Abbas ◽  
Mohamed Adel Taha ◽  
Adham Ezzat Ragab ◽  
Ehab Adel El-Danaf ◽  
Mohamed Ibrahim Abd El Aal
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Solid State ◽  
Equal Channel Angular Pressing ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aluminum Alloy 6061 ◽  
Angular Pressing ◽  
Alloy 6061

Solid state recycling through hot extrusion is a promising technique to recycle machining chips without remelting. Furthermore, equal channel angular pressing (ECAP) technique coupled with the extruded recycled billet is introduced to enhance the mechanical properties of recycled samples. In this paper, the surface roughness of solid state recycled aluminum alloy 6061 turning chips was investigated. Aluminum chips were cold compacted and hot extruded under an extrusion ratio (ER) of 5.2 at an extrusion temperature (ET) of 425°C. In order to improve the properties of the extruded samples, they were subjected to ECAP up to three passes at room temperature using an ECAP die with a channel die angle(Φ)of 90°. Surface roughness (RaandRz) of the processed recycled billets machined by turning was investigated. Box-Behnken experimental design was used to investigate the effect of three machining parameters (cutting speed, feed rate, and depth of cut) on the surface roughness of the machined specimens for four materials conditions, namely, extruded billet and postextrusion ECAP processed billets to one, two, and three passes. Quadratic models were developed to relate the machining parameters to surface roughness, and a multiobjective optimization scheme was conducted to maximize material removal rate while maintaining the roughness below a preset practical value.

scholarly journals EVALUATION OF SURFACE ROUGHNESS AND MATERIAL REMOVAL RATE IN ELECTRICAL DISCHARGE MACHINING OF AL-ALLOY WITH 10%SIC

2022 ◽  
Vol 23 (1) ◽  
pp. 349-357
Author(s):  
Abbas Fadhil
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Al Alloy ◽  
Aluminum Alloy 6061 ◽  
Alloy 6061

Aluminum-based metallic matrix compounds are widely used in industrial and aircraft manufacturing due to their advanced characteristics, such as toughness and high strength resistance to weight ratio, etc. Silicon carbide is an important industrial ceramic and it is the fourth hardest ceramic after diamond, boron nitride, and boron carbide. Owing to its low fracture toughness, it is difficult to machine silicon carbide using traditional machining processes. Electrical discharge machine can machine such materials irrespective of their hardness. Aluminum alloy 6061 and 10% SiC based-metal matrix composite were used as a workpiece that was produced by stir casting. In the experimental investigation, pulse current Pc (10, 20, and 30 A), pulse on (Pon) duration (100, 150, and 200 ?sec), and pulse off (Poff) duration (6, 12, and 24 ?sec) were treated as the input variables. The output responses were surface roughness (SR) and material removal rate (MRR). The best value for surface roughness (Ra) reached (1.032 µm) at Pc (10 A), Pon duration (100 ?sec) and Poff (15 ?sec). Also, the best result for the productivity of the process (MRR) reached (69.49 × 10-3 g/min) at Pc (30 A) Pon, (200 ?sec) and (6 ?sec) Poff. Therefore, the experimental outcomes were optimized for surface roughnes and material removal rate by adding 10% SiC to aluminum alloy 6061. ABSTRAK: Sebatian matrik logam berasaskan aluminium telah digunakan secara meluas dalam industri pembuatan dan pesawat kerana ciri-cirinya yang canggih, seperti ketahanan dan daya rintangan yang tinggi kepada nisbah berat, dan lain-lain. Silikon karbida adalah seramik industri yang penting dan ia merupakan seramik keempat terkuat setelah berlian, boron nitrida dan boron karbida. Disebabkan ketahanan frakturnya yang rendah, adalah sukar bagi menghasilkan mesin silikon karbida menggunakan proses pemesinan tradisional. Mesin pelepasan elektrik mampu menghasilkan mesin menggunakan bahan tersebut tanpa mengira kekerasan. Aloi aluminium 6061 dan komposit matrik logam berasaskan SiC 10% telah digunakan sebagai bahan kerja yang terhasil melalui tuangan kacauan. Melalui penyelidikan eksperimen, detik arus Pc (10, 20, dan 30 A), detik hadir (Pon) berdurasi (100, 150, dan 200 ?sec), dan detik henti (Poff) berdurasi (6, 12, dan 24 ?sec) dirawat sebagai pemboleh ubah input. Respon pengeluaran adalah kekasaran permukaan (SR) dan kadar penyingkiran bahan (MRR). Nilai terbaik bagi kekasaran permukaan (Ra) telah mencapai (1.032 µm) pada Pc (10 A), berdurasi Pon (100 ?sec) dan Poff (15 ?sec). Tambahan, hasil terbaik bagi proses produktiviti (MRR) mencapai (69.49 × 10-3 g/min) pada Pc (30 A) Pon, (200 ?sec) dan (6 ?sec) Poff. Oleh itu, hasil eksperimen dioptimumkan bagi permukaan kasar dan kadar penyingkiran bahan dengan tambahan 10% SiC ke aloi aluminium 6061.

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