Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

Effects of Cutting Fluids on Surface Roughness in Single-Point Diamond Turning of Rapidly Solidified Aluminium (RSA 431)

2020 ◽  
Vol 853 ◽  
pp. 18-23
Author(s):  
F.A Oyekunle ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Rapidly Solidified

Single-point diamond turning is a technique of ultra-high precision machining that provides excellent quality of surface for mirrors, spherical and aspherical components. In SPDT just like other machining processes, cutting fluid plays an important role in metal removal and tool condition which largely influence the surface of diamond turned surface. In this paper, the surface roughness of diamond turned RSA 431 was studied by investigating the effect of kerosene mist and water as cutting fluids. Higher order response surface of Box-Behnken design was generated using fewer runs than a normal factorial technique. The cutting parameters that were varied for both experiments were depth of cut, feed and, speed. Taylor Hobson PGI Dimension XL surface Profilometer was used to measure the surface roughness after each experimental run. The results show that water when used as cutting fluid during machining, produces better surface roughness than kerosene mist. Predictive models for surface roughness were developed for each experiment. Values from the Mean Absolute Percent Error (MAPE) was used to evaluate and compare the two models to determine the accuracy. RSM also proved to be a better methodology of predicting surface roughness.

Optimisation of the Bauer Equation Using the Least Squares Method for Thermoplastics Turning

2018 ◽  
Vol 8 (1) ◽  
pp. 21-36
Author(s):  
János Farkas ◽  
Etele Csanády ◽  
Levente Csóka
Keyword(s):  
Surface Roughness ◽  
Least Squares Method ◽  
Composite Ceramic ◽  
Cutting Parameters ◽  
Machining Process ◽  
Tool Geometry ◽  
Machining Processes ◽  
Simple Formulation ◽  
Plastic Composite ◽  
Cutting Speeds

A number of equations are available for predicting the output of machining processes. These equations are most commonly used for the prediction of surface roughness after tooling. Surface roughness can be influenced by many factors, including cutting parameters, tool geometry and environmental factors such as the coolant used. It is difficult to create a universally applicable equation for all machining because of the variations in different materials' behaviours (e.g. metal, wood, plastic, composite, ceramic). There are also many differences between the various types of machining process such as the machining tools, rotational or translational movements, cutting speeds, cutting methods, etc. The large number of parameters required would make such an equation unusable, and difficult to apply quickly. The goal is thus to create a simple formulation with three or four inputs to predict the final surface roughness of the machined part within adequate tolerances. The two main equations used for this purpose are the Bauer and Brammertz formulas, both of which need to be optimised for a given material. In this paper, the turning of thermoplastics was investigated, with the aim of tuning the Bauer formula for use with thermoplastics. Eleven different plastics were used to develop a material-dependent surface roughness equation. Only new tooling inserts were used to eliminate the effects of tool wear.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

Study of Cutting Forces and Surface Roughness in Milling of Carbon Fibre Composite (CFC) With Conventional and and Pressurized CO2 Cutting Fluids

2015 ◽  
Author(s):  
Aishah Najiah Dahnel ◽  
Christopher Kibbler ◽  
Stuart Barnes ◽  
Helen Ascroft
Keyword(s):  
Surface Roughness ◽  
Carbon Fibre ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Dry Milling ◽  
Carbon Fibre Composites ◽  
Cutting Speeds

Carbon Fibre Composites (CFC) are commonly used in aerospace, automotive and civil industries to manufacture high performance products which require high strength with low weight. They are usually produced to near net shape, however machining such as milling is frequently performed to achieve dimensional accuracy. This paper presents the effect of using conventional (water-based) and carbon dioxide (CO2) cutting fluids during milling of CFC on cutting forces, temperature and surface roughness in comparison to dry milling. Milling experiments were conducted using uncoated tungsten carbide milling routers at a constant feed rate and depth of cut of 0.025 mm/rev and 5 mm, respectively. Cutting speeds used were 100, 150 and 200 m/min. Cutting forces were measured using a dynamometer, temperatures during milling were measured at the workpiece by thermocouples and surface roughness (Ra) of the milled surfaces were measured using a surface profilometer. Milling with conventional and CO2 cutting fluids resulted in higher cutting forces than dry milling at all cutting speeds used. This was attributed to cooling of the CFC, which retained the strength of polymer matrix during machining. Cutting temperatures were the highest and reached beyond 100°C during dry milling. The use of conventional cutting fluid during milling provided significant cooling to the workpiece, in which cutting temperatures were maintained below 30°C at all cutting speeds used. Cooling the workpiece during milling with CO2 cutting fluid resulted in cutting temperatures within the range of 65–86°C. Even though the application of cutting fluids during milling generated higher cutting forces than dry milling, it produced favourable results in terms of surface finish. The use of cutting fluid during machining CFC is shown to be highly effective in sustaining the strength of CFC materials as a result of low cutting temperature.

Experimental investigation of cutting temperature and surface roughness for different cutting fluids during turning of Duplex stainless steel-2205 under minimum quantity lubrication technique

2021 ◽  
Vol 15 (2) ◽  
pp. 8042-8056
Author(s):  
Prashantha Kumar S T ◽  
Thirtha Prasada HP
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Deionized Water ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Minimum Quantity

Duplex stainless steel (DSS)-2205 comes under hard to machine material owing to its inherent properties but more applications in severe working conditions hence, selection of turning process parameters and suitable cutting fluids of DSS-2205 is essential. In the present work, investigate the performance of Deionized water, neat cut oil, and emulsified fluid on cutting temperature and surface roughness during turning of duplex stainless steel-2205 under minimum quantity lubrication technique. Based on a face-centered composite design, 20 experiments were conducted with varying speed, feed, and depth of cut in three levels for three different fluids. Analysis of variance (ANOVA) is used to identify significant parameters that affect the response. Numerical optimization was carried out under Desirability Function Analysis (DFA) for cutting temperature during deionized water cutting fluid for surface roughness during emulsified cutting fluid. Depth of cut is the significant factor for cutting temperature contribution is 74.83% during Deionized water as a fluid, and feed is the significant factor for surface roughness contribution is 93.57% during emulsified fluid. The optimum cutting parameters were determined for speed (50m/min), feed (0.051mm/rev) and depth of cut (0.4mm). Experimental results revealed that Deionized water gives better results for reduced the cutting temperature and emulsified fluid for surface roughness reduction.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

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.

Comparative Analysis on Wiper and Standard Tools in Dry Finish Turning of Martensitic Stainless Steel AISI 420

2013 ◽  
Vol 845 ◽  
pp. 765-769 ◽  
Author(s):  
Guilherme Cortelini Rosa ◽  
André J. Souza ◽  
Flávio J. Lorini
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Residual Stresses ◽  
Martensitic Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Finish Turning ◽  
Aisi 420 ◽  
Steel Aisi ◽  
Stainless Steel Aisi

Machining performance consists to associate the optimal process and cutting parameters and maximum material removal rate with the most appropriate tool while controlling the machined surface state. This work verifies the influence of standard and wiper cutting tools on generated surface roughness and residual stress in dry finish turning operation of the martensitic stainless steel AISI 420 in a comparative way. Tests are conducted for different combinations of tool nose geometry, feed rate and depth of cut being analyzed through the Design of Experiments regarding to surface roughness parametersRaandRt. Moreover, the formation of residual stresses in the material (using the technique of X-Ray Diffraction) was evaluated after the machining process for these two cutting geometries and thereafter the result was compared between them. An ANOVA is performed to clarify the influence of cutting parameters on generated surface roughness, which outputs inform that cutting tool geometry is the most influent onRaandRt. It is concluded that analyzed wiper inserts present low performance for low feed rates. Regarding the analysis of the residual stresses it can be stated that for standard and wiper tools the values collected show that for finish turning the compression stresses were found. It can be observed that the greatest amount of compressive stress has been found for the standard tool.

Effects of Cutting Condition on Surface Roughness when Turning Untreated and Sb-Treated Al-11%Si Alloys Using PVD Coated Tools

2013 ◽  
Vol 315 ◽  
pp. 413-417 ◽  
Author(s):  
Mohsen Marani Barzani ◽  
Mohd Yusof Noordin ◽  
Ali Akhavan Farid ◽  
Saaed Farahany ◽  
Ali Davoudinejad
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Manufacturing Processes ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Fabrication Cost ◽  
Coated Tools ◽  
Experimental Trials ◽  
Cutting Speeds

Surface roughness is an important output in different manufacturing processes. Its characteristic affects directly the performance of mechanical components and the fabrication cost. In this current work, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness in turning the untreated and Sb-treated Al-11%Si alloys. Experimental trials carried out using PVD TIN coated inserts. Experiments accomplished under oblique dry cutting when three different cutting speeds have been used at 70, 130 and 250 m/min with feed rates of 0.05, 0.1 and 0.15 mm/rev, whereas depth of cut kept constant at 0.05 mm. The results showed that Sb-treated Al-11%Si alloys have poor surface roughness in comparison to untreated Al-11%Si alloy. The surface roughness values reduce with cutting speed increment from 70 m/min to 250 m/min. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.

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.

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