Experimental and Computational investigations on the quality characteristics of laser beam machined metal matrix composite reinforced with ZrO2 particles

2018 ◽  
Vol 1 (1) ◽  
pp. 248-267
Author(s):  
Vikas Sharma ◽  
Vinod Kumar
Keyword(s):  
Surface Roughness ◽  
Heat Affected Zone ◽  
Metal Matrix ◽  
Research Work ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Quality Characteristics ◽  
Workpiece Material ◽  
Zone Width ◽  
Input Variables

The research work explores the parametric influence of laser input variables on surface roughness and heat affected zone width. The workpiece material used as metal matrix aluminum 5052 alloy reinforced with ZrO2 particles. The computational analysis has been carried out using finite element method by taking laser power and arc radius profiles as variables. The mathematical model has been generated using Box-Behnken method for the analysis of variance. The machined samples have been analyzed using optical microscope and surface tester for measurement of quality characteristics. It has been analyzed that the effect of interaction of parameters has significant effect on surface roughness and heat affected zone width. Moreover, the influence of laser cutting speed, quantity of reinforced particles and laser cut path profile proved to be significant parameters for quality characteristics. The von-misses stress and temperature values found to be highest in case of complex cutting profiles as compared to linear trajectories.

Application of Box-Behnken design and response surface methodology for multi-optimization of laser cutting of AA5052/ZrO2 metal−matrix composites

2016 ◽  
Vol 232 (8) ◽  
pp. 652-668
Author(s):  
Vikas Sharma ◽  
Vinod Kumar
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Heat Affected Zone ◽  
Metal Matrix ◽  
Laser Cutting ◽  
Research Work ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Laser Source ◽  
Box Behnken Design

A laser source is most popular in industrial world for its high cutting efficiency and productivity. In the present research work, laser cutting of aluminium metal−matrix composite has been studied. The investigations have been done to analyse the influence of various parameters on surface and quality characteristics of aluminium alloy 5052 reinforced with ZrO2 particles. The effect of laser parameters was analysed on striation angle, heat affected zone and kerf deviation. Response surface methodology has been applied using Box-Behnken design for the statistics analysis. Heat affected zone and striation formation of laser cut surface were examined using scanning electron microscope and optical microscope. The effect of arc radius, cutting speed and percentage of reinforced particles was found to be significant on all output characteristics. The predicted response surface methodology (RSM) model was validated with experimental data for determination of accuracy level.

Investigating the quality characteristics of Al5052/SiC metal matrix composites machined by CO2 laser curve cutting

2015 ◽  
Vol 232 (1) ◽  
pp. 3-19
Author(s):  
Vikas Sharma ◽  
Vinod Kumar
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix ◽  
Desirability Function ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Quality Characteristics ◽  
X Ray ◽  
Sic Particles ◽  
Quality Aspects

This article explores the quality characteristics of laser curve cutting of metal matrix aluminium 5052 alloy reinforced with SiC particles. These alloys are extensively used in aerospace industries due to their unique mechanical properties. The response surface methodology has been used to design the mathematical models with respect to input and output characteristics parameters. The desirability function approach has been used to optimize the input parameters like cutting speed, laser power, stand-off distance, nozzle diameter, nitrogen gas pressure, percentage of reinforced SiC particles, arc radius by considering multiple-performance characteristics. The various quality aspects of machined specimens were analysed using optical microscope, scanning electron microscopy, X-ray diffraction and energy-dispersive X-ray analysis techniques. The response surface methodology predicted models were validated by performing various confirmatory experiments. The percentage of error for the dross height, kerf taper and kerf width was found to be 4.62%, 6.55% and 5.04 % which signifies that predicted model is adequate.

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.

Comparison of machining characteristics of metal matrix composites using CO2 laser curve cutting process

2017 ◽  
Vol 232 (3) ◽  
pp. 349-368 ◽  
Author(s):  
Vikas Sharma ◽  
Vinod Kumar
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Morphological Changes ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Composites Materials ◽  
Input Variables ◽  
Output Characteristics ◽  
Metal Matrix Composite Material ◽  
Machining Characteristics

In the present work, the effects of input variables of laser beam machining on the machining characteristics of the metal matrix composites reinforced with SiC, Al2O3, and ZrO2 particles were investigated. The comparison of the machining characteristics has been done to analyze the behavior of various reinforced particles with the variation of laser machining variables. Various output characteristics such as dross height, kerf deviation, and striations angle have been investigated and compared with each metal matrix composite material. Parameters such as cutting speed, reinforced particles, and cut profile were found to be the most significant factors influencing the various output characteristics. The morphological changes in the structure have been examined using scanning electron microscopy and X-ray diffraction technique for the agglomeration of the reinforced particles. The crack and recast layer formation has been examined in the specimens of higher quantity of the reinforced particles. It was analyzed that the metal matrix composites material reinforced with SiC particles has shown different behaviors as compared to other metal matrix composites materials.

Statistical Analysis of Process Parameters in Drilling of Al/Al2O3p Metal Matrix Composites

2014 ◽  
Vol 14 (3) ◽  
pp. 171-175 ◽  
Author(s):  
Yashvir Singh ◽  
Amneesh Singla ◽  
Ajay Kumar
Keyword(s):  
Surface Roughness ◽  
Statistical Analysis ◽  
Process Parameters ◽  
Metal Matrix ◽  
Design Method ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Signal To Noise ◽  
Drilling Parameters

AbstractThis paper presents a statistical analysis of process parameters for surface roughness in drilling of Al/Al2O3p metal matrix composite. The experimental studies were conducted under varying spindle speed, feed rate, point angle of drill. The settings of drilling parameters were determined by using Taguchi experimental design method. The level of importance of the drilling parameters is determined by using analysis of variance. The optimum drilling parameter combination was obtained by using the analysis of signal-to-noise ratio. Through statistical analysis of response variables and signal-to-noise ratios, the determined significant factors are depth of cut and drill point angle with the contributions of 87% and 12% respectively, whereas the cutting speed is insignificant contributing by 1% only. Confirmation tests verified that the selected optimal combination of process parameter through Taguchi design was able to achieve desired surface roughness.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

The Cutting Speed Influences on Tool Wear of ZTA Ceramic Cutting Tools and Surface Roughness of Work Material Stainless Steel 316L during High Speed Machining

2016 ◽  
Vol 840 ◽  
pp. 315-320 ◽  
Author(s):  
Afifah Mohd Ali ◽  
Norazharuddin Shah Abdullah ◽  
Manimaran Ratnam ◽  
Zainal Arifin Ahmad
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
High Speed ◽  
Dense Body ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Stainless Steel 316L ◽  
Crater Wear ◽  
Matlab Programming

The purpose of this research is to find the effects of cutting speed on the performance of the ZTA ceramic cutting tool. Three types of ZTA tools used in this study which are ZTA-MgO(micro), ZTA-MgO(nano) and ZTA-MgO-CeO2. Each of them were fabricated by wet mixing the materials, then dried at 100°C before crushed into powder. The powder was pressed into rhombic shape and sintered at 1600°C at 4 hours soaking time to yield dense body. To study the effect of the cutting speed on fabricated tool, machining was performed on the stainless steel 316L at 1500 to 2000 rpm cutting speed. Surface roughness of workpiece was measured and the tool wears were analysed by using optical microscope and Matlab programming where two types of wear measured i.e. nose wear and crater wear. Result shows that by increasing the cutting speed, the nose wear and crater wear increased due to high abrasion. However, surface roughness decreased due to temperature rise causing easier chip formation leaving a good quality surface although the tool wear is increased.

Investigations on surface roughness and microhardness of turned AM alloy

2020 ◽  
pp. 095440622097616
Author(s):  
Sunil Dutta ◽  
NSK Reddy
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Average Roughness ◽  
Study Results ◽  
Superior Surface ◽  
Input Variables ◽  
Response Variables

Manufacturers in different sectors look for materials exhibiting good mechanical properties, high machinability, and superior surface integrity. The machinability of Mg alloys is one of the vital aspects which requires an exhaustive survey during their selection for different applications. The study examines the surface integrity of a fabricated AM alloy (Mg alloy with 7 wt%Al-0.9 wt%Mn) through dry turning. During the experiments, the input variables of turning viz. cutting speed( v), depth of cut (DOC), and feed( f) is altered and applied to the workpiece. The data obtained for the two response variables viz. surface roughness and microhardness accentuate the maximum influence of feed, followed by DOC and speed. For validation a two-stage methodology was adopted; In the first stage, the validation was done with the help of Analysis of variance (ANOVA); the results show the % contribution of feed, speed, and DOC on average roughness is 66.94%, 5.91%, and 27.23% and on microhardness is 47%, 8.3%, and 44.57%, respectively. Subsequently, in the second stage, the surface plots are drawn for both the response variables to ascertain the ANOVA outcomes; the shape of the plots corroborates the experimental and ANOVA results. The study results provide vital insights for parameter selection to get improved results on surface roughness and microhardness during machining of AM alloy.

Wire Electro Discharge Machining of Al/SiC Metal Matrix Composite

2011 ◽  
Vol 121-126 ◽  
pp. 564-567
Author(s):  
Bao Ji Ma ◽  
Yu Quan Zhu ◽  
Xiao Li Jin
Keyword(s):  
Surface Roughness ◽  
Current Pulse ◽  
Pulse Duration ◽  
Cutting Speed ◽  
Machining Performance ◽  
Peak Current ◽  
Positive Effects ◽  
Electro Discharge Machining ◽  
Input Variables ◽  
Pulse On Time

The machining characteristics of SiC/Al composite using wire electro discharge machining (WEDM) were investigated in this study. Material cutting speed and surface roughness value were adopted to evaluate the machinability. Peak current, pulse on time, pulse duration and working voltage were selected as the input variables to investigate the machining performance. Effects of input variables on the cutting speed and surface roughness were experimentally tested. Peak current, pulse on time and working voltage were confirmed to have positive effects on cutting speed and surface roughness value. Whereas the cutting speed and surface roughness value decrease with the increase of pulse duration.

scholarly journals The Experimental Investigation of Surface Roughness After Dry Turning of Steel S235

2019 ◽  
Vol 26 (4) ◽  
pp. 179-184
Author(s):  
Justyna Molenda
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Scientific Work ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Important Indicator

AbstractNowadays lot of scientific work inspired by industry companies was done with the aim to avoid the use of cutting fluids in machining operations. The reasons were ecological and human health problems caused by the cutting fluid. The most logical solution, which can be taken to eliminate all of the problems associated with the use of cooling lubricant, is dry machining. In most cases, however, a machining operation without lubricant finds acceptance only when it is possible to guarantee that the part quality and machining times achieved in wet machining are equalled or surpassed. Surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered as one of the most important parameter in industry. Today the quality of surface finish is a significant requirement for many workpieces. Thus, the choice of optimized cutting parameters is very important for controlling the required surface quality. In the present study, the influence of different machining parameters on surface roughness has been analysed. Experiments were conducted for turning, as it is the most frequently used machining process in machine industry. All these parameters have been studied in terms of depth of cut (ap), feed rate (f) and cutting speed (vc). As workpiece, material steel S235 has been selected. This work presents results of research done during turning realised on conventional lathe CDS 6250 BX-1000 with severe parameters. These demonstrate the necessity of further, more detailed research on turning process results.

Sign in / Sign up

Export Citation Format

Share Document