scholarly journals A Survey on the Effects of Cutting Parameters on Surface Roughness When Milling 40Cr Steel Using End Mill Cutter

2020 ◽  
Vol 5 (1) ◽  
pp. 33-36
Author(s):  
Nguyen Hong Son
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Regression Equations ◽  
Face Mill ◽  
Mill Cutter ◽  
The Relationship ◽  
40Cr Steel

In this paper, the empirical research on the effects of cutting parameters on surface roughness when milling 40Cr steel with face mill is conducted. The cutting parameters in this study include the cutting speed, feed rate and depth of cut. The tests are conducted in the form of Central Composite Design. The analysis shows that, for both Ra and Rz: (1) the feed rate has the greatest effect on surface roughness, followed by the degree of influence of the depth of cut, cutting speed with insignificant effects on surface roughness. (2) only the interaction between the feed rate and depth of cut have a significant effect on both Ra and Rz; the interaction between the cutting speed and feed rate, the interaction between the cutting speed and depth of cut have negligible effects on the surface roughness. In addition, the regression equations showing the relationship between Ra, Rz and cutting parameters is developed in this study.

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.

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.

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

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 Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

Hard Turning of Hot Work Steel X38CRMOV5-3: Evaluation of Surface Roughness and Current Values Using Cutting Parameters

2020 ◽  
Author(s):  
Ali Kemal Cakir
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Motor Current ◽  
Design Factors

This study evaluates the surface roughness and current values using cutting parameters in the turning of AISI H11 being hot work tool steel under dry machining conditions. The selected design factors are the depth of cut, feed rate, cutting speed. A design of experiments was used to carry out this research. The obtained results were analyzed to determine the effects of input parameters on the resultant surface roughness, current using the analysis of variance (ANOVA) and the Response Surface Methodology (RSM). The experimental results showed that increasing feed rate increased the surface roughness, and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate on the surface roughness. Also, the motor current values were influenced by the 38,48% depth of cut, 23,98% cutting speed, 25,52% feed rate, respectively.

Experimental Study on the Relationship between Surface Roughness and Cutting Parameters when Face Milling High Strength Steel

2010 ◽  
Vol 139-141 ◽  
pp. 782-787
Author(s):  
Yue Ding ◽  
Wei Liu ◽  
Xi Bin Wang ◽  
Li Jing Xie ◽  
Jun Han
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Strength Steel ◽  
Cutting Speed ◽  
High Strength ◽  
Face Milling ◽  
Depth Of Cut ◽  
Radial Depth ◽  
The Relationship ◽  
Axial Depth

In this study, surface roughness generated by face milling of 38CrSi high-strength steel is discussed. Experiments based on 24 factorial design and Box-Behnken design method are conducted to investigate the effects of milling parameters (cutting speed, axial depth of cut and radial depth of cut and feed rate) on surface roughness, and a second-order model of surface roughness is established by using surface response methodology (RSM); Significance tests of the model are carried out by the analysis of variance (ANOVA). The results show that the most important cutting parameter is feed rate, followed by radial depth of cut, cutting speed and axial depth of cut. Moreover, it is verified that the predictive model possesses highly significance by the variance examination at a level of confidence of 99%. And the relationship between surface roughness and the important interaction terms is nonlinear.

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.

The Investigation of Prediction Surface Roughness from Machining Forces in End Milling Processes

2011 ◽  
Vol 486 ◽  
pp. 91-94 ◽  
Author(s):  
Jabbar Abbas ◽  
Amin Al-Habaibeh ◽  
Dai Zhong Su
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Irregular Waves ◽  
Depth Of Cut ◽  
End Mill ◽  
Machined Surface ◽  
Machining Forces ◽  
Mill Cutter

Surface roughness is one of the most significant parameters to determine quality of machined parts. Surface roughness is defined as a group of irregular waves in the surface, measured in micrometers (μm). Many investigations have been performed to verify the relationship between surface roughness and cutting parameters such as cutting speed, feed rate and depth of cut. To predict the surface produced by end milling, surface roughness models have been developed in this paper using the machining forces by assuming the end mill cutter as a cantilever beam rigidly or semi- rigidly supported by tool holder. An Aluminium workpiece and solid carbide end mill tools are used in this work. Model to predict surface roughness has been developed. Close relationship between machined surface roughness and roughness predicted using the measured forces signals.

scholarly journals Prediction of cutting tool vibration and surface roughness in hard turning of AISI52100 steel

2018 ◽  
Vol 211 ◽  
pp. 03011
Author(s):  
Nitin Ambhore ◽  
Dinesh Kamble ◽  
Satish Chinchanikar
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Vibration Amplitude ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Vibration Signals ◽  
Cutting Parameter ◽  
Acceleration Amplitude

The changing behavior of vibration signals with varying cutting parameters (cutting speed, feed rate and depth of cut) for turning hardened AISI52100 steel has been studied and reported. The vibration response of cutting tool in all three mutually perpendicular directions, namely, in feed Vx, radial Vy and, tangential Vz directions have been captured by mounting piezoelectric tri-axial accelerometer close to the cutting tool. Experiments are planned and conducted as per Central composite rotatable design of Surface response methodology. The second order multiple regression models are developed to correlate cutting parameters with vibration acceleration and surface roughness. The coefficient of regression R2 for all models is found close to 0.92 which shows that the developed models are reliable and provide an excellent explanation between the cutting parameter and the vibration of cutting tool within limits. The analysis of the results revealed that cutting conditions are having prominent and mixed type effect on vibration signals. The acceleration amplitude Vx, Vy and Vz increases with increase in cutting speed, and depth of cut. The vibration amplitude Vx, Vy and Vz initially increases as feed increases and, with further increase in feed, the vibration amplitude decreases. The surface roughness is highly influenced by the feed rate followed by cutting speed whereas the depth of cut was found less significant. The fluctuation in frequency is observed in all directions. However, the band of frequency remains within a certain range. Within selected cutting parameter range, the maximum acceleration amplitude is observed in frequency band of 4 kHz - 16 kHz.

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