Effect of cutting tool lead angle on machining forces and surface finish of CFRP laminates

2016 ◽  
Vol 23 (5) ◽  
pp. 543-550 ◽  
Author(s):  
Seyedbehzad Ghafarizadeh ◽  
Jean-François Chatelain ◽  
Gilbert Lebrun
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Lower Surface ◽  
Machining Parameters ◽  
Cfrp Laminates ◽  
Lead Angle ◽  
Reinforced Plastics

AbstractMachining is one of the most practical processes for finishing operations of composite components, allowing high-quality surface and controlled tolerances. The high-precision surface milling of carbon fiber-reinforced plastics (CFRP) is particularly applicable in the assembly of complex components requiring accurate mating surfaces as well as for surface repair or mold finishing. CFRP surface milling is a challenging operation because of the heterogeneity and anisotropy of these materials, which are the source of several types of damage, such as delamination, fiber pullout, and fiber fragmentation. To minimize the machining problems of CFRP milling and improve the surface quality, this research focuses on the effect of multiaxis machining parameters, such as the feed rate, cutting speed, and lead angle, on cutting forces and surface roughness. The results show that the surface roughness and cutting forces increase with the feed rate, whereas their variations are not uniform when changing the cutting speed. Generally, a lower surface roughness was achieved by using a lower cutting feed rate (0.063 mm/rev) and higher cutting speeds (250–500 m/min). It was also found that the cutting forces and surface roughness vary significantly and nonlinearly with the lead angle of the cutting tool with respect to the surface.

scholarly journals Analysis of Surface Roughness and Cutting Forces in Hard Turning of 42CrMo4 Steel using Taguchi and RSM Method

Mechanika ◽  
2020 ◽  
Vol 26 (3) ◽  
pp. 231-241 ◽  
Author(s):  
Mustafa ÖZDEMİR ◽  
Mehmet Tuncay KAYA ◽  
Hamza Kemal AKYILDIZ
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Forces ◽  
Tangential Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Radial Force ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Feed Force

In this study, effects of cutting speed (V), feed rate (f), depth of cut (a) and tool tip radius (R) on  surface roughness (Ra, Rz, and Rt) and cutting forces (radial force (Fx), tangential force (Fy), and feed force (Fz)) in hard finish turning processes of hardened 42CrMo4 (52 HRC) material was investigated experimentally. Taguchi’s mixed level parameter design (L18) is used for the experimental design (2x1,3x3). The signal-to-noise ratio (S/N) was used in the evaluation of test results.  By using Taguchi method, cutting parameters giving optimum surface roughness and cutting forces were determined. Regression analyses are applied to predict surface roughness and cutting forces. Analysis of variance (ANOVA) is used to determine the effects of the machining parameters on surface roughness and cutting forces. According to ANOVA analysis, the most important cutting parameters were found to be feed rate for surface roughness and depth of cut among cutting forces.  By conducting validation experiments, optimization was seen to be applied successfully.

PERFORMANCE OF UNCOATED CARBIDE CUTTING TOOL WHEN MACHINING CAST IRON IN DRY CUTTING CONDITION

2009 ◽  
Vol 23 (06n07) ◽  
pp. 1796-1802 ◽  
Author(s):  
A. G. JAHARAH ◽  
C. H. CHE HASSAN ◽  
M. J. GHAZALI ◽  
A. B. SULONG ◽  
M. Z. OMAR ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Carbide Cutting Tool ◽  
Cutting Speeds

This paper presents the performance of uncoated carbide cutting tool when machining cast iron in dry cutting conditions. Experiments were conducted at various cutting speeds, feed rates, and depths of cut according to Taguchi method design of experiment using a standard orthogonal array L 9(34). The effects of cutting speeds (100-146 m/min), feed rates (0.20-0.35 mm/tooth) and depths of cut (1.0-2.0 mm) on the tool life, surface roughness and cutting forces were evaluated using ANOVA. Results showed that the effects of cutting speed, depth of cut and the feed rate were similar affecting the failure of the carbide cutting tools within the range of tested machining parameters. The contribution of cutting speed, feed rate, and depth of cut in controlling the tool life were 32.12%, 38.56% and 29.32% respectively. Whereas, the cutting speed was the main factor influencing the average surface roughness (Ra) value followed by feed rate. These factors contribute 60.53% and 35.59% respectively to the Ra value. On the other hand, cutting forces generated were greatly influenced by the depth of cut (66.52%) and the feed rate (32.6%). Cutting speed was found insignificant in controlling the generated cutting forces.

scholarly journals Effect of Machining Parameters in Milling Aluminum Alloy 7075-T6 under MQL Condition

2019 ◽  
Vol 9 (2) ◽  
pp. 109-113
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Aluminum Alloy 7075

Minimum quantity lubrication (MQL) is an eco-friendly method, where a small amount of fluid was sprayed to cutting edge in mist form with the aid of the air. The foregoing studies revealed that inappropriate machining parameters without the assistance of the cutting fluid methods became a major challenge in milling aluminum alloy 7075-T6. The paper presents the findings of the experimental work to assess the effect of machining parameters towards cutting tool life and machined surface roughness in milling aluminum alloy 7075-T6 at high cutting speed under MQL condition. An eight-run experiment was designed according to full factorial design based upon two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analyzed employed ANOVA to determine the significant machining parameters. The cutting tool life and machined surface roughness were assigned by the rejection criterion of tool flank wear in the milling operation. The optical microscope and portable surface roughness tester were applied to analyze tool wear and average surface roughness value. Cutting speed and feed rate were significantly contributing to the tool life and surface roughness. The longest tool lifespan of 20.14 minutes and lowest surface roughness value of 0.569 µm were obtained at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter which are 0.12 mm/tooth and 1.40 mm.

Experimental investigations of cutting parameters’ influence on cutting forces and surface roughness in turning of Inconel alloy X-750 with biodegradable vegetable oil

2015 ◽  
Vol 231 (9) ◽  
pp. 1516-1527 ◽  
Author(s):  
Ahmadreza Hosseini Tazehkandi ◽  
Mohammadreza Shabgard ◽  
Farid Pilehvarian ◽  
Nakisa Farshfroush
Keyword(s):  
Surface Roughness ◽  
Vegetable Oil ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Inconel Alloy ◽  
Coated Carbide

Nickel-based Inconel X-750 superalloy is widely applied in aerospace industry and manufacturing of gas turbine blades, power generators and heat exchangers due to its exclusive properties. As a consequence of low heat transfer coefficient and work-hardening properties, this alloy is known as a poorly machinable alloy. In this work, effect of machining parameters (cutting speed, feed rate and depth of cut) on cutting forces and surface roughness was investigated during turning of Inconel alloy X-750 with coated carbide tool. In order to meet the demands of the environment-friendly cutting processes and human health, biodegradable vegetable oil (BioCut 4600) was selected as the cutting fluid. The results were analyzed using response surface methodology and statistical analysis of variance, and mathematical models for cutting forces and surface roughness were proposed. Results indicated that feed rate and cutting speed were the most effective parameters on the surface roughness. However, depth of cut was the most effective parameter on cutting forces in comparison with cutting speed and feed rate. Eventually, in order to achieve the main aims of industrial production in large amounts and green manufacturing, the ranges for the best cutting conditions were presented.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

scholarly journals Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 9 ◽  
Author(s):  
Andrzej Matras
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Laser Scanning ◽  
Cutting Tool ◽  
Scanning Speed ◽  
Milling Process ◽  
Face Milling ◽  
Machining Parameters ◽  
The Face ◽  
Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

Multiresponse optimization of drillability factors and mechanical properties of chitosan-reinforced polypropylene composite

2020 ◽  
pp. 089270572093916
Author(s):  
Nafiz Yaşar ◽  
Mustafa Günay ◽  
Erol Kılık ◽  
Hüseyin Ünal
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Thrust Force ◽  
Flexural Modulus ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Uniaxial Tensile ◽  
Machining Parameters ◽  
Molding Method ◽  
Machining Conditions

In this study, the mechanical and machinability characteristics of chitosan (Cts)-filled polypropylene (PP) composites produced by injection molding method were analyzed. Uniaxial tensile, impact, hardness, and three-point flexural tests were used to observe the influence of Cts filler on the mechanical behavior of PP. For the machinability analysis of these materials, drilling experiments based on Taguchi’s L27 orthogonal array were performed using different drill qualities and machining parameters. Then, machining conditions are optimized through grey relational analysis methodology for machinability characteristics such as thrust force and surface roughness obtained from drilling tests. The results showed that tensile, flexural strength, and percentage elongation decreased while impact strength increased with adding the Cts filler to PP. Moreover, it was determined that the tensile and flexural modulus of elasticity increased significantly and there was a slight increase in hardness. Thrust forces decreased while surface roughness values increased when the Cts filler ratio and feed rate was increased. The optimal machining conditions for minimizing thrust force and surface roughness was obtained as PP/10 wt% Cts material, uncoated tungsten carbide drill, feed rate of 0.05 mm/rev, and cutting speed of 40 m/min. In this regard, PP composite reinforced by 10 wt% Cts is recommended for industrial applications in terms of both the mechanical and machinability characteristics.

scholarly journals Optimization of machining parameters in face milling using multi-objective Taguchi technique

2018 ◽  
Vol 12 (2) ◽  
pp. 104-108 ◽  
Author(s):  
Yusuf Fedai ◽  
Hediye Kirli Akin
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Average Roughness ◽  
Multi Objective ◽  
Control Factors ◽  
Average Maximum

In this research, the effect of machining parameters on the various surface roughness characteristics (arithmetic average roughness (Ra), root mean square average roughness (Rq) and average maximum height of the profile (Rz)) in the milling of AISI 4140 steel were experimentally investigated. Depth of cut, feed rate, cutting speed and the number of insert were considered as control factors; Ra, Rz and Rq were considered as response factors. Experiments were designed considering Taguchi L9 orthogonal array. Multi signal-to-noise ratio was calculated for the response variables simultaneously. Analysis of variance was conducted to detect the significance of control factors on responses. Moreover, the percent contributions of the control factors on the surface roughness were obtained to be the number of insert (71.89 %), feed (19.74 %), cutting speed (5.08%) and depth of cut (3.29 %). Minimum surface roughness values for Ra, Rz and Rq were obtained at 325 m/min cutting speed, 0.08 mm/rev feed rate, 1 number of insert and 1 mm depth of cut by using multi-objective Taguchi technique.

Optimization of Surface Roughness by Using Different Cutting Tools for Aluminum Alloy 6063

2020 ◽  
Vol 17 (2) ◽  
pp. 961-966
Author(s):  
Allina Abdullah ◽  
Afiqah Azman ◽  
B. M. Khirulrizwan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Optimum Parameter ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Numerical Control ◽  
Depth Of Cut

This research outlines an experimental study to determine the optimum parameter of cutting tool for the best surface roughness (Ra) of Aluminum Alloy (AA) 6063. For the experiment in this research, cutting parameters such as cutting speed, depth of cut and feed rate are used to identify the effect of both cutting tools which are tungsten carbide and cermet towards the surface roughness (Ra) of material AA6063. The machining operation involved to cut the material is turning process by using Computer Numerical Control (CNC) Lathe machine. The experimental design was designed by Full Factorial. The experiment that had been conducted by the researcher is 33 with 2 replications. The total number of the experiments that had been run is 54 runs for each cutting tool. Thus, the total number of experiments for both cutting tools is 108 runs. ANOVA analysis had been analyzed to identify the significant factor that affect the Ra result. The significant factors that affect the Ra result of AA6063 are feed rate and cutting speed. The researcher used main effect plot to determine the factor that most influenced the surface roughness of AA6063, the optimum condition of surface roughness and the optimum parameter of cutting tool. The factor that most influenced the surface roughness of AA6063 is feed rate. The optimum condition of surface roughness is at the feed rate of 0.05 mm/rev, cutting speed of 600 rpm and depth of cut of 0.10 mm. While the optimum parameter of cutting tool is cermet insert with the lowest value of surface roughness (Ra) result which is 0.650 μm.

Investigations on Surface Roughness Measurement in Minimum Quantity Lubrication Turning of Titanium Alloys Using Response Surface Methodology and Box–Cox Transformation

2016 ◽  
Vol 16 (2) ◽  
pp. 75-88 ◽  
Author(s):  
Munish Kumar Gupta ◽  
P. K. Sood ◽  
Vishal S. Sharma
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Flow Rate ◽  
Feed Rate ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Machining Parameters ◽  
Minimum Quantity ◽  
Box Cox Transformation

AbstractIn the present work, an attempt has been made to establish the accurate surface roughness (Ra, Rq and Rz) prediction model using response surface methodology with Box–Cox transformation in turning of Titanium (Grade-II) under minimum quantity lubrication (MQL) conditions. This surface roughness model has been developed in terms of machining parameters such as cutting speed, feed rate and approach angle. Firstly, some experiments are designed and conducted to determine the optimal MQL parameters of lubricant flow rate, input pressure and compressed air flow rate. After analyzing the MQL parameter, the final experiments are performed with cubic boron nitride (CBN) tool to optimize the machining parameters for surface roughness values i. e., Ra, Rq and Rz using desirability analysis. The outcomes demonstrate that the feed rate is the most influencing factor in the surface roughness values as compared to cutting speed and approach angle. The predicted results are fairly close to experimental values and hence, the developed models using Box-Cox transformation can be used for prediction satisfactorily.

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