scholarly journals Investigation Of The Effects Of Machining Parameters On Tool Life And Surface Roughness During The Face Milling Of The NiTi Shape Memory Alloy With Uncoated Tools

2020 ◽  
Author(s):  
Emre Altas ◽  
Hasan Gokkaya ◽  
Dervis Ozkan
Keyword(s):  
Surface Roughness ◽  
Shape Memory ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Average Surface Roughness ◽  
Nose Radius ◽  
Average Surface ◽  
Milling Operations

Shape memory alloys (SMAs) are increasingly used in the fields of aviation, automotive and biomedicine due to their unique properties. Nickel-Titanium (NiTi) alloy materials, which are one of the shape memory alloys, are among the most frequently used alloy materials. The shape memory and super elastic effects of NiTi alloys, high ductility and deformation hardening make it difficult to shape burr. An additional problem is the formation of a white layer during machining. In this study, surface milling operations were performed in dry cutting conditions with uncoated cutting tools with different nose radii. The processing parameters were determined based on the experience gained as a result of the preliminary tests. Tungsten carbide cutting tools with different nose radii (0.4mm and 0.8mm) were used for the milling operations. Milling was carried out at three different cutting speeds (20, 35, 50 m/min), feed rates (0.03, 0.07, 0.14 mm/tooth), and a constant axial cutting depth (0.7 mm). As a result of our experimental studies, the best tool life was found to be in 0.8 mm nose radius cutting tools at 20 m/min cutting speed and 0.03 mm/tooth feed rate (0.264 mm). The minimum average surface roughness was found after milling with 0.8 mm nose radius cutting tool at 20 m/min cutting speed and 0.03 mm/tooth feed rate (0.346 μm). It has been determined that increasing the cutting tool nose radius reduces both the flank wear over the cutting tool and the average surface roughness.

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.

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.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

scholarly journals Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

2018 ◽  
Vol 142 ◽  
pp. 03002
Author(s):  
Yunhai Jia ◽  
Lixin Zhu
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Boron Nitride ◽  
Feed Rate ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Orthogonal Experimental Design ◽  
Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

INVESTIGATION OF WIPER INSERTS EFFECTS IN TURNING AND MILLING PROCESSES

2021 ◽  
pp. 2150111
Author(s):  
MURAT KIYAK
Keyword(s):  
Surface Roughness ◽  
Cost Saving ◽  
Tool Wear ◽  
Feed Rate ◽  
Turning Process ◽  
Nose Radius ◽  
Turning Operations ◽  
Effective Factors ◽  
Milling Operations ◽  
The Many

The surface roughness is a crucial factor in machining methods. The most effective factors on surface roughness are feed rate and tool nose radius. Due to the many advantages of wiper (multi-nose radius) inserts, their importance and use has been increasing recently. The purpose of this paper is to investigate the effect of wiper inserts on surface roughness and tool wear. In this study, conventional inserts and wiper inserts were experimentally compared separately in milling and turning operations. Compared to conventional inserts, the surface roughness values obtained using wiper inserts improved by 33% in turning operations and approximately 40% in milling operations. It was observed that the production time in the turning process was reduced by about 25% in the case of using wiper inserts compared to the use of conventional inserts. In milling, this ratio was determined to be approximately 43% due to the fact that it has multiple cutting edge. It has been observed that the use of wiper inserts in machining methods creates a significant time and cost saving advantage.

scholarly journals Analysis of Surface Roughness and Flank Wear Using the Taguchi Method in Milling of NiTi Shape Memory Alloy with Uncoated Tools

Coatings ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1259
Author(s):  
Emre Altas ◽  
Hasan Gokkaya ◽  
Meltem Altin Karatas ◽  
Dervis Ozkan
Keyword(s):  
Surface Roughness ◽  
Shape Memory Alloy ◽  
Shape Memory ◽  
Flank Wear ◽  
Cutting Tools ◽  
Dominant Factor ◽  
Niti Shape Memory Alloy ◽  
Machining Parameters ◽  
Nose Radius ◽  
Dry Cutting

The aim of this study was to optimize machining parameters to obtain the smallest average surface roughness (Ra) and flank wear (Vb) values as a result of the surface milling of a nickel-titanium (NiTi) shape memory alloy (SMA) with uncoated cutting tools with different nose radius (rε) under dry cutting conditions. Tungsten carbide cutting tools with different rε (0.4 mm and 0.8 mm) were used in milling operations. The milling process was performed as lateral/surface cutting at three different cutting speeds (Vc) (20, 35 and 50 m/min), feed rates (fz) (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The effects of machining parameters in milling experiments were investigated based on the Taguchi L18 (21 × 32) orthogonal sequence, and the data obtained were analyzed using the Minitab 17 software. To determine the effects of processing parameters on Ra and Vb, analysis of variance (ANOVA) was used. The analysis results reveal that the dominant factor affecting the Ra is the cutting tool rε, while the main factor affecting Vb is the fz. Since the predicted values and measured values are very close to each other, it can be said that optimization is correct according to the validation test results.

scholarly journals The examination of the effect of variable cutting speeds on the surface and edge qualities of milled granite materials

2019 ◽  
Vol 11 (7) ◽  
pp. 168781401983631 ◽  
Author(s):  
István Gábor Gyurika ◽  
Tibor Szalay
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Sample Surface ◽  
Average Surface Roughness ◽  
Edge Chipping ◽  
Average Surface ◽  
Grain Sizes ◽  
Natural Stones ◽  
Cutting Speeds

Automated stone manufacturing has undergone considerable development in recent years. Thanks to international research dealing with the cutting, sawing and grinding of different natural stones, processing time shortens and tool-life lengthens. However, the process of stone milling has not been extensively examined yet, primarily because of the novelty of this technology. The aim of the research described in this article is to examine how variable cutting speed affects the quality of workpiece edges while milling granite materials. For the research, sample surfaces were formed on five granite slabs with different average grain sizes using five cutting speed values. Afterwards, changes in the average surface roughness and average edge chipping rate were examined. From the research results, it can be concluded that, due to an increase in cutting speed, the average edge chipping rate will decrease until reaching a borderline speed. In the case of a higher cutting speed, the referent tendency cannot be ascertained. A statistical analysis conducted in the scope of this research showed that if a variable cutting speed is applied, then changes in the quality of the sample surface edge can be inferred from the development trends of average surface roughness.

Optimization of Machining Condition in WEDM for Titanium Grade 6 Using MOORA Coupled with PCA — A Multivariate Hybrid Approach

2017 ◽  
Vol 16 (02) ◽  
pp. 81-99 ◽  
Author(s):  
Himadri Majumder ◽  
Kalipada Maity
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Hybrid Approach ◽  
Cutting Speed ◽  
Kerf Width ◽  
Average Surface Roughness ◽  
Average Surface ◽  
Titanium Grade ◽  
Pulse On Time ◽  
Pulse Off Time

This paper represents a multivariate hybrid approach, combining Multi-Objective Optimization on the basis of Ratio Analysis (MOORA) and Principal Component Analysis (PCA) to optimize different correlated responses during Wire Electrical Discharge Machining (WEDM) process of titanium grade 6. The response parameters selected are the average cutting speed, average Kerf width and average surface roughness (Ra). All of them have been studied in terms of pulse-ON time, pulse-OFF time, wire feed and wire tension. As indicated by Taguchi’s signal-to-noise ratio, the optimum process parameters were achieved for the desired average cutting speed, average Kerf width and average surface roughness, respectively. At last, the optimum combination of process parameters was validated by affirmation test which gave considerably improved various quality characteristics. Confirmation test outcome revealed that multivariate hybrid approach MOORA coupled with PCA was a competent strategy to decide available cutting parameters for a desired response quality for WEDM of titanium grade 6.

scholarly journals Investigate the Effect of Cutting Parameters on Surface Roughness When Milling X12m Steel

2021 ◽  
pp. 258-263
Author(s):  
Do Thi Kim Lien ◽  
Nguyen Dinh Man ◽  
Phung Tran Dinh
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Negligible Effect ◽  
Depth Of Cut ◽  
The Relationship

In this paper, an experimental study on the effect of cutting parameters on surface roughness was conducted when milling X12M steel. The cutting tool used in this study is a face milling cutter. The material that is used to make the insert is the hard alloy T15K6. The cutting parameters covered in this study include the cutting speed, the feed rate and depth of cut. The experiments are performed in the form of a rotating center composite design. The analysis shows that for both Ra and Rz: (1) the feed rate has the greatest influence on the surface roughness while the depth of cut, the cutting speed has a negligible effect on the surface roughness. (2) only the interaction between the feed rate and the depth of the cut has a significant effect on both Ra and Rz while the interaction between the cutting speed and the feed rate, the interaction between the cutting speed and the depth of cut have a negligible effect on surface roughness. A regression equation showing the relationship between Ra, Rz, and cutting parameters has also been built in this study.

scholarly journals Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Harun Gokce
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Taguchi Method ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Tool Wear ◽  
Wide Range

Stainless steels with unique corrosion resistance are used in applications with a wide range of fields, especially in the medical, food, and chemical sectors, to maritime and nuclear power plants. The low heat conduction coefficient and the high mechanical properties make the workability of stainless steel materials difficult and cause these materials to be in the class of hard-to-process materials. In this study, suitable cutting tools and cutting parameters were determined by the Taguchi method taking surface roughness and cutting tool wear into milling of Custom 450 martensitic stainless steel. Four different carbide cutting tools, with 40, 80, 120, and 160 m/min cutting speeds and 0.05, 0.1, 0.15, and 0.2 mm/rev feed rates, were selected as cutting parameters for the experiments. Surface roughness values and cutting tool wear amount were determined as a result of the empirical studies. ANOVA was performed to determine the significance levels of the cutting parameters on the measured values. According to ANOVA, while the most effective cutting parameter on surface roughness was the feed rate (% 50.38), the cutting speed (% 81.15) for tool wear was calculated.

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