Experimental investigation of process parameters for WEDM of Ti-6Al-4V/TiN composites

2015 ◽  
Vol 22 (6) ◽  
Author(s):  
Levent Urtekin
Keyword(s):  
Feed Rate ◽  
Physical Vapor Deposition ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Performance Tests ◽  
Electric Discharge Machining ◽  
Food Industries ◽  
Heat Treated ◽  
Wire Electric Discharge Machining ◽  
Wire Feed

AbstractTi-6Al-4V alloys are difficult-machine materials. These alloys are extensively used in medicine, chemical units, marine and food industries, and particularly in the aerospace industry. Machinability of Ti-6Al-4V in wire electric discharge machining (WEDM) has been empirically investigated. WEDM performance tests were conducted on TiN coated Ti-6Al-4V alloy with physical vapor deposition (PVD) method, which is harder and has higher wear resistance. The performance of machinability of Ti-6Al-4V and Ti-6Al-4V/TiN materials was analyzed. The most important performance characteristics of WEDM cutting are surface roughness, machining gap, and cutting speed. The tests were conducted under cutting parameters including varying pulse durations (300, 500, 700 μs), tension (50, 100 V) and wire feed rate (5, 8 m/min). Based on tension, pulse duration, and wire feed rate of heat-treated uncoated samples when compared to untreated samples and coated samples, feed rates were found to be at the highest value.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

An Experimental Study of Cutting Force on Large Cutting Depth Turning Titanium Alloy with CBN Tool

2014 ◽  
Vol 800-801 ◽  
pp. 237-240
Author(s):  
Li Fu Xu ◽  
Ze Liang Wang ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Cbn Tool ◽  
Cutting Experiment ◽  
Rough Turning

In this paper, the cutting experiment was used to study the influence of various cutting parameters on cutting force when rough turning titanium alloy (TC4) with the whole CBN tool. The results indicate that among the cutting speed, feed rate and cutting depth, the influence of the cutting depth is the most significant on cutting force; the next is the feed rate and the cutting speed is at least.

Optimization and Prediction of Machining Responses Using Response Surface Methodology and Adaptive Neural Network by Wire Electric Discharge Machining of Alloy-X

2021 ◽  
Vol 1026 ◽  
pp. 28-38
Author(s):  
I. Vishal Manoj ◽  
S. Narendranath ◽  
Alokesh Pramanik
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
Artificial Neural Network ◽  
Response Surface ◽  
Electric Discharge ◽  
Cutting Speed ◽  
Electric Discharge Machining ◽  
Surface Method ◽  
Wire Electric Discharge Machining ◽  
Pulse On Time

Wire electric discharge machining non-contact machining process based on spark erosion technique. It can machine difficult-to-cut materials with excellent precision. In this paper Alloy-X, a nickel-based superalloy was machined at different machining parameters. Input parameters like pulse on time, pulse off time, servo voltage and wire feed were employed for the machining. Response parameters like cutting speed and surface roughness were analyzed from the L25 orthogonal experiments. It was noted that the pulse on time and servo voltage were the most influential parameters. Both cutting speed and surface roughness increased on increase in pulse on time and decrease in servo voltage. Grey relation analysis was performed to get the optimal parametric setting. Response surface method and artificial neural network predictors were used in the prediction of cutting speed and surface roughness. It was found that among the two predictors artificial neural network was accurate than response surface method.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

Statistical Cutting Force Model for Orthogonal Cutting of Polytetrafluoroethylene (PTFE) Composites

2013 ◽  
Author(s):  
Felicia Stan ◽  
Daniel Vlad ◽  
Catalin Fetecau
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Polynomial Regression ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Force Model

This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA). Statistical models that correlate the cutting force with process variables were developed using ANOVA and polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake face was identified, the former decreasing with an increasing normal force.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

Modelling of Electrostatic Charge in Ultra-High Precision Diamond Turning of Contact Lens Polymer

2019 ◽  
Vol 298 ◽  
pp. 135-140
Author(s):  
Muhammad Mukhtar Liman ◽  
Khaled Abou El Hossein
Keyword(s):  
High Precision ◽  
Contact Lens ◽  
Feed Rate ◽  
Contact Lenses ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Electrostatic Charge ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Electrostatic Charges

The electrostatic charges encountered by a cutting tool when turning advanced contact lenses are important as they reflect the quality and condition of the tool, machine, fixture, and sometimes even the surface finished which is responsible for tool wear and poor surface quality. This study investigates the influence of cutting parameters namely cutting speed, feed rate and depth of cut on electrostatic charge (ESC) which play the leading role in determining the machine economics and quality of machining contact lens polymers. An electrostatic charge model based on response surface statistical method is developed for reliably predicting the values of static charging based on its relationship to cutting parameters in ultra-high precision diamond turning of contact lenses. It is clearly seen that all the model terms are significant with cutting speed having the highest degree of significance followed by feed rate and the interaction of speed and feed. However, depth of cut has the lowest degree of significance on the electrostatics charge.

scholarly journals Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2998 ◽  
Author(s):  
Kubilay Aslantas ◽  
Mohd Danish ◽  
Ahmet Hasçelik ◽  
Mozammel Mia ◽  
Munish Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Cutting Speed ◽  
Small Diameter ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Depth Of Cut ◽  
Turning Process ◽  
Micro Turning

Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.

scholarly journals Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1014 ◽  
Author(s):  
Sánchez Hernández ◽  
Trujillo Vilches ◽  
Bermudo Gamboa ◽  
Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Transient State ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Crater Wear ◽  
Force Amplitude

In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

Analysis and Experimental Design of Damper System and Cutting Parameters of CNC Router

2019 ◽  
Vol 894 ◽  
pp. 82-89
Author(s):  
Van Thuy Tran ◽  
Huu Loc Nguyen ◽  
Hoang Hiep Nguyen
Keyword(s):  
Dynamic Behavior ◽  
Feed Rate ◽  
Vibration Amplitude ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cnc Machine ◽  
Cutting Depth ◽  
System Effect ◽  
Comparison Results ◽  
Spindle Vibration

. An understanding of the dynamic characteristics of a CNC machine is a vital element in the control of the machine which has a direct effect on the machining precision. The ways in which energy is dissipated, such as friction and damping, have a significant effect on the dynamic behavior and spindle vibration of a CNC machine. The paper presents kinetic analysis of the CNC machine damper system, effect of the damper and the cutting parameters such as feed rate, cutting speed, and cutting depth on the dynamic behavior and spindle vibration of a CNC machine. Experimental results have established a second-order regression equation that demonstrates the effect of three parameters such as feed rate, cutting speed, and cutting depth on the vibration amplitude of the spindle. In addition, the comparison results show that the spindle head vibration amplitude of the machine using the damper is smaller than the spindle head vibration amplitude of the machine not using the damper.

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