scholarly journals A Fuzzy Logic Model for the Analysis of Ultrasonic Vibration Assisted Turning and Conventional Turning of Ti-Based Alloy

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6572
Author(s):  
Riaz Muhammad
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Process Zone ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Zone Temperature

Titanium and its alloys are largely used in various applications due its prominent mechanical properties. However, the machining of titanium alloys is associated with assured challenges, including high-strength, low thermal conductivity, and long chips produced in conventional machining processes, which result in its poor machinability. Advanced and new machining techniques have been used to improve the machinability of these alloys. Ultrasonic vibration assisted turning (UVAT) is one of these progressive machining techniques, where vibrations are imposed on the cutting insert, and this process has shown considerable improvement in terms of the machinability of hard-to-cut alloys. Therefore, selecting the right cutting parameters for conventional and assisted machining processes is critical for obtaining the anticipated dimensional accuracy and improved surface roughness of Ti-alloys. Hence, fuzzy-based algorithms were developed for the ultrasonic vibration assisted turning (UVAT) and conventional turning (CT) of the Ti-6Al7Zr3Nb4Mo0.9Nd alloy to predict the maximum process zone temperature, cutting forces, surface roughness, shear angle, and chip compression ratio for the selected range of input parameters (speed and depth-of-cut). The fuzzy-measured values were found to be in good agreement with the experimental values, indicating that the created models can be utilized to accurately predict the studied machining output parameters in CT and UVAT processes. The studied alloy resulted in discontinued chips in both the CT and UVAT processes. The achieved results also demonstrated a significant decline in the cutting forces and improvements in the surface quality in the UVAT process. Furthermore, the chip discontinuity is enhanced by the UVAT process due to the higher process zone temperature and the micro-impact imposed by the cutting tool on the workpiece.

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.

Stresses in Ultrasonically Assisted Turning

2006 ◽  
Vol 5-6 ◽  
pp. 351-358 ◽  
Author(s):  
N. Ahmed ◽  
A.V. Mitrofanov ◽  
Vladimir I. Babitsky ◽  
Vadim V. Silberschmidt
Keyword(s):  
Ultrasonic Vibration ◽  
Vibration Frequency ◽  
Cutting Forces ◽  
Plastic Material ◽  
Process Zone ◽  
Three Dimensional ◽  
Rate Sensitivity ◽  
High Strength ◽  
Material Model ◽  
Shear Stresses

Ultrasonically assisted turning (UAT) is a novel material-processing technology, where high frequency vibration (frequency f ≈ 20kHz, amplitude a ≈15μm) is superimposed on the movement of the cutting tool. Advantages of UAT have been demonstrated for a broad spectrum of applications. Compared to conventional turning (CT), this technique allows significant improvements in processing intractable materials, such as high-strength aerospace alloys, composites and ceramics. Superimposed ultrasonic vibration yields a noticeable decrease in cutting forces, as well as a superior surface finish. A vibro-impact interaction between the tool and workpiece in UAT in the process of continuous chip formation leads to a dynamically changing stress distribution in the process zone as compared to the quasistatic one in CT. The paper presents a three-dimensional, fully thermomechanically coupled computational model of UAT incorporating a non-linear elasto-plastic material model with strain-rate sensitivity and contact interaction with friction at the chip–tool interface. 3D stress distributions in the cutting region are analysed for a representative cycle of ultrasonic vibration. The dependence of various process parameters, such as shear stresses and cutting forces on vibration frequency and amplitude is also studied.

Experimental Investigations of Cutting Parameters Influence on Cutting Forces and Surface Roughness of Quartz Glass

2013 ◽  
Vol 641-642 ◽  
pp. 367-370
Author(s):  
Gui Qiang Liang ◽  
Fei Fei Zhao
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Diamond Wheel ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Feed Force

Abstract In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed rate and depth of cut) on cutting forces (feed force, thrust force and cutting force) and surface roughness in milling of Quartz glas using diamond wheel. The cutting process in the up-cut milling of glass is discussed and the cutting force measured. The cutting force gradually increases with the cutter rotation at the beginning of the cut, and oscillates about a constant mean value after a certain undeformed chip thickness. The results show that cutting forces and surface roughness do not vary much with experimental cutting speed in the range of 55–93 m/min. The suggested models of cutting forces and surface roughness and adequately map within the limits of the cutting parameters considered.

Surface Roughness Predictive Model of UNS A97075 Aluminum Pieces Obtained by Dry Turning Tests Based on the Cutting Forces

2012 ◽  
Vol 217-219 ◽  
pp. 1628-1635 ◽  
Author(s):  
Beatriz De Agustina ◽  
Eva María Rubio ◽  
Miguel Ángel Sebastián
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Predictive Model ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Turning ◽  
Frequency Domains ◽  
Range Of Values ◽  
Roughness Measurements

The present work shows an experimental study for a first approach of a surface roughness predictive model of UNS A97075 aluminum pieces obtained by dry turning tests based on the cutting forces. In a first step, a design of experiments (DOE) 25 was employed to analyse the influence of the cutting parameters and type of tool on the surface roughness with the objective to find out a combination of cutting conditions that allow obtaining a range of values of surfaces roughness according to the aeronautical specifications requierements. The factors considered for this design were the feed rate, spindle speed, depth of cut, type of tool (nose radious) and machined length (zone of the workpiece where the surface roughness measurements are taken). The obtained data was analysed by means of the analysis of variance (ANOVA) method. And secondly, with the previous selected conditions selected it was developed by multiple regression a model to predict the surface roughness by measuring the cutting forces generated during the dry turning tests of aluminum alloy UNS A97075 pieces. The predictive model of surface roughness obtained includes statistical values calculated from the forces sygnal in time and frequency domains.

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.

Surface Roughness Optimization in Machining of Titanium Alloy (Ti-6Al-4V)

2014 ◽  
Vol 984-985 ◽  
pp. 42-47
Author(s):  
J. Nithyanandam ◽  
Sushil Laldas ◽  
K. Palanikumar
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Thermal Properties ◽  
Cutting Speed ◽  
Weight Ratio ◽  
High Strength ◽  
Cutting Parameters ◽  
Ratio Method ◽  
Depth Of Cut ◽  
Nose Radius

Titanium is one of the important kinds of material used in different engineering fields. They have very good properties like high strength to weight ratio, superior corrosion resistance and thermal properties. They are very attractive materials and has application aerospace, biomedical and automotive field. they are classified to be “difficult-to-Machine materials” as they posses poor thermal properties, poor machinability, etc.The prime important is with the study of machining characteristics and the optimization of the cutting parameters. In this paper Titanium alloy (Ti-6Al-4V) is taken, the dry turning experiments are carried out in semi-automatic lathe using poly crystalline diamond (PCD) cutting tool insert. The taguchi’s design of L27orthogonal array is done by four machining factors namely cutting speed, feed, nose radius and depth of cut at three levels. The optimal machining conditions are arrived by Signal-Noise ratio method with respect to surface roughness (Ra). The analysis of variance (ANOVA) and the percentage of contribution of feed, cutting speed, nose radius and depth of cut for better surface roughness is validated using S/N ratio. In this result indicated that the feed is a vital parameter followed by cutting speed, the nose radius and then by depth of cut. The worn out surface of the insert is examined by using scanning electron microscope (SEM).

scholarly journals Effect of Cutting Insert Type on Surface Roughness of Hardened AISI 420 Stainless Steel

2021 ◽  
Vol 4 (1) ◽  
pp. 171-185
Author(s):  
Anıl Berk Dalkıran ◽  
Furkan Yılmaz ◽  
Samet Emre Bilim
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Feed Rate ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 420 ◽  
Cutting Insert ◽  
Coated Carbide

AISI 420 stainless steel is one of the alloys that can be used in various applications due to its malleability, high strength, and weldability. In this study, the effects of cutting parameters (feed rate, depth of cut, and cutting speed) on the surface roughness were investigated during the turning of AISI 420 under dry test conditions using coated carbide and ceramic cutting inserts. Response surface methodology, analysis of variance, and statistical methods of the main effect plot were applied to investigate the effects of input parameters on response values. The results of this study showed that feed rate followed by the depth of cut had the most significant effect on output parameters. According to the experimental data, as the feed rate and depth of cut increase, the surface roughness increases.

scholarly journals Analysis of Surface Roughness and Cutting Forces in Hard Turning of 42CrMo4 Steel using Taguchi and RSM Method

Mechanika ◽  
2020 ◽  
Vol 26 (3) ◽  
pp. 231-241 ◽  
Author(s):  
Mustafa ÖZDEMİR ◽  
Mehmet Tuncay KAYA ◽  
Hamza Kemal AKYILDIZ
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Forces ◽  
Tangential Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Radial Force ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Feed Force

In this study, effects of cutting speed (V), feed rate (f), depth of cut (a) and tool tip radius (R) on  surface roughness (Ra, Rz, and Rt) and cutting forces (radial force (Fx), tangential force (Fy), and feed force (Fz)) in hard finish turning processes of hardened 42CrMo4 (52 HRC) material was investigated experimentally. Taguchi’s mixed level parameter design (L18) is used for the experimental design (2x1,3x3). The signal-to-noise ratio (S/N) was used in the evaluation of test results.  By using Taguchi method, cutting parameters giving optimum surface roughness and cutting forces were determined. Regression analyses are applied to predict surface roughness and cutting forces. Analysis of variance (ANOVA) is used to determine the effects of the machining parameters on surface roughness and cutting forces. According to ANOVA analysis, the most important cutting parameters were found to be feed rate for surface roughness and depth of cut among cutting forces.  By conducting validation experiments, optimization was seen to be applied successfully.

Tool Wear and Surface Roughness in Diamond Cutting of Die Steels

2013 ◽  
Vol 589-590 ◽  
pp. 227-231 ◽  
Author(s):  
Lai Zou ◽  
Guo Jun Dong ◽  
Ming Zhou
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Cutting Parameters ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Die Steels ◽  
Micro Morphology

This paper performed a series of experimental investigations for typical die steels with ultrasonic vibration assisted turning. The micro-morphology of rake face and flank face of diamond was detected by scanning electron microscopy, and the roughness of machined surface was measured by Form Talysurf. In order to clarify the influence laws of cutting parameters and tool geometric parameters on tool wear and surface quality. The results revealed that the wear of diamond and surface roughness rely heavily on the feed rate, and have less relativity with the relief angle and the depth of cut to an extent. In addition, the function mechanism of ultrasonic vibration turning had been analyzed, it exhibited that this technological measure has enhanced tool life and improved surface quality to a large extent.

Experimental Investigation on Ultrasonic Vibration Assisted Turning of Stainless Steels with PCD Tool

2013 ◽  
Vol 690-693 ◽  
pp. 2026-2029 ◽  
Author(s):  
Guo Jun Dong ◽  
Lai Zou ◽  
Ming Zhou
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Stainless Steels ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Cutting Operation ◽  
Micro Morphology

The demand for surface quality and dimensional accuracy of ferrous metallic components has increased markedly at present. Whereas, it is clear known that diamond tool could not be used for cutting operation of ferrous metals ascribed to excessive tool wear. In this paper, a series of experimental investigations for various stainless steels with ultrasonic vibration assisted turning were proposed. The micro-morphology of rake and flank face of diamond was detected by scanning electron microscopy, in order to discuss the influence law of material composition on tool wear. In addition, the effect of cutting parameters such as depth of cut, feed rate and amplitude on tool wear and surface quality were deeply studied with ultrasonic vibration cutting. The results revealed that this technological measure has enhanced tool life, decreased cutting force and improved surface quality to a large extent.

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