scholarly journals Influence of Cutting Parameters to Surface Area Roughness in Dimple Machining Using Milling Process

2021 ◽  
Vol 18 (3) ◽  
Author(s):  
M.A. Hanafiah ◽  
A.A. Aziz ◽  
A.R. Yusoff
Keyword(s):  
Surface Area ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Ball End Mill

Surface quality is among the predominant criterion in measuring machining process performance, including milling. It is extremely dependent on the process variable, such as cutting parameters and cutting tool conditions. The main intention of this research work is to study the effect of the milling machining parameters, including depth of cut, spindle speed, feed rate as well as machining pattern to the final surface area roughness of the fabricated dimple structure. The concave profile of the dimple is machined at the right angle to a flat Al6061 specimen using a ball end mill attached to a 3-axis CNC milling machine, and the surface area of the concave profile is measured using 3D measuring laser microscope. It is observed that surface area roughness reacts with the spindle speed and feed rate with different tool sizes. Based on the result gained, the work has successfully characterised the influence of studied milling parameters on the dimple surface area roughness, where within the range of the studied parameter, the surface area roughness varies only less than 2.2 μm. The research work will be continued further on the incline milling technique and micro size ball end mill.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

Analysis of Machining Parameters in Turning Operation on Duplex 2205 by using RSM for Vehicle Structure

2019 ◽  
Vol 11 (1) ◽  
Author(s):  
V. Vijayan ◽  
B. Sureshkumar ◽  
G. Sathishkumar ◽  
R. Yokeshwaran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Operation ◽  
Feed Force ◽  
Cylindrical Parts

Turning is the machining process carried out to make cylindrical parts. Since the process is economical and the flexibility of turning operation is high, the process has become highly versatile among the industrial scenario. The design of experiments concept along with response surface methodology is used to analyze the machining parameters such as spindle seed, feed rate and depth of cut, of the turning operation. Three levels of spindle speed, feed rate and depth of cut are used as input parameters and their corresponding responses such as material removal rate (M.R.R), surface roughness, feed force, thrust force and cutting force are considered as the output parameters. The main aim of this experimentation process is to identify the optimal process parameters to get high M R R and low surface roughness. During high spindle speed, the M R R is high and vice versa. Surface roughness is high when its corresponding spindle speed and depth of cut is high. A high spindle speed, the chip formation is continuous whereas in medium speed, discontinuous chip is formed. M.R.R is high when spindle speed, depth of cut and feed rate are high.

Prediction of Surface Roughness and Optimization of Cutting Parameters in CNC Turning of Rotational Features

2020 ◽  
Vol 38 (8A) ◽  
pp. 1143-1153
Author(s):  
Yousif K. Shounia ◽  
Tahseen F. Abbas ◽  
Raed R. Shwaish
Keyword(s):  
Surface Roughness ◽  
Linear Regression ◽  
Regression Model ◽  
Linear Regression Model ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Non Linear ◽  
Optimization Of Cutting Parameters

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

scholarly journals Penerapan Metode Taguchi untuk Optimasi Setting Parameter CNC Milling Terhadap Kekasaran Permukaan Material

2020 ◽  
Vol 2 (2) ◽  
pp. 49-60
Author(s):  
Farizi Rachman Farizi Rachman ◽  
Bayu Wiro K ◽  
Tri Andi Setiawan ◽  
Pradita Nurkholies
Keyword(s):  
Feed Rate ◽  
Base Plate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
End Mill

Industri manufaktur di Indonesia semakin meningkat seiring dengan tingkat kebutuhan manusia yang beraneka ragam dan memicu berkembangnya teknologi, salah satunya industri proses permesinan atau machining. Kualitas produk yang baik dapat dilihat dari tingkat kekasaran permukaannya karena kekasaran permukaan dapat mempengaruhi performa yang berkaitan dengan aspek fungsional dari produk. Pada penelitian ini telah dilakukan optimasi setting parameter CNC milling terhadap kekasaran permukaan pada material S50C dengan end mill HSS diameter 8 mm. Material S50C banyak digunakan dalam manufaktur mesin seperti mekanis base plate, roda gigi, standart punch head dan komponen mesin lainnya. Penelitian ini menggunakan metode Taguchi. Parameter yang digunakan yaitu spindle speed, Feed rate dan depth of cut dengan cairan pendingin sebagai variabel konstan. Parameter optimum untuk mendapatkan nillai kekasaran yang rendah yaitu spindle speed 1100 rpm, feed rate 46 mm/min dan depth of cut 0.5 mm. Dengan taraf signifikansi 0.1 menunjukkan bahwa spindle speed berpengaruh secara signifikan dengan kontribusi 38.42% diikuti feed rate dengan kontribusi 34.16%.

Analysis and optimisation of machinability behavior of GFRP composites using fuzzy logic

2015 ◽  
Vol 11 (1) ◽  
pp. 102-119 ◽  
Author(s):  
Jenarthanan Poornachary Mugundhu ◽  
Suresh Subramanian ◽  
Ajay Subramanian
Keyword(s):  
Fuzzy Logic ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Mechanical And Thermal Properties ◽  
Machining Parameters ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Useful Life

Purpose – Glass fibre reinforced plastics (GFRP) contain two phases of materials with drastically distinguished mechanical and thermal properties, which brings in complicated interactions between the matrix and the reinforcement during machining. Surface quality and dimensional precision will greatly affect parts during their useful life especially in cases where the components will be in contact with other elements or materials during their useful life. The purpose of this paper is to discuss the application of the Taguchi method with fuzzy logic to optimise the machining parameters for machining of GFRP composites with multiple characteristics. Design/methodology/approach – The machining tests were performed on a CNC milling machine using solid carbide (K10) End mill cutting tool with three different helix angles. Experiments were planned using Taguchi’s orthogonal array with the cutting conditions prefixed. Findings – The machining parameters, namely, helix angle of the end mill cutter, spindle speed, feed rate, depth of cut, and work piece fibre orientation (specially applied to the GFRP composites) were optimised with considerations of multiple response characteristics, including machining force, material removal rate, and delamination. The results from confirmation runs indicated that the determined optimal combination of machining parameters improved the performance of the machining process. Originality/value – Multi-response optimisation of machinability behaviour of GFRP composites using fuzzy logic has not been attempted previously.

An Experimental Study of Hard Dry Milling Based on Multi-Sensor Process Monitoring and Analysis

2010 ◽  
Vol 108-111 ◽  
pp. 1086-1091
Author(s):  
Li Bing Liu ◽  
Xi Wang ◽  
Wei Wu Zhong ◽  
Hui Yu ◽  
Dong Ting Liao ◽  
...  
Keyword(s):  
Virtual Instrument ◽  
Wavelet Packet ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Hard Milling ◽  
Vibration Signals ◽  
Ae Signals

This paper aims to collect the acoustic emission (AE), the vibration and the temperature signals produced in the hard dry milling of the die steel by using a signal collecting system based on multi-sensor and virtual instrument. Then the signals are processed by the wavelet transform and the wavelet packet transform. So we could pick up some regular pattern which could reflect the characteristic of the machining process from the results. The cutting parameters are set with single factor method and the experiment primarily focuses on researching the effect of changing the cutting parameters on the three signals mentioned forward. Through the experiment, some conclusions could be drawn as follow. In the process of the die steel’s hard dry milling, the spindle speed has a great effect on the AE signals. The temperature is mainly involved with the spindle speed and the depth of cut. The vibration signals have any clear pattern when the cutting parameter changes, but the energy of the vibration signals concentrate mostly on the first frequency band. Furthermore, the process of the hard milling is more stable.

scholarly journals Surface roughness of thermally treated wood cut with different parameters in CNC router machine

BioResources ◽  
2021 ◽  
Vol 16 (3) ◽  
pp. 5133-5147
Author(s):  
Hüseyin Pelit ◽  
Mustafa Korkmaz ◽  
Mehmet Budakçı
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Treatment Temperature ◽  
Spindle Speed ◽  
Numerical Control ◽  
Machining Parameters ◽  
End Mill ◽  
Cnc Machine ◽  
Cnc Router ◽  
Thermally Treated

The effects of different machining parameters on surface roughness values of thermally treated pine, beech, and linden woods cut in a computer numerical control (CNC) router machine were examined. Wood specimens were thermally treated at 170, 190, and 210 °C for 2 h. Then, specimens were cut in the radial and tangential directions with three different spindle speeds (12000, 15000, and 18000 rpm) and three different feed rates (3000, 4000, and 6000 mm/min) using two different end mill tools (spiral and straight) on the CNC machine. The end mill type significantly affected the roughness values of the untreated and thermally treated specimens in both directions. Lower roughness values were found in the specimens (especially pine) machined with the straight end mill compared to those machined with the spiral end mill. Roughness generally decreased in the thermally treated specimens. However, thermal treatment temperature did not have a notable effect on roughness. As the spindle speed increased, the roughness values of all specimens decreased. In contrast, as the feed rate increased, the roughness values increased. Therefore, the end mill type, feed rate, and spindle speed were the most influential parameters on the roughness.

scholarly journals The influence of machining parameters on surface roughness of MDF in milling operation

BioResources ◽  
2019 ◽  
Vol 14 (2) ◽  
pp. 3266-3277
Author(s):  
Ümmü K. İşleyen ◽  
Mehmet Karamanoğlu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Medium Density Fiberboard ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Operation ◽  
Four Levels ◽  
Tool Diameter

This paper examined the effect of machining parameters on surface roughness of medium density fiberboard (MDF) machined using a computer numerical control (CNC) router. The machining parameters such as spindle speed, feed rate, depth of cut, and tool diameter were examined for milling. The experiments were conducted at two levels of spindle speeds, four levels of feed rates, two levels of tool diameters, and two levels of axial depths of cut. The surface roughness values of MDF grooved by CNC were measured with stylus-type equipment. Statistical methods were used to determine the effectiveness of the machining parameters on surface roughness. The influence of each milling parameter affecting surface roughness was analyzed using analysis of variance (ANOVA). The significant machining parameters affecting the surface roughness were the feed rate, spindle speed, and tool diameter (p < 0.05). There was no significant influence of axial depth of cut on the surface roughness. The surface roughness decreased with increasing spindle speed and decreasing feed rate. The value of surface roughness increased with the increase of tool diameter.

Modelling of Surface Roughness in Ultra-High Precision Turning of an RGP Contact Lens Polymer

2017 ◽  
Vol 753 ◽  
pp. 183-187 ◽  
Author(s):  
Muhammad M. Liman ◽  
Khaled Abou-El-Hossein ◽  
Abubakar I. Jumare ◽  
Peter Babatunde Odedeyi ◽  
Abdulqadir N. Lukman
Keyword(s):  
Surface Roughness ◽  
Contact Lens ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Quadratic Model ◽  
Depth Of Cut ◽  
Optimal Cutting Parameters ◽  
Diamond Cutting Tool

Contact lens manufacture requires high accuracy and surface integrity. Surface roughness an important response because it has direct influence toward the part performance and the production cost. Hence, choosing optimal cutting parameters will not only improve the quality measure but also the productivity. This research work is therefore aimed at developing a predictive surface roughness model and investigate a finish cutting conditions of ONSI-56 contact lens polymer with a monocrystalline diamond cutting tool. In this work, a novel surface roughness prediction model, in which the feed rate, cutting speed and depth of cut are considered is developed. This combined process was successfully modeled using a Box–Behnken design (BBD) with response surface methodology (RSM). The effects of feed rate, cutting speed and depth of cut were investigated. Analysis of variance (ANOVA) showed that the proposed quadratic model effectively interpreted the experimental data with coefficients of determination of R2 = 0.89 and adjusted R2 = 0.84. The worse surface value was obtained at high feedrate and low spindle speed.

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