scholarly journals Modelling and Analysis of Surface Evolution on Turning of Hard-to-Cut CLARM 30NiCrMoV14 Steel Alloy

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1751
Author(s):  
Syed Muhammad Raza ◽  
Aqib Mashood Khan ◽  
Muhammad Umar Farooq ◽  
Asif Iqbal ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Mathematical Modelling ◽  
Surface Finish ◽  
Feed Rate ◽  
Rotational Speed ◽  
Prediction Models ◽  
Pressure Vessels ◽  
Depth Of Cut ◽  
Central Component ◽  
Steel Alloy ◽  
Input Parameters

Industrial practitioners are working on predictive solutions for the precise evaluation of input parameters and processed surfaces of engineering materials. To aid the aeronautical industry, this study is an effort to develop the mathematical modelling for comprehensive surface analysis of input parameters and surface finish after dry machining of CLARM HBR, a steel alloy with attractive mechanical properties and wide applications in large caliber gun barrels and high-pressure vessels. Feed rate, rotational speed, and depth of cut were taken as quantitative parameters, whereas machining time was considered as a categorical factor with a classification of three levels. Response surface methodology (RSM) with a central component design has been used for the constitution of the experimental design, mathematical modelling, and analysis of developed models. Eighteen samples were prepared to perform the experimentation for the development of prediction models. The adequacy of the developed models was verified using analysis of variance (ANOVA), and the models were validated using confirmatory trial experiments, which revealed the experimental results agreeing with predictions. The feed rate was the most significant parameter in achieving the desired surface finish. An increase in rotational speed at a low feed rate resulted in very fine surface texture, as though it deteriorated the surface finish at higher feed rates. The superior surface quality obtained was 0.137 μm at parametric settings of 0.19 mm/rev feed, 90 rpm speed, 3 mm depth of cut, and 4 min time. Overall, higher values of surface roughness were frecorded in the third level of process variable time. The developed empirical models are expected to aid manufacturers and machining practitioners in the prediction of the desired surface finish concerning different parameters before the experimentations.

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.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Investigation of Chip and Surface Roughness when Milling AISI304 Stainless Steel

2017 ◽  
Vol 889 ◽  
pp. 152-158
Author(s):  
K. Kadirgama ◽  
K. Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Feed Rate ◽  
Prediction Models ◽  
Cutting Speed ◽  
Experimental Result ◽  
Quadratic Model ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Axial Depth

Stainless steel was used for many engineering applications. The optimum parameters needs to be identify to save the cutting tool usage and increase productivity. The purpose of this study is to develop the surface roughness mathematical model for AISI 304 stainless steel when milling using TiN (CVD) carbide tool. The milling process was done under various cutting condition which is cutting speed (1500, 2000 and 2500 rpm), feed rate (0.02, 0.03 and 0.04 mm/tooth) and axial depth (0.1, 0.2 and 0.3 mm). The first order model and quadratic model have been developed using Response Surface Method (RSM) with confident level 95%. The prediction models were comparing with the actual experimental results. It is found that quadratic model much fit the experimental result compare to linear model. In general, the results obtained from the mathematical models were in good agreement with those obtained from the machining experiments. Besides that, it is shown that the influence of cutting speed and feed rate are much higher on surface roughness compare to depth of cut. The optimum cutting speed, feed rate and axial depth is 2500 rpm, 0.0212 mm/tooth and 0.3mm respectively. Besides that, continues chip is produced at cutting speed 2500 rpm meanwhile discontinues chip produced at cutting speed 1500 rpm.

scholarly journals Effect of Cutting Depth and Feed Speed to Surface Roughness in Lathe Process of Screw Conveyor Shaft (Case Study: PT. RAPP)

2020 ◽  
Vol 64 (2) ◽  
pp. 59-62
Author(s):  
Junaidi Abdul Khair ◽  
◽  
Deni Pranata ◽  
Ujang Nurhadek ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Rotational Speed ◽  
High Speed ◽  
Feeding Rate ◽  
Production Quality ◽  
Screw Conveyor ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Turning Process

The metalworking process is one of the most important things in manufacturing of machine components, such as lathe process. Therefore, it is required continuously innovation to improve production quality. There are several ways to do this, for example by choosing the right type of tool, depth of cut, and spindle speed. In turning process for the production of goods is very important to produce a precision product in accordance to desiring of size and roughness. The turning speed of a lathe has a type of spindle rotation rate that is used according to production requirements, which uses a rotational speed that can be changed the rate of rotation of the machine, in order to determine the level of surface roughness in the turning process. One is affected the optimal conditions of the turning speed and feeding rate. In this paper, the variations of different rotational speed levels of low speed, medium speed and high speed according to variations of feeding rate in order to know the difference in roughness results for the screw conveyor shaft operation. The roughness was measured on the surface turning process using a reference of surface roughness stand comparator (ISO2632 / I-1975). The result of test revealed the greater speed of feed rate, the greater value of roughness. Reversely, the smaller speed of feed rate affected the lower roughness value.

scholarly journals The Outcome of Turning Factors on the Machining Characteristics While Turning 655M13 Steel Alloy using Tialn Coated Carbide Insert

2020 ◽  
Vol 9 (3) ◽  
pp. 1251-1260 ◽  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Models ◽  
Tangential Force ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Steel Alloy ◽  
Nose Radius ◽  
Feed Force ◽  
Coated Carbide

This exploration is carried out to reveal the outcome of turning factors such as cutting velocity, depth of cut and feed rate on the surface roughness, mean cutting force and tool-work interface temperature on turning cylindrical 655M13 steel alloy components. The experiments are designed based on (33) full factorial design and conducted on a turning centre with Titanium Aluminium Nitride (TiAlN) layered carbide tool of 0.8mm nose radius, simultaneously cutting forces such as feed force, thrust force and tangential force and the tool-work interface temperature are observed using calibrated devices. The surface roughness of the turned steel alloy parts is deliberated by means of a precise surface roughness apparatus. Prediction models are created for average surface roughness, mean cutting force and tool-work interface temperature by nonlinear regression examination with the aid of MINITAB numerical software. The optimum machining conditions are confirmed with the aid of a Genetic Algorithm. The outcome of each turning factor on the surface roughness, mean cutting force and tool-work interface temperature is studied and presented accordingly.

scholarly journals On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2036 ◽  
Author(s):  
Adel T. Abbas ◽  
Magdy M. El Rayes ◽  
Monis Luqman ◽  
Noha Naeim ◽  
Hussien Hegab ◽  
...  
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Steel Alloy ◽  
Aisi 4340 Steel ◽  
Aisi 4340

This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.

The Study of Surface Finish in Face Milling of Stainless Steel: AISI 304

2013 ◽  
Vol 650 ◽  
pp. 606-611 ◽  
Author(s):  
Songsak Luejanda ◽  
Komson Jirapattarasilp
Keyword(s):  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
Aisi 304 ◽  
Steel Aisi ◽  
Stainless Steel Aisi

This research was to study the effect of face milling on the surface finish of stainless steel: AISI 304. The experiment was applied on three factors and were consisted of three levels of cutting speed, depth of cut and feed rate. The face milling process was chosen to experiment which used face milling cutter with insert carbide tool. The surface roughness average (Ra) was applied to indicating for surface finish. The experiment results were analyzed by ANOVA. The main factors and factors interaction that affected to surface finish were investigated. Effect of cutting speed, feed rate and depth of cut on surface finish of stainless steel: AISI 304 was discussed.

Effect of Amount of Cutting Fluid on Surface Finish of Turned Parts

2011 ◽  
Vol 87 ◽  
pp. 170-177
Author(s):  
M.N. Islam
Keyword(s):  
Surface Finish ◽  
Feed Rate ◽  
Orthogonal Array ◽  
Roughness Parameter ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Arithmetic Average ◽  
Steel Aisi ◽  
Turned Parts

This paper presents the experimental and analytical results of the effect that the amount of cutting fluid has on the surface finish of turned parts. The experiments were planned using Taguchi’s orthogonal array methodology. A three-level, four-parameter orthogonal array (L81) was selected for designing the experiments. The selected four input parameters are cutting speed, feed rate, depth of cut, and amount of cutting fluid. Mild steel AISI 1030 was chosen as the work material. A total of 81 experimental runs were conducted, and the surface roughness parameter arithmetic average was measured offline using a surface finish analyzer. Subsequently, the results were analyzed applying three methods—traditional analysis, Pareto ANOVA, and the Taguchi method. The results indicate that the amount of cutting fluid has a negligible effect on surface finish. However, the interaction between the two major contributors—cutting speed and feed rate—is influenced noticeably by the amount of cutting fluid.

Machining Apprenticeship Based on Experimental Training Practice

2011 ◽  
Vol 692 ◽  
pp. 83-92
Author(s):  
Pedro Jose Arrazola ◽  
A. Villar ◽  
R. Fernández ◽  
J. Aperribay
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Feed Rate ◽  
Cutting Forces ◽  
Theoretical Calculations ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Practical Training ◽  
Input Parameters

This article describes a practical machining training aiming that the students acquire the theoretical-practical knowledge of chip formation process. The training takes place after theoretical lessons of machining processes. Thus, this practice allows strengthening the knowledge gained during the lessons. The practical training lasts for five hours, and the student assisted by the teacher analyses the influence of some machining entry parameters (cutting speed, feed rate...) on exit parameters like: (I) cutting forces and power consumption, (II) surface roughness, and (III) chip typology. The practical session is carried out on an experimental set-up (Lathe CNC Danobar 65) equipped with sensors and devices to measure forces (sensor Kistler 9121) and power consumption. In addition, a portable rugosimeter (Hommelwerke) is employed to perform surface roughness measurements. No especial devices are needed for the chip typology analysis. In the case of cutting forces and power consumption, the following input parameters influences are analysed: feed rate, depth of cut and cutting speed. In the case of surface roughness analysis, the following input parameters influences are analysed: feed rate and nose radius of the cutting insert. Finally, regarding chip typology feed rate and depth of cut are examined. The experimental results are compared with model predictions (theoretical calculations) for the three issues studied. The students have to compare both results: theoretical an empirical and they need to explain the reasons when discrepancies appear. Results obtained during the last years demonstrate the student acquires better knowledge of the machining process, and at the same time realises of the process complexity.

scholarly journals Influence of Process Parameters on the Surface Roughness during turning operation of High Strength Steel

2016 ◽  
Vol 5 (2) ◽  
pp. 100 ◽  
Author(s):  
Adel Taha Mohamed Abbas
Keyword(s):  
Surface Finish ◽  
Feed Rate ◽  
High Strength Steel ◽  
High Strength ◽  
Machining Process ◽  
Depth Of Cut ◽  
Influence Of Process Parameters ◽  
Gun Barrel ◽  
The Impact ◽  
Design Drawing

<p class="1Body">High strength steels are used in many high-end applications. Due to the high cost of raw material, manufacturing engineers should be very careful during their machining process. Surface finish is the critical factor in the turning process of combustion chambers of gun barrels. It should conform to the required accuracy values. This paper analyzes the impact and parameters of the process have on the roughness of the surface. The impact is analyzed during turning operations of high strength steel material. The parameters considered include feed rate, depth of cut and cutting speed. The test plan was implemented through 125 test specimens. The latters were divided into 25 groups. Each five groups were subjected to one common machining speed. Each group was machined using five levels of cutting depth. Each depth was processed using feed rate having five levels. Tessa was used for the examination of the roughness of surface. The experimental findings were compared to the requirement of the surface finish on the basis of the design drawing of gun barrel. The combination of the process variables showed excellent agreement with the design drawing of gun barrels.</p>

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