scholarly journals Effect of Cutting Parameter on Material Removal Rate and Surface Roughness in Deep Drilling Process

2016 ◽  
Vol 2 (5) ◽  
Author(s):  
Mostafa A. Abdullah  , Ahmed B. Abdulwahhab   ,   Atheer R.
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Cutting Conditions ◽  
Drilling Process ◽  
Tool Diameter ◽  
Twist Drills

In the curents study aimed to assess the effects of cutting conditions  (spindle speed, feed rate, tool diameter) parameters as input impact on material removal rate (MRR) and surface roughness (Ra) as output of steel (AISI 1015). A number of drilling experiments were conducted using the L9 orthogonal array on conventional drilling machine with use feed rate (0.038,0.076,0.203) mm/rev and spindle speed (132,550,930) rpm and tool diameter (11,15,20) mm HSS twist drills under dry cutting conditions. Analysis of variance (ANOVA) was employed to determine the most significant control factors affecting on surface roughness and MRR. The result shown the tool diameter the important factor effect with (64.08%) and (76.12%) on MRR and surface roughness respectively.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

scholarly journals The Application of WSM, WPM and WASPAS Multicriteria Methods for Optimum Operating Conditions Selection in Machining Operations

2021 ◽  
Vol 10 (1) ◽  
pp. 1-14
Author(s):  
Onoyeyan Onajite ◽  
Sunday Ayoola Oke
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Operating Conditions ◽  
Depth Of Cut ◽  
Multicriteria Methods ◽  
Machining Operations

Optimal condition selection in machining operations is an imperative decision for the process engineer as it influences improved tool life and surface roughness values. As the aluminium market is extremely competitive, process engineers strive to understand what to do to gain preference from prospective customers. From this viewpoint, the criteria responsible for operating decisions should be examined. In this paper the WSM, WPM and WASPAS multicriteria methods are proposed for optimal machining conditions for turned aluminium bars. A stepwise methodology of the WSM, WPM and WASPAS methods is detailed. The proposed technique was tested on published data regarding the turning of an aluminium bar, machined on a lathe machine. The case study consists of three input parameters (spindle speed, feed rate and depth of cut) and four responses (cutting temperature, cutting force, surface roughness and material removal rate). After analysing the experimental data using the models, the entropy method chose material removal rate was chosen as the best. Using the three other models, the best selection was run 17 which correspond to an input parameter of 605 rpm spindle speed, 0.12 mm/rev feed rate and 1.8 mm depth of cut. This article offers a completely new approach to operating condition selection in the turning of the aluminium bar. In the current aluminium market, it is extremely important to understand the operating conditions of the machine for enlarged customer patronage and sustainability. The unique feature of this approach is the elevated level of reliability it exhibits.

scholarly journals Multi Response Optimization of Process Parameters in Drilling Operation for Jute and Basalt Fabric Composite Material

2019 ◽  
Vol 9 (1) ◽  
pp. 389-394 ◽  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spare Parts ◽  
Spindle Speed ◽  
Drill Bit ◽  
Taguchi Analysis ◽  
Delamination Factor

Natural fabric Reinforced polymer (NFRP) composites are the materials by a matrix and a reinforcement of natural fibre. NFRPs are the materials with low density, high molding flexibility, environmentally friendly and have wide range of applications extending from products of commodity to aerospace, defence, automobile spare parts, and bicycle frames applications. In this work the effect of cutting parameters in drilling Natural fabric reinforced composites were studied. Experiments were conducted to study the effect of drill bit diameter, spindle speed and feed rate on Material Removal Rate (MRR), Surface Roughness, Circularity of Hole and Delamination Factor. Theoretical calculations are done to calculate Material Removal Rate and Delamination Factor. Surface Roughness and Circularity of Hole measured by Surface Roughness Tester and Coordinate Measuring Machine (CMM) respectively. The input parameters considered were 6mm, 8mm and 10mm diameter drill bits, spindle speeds of 600rpm, 1200rpm & 1800rpm, feed rates of 0.1rev/min, 0.2rev/min and 0.3rev/min. Experiments were carried as per Taguchi Experimental Design (L9 ) to get the optimum values of MRR, Surface Roughness, And Circularity Of Hole and Delamination Factor. Optimization was done using Taguchi Analysis, Grey Taguchi Analysis and Multi Attribute Decision Making (MADM) Method. The optimal solution for the multiple response system of drilling of NFRP were diameter of drill bit of 10 mm, Spindle speed 600 rpm and at 0.3 mm/rev feed rate. MADM process concluded that, Circularity of Hole was most preferred response than followed by Material Removal Rate, Surface Roughness and Delamination Factor

scholarly journals Multi-Objective Process Parameter Optimization for Surface Roughness and Material Removal Rate in Face Milling of Al 6061 T6 Alloy

2019 ◽  
Vol 9 (2) ◽  
pp. 137-142
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Al 6061

This study uses Taguchi methodology and Gray Relational Analysis approach to explore the optimization of face milling process parameters for Al 6061 T6 alloy.Surface Roughness (Ra), Material Removal Rate (MRR) has been identified as the objective of performance and productivity.The tests were performed by selecting cutting speed (mm / min), feed rate (mm / rev) and cutting depth (mm) at three settings on the basis of Taguchi's L9 orthogonal series.The grey relational approach was being used to establish a multiobjective relationship between both the parameters of machining and the characteristics of results. To find the optimum values of parameters in the milling operation, the response list and plots are used and found to be Vc2-f1-d3. To order to justify the optimum results, the confirmation tests are performed.The machining process parameters for milling were thus optimized in this research to achieve the combined goals such as low surface roughness and high material removal rate on Aluminum 6061 t6.It was concluded that depth of cut is the most influencing parameter followed by feed rate and cutting velocity.

Investigation of Orthogonal Turn-Milling for Higher Machining Efficiency and Accuracy: Relationship Between Material Removal Rate and Measured Tool Flank Temperature

2020 ◽  
Author(s):  
Koji Shimanuki ◽  
Akira Hosokawa ◽  
Tomohiro Koyano ◽  
Tatsuaki Furumoto ◽  
Yohei Hashimoto
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Speed Ratio ◽  
3D Cad ◽  
Revolution Speed ◽  
Tool Diameter ◽  
Chip Geometry ◽  
Turn Milling

Abstract Tool flank temperature at various intervals after cutting in dry turn-milling of AISI 1045 steel is measured using a two-color pyrometer with an optical fiber. Complicated undeformed chip geometry, which depends on cutting tool diameter, nose radius, number of tooth, workpiece diameter, tool-work revolution speed ratio, depth of cut, feed per tooth, tool axis offset and cutting distance, is analyzed and visualized by the 3D-CAD system. The effect of cutting parameters associated with material removal rate MRR such as workpiece diameter, workpiece revolution speed and feed rate on tool flank temperature is investigated in this paper. Workpiece diameter affects tool flank temperature, and 10 mm larger diameter causes approximately 40 °C higher temperature in any workpiece revolution speed due to the variation of undeformed chip geometry analyzed by 3D-CAD. Tool flank temperature increases with feed rate and workpiece revolution speed because the cross-sectional cutting area of undeformed chip increases with workpiece revolution speed, and cutting time during the engagement of each flute also increases with feed rate. Almost same values are obtained between the tool flank temperature and the material removal rate MRR when both workpiece revolution speed and feed rate are changed.

scholarly journals Effect of Machine Feed Rate on Kerf-Width, Material Removal Rate, and Surface Roughness in Machining of Al/SiC Composite Material with Wire Electrical Discharge Machine

2020 ◽  
Vol 70 (1) ◽  
pp. 81-88
Author(s):  
Manoj Modi ◽  
Gopal Agarwal ◽  
Swati D Chaugaonkar ◽  
Umesh Bhatia ◽  
Veerendra Patil
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Kerf Width ◽  
Discharge Machine ◽  
Wire Electric Discharge Machining ◽  
The Impact

AbstractThe impact of machine feed rates of Wire Electric Discharge Machining on the kerf-width (K-width), material-removal-rate (MR-R), and surface-roughness (S-R) in the machining of Al/SiC composite is practically analysed. The relation among the feed rates of machine and K-width, MR-R, S-R is graphically acquired. It is demonstrated that lesser rate of feed is responsible for generation of larger K-width, lesser MR-R, and good finish as compared to more feed rate.

scholarly journals Optimal Seeking Surface Roughness and Material Removal Rate Responses of Hardened AISI 4340 High Strength Low AlloySteel in Dry Sustainable Environment

2021 ◽  
Vol 40 (1) ◽  
pp. 116-129
Author(s):  
Amar ul Hassan Khawaja ◽  
Mirza Jahanzaib ◽  
Shahzad Zaka
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
High Strength ◽  
Depth Of Cut ◽  
Sustainable Environment ◽  
Coated Carbide ◽  
Aisi 4340

The aim of this research is to study the machinability aspects of hardened AISI 4340 High Strength Low Alloy (HSLA) steel (50 ± 2 HRC (Hardness Rockwell C)). The experimental investigation using coated carbide inserts is carried out during the dry hard milling process in a sustainable environment. The input parameters in the study are speed, feed rate and depth of cut and the responses are Average surface Roughness (Ra) and Material Removal Rate (MRR) that are selected through screening. Central Composite Design (CCD) in response surface methodology has been utilized as the experimental design technique with twenty experiments. Analysis of variance has been employed to examine the momentous machining parameters and responses. A mathematical model has been developed to optimize the surface roughness and material removal rate. It has been observed that the most significant factor for Ra is feed rate while for MRR depth of cut is the most significant factor. The results show that the minimum value of Ra ~ 0.098 μm is achieved at speed ~ 1000 RPM, feed rate ~ 300 mm/min and depth of cut ~ 0.2 mm while the maximum value of MRR ~ 6.35 cm3/min is attained at feed rate ~ 500mm/min and depth of cut ~ 0.4 mm regarding less or no effect of speed ~ 500-1000 RPM. The average forecast error for the validation information has been observed to be 3.35%. for Ra and 3.2% for MRR. Further, it is investigated that good surface finish like grinding and dimensional accuracy can be achieved with coated carbide tools.

Study on the Material Removal Rate of Nano-ZrO2 Ceramics under Ultrasonic Vibration Assisted Diamond Fly-Cutting

2018 ◽  
Vol 932 ◽  
pp. 30-35
Author(s):  
Yan Yan Yan ◽  
Yi Fan Lv ◽  
Jun Li Liu
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Cutting Depth ◽  
Four Levels

According to the removal mechanism of ductile regime machining of nanoZrO2 ceramics and the dynamic characteristics of ultrasonic vibration assisted diamond flying cutting (UVADFC), the model of the material removal rate (MRR) of nanoZrO2 ceramics under UVADFC and diamond flying cutting (DFC) have been proposed by infinitesimal method,. In this paper, the experiment of three factors and four levels was carried out to study the relationships between MRR and the machining parameters (cutting depth , spindle speed n and feed rate c). The results of the experiment shows that UVADFC is a cost-effective method which is applied to the machining of nanoZrO2 ceramics, and the MRR of nanoZrO2 ceramics under UVADFC is 1.3-2 times greater than that of DFC, and the degree of the factors significantly influence on the MRR of nanoZrO2 ceramics are feed rate, cutting depth, spindle speed in a sequence whether it is DFC or UVADFC. The results will shed more light on the material removal mechanism of UVADFC.

Influences of Varying Combination of Feed Rate and Depth of Cut to Tool Wear Rate and Surface Roughness: High Speed Machining Technique in Non-High Speed Milling Machine

2014 ◽  
Vol 903 ◽  
pp. 194-199
Author(s):  
Mohd Zairulnizam Zawawi ◽  
Mohd Ali Hanafiah Shaharudin ◽  
Ahmad Rosli Abdul Manaf
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Tool Wear Rate

Machining technique using high spindle speed, high feed rate and shallow depth of cut utilize in High Speed Milling (HSM) machines offer several benefits such as increase of productivity, elimination of secondary and semi-finishing process, reduce tool load and small chips produced. By adjusting some of the machining parameters, non-HSM machine having lower spindle speed and feed rate could also take advantages some of the benefits mentioned above when applying the HSM technique. This experiment investigate the effects of varying combination of depth of cut and feed rate to tool wear rate and surface roughness during end milling of Aluminum and P20 tool steel in dry condition. The criterion for tool wear before it gets rejected is based on maximum flank wear, Vb of 0.6mm. Material removal rate, spindle speed and radial depth of cut are constant in this experiment. After preliminary machining trials, the combination starts with depth of cut of 2mm and feed rate of 45mm/min until the smallest depth of cut and highest feed rate of 0.03mm and 3000mm/min respectively. The obtained result shows that for both materials, feed rate significantly influences the surface roughness value while depth of cut does not as the surface roughness value keep increasing with the increase of feed rate and decreasing depth of cut. Whereas, tool wear rate almost remain unchanged indicates that material removal rate strongly contribute the wear rate. With no significant tool wear rate, this study demonstrates that HSM technique is possible to be applied in non-HSM machine with extra benefits of eliminating semi-finishing operation, reducing tool load for finishing, machining without coolant and producing smaller chip for ease of cleaning.

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