Effects of machining method and technique on galvanized steel material properties

Machining or metal cutting operation is the process of removing unwanted material in the form of chips, from a block of metal, using cutting tool is the most widely used industrial practice for which sustainable manufacturing is an appropriate approach. Aligning with rapidly changing scenario in manufacturing industries, applications of optimization techniques in metal cutting processes is essential for a manufacturing unit to respond effectively to severe competitiveness and increasing demand of quality product in the market. When machining structural parts with high material removal rates, the stiffness of the machine tool can be one of the limited factors due to the machining vibrations or called chatter vibrations. Computer Numerical Controller (CNC) machining is one of the machining method used to get a high accuracy results in product and Wire Electrical Discharge Machining (WEDM) is one of the advanced technique primarily used for hard metals or those that would be very difficult to machine with traditional techniques, such as conventional milling operation. Due to this non-contact operation towards the work piece, it shallower the heat-affected zone (HAZ) which may effect on the material properties. In this paper, galvanized steel has been used to identify the changes in its mechanical properties by using tensile test with both machining methods and techniques to produce the T-bone specimen. Hence the static or tensile properties of the specimen is obtained, a good machining procedure could be determined. Therefore, it will decrease the strength of material and increase the durability and reliability of product.

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The Effect of Prior Cutting Conditions on the Shear Mechanics of Orthogonal Machining

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2830089 ◽

1998 ◽

Vol 120 (1) ◽

pp. 13-20 ◽

Cited By ~ 6

Author(s):

R. Stevenson ◽

D. A. Stephenson

Keyword(s):

Material Properties ◽

Metal Cutting ◽

Orthogonal Cutting ◽

Rake Angle ◽

Cnc Machining ◽

Machining Process ◽

Depth Of Cut ◽

Prior History ◽

Machining Conditions ◽

The Difference

It has been proposed several times in the metal-cutting literature that the machining process is non-unique and that the instantaneous machining conditions depend on the prior machining conditions (e.g. depth of cut, rake angle etc.). To evaluate the validity of this concept, a series of experiments was conducted using a highly accurate CNC machining center. For these experiments, the machining conditions were changed during the course of an orthogonal cutting experiment in a repeatable manner and the measured forces compared as a function of prior history. Tests were conducted on several tempers of 1100 aluminum and commercial purity zinc to evaluate the effect of material properties on the machining response. It was found that the change in measured cutting forces which could be ascribed to prior machining history was less than 3 percent and that material properties, particularly work hardening response, had no discernible effect on the magnitude of the difference.

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Modeling and Optimization of Micro Electro Discharge Machining Process: A Review

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.622-623.590 ◽

2012 ◽

Vol 622-623 ◽

pp. 590-594 ◽

Cited By ~ 1

Author(s):

P. Sivaprakasam ◽

P. Hariharen ◽

S. Kathikheyen ◽

S. Balusamy

Keyword(s):

Process Parameters ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Optimization Techniques ◽

Machining Process ◽

Work Piece ◽

Machining Performance ◽

Micro Electrical Discharge Machining ◽

Electro Discharge Machining ◽

Short Period

Micro Electrical discharge machining (µEDM) is an electro thermal process, the cutting force is negligibly small and material removal occurs irrespective of hardness of work piece material .Micro electrical discharge machining process is capable of machining of complex shape, which is difficult to machine in conventional machining process. Last decade, the EDM process involved demand for machining requirements with short period. Since the major risk of wire breakage, deflections of electrodes were affecting the performance accuracy of EDM operation. This paper describe about a comprehensive review of micro electro discharge machining process and its process optimization techniques used for last 10 years. Micro electro discharge machining has more important given to difficult to machine materials. In order to improve the surface integrity and performance of process, need to select proper process parameters. It reports on the Micro EDM research involving the optimization of the process parameters surveying the influence of the various factors affecting the machining performance and productivity.

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A review of optimization techniques in metal cutting processes

Computers & Industrial Engineering ◽

10.1016/j.cie.2005.10.001 ◽

2006 ◽

Vol 50 (1-2) ◽

pp. 15-34 ◽

Cited By ~ 286

Author(s):

Indrajit Mukherjee ◽

Pradip Kumar Ray

Keyword(s):

Metal Cutting ◽

Optimization Techniques ◽

Cutting Processes

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Analytical Modelling of Temperature Distribution Using Potential Theory by Reference to Broaching of Nickel-Based Alloys

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.769.139 ◽

2013 ◽

Vol 769 ◽

pp. 139-146 ◽

Cited By ~ 8

Author(s):

Sascha Gierlings ◽

Matthias Brockmann

Keyword(s):

Metal Cutting ◽

Temperature Fields ◽

Aviation Industry ◽

Work Piece ◽

Machined Surface ◽

Tool Wear Mechanisms ◽

Critical Components ◽

Aero Engines ◽

Tool Centre Point ◽

Cutting Processes

Knowledge of temperature fields and heat flow evolving during metal cutting processes is of significant importance for ensuring and predicting the product`s quality. Furthermore, this knowledge enables an improved usage of resources, such as machine tools and tool deployment. The strength of the heat sources as a result of the process and the distribution of the temperature in the material directly influence the tool wear mechanisms, wear rate, thermo-elastic deflection of the tool centre point and the amount of heat flowing into the newly generated work piece surface. Especially the latter effect is of crucial importance when it comes to safety critical components as they are employed in aero-engines. In aviation industry, the surface integrity is used as a complex quality measure summarising several aspects at the machined surface and sub-surface out of which many issues are predominantly thermal issues (e.g. temperature driven hardening of the work piece material, re-cast and white etching layers as well as residual stress profiles).

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EXPERIMENTAL INVESTIGATION AND DEVELOPMENT OF MATHEMATICAL CORRELATIONS OF CUTTING PARAMETERS FOR MACHINING GRAPHITE WITH CNC WEDM

Journal of Mechanical Engineering ◽

10.3329/jme.v40i1.3474 ◽

1970 ◽

Vol 40 (1) ◽

pp. 63-67

Author(s):

Ch. V. S. ParameswaraRao ◽

M. M. M. Sarcar

Keyword(s):

Discharge Current ◽

Metal Cutting ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Cutting Speed ◽

Dimensional Accuracy ◽

Graphical Form ◽

Work Piece ◽

Machining Parameters ◽

Spark Gap

The Wire cut electrical discharge machining is found to have tremendous potential in the present day metal cutting process, for achieving improved geometric features of work pieces, dimensional accuracy, surface finish etc. Improving the productivity in CNC WEDM depends solely on optimization of various process parameters viz... discharge current, thickness etc. Thus the present work is aimed at experimental evaluation of those machining parameters for different sizes of Graphite which is a prominent electrode material. Further the effect of these parameters on cutting speed, spark gap and material removal rate is investigated and best suited values are obtained for stable and controlled machining with least wire breakage. Based on the experimental results, empirical correlations are established and validated to evaluate the above parameters analytically for different work piece sizes. The correlations are found useful for finding the best suited discharge current, spark gap, cutting speed and cutting time under various cutting conditions. The results are represented in graphical form also. Key Words: WEDM, Cutting speed, MRR, Spark gap, Mathematical correlations doi: 10.3329/jme.v40i1.3474 Journal of Mechanical Engineering, Vol. ME40, No. 1, June 2009 63-67

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Analysis of Main Optimization Techniques in Predicting Surface Roughness in Metal Cutting Processes

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.217-219.2171 ◽

2012 ◽

Vol 217-219 ◽

pp. 2171-2182 ◽

Cited By ~ 4

Author(s):

Eva M. Rubio ◽

María Villeta ◽

Adolfo J. Saá ◽

Diego Carou

Keyword(s):

Surface Roughness ◽

Metal Cutting ◽

Cutting Tool ◽

Industrial Sector ◽

Optimization Techniques ◽

Machining Parameters ◽

Future Trends ◽

Advantages And Disadvantages ◽

Adequate Information ◽

Cutting Processes

This paper collects the main methodologies and tools employed for predicting the surface roughness. The goal of this work is to provide compact and adequate information that could be useful in metal cutting industries to select the techniques and optimization tools that best suit to their needs and particular requirements. Each approach, with its advantages and disadvantages, is outlined and the present and future trends are discussed. As result, a quick guide for using practitioners of mentioned industrial sector is provided in form of tables that relate: machining parameters, cutting tool properties, workpiece properties and cutting phenomena with the different techniques and optimization tools usually employed to analyze the different parameters and phenomena involved in the process of surface roughness generation.

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Investigation of Machining Parameters for Burr Minimization in CNC Turning of Brass Using RSM and GA

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.627.54 ◽

2014 ◽

Vol 627 ◽

pp. 54-59 ◽

Cited By ~ 1

Author(s):

R. Ravikumar ◽

M. Mohamed Abdul Hafeez

Keyword(s):

Metal Cutting ◽

Cutting Parameters ◽

Optimization Techniques ◽

Cutting Process ◽

Depth Of Cut ◽

Work Piece ◽

Feed Speed ◽

Machining Parameters ◽

Cnc Turning ◽

Control Factors

CNC turning is one among the metal cutting process in which quality of the finished product depends mainly upon the machining parameters such as feed, speed, depth of cut, type of coolant used, types of inserts used etc. Similarly the work piece material plays an important role in metal cutting process. This study involves in indentifying the optimized parameters in CNC turning of Brass. To identify and measure the formation of burrs in the turned samples, are examined under scanning electron microscope (SEM). The optimization techniques used in this study are Response surface methodology, and Genetic algorithm. Several comparisons were made between cutting parameters with surface roughness. These optimization techniques are very helpful in indentifying the optimized control factors with high level of accuracy.

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Analytical model of temperature distribution in metal cutting based on Potential Theory

Mechanical Sciences ◽

10.5194/ms-6-89-2015 ◽

2015 ◽

Vol 6 (2) ◽

pp. 89-94 ◽

Cited By ~ 6

Author(s):

F. Klocke ◽

M. Brockmann ◽

S. Gierlings ◽

D. Veselovac

Keyword(s):

Potential Theory ◽

Analytical Model ◽

Metal Cutting ◽

Orthogonal Cutting ◽

Temperature Fields ◽

Wear Behaviour ◽

Work Piece ◽

Machining Processes ◽

Major Interest ◽

Cutting Processes

Abstract. Temperature fields evolving during metal cutting processes have also been of major interest. Temperatures in the tool influence the wear behaviour and hence costs, temperatures in the work-piece are directly responsible for later product quality. Due to the high significance of temperatures, many modelling attempts for temperature fields have been conducted, however failed to deliver satisfying results. The present paper describes a novel analytical model using complex functions based on potential theory. Relevant heat sources in metal cutting as well as changing material constants are considered. The model was validated by an orthogonal cutting process and different real machining processes.

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