Optimizing Milling Process Parameters of Bovine Horns forMaximizing Surface Quality and Minimizing Power Consumption

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (Al2O3), and the variable process parameters were cutting speed and feed rate. Power consumption and surface quality were utilized as the machining responses to characterize the process performance. Surface quality was examined by evaluating the final surface roughness and surface integrity of the machined surface. The results revealed a reduction in power consumption when MQL and MQL + Al2O3 strategies were applied compared to the dry case by averages of 4.7% and 8.6%, respectively. Besides, a considerable reduction in the surface roughness was noticed with average values of 40% and 44% for MQL and MQL + Al2O3 strategies, respectively, when compared to the dry condition. At the same time, the reduction in generated surface roughness obtained by using MQL + Al2O3 condition was marginal (5.9%) compared with using MQL condition. Moreover, the results showed that the improvement obtained in the surface quality when using MQL and MQL + Al2O3 coolants increased at higher cutting speed and feed rate, and thus, higher productivity can be achieved without deteriorating final surface quality, compared to dry conditions. From scanning electron microscope (SEM) analysis, debris, furrows, plastic deformation irregular friction marks, and bores were found in the surface texture when machining under dry conditions. A slight smoother surface with a nano-polishing effect was found in the case of MQL + Al2O3 compared to the MQL and dry cooling strategies. This proves the effectiveness of lubricant with nanoparticles in reducing the friction and thermal damages on the machined surface as the friction marks were still observed when machining with MQL comparable with the case of MQL + Al2O3.

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MULTI-OBJECTIVE OPTIMIZATION OF END MILLING PROCESS PARAMETERS IN MACHINING OF EN 31 STEEL: APPLICATION OF AHP EMBEDDED WITH VIKOR AND WASPAS METHODS

i-manager’s Journal on Mechanical Engineering ◽

10.26634/jme.8.4.14676 ◽

2018 ◽

Vol 8 (4) ◽

pp. 39

Author(s):

AJAY KUMAR. G VENKATA ◽

VARDHAN REDDY D. VISHNU ◽

NAGARAJU NAKKA ◽

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...

Keyword(s):

Process Parameters ◽

End Milling ◽

Milling Process ◽

Multi Objective Optimization ◽

Multi Objective ◽

En 31 ◽

End Milling Process

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TOPSIS based selection of optimal end milling process parameters

10.1063/5.0024275 ◽

2020 ◽

Author(s):

A. Singh ◽

I. Shivakoti ◽

Z. Mustafa ◽

R. Phipon ◽

A. Sharma

Keyword(s):

Process Parameters ◽

End Milling ◽

Milling Process ◽

End Milling Process ◽

Selection Of

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Influence of High-Productivity Process Parameters on the Surface Quality and Residual Stress State of AISI 316L Components Produced by Directed Energy Deposition

Journal of Materials Engineering and Performance ◽

10.1007/s11665-021-05954-3 ◽

2021 ◽

Author(s):

Gabriele Piscopo ◽

Alessandro Salmi ◽

Eleonora Atzeni

Keyword(s):

Surface Roughness ◽

Residual Stresses ◽

Surface Quality ◽

Process Parameters ◽

Energy Deposition ◽

Industrial Applications ◽

High Productivity ◽

Directed Energy Deposition ◽

Productivity Process ◽

Directed Energy

AbstractThe production of large components is one of the most powerful applications of laser powder-directed energy deposition (LP-DED) processes. High productivity could be achieved, when focusing on industrial applications, by selecting the proper process parameters. However, it is of crucial importance to understand the strategies that are necessary to increase productivity while maintaining the overall part quality and minimizing the need for post-processing. In this paper, an analysis of the dimensional deviations, surface roughness and subsurface residual stresses of samples produced by LP-DED is described as a function of the applied energy input. The aim of this work is to analyze the effects of high-productivity process parameters on the surface quality and the mechanical characteristics of the samples. The obtained results show that the analyzed process parameters affect the dimensional deviations and the residual stresses, but have a very little influence on surface roughness, which is instead dominated by the presence of unmelted particles.

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The Impact of Ball Milling Process Parameters on the Preparation of Nano Silicon Powder

Integrated Ferroelectrics ◽

10.1080/10584587.2021.1911318 ◽

2021 ◽

Vol 217 (1) ◽

pp. 255-264

Author(s):

Xiaomeng Zhu ◽

Xiaolan Cai ◽

Shuang Zhang ◽

Lei Wang ◽

Xudong Cui

Keyword(s):

Ball Milling ◽

Process Parameters ◽

Silicon Powder ◽

Milling Process ◽

Ball Milling Process ◽

Nano Silicon ◽

The Impact

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Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽

10.3390/machines9040075 ◽

2021 ◽

Vol 9 (4) ◽

pp. 75

Author(s):

Nikolaos E. Karkalos ◽

Panagiotis Karmiris-Obratański ◽

Szymon Kurpiel ◽

Krzysztof Zagórski ◽

Angelos P. Markopoulos

Keyword(s):

Surface Roughness ◽

Surface Quality ◽

Process Parameters ◽

Manufacturing Industry ◽

High Surface ◽

Cutting Tools ◽

Cutting Speed ◽

Depth Of Cut ◽

High Surface Quality ◽

Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

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