Effect of cutting conditions on surface roughness in finish turning of Hastelloy-X superalloy

The influence of cooling conditions and surface topography after finish turning of Ti6Al4V titanium alloy on corrosion resistance and surface bioactivity was analyzed. The samples were machined under dry and minimum quantity lubrication (MQL) conditions to obtain different surface roughness. The surface topographies of the processed samples were assessed and measured using an optical profilometer. The produced samples were subjected to electrochemical impedance spectroscopy (EIS) and corrosion potential tests (Ecorr) in the presence of simulated body fluid (SBF). The surface bioactivity of the samples was assessed on the basis of images from scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analysis. The inspection of the surfaces of samples after turning under dry and MQL conditions revealed unevenly distributed precipitation of hydroxyapatite compounds (Ca/P) with a molar ratio in the range of 1.73–1.97. Regardless of the cutting conditions and surface roughness, the highest values of Ecorr ~0 mV were recorded on day 7 of immersion in the SBF solution. The impedance characteristics showed that, compared to the MQL conditions, surfaces machined under dry conditions were characterized by greater resistance and the presence of a passive layer on the processed surface. The main novelty of the paper is the study of the effect of ecological machining conditions, namely, dry and MQL cutting on the corrosion resistance and surface bioactivity of Ti6Al4V titanium alloy after finish turning. The obtained research results have practical significance. They can be used by engineers during the development of technological processes for medical devices made of Ti6Al4V alloy to obtain favorable functional properties of these devices.

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Effect of cutting conditions on surface roughness in finish turning Hastelloy® X superalloy

Materials Today Proceedings ◽

10.1016/j.matpr.2020.10.211 ◽

2020 ◽

Author(s):

Tiago B. Oschelski ◽

Wilson T. Urasato ◽

Heraldo J. Amorim ◽

André J. Souza

Keyword(s):

Surface Roughness ◽

Cutting Conditions ◽

Finish Turning

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Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

Volume 4A: Dynamics, Vibration, and Control ◽

10.1115/imece2016-68207 ◽

2016 ◽

Author(s):

Issam Abu-Mahfouz ◽

Amit Banerjee ◽

A. H. M. Esfakur Rahman

Keyword(s):

Surface Roughness ◽

Fuzzy Clustering ◽

Wavelet Transforms ◽

Fourier Transforms ◽

End Milling ◽

Cutting Conditions ◽

Depth Of Cut ◽

Cutting Condition ◽

Machined Surface ◽

Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

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Effect of Cutting Parameters on Surface Roughness in Turning of Bone

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.845.708 ◽

2013 ◽

Vol 845 ◽

pp. 708-712 ◽

Cited By ~ 1

Author(s):

P.Y.M. Wibowo Ndaruhadi ◽

S. Sharif ◽

M.Y. Noordin ◽

Denni Kurniawan

Keyword(s):

Surface Roughness ◽

Bone Tissue ◽

Influencing Factor ◽

Cutting Speed ◽

Cutting Parameters ◽

Cutting Conditions ◽

Machining Process ◽

Turning Operation ◽

Cutting Direction

Surface roughness indicates the damage of the bone tissue due to bone machining process. Aiming at inducing the least damage, this study evaluates the effect of some cutting conditions to the surface roughness of machined bone. In the turning operation performed, the variables are cutting speed (26 and 45 m/min), feed (0.05 and 0.09 mm/rev), tool type (coated and uncoated), and cutting direction (longitudinal and transversal). It was found that feed did not significantly influence surface roughness. Among the influencing factor, the rank is tool type, cutting speed, and cutting direction.

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Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.382 ◽

2010 ◽

Vol 443 ◽

pp. 382-387 ◽

Cited By ~ 6

Author(s):

Somkiat Tangjitsitcharoen ◽

Suthas Ratanakuakangwan

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Cutting Forces ◽

Cutting Temperature ◽

Cutting Conditions ◽

Cutting Condition ◽

Nose Radius ◽

Dry Cutting ◽

Cnc Turning ◽

Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

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Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

IIUM Engineering Journal ◽

10.31436/iiumej.v2i1.339 ◽

1970 ◽

Vol 2 (1) ◽

Author(s):

A.K.M.N. Amin, M.A. Rizal, and M. Razman

Keyword(s):

Surface Roughness ◽

Metal Cutting ◽

Metal Removal ◽

End Milling ◽

Cutting Speed ◽

Cutting Conditions ◽

End Mill ◽

Machined Surface ◽

Operating Cycle ◽

Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC. Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed. It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

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Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.541-542.785 ◽

2014 ◽

Vol 541-542 ◽

pp. 785-791 ◽

Cited By ~ 1

Author(s):

Joon Young Koo ◽

Pyeong Ho Kim ◽

Moon Ho Cho ◽

Hyuk Kim ◽

Jeong Kyu Oh ◽

...

Keyword(s):

Surface Roughness ◽

Surface Integrity ◽

Cutting Forces ◽

High Speed ◽

Surface Condition ◽

Cutting Conditions ◽

Depth Of Cut ◽

Thin Wall ◽

Machined Surface ◽

High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

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Experimental Investigations of the Machinability of Titanium Alloy TC4 with Different Hydrogen Contents

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.418-420.1307 ◽

2011 ◽

Vol 418-420 ◽

pp. 1307-1311

Author(s):

Jun Hu ◽

Yong Jie Bao ◽

Hang Gao ◽

Ke Xin Wang

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Cutting Force ◽

Hydrogen Content ◽

Experimental Results ◽

Cutting Conditions ◽

Experimental Investigations ◽

Cutting Condition ◽

The Given

The experiments were carried out in the paper to investigate the effect of adding hydrogen in titanium alloy TC4 on its machinability. The hydrogen contents selected were 0, 0.25%, 0.49%, 0.63%, 0.89% and 1.32%, respectively. Experiments with varing hydrogen contents and cutting conditions concurrently. Experimental results showed that the cutting force of the titanium alloy can be obviously reduced and the surface roughness can be improved by adding appropriate hydrogen in the material. In the given cutting condition, the titanium alloy TC4 with 0.49% hydrogen content showed better machinability.

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