scholarly journals Research on tool wear factors for milling wood-plastic composites based on response surface methodology

BioResources ◽  
2020 ◽  
Vol 16 (1) ◽  
pp. 151-162
Author(s):  
Weihua Wei ◽  
Yingli Li ◽  
Yuantong Li ◽  
Yiqi Xu ◽  
Changyong Yang
Keyword(s):  
Response Surface Methodology ◽  
Tool Wear ◽  
Response Surface ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Feed Speed ◽  
Cutting Depth ◽  
Wood Plastic Composites ◽  
Plastic Composites

A high-speed milling experiment on wood-plastic composites was performed using cemented carbide tools, and the resulting wear pattern was studied. The influence of the cutting parameters, the cutting speed, feed speed, and axial cutting depth on the tool wear was studied via response surface methodology, and the influence of the interaction of the cutting parameters on tool wear was analyzed. Three-dimensional surface graphs and contour plots of the tool wear results were established. According to the experimental results, a mathematical model of the tool wear based on the second-order response surface methodology was established, and the model was utilized to verify its feasibility. The results show that the nose width (NW) increases with the increase of the cutting speed and axial cutting depth and decreases with the increase of feed speed. Among the factors affecting tool wear, the cutting speed had the greatest influence, followed by the feed rate, with the axial cutting depth affecting tool wear the least. According to the results of the interaction between the tool wear and the cutting parameters, a low feed speed and small axial cutting depth can be selected to ensure long tool life; for low-speed cutting, a high feed speed and large axial cutting depth can be adopted to ensure tool life while improving machining efficiency.

Modeling and Experimental Study on Cutting Force of Diamond Circular Saw in Cutting Granite Using Response Surface Methodology

2013 ◽  
Vol 652-654 ◽  
pp. 2191-2195 ◽  
Author(s):  
Zheng Mei Zhang ◽  
Hai Wen Xiao ◽  
Gui Zhen Wang ◽  
Shu Zhong Zhang ◽  
Shu Qin Zhang
Keyword(s):  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
Cutting Speed ◽  
Feed Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
First Order ◽  
Circular Saw

Based on experiment of sawing Wulian red granite with diamond circular saw, the relations between the cutting force with machining parameters are studied. Cutting speed, feed rate and cutting depth are considered as the process parameters. The cutting force in sawing granite operation are measured and the experimental results are then analyzed using response surface methodology. From the analysis, it is seen that the cutting force Fx , Fy and Fz are reduced with the increase of cutting speed and increased with the increase of feed rate and cutting depth, and the mathematical models of the cutting force are developed. By ANOVA for the cutting force models, It is concluded that the models are significant at 95% confidence level and the significant effects are the first-order of cutting speed, feed speed, cutting depth and the quadratic of cutting depth.

Experimental Study on Tool Wear in Cutting Titanium Alloy Ti6Al4V

2011 ◽  
Vol 239-242 ◽  
pp. 2011-2014
Author(s):  
Yue Feng Yuan ◽  
Wu Yi Chen ◽  
Wen Ying Zhang
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Linear Regression Analysis ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Aged Condition ◽  
Cutting Depth ◽  
Solution Treated ◽  
Titanium Alloy Ti6al4v

Tool wear experiments in turning titanium alloy Ti6Al4V in the solution-treated and aged condition were carried out; the influence rules of cutting parameters such as cutting speed, feed rate and cutting depth on the tool life were obtained. Experimental formula of tool wear was regressed based on multi-variable linear regression analysis, it could predict tool life under certain conditions.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Tool-Life Testing by Response Surface Methodology—Part 2

1964 ◽  
Vol 86 (2) ◽  
pp. 111-116 ◽  
Author(s):  
S. M. Wu
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Tool Life ◽  
Statistical Significance ◽  
Cutting Speed ◽  
Order Effect ◽  
Second Order ◽  
First Order ◽  
Independent Variable ◽  
Basic Philosophy

This paper is a continuation of a previous paper in which the basic philosophy of response surface methodology has been explained and a first-order tool-life-predicting equation has been developed. This part of the paper illustrates the development of a second-order tool-life-predicting equation in 18 and 24 tests. It was found that the second-order effect did not show statistical significance within the cutting ranges of this project; however, the second-order effect of cutting speed has been found important by the study of residuals. If only one independent variable is investigated, a minimal number of tests can be used to find a second-order equation. Examples of designs in three, five, and six tests are illustrated.

Multi-Objective Optimization Using Box-Behken of Response Surface Methodology for High-Speed Machining of Inconel 718

2014 ◽  
Vol 629 ◽  
pp. 487-492 ◽  
Author(s):  
Mohd Shahir Kasim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
E. Mohamad ◽  
Raja Izamshah ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling

This study was carried out to investigate how the high-speed milling of Inconel 718 using ball nose end mill could enhance the productivity and quality of the finish parts. The experimental work was carried out through Response Surface Methodology via Box-Behnken design. The effect of prominent milling parameters, namely cutting speed, feed rate, depth of cut (DOC), and width of cut (WOC) were studied to evaluate their effects on tool life, surface roughness and cutting force. In this study, the cutting speed, feed rate, DOC, and WOC were in the range of 100 - 140 m/min, 0.1 - 0.2 mm/tooth, 0.5 - 1.0 mm and 0.2 - 1.8 mm, respectively. In order to reduce the effect of heat generated during the high speed milling operation, minimum quantity lubrication of 50 ml/hr was used. The effect of input factors on the responds was identified by mean of ANOVA. The response of tool life, surface roughness and cutting force together with calculated material removal rate were then simultaneously optimized and further described by perturbation graph. Interaction between WOC with other factors was found to be the most dominating factor of all responds. The optimum cutting parameter which obtained the longest tool life of 60 mins, minimum surface roughness of 0.262 μm and resultant force of 221 N was at cutting speed of 100 m/min, feed rate of 0.15 mm/tooth, DOC 0.5 m and WOC 0.66 mm.

Modelling and Analysis of Relationship between Cutting Parameters Surface Roughness and Cutting Forces Using Response Surface Methodology when Hard Turning with Coated Ceramic Inserts

2016 ◽  
Vol 686 ◽  
pp. 19-26 ◽  
Author(s):  
Ildikó Maňková ◽  
Marek Vrabeľ ◽  
Jozef Beňo ◽  
Mária Franková
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Oxide Ceramic ◽  
Cutting Force Components ◽  
Force Components

Experimental research and modeling in the field of turning hardened bearing steel with hardness of 62 HRC using TiN coated mixed oxide ceramic inserts is presented. The main objective of the article is investigation the relationship between cutting parameters (cutting speed and feed rate) and output machining variables (surface roughness and cutting force components) through the response surface methodology (RSM). The mathematical model of the effect of process parameters on the cutting force components and surface roughness is presented. Moreover, the influence of TiN coating on above mentioned variables was monitored. The design of experiment according to Taguchi L9 orthogonal matrix (32) was applied for trials. Pearson´s correlation matrix was used to examine the dependence between the factors (f, vc) and the machining variables (surface roughness and cutting force components). The results show how much surface roughness and cutting force components is influenced by cutting speed and feed in hard turning with coated ceramics.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

scholarly journals Optimization of Cutting Parameters on Turning Process Based on Surface Roughness Using Response Surface Methodology

2011 ◽  
Vol 117-119 ◽  
pp. 1561-1565
Author(s):  
Muhammad Yusuf ◽  
Mohd Khairol Anuar Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Optimization Of Cutting Parameters

This paper describes effect of cutting parameters on surface roughness for turning of aluminium alloy 7050 using carbide cutting tool with dry cutting condition. The model is developed based on cutting speed, feed rate and depth of cut as the parameters of cutting process. The selection of cutting process was based on the design of experiments Response Surface Methodology (RSM). The objective of this research is finding the optimum cutting parameters based on surface roughness. The relation between cutting parameters and surface roughness were discussed.

Tool Life in High Speed Turning with Negative Rake Angle

2011 ◽  
Vol 264-265 ◽  
pp. 1009-1014 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz H.F. Al Hazza
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
High Speed Cutting ◽  
Life Estimation ◽  
High Speed Turning

The present work studies some aspects of turning process applied on mild steel using cermets tools at high speed cutting (1000mm/min) by using negative rake angle (0 to-12). The influence of increasing the cutting speed and negative rake angle on flank tool wear, cutting forces, feeding forces and tool temperature were analyzed. The research studies and concentrates on the tool life estimation and the effect of the negative rake angle and higher cutting speed on tool life. It was found that the maximum tool life is obtained in (-6) rake angle for the cutting parameters.

Empirical Expression of Tool Wear When Face Milling 416 SS

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Increase Tool Life ◽  
The Cost

During a machining process, cutting parameters must be taken into account, since depending on them the cutting edge starts to wear out to the point that tool can fail and needs to be change, which increases the cost and time of production. Since wear is a negative phenomenon on the cutting tool, due to the fact that tool life is reduced, it is important to optimize the cutting variables to be used during the machining process, in order to increase tool life. This research is focused on the influence of cutting parameters such as cutting speed, feed per tooth and axial depth of cut on tool wear during a face milling operation. The Taguchi method is applied in this study, since it uses a special design of orthogonal array to study the entire parameters space, with only few numbers of experiments. Also a relationship between tool wear and the cutting parameters is presented. For the studies, a martensitic 416 stainless steel was selected, due to the importance of this material in the machining of valve parts and pump shafts.

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