scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Performance assessment of energy efficient and eco-friendly turning of Nimonic C-263: A comparative study on MQL and cryogenic machining

2021 ◽  
pp. 095440542110619
Author(s):  
Prashant S Jadhav ◽  
Chinmaya P Mohanty
Keyword(s):  
Work Environment ◽  
Manufacturing Industry ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cryogenic Machining ◽  
Machined Surface ◽  
Machining Strategies ◽  
The Impact

Nimonic C-263 is predominantly used in the manufacturing of heat susceptible intricate components in the gas turbine, aircraft, and automotive industries. Owing to its high strength, poor thermal conductivity, the superalloy is difficult to machine and causes rapid tool wear during conventional machining mode. Moreover, the unpleasant machining noise produced during machining severely disrupts the tool engineer’s concentration, thereby denying a precise and environment friendly machining operation. Hence, close dimensional accuracy, superior machined surface quality along with production economy, and pleasant work environment for the tool engineers is the need of an hour of the current manufacturing industry. To counter such issues, the present work attempts to compare and explore the machinability of two of the most popular machining strategies like minimum quantity lubrication (MQL) and cryogenic machining process during turning of Nimonic C-263 work piece in order to achieve an ideal machining environment. The machining characteristics are compared in terms of surface roughness (SR), power consumption (P), machining noise (S), nose wear (NW), and cutting forces (CF) to evaluate the impact of machining variables like cutting speed (Vc), feed (f), and depth of cut (ap) with a detailed parametric study and technical justification. Yet again, an investigation is conducted to compare both the machining strategies in terms of qualitative responses like chip morphology, total machining cost, and carbon emissions. The study revealed that cryogenic machining strategy is adequately proficient over MQL machining to deliver energy proficient and gratifying work environment for the tool engineers by reducing the cost of machining and improving their work efficiency.

Technological Investigation of Effect of Machining Parameter on Tool Life

2020 ◽  
Vol 22 (4) ◽  
pp. 41-53
Author(s):  
Manojkumar Sheladiya ◽  
◽  
Shailee Acharya ◽  
Ghanshyam Acharya ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Time ◽  
Machining Parameter

Introduction. The machinability is typical criteria to be investigated and different authors suggested different parameters describing its quantification. Different parameters i. e. speed, feed, depth of cut, tool work-piece combination, machine types and its condition, cutting fluid, machinist expertise, etc. are contributing directly to the tool life. The selection of the tool for the machining impacts greatly on the economic viability of the machining in terms of energy usage and tooling costs. The method of investigation. The current research emphasis mainly on tool life investigation when machining the mild steel specimens ISRO 50, BIS 1732:1989 at constant cutting speed i.e. 200 m / min. In the industries the mild steel material is commonly used for various products manufacturing. Considering the high demands on productivity and surface finish, machining at 200 m / min is the preferred. The computerized numerical control machine (CNC DX-150) is used for the turning. The four corner insert (TNMG 120408) is used for different machining times i.e. 10, 15, 20 and 25 minutes respectively. The flank wear of the tool is measured with calibrated optical microscope. The temperature of the tool corner during machining is continuously measured for possible impact of temperature on bonding properties of the tool insert and impact on red hardness. Results and discussion. The plot of flank wear vs. machining time will give the value of tool life. The other quality output parameter, such as surface roughness, is measured after machining, indicating surface irregularities in root means square value. Efforts have been made to identify the relationship of tool life, machining time, the quantity of metal removed, surface roughness, and tool bit temperature.

In-Process Monitoring and Prediction of Surface Roughness in CNC Turning Process

2011 ◽  
Vol 199-200 ◽  
pp. 1958-1966 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
Cutting Speed ◽  
Least Square ◽  
Depth Of Cut ◽  
Turning Process ◽  
Roughness Model ◽  
Force Ratio ◽  
Cnc Turning Process

The objective of this research is to propose a practical model to predict the in-process surface roughness during the turning process by using the cutting force ratio. The proposed in-process surface roughness model is developed based on the experimentally obtain result by employing the exponential function with six factors of the cutting speed, the feed rate, the rank angle the tool nose radius, the depth of cut, and the cutting force ratio. The multiple regression analysis is utilized to calculate the regression coefficients with the use of the least square method. The prediction accuracy of the in-process surface roughness model has been verified to monitor the in-process predicted surface roughness at 95% confident level. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It has been proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

scholarly journals Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 840 ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Mozammel Mia
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Desirability Function ◽  
Interactive Effect ◽  
Cutting Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

Influence of process variables on machining characteristics in turning of novel AM alloy

2020 ◽  
pp. 095440542097809
Author(s):  
Sunil Dutta ◽  
Suresh Kumar Reddy Narala
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Flank Wear ◽  
Surface Condition ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Input Parameters ◽  
Response Variables

In this paper, the machinability of a fabricated AM alloy (Mg-7 wt%Al-0.9 wt%Mn) has been examined. The novel AM alloy was subjected to turning using a systemized CNC setup. The input turning variables: feed ( f), cutting speed ( v), and depth of cut (DOC) were suitably altered to analyze effects on response variables such as cutting force ( Fc), cutting temperature ( T), and tool life ( TL). Subsequently, the microstructure characterization of the machined surface was done for validating the experimental results. The experimental results established the influence of input parameters on response variables. The cutting force was mostly dominated by DOC, and the cutting temperature was predominantly influenced by cutting speed. The SEM images exhibited the adverse effect of higher values of input parameters on the surface condition. The finest surface was observed at f: 0.1 mm/rev, DOC: 0.5 mm, and v: 115 m/min. Further, the analysis of tool life was done by assessing the flank wear; the measured data showed the significant influence of cutting speed on flank wear. The maximum tool life of 51 min was achieved at the lowest levels of three input parameters.

Relationship Between Measurement of Cutting Force and Sensor Location in Turning Process

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Jaharah A. Ghani ◽  
Poh Siang Jye ◽  
Che Hassan Che Haron ◽  
Muhammad Rizal ◽  
Mohd Zaki Nuawi
Keyword(s):  
Cutting Force ◽  
Strain Gauge ◽  
Cutting Speed ◽  
Strain Gauges ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Sensor Location ◽  
Turning Process ◽  
Feed Force ◽  
Cutting Point

Turning process is widely used in the production of components for automotive and aerospace applications. The machinability of a work material is commonly assessed in terms of cutting tool life, surface finish, and cutting force. These responses are dependent on machining parameters such as cutting speed, feed rate, and depth of cut. In this study, the relationships between cutting force, cutting speed, and sensor location in the turning process were investigated. Strain gauge was chosen as the sensor for the detection of cutting force signal during turning of hardened plain carbon steel JIS S45C. Two strain gauges were mounted on a tool holder at a defined location of I, II, or III at a distance of 37, 42, or 47 mm, respectively, from the cutting point. Only one set of machining experiments was conducted at spindle speed = 1000 rpm, feed = 0.25 mm/rev, and depth of cut = 0.80 mm. The turning process was stopped and the insert was discarded when average flank wear reached 0.30 mm. The main cutting force and the feed force for each cycle measured by the strain gauges at location I, II, and III were collected and analyzed. Results show that when cutting speed was increased, the main cutting force and the feed force were decreased accordingly. The change of was inversely proportional to the change of cutting speed, but the did not decrease continuously and behaved contrarily. A strain gauge placed at a distance of approximately 43 mm from the cutting point was found to be the best and most suitable for sensing accurate force signals.

Prediction of the Cutting Forces on Stainless Steels When Using a Turning Process

2003 ◽  
Author(s):  
Zulay Cassier ◽  
Patricia Mun˜oz-Escalona ◽  
Jannelly Moreno
Keyword(s):  
Stainless Steels ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Turning Process ◽  
High Corrosion Resistance ◽  
Aisi 304 ◽  
Heat Treated

Stainless steels have a great application in the manufacturing process especially due to their characteristic high corrosion resistance. The machining of these materials, the study of the cutting forces, and the power required for the cutting are important parameters to be evaluated. Their relationship with other cutting variables process is crucial for the optimization of the machining process. The results of this research are empirical expressions relating cutting parameters (cutting speed, feed rate and depth of cut) to cutting forces for each stainless steel studied, AISI 304, AISI 420 and AISI 420HT (HT: Heat treated). A general expression was also developed which includes the mechanical properties of these stainless steels. These results enable the user to predict cutting forces when using a turning process.

The Effect of Cutting Parameters on Power Consumption during Turning Nickel Based Alloy

2013 ◽  
Vol 845 ◽  
pp. 799-802 ◽  
Author(s):  
Rusdi Nur ◽  
M.Y. Noordin ◽  
S. Izman ◽  
Denni Kurniawan
Keyword(s):  
Power Consumption ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Turning Process ◽  
Environmental Aspect ◽  
Minimum Power Consumption ◽  
Nickel Based Alloy

Machining process should also consider environmental aspect, with power consumption as one of the criteria. Cutting parameters can be optimized to minimize power consumption. This paper takes a study on turning of nickel-based hastelloy under dry condition (no cutting fluid) which varies cutting speed (150, 200, and 250 m/min) and depth of cut (0.5, 1.0, and 1.5 mm). Power consumption of particular machining process at various cutting parameters was derived and calculated. It was found that minimum power consumption was shown when the turning process was performed at the lowest cutting speed and depth of cut.

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