scholarly journals The Effect of Cutting Fluids and Cutting Speeds to The Vibrations of Milling CNC Machine

2017 ◽  
Vol 16 (2) ◽  
Author(s):  
A Muhammad Fuad Nur Rochim ◽  
Indri Yaningsih ◽  
Heru Sukanto
Keyword(s):  
Cutting Force ◽  
External Force ◽  
Face Milling ◽  
Cutting Process ◽  
Machining Process ◽  
Cutting Fluids ◽  
Cnc Machine ◽  
Accelerometer Sensor ◽  
Slot Milling ◽  
Cutting Speeds

Vibration that occur in machining process is forced vibration. This vibration caused by external force excitation. External force that cause vibration in machining process is cutting force. This research was aims to determine the effect of cutting fluids and cutting speeds to vibration in milling process. The specimens were made using a cutting process type face milling, profile milling, pocket milling, and slot milling. Cutting speeds was variated at 62.83 m/min; 110 m/min; 157.14 m/min; 188.5 m/min. Vibration testing was done using the accelerometer sensor. Vibration response taken is the amplitude. The results show any type of cutting process has a different amplitude. Face milling has the smallest amplitude while slot milling has the biggest one. At cutting speeds parameter, the faster of cutting speeds the smaller of the amplitude. The use of cutting fluids can reduce the friction value between cutting tool and workpiece so that the cutting force will decrease. The use of cutting fluids causing the smaller the cutting force. The increase of the cutting force will cause greater vibration

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

Numerical Simulation of Metal Cutting Process Based on ANSYS/LS-DYNA

2015 ◽  
Vol 727-728 ◽  
pp. 335-338 ◽  
Author(s):  
Song Jie Yu ◽  
Di Di Wang ◽  
Xin Chen
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Plastic Material ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Linear Deformation ◽  
Deformation Problem ◽  
Non Linear ◽  
Elastic Plastic Material

Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.

scholarly journals Development of smart machining system for optimizing feedrates to minimize machining time

2017 ◽  
Vol 5 (3) ◽  
pp. 299-304 ◽  
Author(s):  
Hong-seok Park ◽  
Bowen Qi ◽  
Duck-Viet Dang ◽  
Dae Yu Park
Keyword(s):  
Cutting Force ◽  
Machining Process ◽  
Cnc Machine ◽  
Machining Time ◽  
Virtual Machining ◽  
Milling Operations ◽  
Nc Program ◽  
Machining System ◽  
Optimal Feed ◽  
Smart Machining

Abstract Feedrate optimization is an important aspect of getting shorter machining time and increase the potential of efficient machining. This paper presents an autonomous machining system and optimization strategies to predict and improve the performance of milling operations. The machining process was simulated and analyzed in virtual machining framework to extract cutter-workpiece engagement conditions. Cutting force along the cutting segmentation is evaluated based on the laws of mechanics of milling. In simulation, constraint-based optimization scheme was used to maximize the cutting force by calculating acceptable feedrate levels as the optimizing strategy. The intelligent algorithm was integrated into autonomous machining system to modify NC program to accommodate these new feedrates values. The experiment using optimized NC file which generates by our smart machining system were conducted. The result showed autonomous machining system, was effectively reduced 26%. Highlights The smart machining system was implemented in the CNC machine. Optimal feed rates enhance machine tool efficiency. The smart machining system is reliable to reduce machine time.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

scholarly journals Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel

Metals ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1650
Author(s):  
Angelos P. Markopoulos ◽  
Nikolaos E. Karkalos ◽  
Mozammel Mia ◽  
Danil Yurievich Pimenov ◽  
Munish Kumar Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Tool Steel ◽  
Sustainability Assessment ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Assessment Model ◽  
Machining Process ◽  
Cutting Power ◽  
Slot Milling

The hardened tool steel AISI O1 has increased strength, hardness, and wear resistance, which affects the complexity of the machining process. AISI O1 has also been classified as difficult to cut material hence optimum cutting parameters are required for the sustainable machining of the alloy. In this work, the effect of feed peer tooth (fz), cutting speed (vc), cutting of depth (ap) on surface roughness (Ra, Rt), cutting force (Fx, Fy), cutting power (Pc), machining cost (Ci), and carbon dioxide (Ene) were investigated during the slot milling process of AISI O1 hardened steel. A regression analysis was carried out on the obtained experimental results and the induction of nonlinear mathematical equations of surface roughness, cutting force, cutting power, and machining cost with a high coefficient of determination (R2 = 90.62–98.74%) were deduced. A sustainability assessment model is obtained for optimal and stable levels of design variables when slot milling AISI O1 tool steel. Stable indicators to ensure personal health and safety of operation, P1 values were set to “1” at a cutting speed of 20 m/min or 43.3 m/min and “2” at a cutting speed of 66.7 m/min or 90 m/min. It is revealed that for eco-benign machining of AISI O1, the optimum parameters of 0.01 mm/tooth, 20 m/min, and 0.1 mm should be adopted for feed rate, cutting speed, and depth of cut respectively.

Characterization of Cutting Force Induced Surface Shape Variation in Face Milling Using High-Definition Metrology1

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Hai Trong Nguyen ◽  
Hui Wang ◽  
S. Jack Hu
Keyword(s):  
Cutting Force ◽  
Process Monitoring ◽  
Face Milling ◽  
Surface Shape ◽  
Machining Process ◽  
High Definition ◽  
Surface Patterns ◽  
Cutting Processes ◽  
And Control ◽  
The Impact

High-definition metrology (HDM) systems with fine lateral resolution are capable of capturing the surface shape on a machined part that is beyond the capability of measurement systems employed in manufacturing plants today. Such surface shapes can precisely reflect the impact of cutting processes on surface quality. Understanding the cutting processes and the resultant surface shape is vital to high-precision machining process monitoring and control. This paper presents modeling and experiments of a face milling process to extract surface patterns from measured HDM data and correlate these patterns with cutting force variation. A relationship is established between the instantaneous cutting forces and the observed dominant surface patterns along the feed and circumferential directions for face milling. Potential applications of this relationship in process monitoring, diagnosis, and control are also discussed for face milling. Finally a systematic methodology for characterizing cutting force induced surface variations for a generic machining process is presented by integrating cutting force modeling and HDM measurements.

scholarly journals Finite Element Modeling of the Effect of Tool Rake Angle on Cutting Force and Tool Temperature during High Speed Machining of AISI 1045 Steel

2014 ◽  
Vol 939 ◽  
pp. 194-200
Author(s):  
Shamsuddin Sulaiman ◽  
Mohd K.A. Ariffin ◽  
A. Roshan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
High Speed Machining ◽  
Tool Temperature ◽  
Aisi 1045 ◽  
Cutting Speeds

A finite element model (FEM) of an orthogonal metal-cutting process is used to study the influence of tool rake angle on the cutting force and tool temperature. The model involves Johnson-Cook material model and Coulomb’s friction law. A tool rake angle ranging from 0° to 20° and a cutting speed ranging from 300 to 600 m/min were considered in this simulation. The results of this simulation work are consistent optimum tool rake angle for high speed machining (HSM) of AISI 1045 medium carbon steel. It was observed that there was a suitable rake angle between 10° and 18° for cutting speeds of 300 and 433 m/min where cutting force and temperature were lowest. However, there was not optimum rake angle for cutting speeds of 550 and 600 m/min. This paper can contribute in optimization of cutting tool for metal cutting process.

Machining Control of Surface Roughness by Measuring Cutting Forces

2012 ◽  
Vol 498 ◽  
pp. 157-162 ◽  
Author(s):  
Eustaquio García Plaza ◽  
Pedro Jose Núñez López ◽  
Francisco Mata ◽  
A. Sanz
Keyword(s):  
Surface Roughness ◽  
Adaptive Control ◽  
Control System ◽  
Cutting Process ◽  
Machining Process ◽  
Second Phase ◽  
Adaptive Control System ◽  
Cnc Machine ◽  
Cnc Turning ◽  
Phase Surface

The primary aim of this study was to design and develop an on-line control system of finished surfaces in automated machining process by CNC turning. The control system consisted of two basic phases: during the first phase, surface roughness was monitored through cutting force signals; the second phase involved a closed-loop adaptive control system based on data obtained during the monitoring of the cutting process. The system ensures that surfaces roughness is maintained at optimum values by adjusting the feed rate through communication with the PLC of the CNC machine. A monitoring and adaptive control system has been developed that enables the real-time monitoring of surface roughness during CNC turning operations. The system detects and prevents faults in automated turning processes, and applies corrective measures during the cutting process that raise quality and reliability reducing the need for quality control.

scholarly journals Studying of Technological Characteristics in Cutting Zone by Multifunction Measuring System

2012 ◽  
Vol 9 (2) ◽  
pp. 38-42
Author(s):  
Michal Šajgalík ◽  
Andrej Czán ◽  
Marek Szigety ◽  
Róbert Bobrovský
Keyword(s):  
Temperature Field ◽  
Cutting Force ◽  
Cutting Process ◽  
Machining Process ◽  
Measuring System ◽  
Technological Characteristics ◽  
Comprehensive Information ◽  
Cutting Zone

Abstract In this manuscript are described and evaluated processes in cutting zone during machining process by turning based on the results of the multifunction measuring system. This system consists of three different measuring units, which allow to measure and monitor processes in the cutting zone, such as size of components of cutting force, temperature field and its evolution during the cutting process, etc. The results as the data from each unit of multifunction measuring system provide detailed and comprehensive information about processes in cutting zone during the machining and they help to better knowledge of processes in cutting zone during the machining.

The Research on Cutting Force in High-Speed Milling Process of Aluminum Alloy Impeller

2010 ◽  
Vol 142 ◽  
pp. 11-15 ◽  
Author(s):  
Y.B. Liu ◽  
C. Zhao ◽  
X. Ji ◽  
Ping Zhou
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Test Method ◽  
Cutting Process ◽  
Machining Process ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Five Axis ◽  
Cutting Path

High-speed cutting process of cutting force influence variables and variation and ordinary speed cutting are obviously different, in order to study the high-speed cutting process of different parameters on the effect of cutting force, based on five axis high-speed NC machining center, using multi-factor orthogonal test method for high speed milling of aluminum alloy impeller conducted experiments. It was analyzed that cutting force influence factors of 5-axises blade machining process. A private clamp was designed and produced, to measure the cutting force of machining process. It was observe that distribution of 3-dimension cutting forces in cutting path. It was found that the distribution rule of cutting force. With the experiment study on cutting force when high speed cutting aluminum cuprum, the influence disciplinarian of each cutting parameter on cutting force was obtained.

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