Investigation of the shearing length in the orthogonal turning of a steel AISI 1050

2020 ◽  
Vol 62 (8) ◽  
pp. 827-834
Author(s):  
Zülküf Demir
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Steel Material ◽  
Lathe Machine ◽  
Steel Aisi ◽  
Natural Mechanism ◽  
Impossible Task ◽  
Machining Operations

Abstract Vibration amplitudes in machining operations have a deteriorating influence on the outcomes of the processes. Moreover, eradicating them is an impossible task due to the natural mechanism of cutting metals. However, by selecting the optimum cutting parameters, the destructive effects of vibration amplitudes may be diminished to acceptable levels. In the present paper, AISI 1050 steel material was machined, employing carbide inserts and a CNC lathe machine. Cutting tool approaching angles were selected between -5° and 45°, feed rates from 0.1 mm × rev-1 to 0.5 mm × rev-1, cutting depths between 0.5 mm and 2.25 mm, and accordingly CSR values between 1 and 15. The effect of the selected parameters on the chip compression factor (CCF), shearing length feed (SLF), shearing length (SLA), surface roughness, and chip morphology was investigated. Moreover, the effect of CCF, SLF, and SLA on surface roughness, vibration amplitudes, and chip morphology was analyzed as well. It was found that the most influential parameter on shearing length was cutting depth while the feed rate was on the surface roughness. The optimum CCF values were between 1.7 and 2.3, SLF smaller than 1, and SLA around 5. Furthermore, it was shown that the optimum CSR values were 10 and 15, and cutting tool approaching angles 30° and 45°, according to the chip morphology criterion.

Study on the Machinability of Free-Cutting Steels 1214 and 12L15 with Coated Tool

2012 ◽  
Vol 426 ◽  
pp. 151-154 ◽  
Author(s):  
Ying Ying Wei ◽  
Zhi Qiang Liu ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Environmental Friendly ◽  
Coated Tool ◽  
Orthogonal Tests

Research has been done on machinability of two different kinds of free-cutting steels by using coated cutting tool at the condition of different cutting parameters. Orthogonal tests are adopted in order to compare the cutting performance of the two materials. The cutting force, surface roughness, chip morphology and tool wear are investigated, which reveal the influence of Pb and other composition on machinability. The experiment shows that 1215 has more or less better performance than 12L14. It is of great significance for the development of environmental friendly products.

scholarly journals Relationship between surface roughness and chip morphology when turning hardened steel

2020 ◽  
Vol 26 (3) ◽  
pp. 92-98
Author(s):  
Youcef Abidi
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Ceramic Tool ◽  
Machined Surface ◽  
Aisi 1045 ◽  
Steel Aisi ◽  
Mixed Ceramic

AbstractHard machining is a process which has become highly recommended in manufacturing industry to replace grinding and perform production. The important technological parameters that determine this process are tool wear, machined surface roughness, cutting force and morphology of the removed chip. In this work, an attempt has been made to analyse the morphology and form of chip removed during turning of hardened steel AISI 1045 (40HRC) with mixed ceramic tool type CC650. Using a Taguchi plan L9, whose factors are cutting speed and feed rate with three levels for each. Macroscopic and microscopic results of chip morphology were correlated with these two cutting parameters additional to surface roughness. Sufficient experimental results were obtained using the mixed ceramic tool when turning of hardened steel AISI 1045 (40HRC) at high cutting speeds. Roughness of machined surface confirmed that it is influenced by feed rate. Chips show a sawtooth shape for all combinations of the experimental plan used. The chip form changed with cutting parameters variation and given an important indicator of suraface quality for industriel. Having the indicators on the surface quality from simple control of chip without stopping machining give an important advantage in order to maximize production and reduce costs.

scholarly journals Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1783
Author(s):  
Hamza A. Al-Tameemi ◽  
Thamir Al-Dulaimi ◽  
Michael Oluwatobiloba Awe ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Good Practice ◽  
Cutting Tools ◽  
Statistical Design ◽  
Cutting Parameters ◽  
Statistical Design Of Experiments ◽  
Hole Quality ◽  
Coated Tools ◽  
Tool Coating

Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

Comparative Analysis on Wiper and Standard Tools in Dry Finish Turning of Martensitic Stainless Steel AISI 420

2013 ◽  
Vol 845 ◽  
pp. 765-769 ◽  
Author(s):  
Guilherme Cortelini Rosa ◽  
André J. Souza ◽  
Flávio J. Lorini
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Residual Stresses ◽  
Martensitic Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Finish Turning ◽  
Aisi 420 ◽  
Steel Aisi ◽  
Stainless Steel Aisi

Machining performance consists to associate the optimal process and cutting parameters and maximum material removal rate with the most appropriate tool while controlling the machined surface state. This work verifies the influence of standard and wiper cutting tools on generated surface roughness and residual stress in dry finish turning operation of the martensitic stainless steel AISI 420 in a comparative way. Tests are conducted for different combinations of tool nose geometry, feed rate and depth of cut being analyzed through the Design of Experiments regarding to surface roughness parametersRaandRt. Moreover, the formation of residual stresses in the material (using the technique of X-Ray Diffraction) was evaluated after the machining process for these two cutting geometries and thereafter the result was compared between them. An ANOVA is performed to clarify the influence of cutting parameters on generated surface roughness, which outputs inform that cutting tool geometry is the most influent onRaandRt. It is concluded that analyzed wiper inserts present low performance for low feed rates. Regarding the analysis of the residual stresses it can be stated that for standard and wiper tools the values collected show that for finish turning the compression stresses were found. It can be observed that the greatest amount of compressive stress has been found for the standard tool.

Cutting Parameters Optimization of Mild Steel via AIS Heuristics Algorithm

2015 ◽  
Vol 761 ◽  
pp. 132-136
Author(s):  
Adnan Jameel Abbas ◽  
Mohammad Minhat ◽  
Md Nizam Abd Rahman
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Optimum Cutting ◽  
Cutting Velocity ◽  
Cutting Zone ◽  
The Ideal

. The minimum cost and high productivity of the recent industrial renaissance are its main challengers. Selecting the optimum cutting parameters play a significant role in achieving these aims. Heat generated in the cutting zone area is an important factor affecting workpiece and cutting tool properties. The surface finish quality specifies product success and integrity. In this paper, the temperature generated in the cutting zone (shear zone and chip-tool interface zone) and workpiece surface roughness is optimized using an artificial immune system (AIS) intelligent algorithm. A mild steel type (S45C) workpiece and a tungsten insert cutting tool type (SPG 422) is subjected to dry CNC turning operation are used in experiments. Optimum cutting parameters (cutting velocity, depth of cut, and feed rate) calculated by the (AIS) algorithm are used to obtain the simulated and ideal cutting temperature and surface roughness. An infrared camera type (Flir E60) is used for temperature measurement, and a portable surface roughness device is used for roughness measurement. Experimental results show that the ideal cutting temperature (110°C) and surface roughness (0.49 μm) occur at (0.3 mm) cut depth, (0.06 mm) feed rate, and (60 m/min) cutting velocity. The AIS accuracy rates in finding the ideal cutting temperature and surface roughness are (91.70 %) and (90.37 %) respectively. Analysis shows that the predicted results are close to the experimental ones, indicating that this intelligent system can be used to estimate cutting temperature and surface roughness during the turning operation of mild steel.

scholarly journals An Investigation of the Effect of Parameters and Chip Slenderness Ratio on Drilling Process Quality of AISI 1050 Steel

2018 ◽  
Vol 2018 ◽  
pp. 1-9 ◽  
Author(s):  
Zülküf Demir ◽  
Rifat Yakut
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Thrust Force ◽  
Slenderness Ratio ◽  
Chip Morphology ◽  
Drilling Process ◽  
Steel Alloy ◽  
Drilling Operations ◽  
Machining Operations

The chip slenderness ratio is a vital parameter in theoretical and applicable machining operations. In predrilled drilling operations of AISI 1050 steel alloy, HSS drills were employed, and the effect of the selected parameters on the chip slenderness ratio and also the effect of the chip slenderness ratio on the thrust force, surface roughness, drilled hole delamination, tool wear, and chip morphology were investigated. The major parameters, influential on the chip slenderness ratio, were feed rate and point angle, while spindle speed was too small to be negligible. With increasing the chip slenderness ratio, the thrust force and the tool wear decreased, which resulted in appropriate chip morphology, but there were increases in surface roughness. However, the chip slenderness ratio had no effect on the drilled hole delamination.

Hardened Steel Turning by Means of Modern CBN Cutting Tools

2013 ◽  
Vol 581 ◽  
pp. 188-193 ◽  
Author(s):  
Łukasz Ślusarczyk ◽  
Grzegorz Struzikiewicz
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Cutting Depth ◽  
Cutting Rate ◽  
Steel Turning ◽  
The Impact

The paper presents an analysis of the impact of cutting parameters such as cutting rate, feed rate, cutting depth and cutting tool material grade for surface roughness, the components of the total cutting force and chip morphology. We analysed the process of rolling 145Cr steel with a hardness of 55HRC with Wiper type tools with different percentage of CBN. The results and conclusions were presented.

scholarly journals Investigate the Effect of Cutting Parameters on Surface Roughness When Milling X12m Steel

2021 ◽  
pp. 258-263
Author(s):  
Do Thi Kim Lien ◽  
Nguyen Dinh Man ◽  
Phung Tran Dinh
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Negligible Effect ◽  
Depth Of Cut ◽  
The Relationship

In this paper, an experimental study on the effect of cutting parameters on surface roughness was conducted when milling X12M steel. The cutting tool used in this study is a face milling cutter. The material that is used to make the insert is the hard alloy T15K6. The cutting parameters covered in this study include the cutting speed, the feed rate and depth of cut. The experiments are performed in the form of a rotating center composite design. The analysis shows that for both Ra and Rz: (1) the feed rate has the greatest influence on the surface roughness while the depth of cut, the cutting speed has a negligible effect on the surface roughness. (2) only the interaction between the feed rate and the depth of the cut has a significant effect on both Ra and Rz while the interaction between the cutting speed and the feed rate, the interaction between the cutting speed and the depth of cut have a negligible effect on surface roughness. A regression equation showing the relationship between Ra, Rz, and cutting parameters has also been built in this study.

scholarly journals Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Harun Gokce
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Taguchi Method ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Tool Wear ◽  
Wide Range

Stainless steels with unique corrosion resistance are used in applications with a wide range of fields, especially in the medical, food, and chemical sectors, to maritime and nuclear power plants. The low heat conduction coefficient and the high mechanical properties make the workability of stainless steel materials difficult and cause these materials to be in the class of hard-to-process materials. In this study, suitable cutting tools and cutting parameters were determined by the Taguchi method taking surface roughness and cutting tool wear into milling of Custom 450 martensitic stainless steel. Four different carbide cutting tools, with 40, 80, 120, and 160 m/min cutting speeds and 0.05, 0.1, 0.15, and 0.2 mm/rev feed rates, were selected as cutting parameters for the experiments. Surface roughness values and cutting tool wear amount were determined as a result of the empirical studies. ANOVA was performed to determine the significance levels of the cutting parameters on the measured values. According to ANOVA, while the most effective cutting parameter on surface roughness was the feed rate (% 50.38), the cutting speed (% 81.15) for tool wear was calculated.

Effect of Cutting Parameters on Surface Roughness When Milling Hardened AISI D2 Steel (56 HRC) Using Taguchi Techniques

2012 ◽  
Author(s):  
Ahmed Zaidan Mohammed Shammari ◽  
Kamal Ati Amwead ◽  
Auday Shaker Hadi
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Signal To Noise Ratio ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Cold Extrusion ◽  
Depth Of Cut ◽  
Control Factors ◽  
Aisi D2 ◽  
Steel Aisi

The tool steel identifying AISI D2 is commonly used for cold working operations, such as sheet metal forming, cold extrusion and forging operation. To perform in these applications, they must have excellent strength, hardness, and wear resistance. The aim of the present study is to find optimal process parameters for end milling of hardened steel AISI D2 (56 HRC) using Taguchi method. A L25 array, Taguchi’s signal-to-noise ratio and ANOVA are employed to determine effects of many control factors (spindle speed, feed rate, and depth of cut) on surface roughness. In this paper, results show that the spindle speed is most influencing parameters.

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