scholarly journals Influence of the Kinematic System on the Geometrical and Dimensional Accuracy of Holes in Drilling

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4568
Author(s):  
Mateusz Bronis ◽  
Edward Miko ◽  
Lukasz Nowakowski
Keyword(s):  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Hole Quality ◽  
Steel Cylinder ◽  
Taguchi Orthogonal Array ◽  
Orthogonal Array Method ◽  
Kinematic System ◽  
Input Parameters ◽  
Turning Center ◽  
Rotating Workpiece

This article attempts to show how the kinematic system affects the geometrical and dimensional accuracy of through-holes in drilling. The hole cutting tests were performed using a universal turning center. The tool was a TiAlN-coated Ø 6 mm drill bit, while the workpiece was a C45 steel cylinder with a diameter of 30 mm and a length of 30 mm. Three kinematic systems were studied. The first consisted of a fixed workpiece and a rotating and linearly moving tool. In the second, the workpiece rotated, while the tool moved linearly. The third system comprised a rotating workpiece and a rotating and linearly moving tool, but they rotated in opposite directions. The geometrical and dimensional accuracy of the hole was assessed by analyzing the cylindricity, straightness, roundness, and diameter errors. The experiment was designed using the Taguchi orthogonal array method to determine the significance of the effects of the input parameters (cutting speed, feed per revolution, and type of kinematic system) on the accuracy errors. A multifactorial statistical analysis (ANOVA) was employed for this purpose. The study revealed that all the input parameters considered had a substantial influence on the hole quality in drilling.

scholarly journals Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 4046
Author(s):  
Mateusz Bronis ◽  
Edward Miko ◽  
Lukasz Nowakowski
Keyword(s):  
Cutting Speed ◽  
Hole Drilling ◽  
Internal Cooling ◽  
Hole Quality ◽  
The Third ◽  
Kinematic System ◽  
Turning Center ◽  
Dimensional Errors ◽  
The Relationship

This article discusses the relationship between the kinematic system used in drilling and the quality of through-holes. The drilling was done on a CTX Alpha 500 universal turning center using a TiAlN-coated 6.0 mm drill bit with internal cooling, mounted in a driven tool holder. The holes were cut in cylindrical 42CrMo4 + QT steel samples measuring 30 mm in diameter and 30 mm in length. Three types of hole-drilling kinematic systems were considered. The first consisted of a fixed workpiece and a tool performing rotary (primary) and linear motions. In the second system, the workpiece rotated (primary motion) while the tool moved linearly. In the third system, the workpiece and the tool rotated in opposite directions; the tool also moved linearly. The analysis was carried out for four output parameters characterizing the hole quality (i.e., cylindricity, straightness, roundness, and diameter errors). The experiment was designed using the Taguchi approach (orthogonal array). ANOVA multi-factor statistical analysis was used to determine the influence of the input parameters (cutting speed, feed per revolution and type of kinematic system) on the geometrical and dimensional errors of the hole. From the analysis, it is evident that the kinematic system had a significant effect on the hole roundness error.

scholarly journals ptimization the Parameters of Magnetic Abrasive Process Using Taguchi Method to Improve the Surface Roughness

2017 ◽  
Vol 13 (2) ◽  
Author(s):  
Shakir M Mousa
Keyword(s):  
Surface Roughness ◽  
Orthogonal Array ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
Quality Level ◽  
Work Piece ◽  
Signal To Noise ◽  
Taguchi Orthogonal Array ◽  
Input Parameters ◽  
Noise Ratio

Abstract   Magnetic abrasive finishing (MAF) process is one of non-traditional or advanced finishing methods which is suitable for different materials and produces high quality level of surface finish where it uses magnetic force as a machining pressure. A set of experimental tests was planned according to Taguchi orthogonal array (OA) L27 (36) with three levels and six input parameters. Experimental estimation and optimization of input parameters for MAF process for stainless steel type 316 plate work piece, six input parameters including amplitude of tooth pole, and number of cycle between teeth, current, cutting speed, working gap, and finishing time, were performed by design of experiment (DOE) and response surface methodology (RSM).These six input parameters in this research were optimized  for all input parameters to improve the surface layer for work piece by using signal-to-noise ratio technique. The obtained results showed that all six input parameters have an influence on the change in surface roughness(∆Ra). In addition, the results showed that the surface roughness of the work piece decreased from 1.130 to 0.370µm that means high level of improvement in the change of surface roughness (0.760)µm. Keywords: MAF process, MINITAB software, parameters, Signal-to-Noise ratio, surface roughness, Taguchi orthogonal array.

scholarly journals Mechanism of Chip Formation Process at Grinding

2019 ◽  
Vol 297 ◽  
pp. 09002
Author(s):  
Vyacheslav Shumyacher ◽  
Sergey Kryukov ◽  
Olga Kulik ◽  
Xavier Kennedy
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Processing Parameters ◽  
Abrasive Grain ◽  
Wave Heating ◽  
High Speed Grinding

The mechanism of chip formation process at grinding is described, which involves a high-speed interaction of abrasive grain and metal, which leads to a concentration of thermal energy in front of the dispersing element (grain), causing a locally concentrated shift in the metal microvolume. In “abrasive grain -metal” contact a dissipative structure is formed which existence is supported by exchange of energy and substance with environment. Due to shock compression of the metal microvolume with abrasive grain, shock-wave heating is realized, initiating emission of electrons ionizing the lubricating cooling fluid in the zone of formation of side micro-scratches left by abrasive. The results obtained in the course of the research can be used to explain the mechanisms of chip formation, as well as the course of the physical and mechanical processes occurring on the surface layers of the grinded workpieces. By controlling chip formation processes at high-speed grinding, by optimally selecting the appropriate ratios between cutting speed and other processing parameters, a reduction in process thermal density can be achieved, which, with the highest productivity, will allow to obtain the required quality of the surface layer of the workpieces and a given dimensional accuracy.

Influence of Particle Size on Machinability Behavior in Turning of AA6061-AlN Composites

2019 ◽  
Vol 6 (1) ◽  
pp. 53-74
Author(s):  
Arumugam Mahamani
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Reinforced Composite ◽  
Current Article ◽  
Machining Rate ◽  
Particle Reinforced Composite ◽  
Turning Test

Machinability of the composites and achieving the dimensional accuracy in addition to surface finish at an economic machining rate is still the topic for numerous researchers. The current article describes the variation in machinability characteristics of AA6061-AlN composites under various sizes of reinforcements. Cutting speed, cutting depth and feed rate are preferred to perform the turning test. Cutting force, surface roughness and flank wear are identified to appraise the machinability characteristics. For an identical machining condition, the nano particle reinforced composite has less surface roughness and minimal flank wear and a greater cutting force than the other composites. An increment in cutting speed raises the flank wear and declines the surface roughness and cutting force for all composites. The findings from the experimental investigation help to utilize the turning process for machining the composites with various sizes of reinforcement at the economic rate of machining without compromising the surface quality.

Determination of Surface and Hole Quality in Drilling of AISI D2 Cold Work Tool Steel Using MPMR, MARS and LSSVM

2014 ◽  
Vol 13 (04) ◽  
pp. 237-246 ◽  
Author(s):  
Pijush Samui
Keyword(s):  
Tool Steel ◽  
Cold Work ◽  
Cutting Speed ◽  
Least Square ◽  
Support Vector ◽  
Hole Quality ◽  
Aisi D2 ◽  
Cemented Carbide Drills ◽  
Coated Cemented Carbide ◽  
Cold Work Tool Steel

This paper adopts Minimax Probability Machine Regression (MPMR), Multivariate Adaptive Regression Spline (MARS), and Least Square Support Vector Machine (LSSVM) for prediction of surface and hole quality in drilling of AISI D2 cold work tool steel with uncoated titanium nitride (TiN) and titanium aluminum nitride (TiAlN) monolayer- and TiAlN/TiN multilayer-coated-cemented carbide drills. MPMR is a probabilistic model. MARS is a nonparametric regression technique. LSSVM is developed based on statistical learning algorithm. Cutting tool (t), Feed rate (fr)(mm/rev), and Cutting speed (v)(m/min) have been adopted as inputs of MPMR, MARS, and LSSVM. The output of MPMR, MARS, and LSSVM is Surface roughness (rs) (μm) and Roundness error (re) (μm). A comparative study has been presented between the developed models. The results show that the developed model gives excellent performance.

Application of Taguchi Method Machining to CuA1

2015 ◽  
Vol 789-790 ◽  
pp. 111-115
Author(s):  
M.R. Ibrahim ◽  
Aznizam Abdullah ◽  
A.R. Ab Kadir ◽  
S. Sulaiman
Keyword(s):  
Taguchi Method ◽  
Cutting Speed ◽  
Optimization Method ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Taguchi Optimization ◽  
Taguchi Optimization Method ◽  
Taguchi Orthogonal Array ◽  
Experimental Cutting

This paper is to study the application of Taguchi Method when experimental cutting on Copper (CuA1) generated by a milling machine. The respone of this study is surface roughness while machining with varying machining parameters such as cutting speed, feed rate and depth of cut. This experiment is using end mill HSS Ø16mm with uncoated and 2 flute with sequences of experiment base on the Taguchi Orthogonal array L934which carry out with 9 of experiments. The signal-to-noise (S/N) ratio, the analysis of variance (ANOVA) and confirmation tests with the optimal levels of machining parameters are carried out in order to illustrate the effectiveness of the Taguchi optimization method.

scholarly journals Multi-objective optimization of SKD11 Steel Milling Process by Reference Ideal Method

2021 ◽  
Vol 15 ◽  
pp. 1-16
Author(s):  
Do Duc Trung
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Speed ◽  
Milling Process ◽  
Multi Objective Optimization ◽  
Small Surface ◽  
Multi Objective ◽  
Input Parameters ◽  
Machining Productivity ◽  
Ideal Method

For all machining cutting methods, surface roughness is a parameter that greatly affects the working ability and life of machine elements. Cutting force is a parameter that not only affects the quality of the machining surface but also affects the durability of cutter and the level of energy consumed during machining. Besides, material removal rate (MRR) is a parameter that reflects machining productivity. Workpiece surface machining with small surface roughness, small cutting force and large MRR is desirable of most machining methods. This article presents a study of multi-objective optimization of milling process using a face milling cutter. The experimental material used in this study is SKD11 steel. Taguchi method has been applied to design an orthogonal experimental matrix with 27 experiments (L27). In which, five parameters have been selected as the input parameters of the experimental process including insert material, tool nose radius, cutting speed, feed rate and cutting depth. Reference Ideal Method (RIM) is applied to determine the value of input parameters to ensure minimum surface roughness, minimum cutting force and maximum MRR. Influence of the input parameters on output parameters is also discussed in this study.

Influence of process variables on machining characteristics in turning of novel AM alloy

2020 ◽  
pp. 095440542097809
Author(s):  
Sunil Dutta ◽  
Suresh Kumar Reddy Narala
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Flank Wear ◽  
Surface Condition ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Input Parameters ◽  
Response Variables

In this paper, the machinability of a fabricated AM alloy (Mg-7 wt%Al-0.9 wt%Mn) has been examined. The novel AM alloy was subjected to turning using a systemized CNC setup. The input turning variables: feed ( f), cutting speed ( v), and depth of cut (DOC) were suitably altered to analyze effects on response variables such as cutting force ( Fc), cutting temperature ( T), and tool life ( TL). Subsequently, the microstructure characterization of the machined surface was done for validating the experimental results. The experimental results established the influence of input parameters on response variables. The cutting force was mostly dominated by DOC, and the cutting temperature was predominantly influenced by cutting speed. The SEM images exhibited the adverse effect of higher values of input parameters on the surface condition. The finest surface was observed at f: 0.1 mm/rev, DOC: 0.5 mm, and v: 115 m/min. Further, the analysis of tool life was done by assessing the flank wear; the measured data showed the significant influence of cutting speed on flank wear. The maximum tool life of 51 min was achieved at the lowest levels of three input parameters.

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