scholarly journals Cryogenic milling and formation of nanostructured machined surface of AISI 4340

2020 ◽  
Vol 9 (1) ◽  
pp. 1104-1117
Author(s):  
Shalina Sheik Muhamad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron ◽  
Hafizal Yazid
Keyword(s):  
End Milling ◽  
Testing Machine ◽  
Machining Process ◽  
Depth Of Cut ◽  
Case Hardening ◽  
Machining Parameters ◽  
Machined Surface ◽  
Radial Depth ◽  
Coated Carbide ◽  
Aisi 4340

AbstractHardened layers are commonly required for automotive components after their production using a machining process in order to enhance the service life of these components. This study investigates the possibility of producing a nanostructured machined surface which can increase the hardness of the machined surface by varying the machining parameters under cryogenic conditions in end milling of AISI 4340. The end milling experiments were performed using multi-layered TiAlN- and AlCrN-coated carbide. Prior to the experiment, a finite element method (FEM) was used to simulate the cutting temperature generated and it had been found that at cutting speed of 200–300 m/min, feed rate of 0.15–0.3 mm/tooth, axial depth of cut of 0.3–0.5 mm, and radial depth of cut of 0.2–0.35 mm, the temperature generated can be sufficiently high to cause austenitic transformation. A field emission scanning electron microscope (FESEM) equipped with angle selective backscattered (AsB) detection analysis was used to investigate the microstructure and machined-affected layers of the machined surfaces. The crystallographic orientation/phase change and nano-hardness were analysed through X-ray diffraction (XRD) and a nano-hardness testing machine. The results showed that the cryogenic machining had significantly affected the surface integrity characteristics of the AISI 4340 alloy due to refined microstructure, favourable phase structure, and higher hardness near the surface layer. The results of this study may be useful in providing an insight into a potential technological shift from conventional surface case hardening processes to the present technique.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Modeling & Analysis of End Milling Process Parameters Using Artificial Neural Networks

2014 ◽  
Vol 592-594 ◽  
pp. 2733-2737 ◽  
Author(s):  
G. Harinath Gowd ◽  
K. Divya Theja ◽  
Peyyala Rayudu ◽  
M. Venugopal Goud ◽  
M .Subba Roa
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Artificial Neural ◽  
End Milling Process

For modeling and optimizing the process parameters of manufacturing problems in the present days, numerical and Artificial Neural Networks (ANN) methods are widely using. In manufacturing environments, main focus is given to the finding of Optimum machining parameters. Therefore the present research is aimed at finding the optimal process parameters for End milling process. The End milling process is a widely used machining process because it is used for the rough and finish machining of many features such as slots, pockets, peripheries and faces of components. The present work involves the estimation of optimal values of the process variables like, speed, feed and depth of cut, whereas the metal removal rate (MRR) and tool wear resistance were taken as the output .Experimental design is planned using DOE. Optimum machining parameters for End milling process were found out using ANN and compared to the experimental results. The obtained results provβed the ability of ANN method for End milling process modeling and optimization.

Cutting Force Changes during One Cut in End Milling with a Throw-Away Insert - Difference between Up-Cut and Down-Cut –

2019 ◽  
Vol 825 ◽  
pp. 123-128
Author(s):  
Kota Matsuda ◽  
Ryutaro Tanaka ◽  
Katsuhiko Sekiya ◽  
Keiji Yamada
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Tangential Force ◽  
Chip Thickness ◽  
Radial Force ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Aisi 1045 ◽  
Tangential Forces ◽  
Coated Carbide

In this study, the transition of cutting force in the tangential and radial direction during one cut was investigated in milling of AISI-1045, AISI-304, and Ti-6Al-4V with a TiN coated carbide throw-away insert. In the case of 1045 and Ti-6Al-4V, there was not obvious difference in tangential forces between up-cut and down-cut. However, up-cut showed larger radial force than down-cut in any material. In down-cut, tangential force showed almost the same regardless of radial depth of cut. 304 and Ti-6Al-4V caused larger radial force with the increase of radial depth of cut at the same cut chip thickness.

scholarly journals Non-Invasive Estimation of Machining Parameters during End-Milling Operations Based on Acoustic Emission

Sensors ◽  
2020 ◽  
Vol 20 (18) ◽  
pp. 5326
Author(s):  
Andrés Sio-Sever ◽  
Erardo Leal-Muñoz ◽  
Juan Manuel Lopez-Navarro ◽  
Ricardo Alzugaray-Franz ◽  
Antonio Vizan-Idoipe ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
End Milling ◽  
Low Cost ◽  
Milling Process ◽  
Machining Process ◽  
Measuring System ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Processes ◽  
Non Invasive

This work presents a non-invasive and low-cost alternative to traditional methods for measuring the performance of machining processes directly on existing machine tools. A prototype measuring system has been developed based on non-contact microphones, a custom designed signal conditioning board and signal processing techniques that take advantage of the underlying physics of the machining process. Experiments have been conducted to estimate the depth of cut during end-milling process by means of the measurement of the acoustic emission energy generated during operation. Moreover, the predicted values have been compared with well established methods based on cutting forces measured by dynamometers.

Evaluation of the Surface Integrity when Machining LM6 Aluminum Metal Matrix Composites Using Coated and Uncoated Carbide Cutting Tools

2013 ◽  
Vol 465-466 ◽  
pp. 1049-1053 ◽  
Author(s):  
Abu Bakar Mohd Hadzley ◽  
Ahmad Siti Sarah ◽  
Raja Abdullah Raja Izamshah ◽  
Amran Ali Mohd ◽  
Mohd Shahir Kasim ◽  
...  
Keyword(s):  
Metal Matrix Composites ◽  
Surface Integrity ◽  
Feed Rate ◽  
Metal Matrix ◽  
End Milling ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Radial Depth ◽  
Coated Carbide

Metal matrix composite is composite material that combines the metallic properties of matrix alloys and additional element to reinforce the product. This paper evaluates the machining performance of uncoated carbide and coated carbide in terms of surface integrity during end milling of LM6 aluminium MMC. The parameter of cutting speed, feed rate and axial depth of cut were kept constant at 3000 rpm spindle speed, 60 mm/min feed rate and 0.5 axial dept of cut. The radial depth of cut were varied from 0.01mm to 0.1 mm. The results indicated that uncoated carbide show the better performance in terms of surface roughness and surface profile, as compared to coated carbide. On the other hand, coated carbide cutting tools suffered with built-up-edge formation at the tool edge, hence caused shearing effect and deterioration at the tool-chip interface. This study is expected to provide understanding of machining metal matrix composites based materials.

scholarly journals Turning operation of AISI 4340 steel in flooded, near-dry and dry conditions: a comparative study on tool-work interface temperature

2019 ◽  
Vol 23 (1) ◽  
pp. 172-182 ◽  
Author(s):  
Milon Selvam Dennison ◽  
Sivaram N M ◽  
Debabrata Barik ◽  
Senthil Ponnusamy
Keyword(s):  
Cutting Tool ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cutting Velocity ◽  
Dry Conditions ◽  
Cylindrical Steel ◽  
Coated Carbide ◽  
Full Factorial ◽  
Aisi 4340

Abstract The objective of this study is to analyse the effect of tool-work interface temperature observed during the turning of AISI 4340 cylindrical steel components in three machining conditions, namely flooded, near-dry and dry conditions with three separate CNMG-PEF 800 diamond finish Titanium Nitride (TiN) coated carbide cutting tool. The machining parameters considered in this study are cutting velocity, feed rate and depth of cut. The experiments were planned based on full factorial design (33) and executed in an All Geared Conventional Lathe. The tool-work interface temperature was observed using a K-type tool-work thermocouple, while the machining of steel, and subsequently, a mathematical model was developed for the tool-work interface temperature values through regression analysis. The significance of the selected machining parameters and their levels on tool-work interface temperature was found using analysis of variance (ANOVA) and F-test. The results revealed that machining under near-dry condition exhibited lesser temperature at the tool-work interface, which is the sign of producing better quality products in equivalence with the machining under flooded condition.

Preheating in End Milling of AISI D2 Hardened Steel with Coated Carbide Inserts

2009 ◽  
Vol 83-86 ◽  
pp. 56-66 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim ◽  
A.M.K. Hafiz
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Inductive Heating ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Coated Carbide

This study was conducted to investigate the effect of preheating through inductive heating mechanism in end milling of AISI D2 hardened steel (60-62 HRC) by using coated carbide tool inserts. Apart from preheating, two other machining parameters such as cutting speed and feed were varied while the depth of cut constant was kept constant. Tool wear phenomenon and machined surface finish were found to be significantly affected by preheating temperature and other two variables. End milling operation was performed on a Vertical Machining Centre (VMC). Preheating of the work material to a higher temperature range resulted in a noticeable reduction in tool wear rate leading to a longer tool life. In addition, improved surface finish was obtained with surface roughness values lower than 0.4 μm, leaving a possibility of skipping the grinding and polishing operations for certain applications.

Surface Intergrity of Inconel 718 under MQL Condition

2010 ◽  
Vol 150-151 ◽  
pp. 1667-1672 ◽  
Author(s):  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
Mohd Shahir Kasim ◽  
T.K. Soon ◽  
Gusri Akhyar Ibrahim ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Machining Process ◽  
Graphical Form ◽  
Depth Of Cut ◽  
Optimum Process ◽  
Machined Surface ◽  
Coated Carbide

The purpose of this study is to investigate the effect of turning parameters on the surface integrity of Inconel 718. The turning parameters studied were cutting speed of 90, 120, 150 m/min, feed rate of 0.15, 0.25, 0.25mm/rev and depth of cut of 0.3, 0.4, 0.5 mm under minimum quantity lubricant (MQL) using coated carbide tool. surface response methodology (RSM) design of experiment using Box-Behnken approach has been employed consisting of various combination of turning parameters Surface roughness, surface topography, microstructure and the micro hardness of the machined surface were studied after the machining process. Feed rate was found to be the most significant parameter affecting the surface roughness. The optimum parameter was obtained with Ra equal to 0.243 µm at cutting speed of 150 m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm. A mathematical model for surface roughness was developed using Response Surface Methodology. The effect of turning parameters and factor interactions on surface roughness is presented in 3D graphical form, which helps in selecting the optimum process parameters to achieve the desired surface quality.

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