scholarly journals A Study on Optimal Machining Conditions and Energy Efficiency in Plasma Assisted Machining of Ti-6Al-4V

Materials ◽  
2019 ◽  
Vol 12 (16) ◽  
pp. 2590
Author(s):  
Young-Hun Lee ◽  
Choon-Man Lee
Keyword(s):  
Energy Efficiency ◽  
Depth Of Cut ◽  
Specific Cutting Energy ◽  
Processing Conditions ◽  
Signal To Noise ◽  
Cutting Energy ◽  
Machining Conditions ◽  
Optimal Processing ◽  
Response Optimization ◽  
Conventional Machining

This research objective was to determine the significant parameters for effective plasma assisted machining (PAM) of Ti-6Al-4V and to derive optimal processing conditions. PAM parameters such as feed rate, spindle speed, and depth of cut have significant effects on its machining characteristic. In this study, the design of experiments (DOE) was used to select optimal machining conditions for PAM. The signal-to-noise (S/N) ratio was analyzed using the Taguchi method and the contributions of the factors were determined using analysis of variance (ANOVA). Finally, the optimal PAM machining conditions were selected using response optimization. In addition, the energy efficiency of conventional machining (CM) and the PAM were compared. The energy efficiency was analyzed by specific cutting energy. The cutting force and surface roughness of PAM decreased by 60.2% and 70.5%, respectively, in optimal PAM machining conditions.

Micro-Machinability Studies of Single Crystal Silicon Using Diamond End-Mill

2016 ◽  
Author(s):  
Zi Jie Choong ◽  
Dehong Huo ◽  
Patrick Degenaar ◽  
Anthony O’Neill
Keyword(s):  
Size Effect ◽  
Single Crystal Silicon ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Crystal Silicon ◽  
Edge Chipping ◽  
Cutting Energy ◽  
Machining Conditions

This paper presents the research on the machinability studies in micro-milling of (001) silicon wafer. Excessive generation of undesirable surface and subsurface damages such as surface edge chipping often occurs when machined at depth of cut of several hundreds of microns. Ideal machining strategy to reduce the generation of edge chipping is required. Investigations on the effect of machining conditions on the cutting performances and size effect on the specific cutting energy in silicon micro-milling were conducted. These investigations provide understandings on the behavior of cutting mechanism during machining and helps to identify suitable machining parameters for fracture free machining using diamond end mills. Full slot milling were performed along <100> and <110> directions on a (001) surface wafer under various machining conditions. Results show that machined surfaces along <100> were of better quality than those along <110> and is in agreement with previous studies. Furthermore, good machining quality was achieved when machined at depth of cut of 10 μm or feed per tooth of 0.075 μm/tooth, regardless of the machining conditions. In addition, investigation for the size effect on specific cutting energy also shows that brittle mode machining begins when feed per tooth increases beyond 0.4 μm/tooth.

Pulsed Laser Surface Treatment for Improvement of Machinability

2016 ◽  
Vol 725 ◽  
pp. 641-646
Author(s):  
Takuya Inoue ◽  
Keiji Yamada ◽  
Katsuhiko Sekiya ◽  
Ryutaro Tanaka ◽  
Yasuo Yamane
Keyword(s):  
Surface Treatment ◽  
Cutting Force ◽  
Pulsed Laser ◽  
High Hardness ◽  
Laser Surface ◽  
Depth Of Cut ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Die Steels ◽  
Actual Depth

The surface of worn dies are often machined to remove the worn layer and then to re-form its shape. But, in machining operations for hardened materials, the high cutting force sometimes yields bending deflection of low stiffness tools, and results the decrease in productivity and accuracy.In this study, surface treatment by pulsed laser is applied for the high hardness materials to improve the machinability in the machining operation. Die steels are used as work material machined with ball endmills of carbide in the experiments where the cutting force and the actual depth of cut are measured to obtain the specific cutting energy and to evaluate the machinability. In endmilling operations of the nitrided die steels, the actual depth of cut is decreased by the bending deflection of endmill. However, the surface treatment with laser moderates the decreasing of the actual depth of cut. It is confirmed that the surface of workpiece pre-treated with laser has larger roughness than un-treated ones, and the specific cutting energy is decreased by laser surface pre-treatment.

Energy Efficiency in Thermally Assisted Machining of Titanium Alloy: A Numerical Study

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
J. Ma ◽  
X. Ge ◽  
S. Lei
Keyword(s):  
Energy Efficiency ◽  
Titanium Alloy ◽  
Total Energy ◽  
Numerical Study ◽  
Cutting Speed ◽  
Operating Conditions ◽  
Energy Utilization ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Cutting Energy

This study investigates the energy utilization and efficiency in thermally assisted machining (TAM) of a titanium alloy using numerical simulation. AdvantEdge finite element method (FEM) is used to conduct the simulation of orthogonal machining of the workpiece. Thermal boundary conditions are specified to approximate laser preheating of the workpiece material. The effects of operating conditions (preheat temperature, cutting speed, depth of cut, and rake angle) on mechanical cutting energy, preheat energy, and energy efficiency are investigated. The results show that preheating the workpiece reduces the cutting energy but increases the total energy in TAM. There is significant potential to maximize total energy efficiency in TAM by optimal design of heating strategies and machining conditions.

Energy Efficient Process Planning Based on Numerical Simulations

2011 ◽  
Vol 223 ◽  
pp. 212-221 ◽  
Author(s):  
Reimund Neugebauer ◽  
Carsten Hochmuth ◽  
Gerhard Schmidt ◽  
Martin Dix
Keyword(s):  
Energy Efficiency ◽  
Numerical Simulations ◽  
Process Design ◽  
Energy Efficient ◽  
Metal Cutting ◽  
Value Added ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Process Adjustment ◽  
Cutting Processes

The main goal of energy-efficient manufacturing is to generate products with maximum value-added at minimum energy consumption. To this end, in metal cutting processes, it is necessary to reduce the specific cutting energy while, at the same time, precision requirements have to be ensured. Precision is critical in metal cutting processes because they often constitute the final stages of metalworking chains. This paper presents a method for the planning of energy-efficient machining processes based on numerical simulations. It encompasses two levels of planning flexibility: process adjustment and process design. At the process adjustment level, within the constraints of existing machines and tools, numerical simulations of orthogonal cutting are used to determine cutting parameters for increased energy efficiency. In this case, the model encompasses specific cutting energy, tool wear, chip geometry, and burr shape. These factors determine the energy and resources required for the chip formation itself, tool replacements, cleaning and deburring and with that the overall energy efficiency and precision. In the context of process design, with the ability to select machines, machine configurations, tools, and cooling systems, numerical simulations of cutting processes that incorporate machine and tool conditions are applied in the planning of energy-efficient machining. The method is demonstrated for the case of drilling processes and supported by experimental investigations that identify the main influences on energy efficiency in drilling.

Optimization of Cutting Parameters Based on Specific Cutting Energy Consumption for Aluminum 6010 by Using the Analysis of Variance (ANOVA)

2016 ◽  
Vol 842 ◽  
pp. 14-18
Author(s):  
Sri Raharno ◽  
Yatna Yuwana Martawirya ◽  
Heng Rath Visith ◽  
Jeffry Aditya Cipta Wijaya
Keyword(s):  
Energy Consumption ◽  
Analysis Of Variance ◽  
Minimum Energy ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Manufacturing Industries ◽  
Depth Of Cut ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Minimum Energy Consumption

Manufacturing industries have consumed 30% of the total world energy. The main energy source used in those manufacturing industries is the electricity generated from fossil fuels such as oil, gas, and coal as a result in causing the environmental and economic issues. This paper presents an experimental study in order to get the minimum energy consumption during turning of aluminum 6010 with the conventional machine tool under dry cutting condition by optimizing the cutting parameters to contribute to those issues. An analysis of variance (ANOVA) was employed to analyze the effects and contribution of depth of cut, feed, and cutting speed on the response variable, specific cutting energy. The result of this experiment showed that the feed was the most significant factor for minimizing energy consumption followed by the cutting speed and the depth of cut. The minimum energy consumption was obtained when the highest level of cutting parameters have been used.

scholarly journals Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions

2019 ◽  
Vol 10 (2) ◽  
pp. 561-573 ◽  
Author(s):  
Muhammad Ali Khan ◽  
Syed Husain Imran Jaffery ◽  
Mushtaq Khan ◽  
Muhammad Younas ◽  
Shahid Ikramullah Butt ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Effective Means ◽  
Sustainable Manufacturing ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Positive Effect

Abstract. Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33 % whereas specific cutting energy and surface roughness were improved by 10 % and 9 % respectively by adapting the optimum machining conditions.

Minimisation of specific cutting energy and back force in turning of AISI 1060 steel

2017 ◽  
Vol 232 (11) ◽  
pp. 2019-2029 ◽  
Author(s):  
Sourabh Paul ◽  
PP Bandyopadhyay ◽  
S Paul
Keyword(s):  
Cutting Tools ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Nose Radius ◽  
Cutting Energy ◽  
High Feed ◽  
Individual Criterion ◽  
Carbide Inserts

A lot of research has been undertaken in the area of conventional machining to study the effect of process parameters, tool geometry, machining environment and so on on machinability. But only recently, the research community has started analysing the carbon footprint of manufacturing processes. But very few articles could be located that attempted simultaneous minimisation of specific cutting energy and back force over a wide domain of process and tool-geometric parameters. This article has experimentally studied the effect of variation in depth of cut, feed, nose radius and tool geometry on simultaneous minimisation of specific cutting energy and back force while turning AISI 1060 steel with uncoated carbide inserts under dry machining environment. Minimisation of specific cutting energy and back force as individual criterion leads to conflicting choice of machining parameters. A combined criterion based on specific cutting energy and back force has been defined and for the minimisation of the same, cutting tools with positive rake need to be used, with high feed and moderate depth of cut.

Sign in / Sign up

Export Citation Format

Share Document