scholarly journals Improving the Performance of Micro-Textured Cutting Tools in Dry Milling of Ti-6Al-4V Alloys

Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 945
Author(s):  
Ze Wu ◽  
Youqiang Xing ◽  
Jiansong Chen
Keyword(s):  
Energy Consumption ◽  
Power Consumption ◽  
Cutting Forces ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Comparison Results ◽  
Physical Effects ◽  
Improved Performance

Micro-textured tools were fabricated by making textures on rake faces and filling them with molybdenum disulfide. Dry milling of Ti-6Al-4V alloys was carried out with the micro-textured tools and conventional tools for comparison. Results showed that micro-textured tools can reduce the resultant cutting forces, cutting temperatures, and power consumption by approximately 15%, 10%, and 5%, respectively. Meanwhile, the developed tools can improve tool lives by approximately 20–25%. The radial width of cut, the cutting speed, and the axial depth of cut all had statistical and physical effects on the energy consumption per unit of volume in dry milling of Ti-6Al-4V alloys, while the feed per tooth seemed to have no significant effect. The mechanism for improved performance of micro-textured tools can be mainly interpreted as their self-lubricating function.

The machinability of Al/B4C composites produced by hot pressing based on reinforcing the element ratio

2016 ◽  
Vol 23 (6) ◽  
pp. 743-750 ◽  
Author(s):  
Ergün Ekici ◽  
Mahmut Gülesin
Keyword(s):  
Surface Roughness ◽  
Wear Mechanism ◽  
Cutting Forces ◽  
Hot Pressing ◽  
Matrix Material ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Reinforcement Ratio ◽  
Depth Of Cut ◽  
Crater Wear

AbstractIn this study, the effects of the particle reinforcement ratio on cutting forces and surface roughness were investigated when milling particle-reinforced metal matrix composite (MMCp) produced by hot pressing with different cutting tools. Alumix 123 alloy as the matrix material and B4C particles with an average size of 27 μm and 5%, 10% and 15% ratio as reinforcing elements were used for the manufacture of composite materials. The experiments were carried out in dry cutting conditions with four different cutting speeds, constant feed rate and depth of cut. Changes depending on the increased reinforcement ratio in cutting forces and surface roughness values were investigated; the effects of 10% B4C reinforced composite on tool wear were also examined. It was observed that cutting forces increased with the increase in cutting speed and particle ratio with carbide cutting tools, and it was seen that the cutting forces on the cutting tools decreased when cutting speed decreased and the cutting forces increased as the reinforcement ratios increased. In addition, with increasing the cutting speed, the surface roughness of the machined surfaces of composite samples increased with the carbide tools, while the cubic boron nitride (CBN) tools have the opposite effect. While it was seen that flank and crater wear occurred on the cemented carbide cutting tools, abrasive, adhesive and other wear mechanism tools in addition to the main wear mechanism, no remarkable flank and crater wear occurred on CBN cutting tools.

scholarly journals Green machining for the dry milling process of stainless steel 304

2019 ◽  
Vol 234 (5) ◽  
pp. 881-899 ◽  
Author(s):  
Trung-Thanh Nguyen ◽  
Mozammel Mia ◽  
Xuan-Phuong Dang ◽  
Chi-Hieu Le ◽  
Michael S Packianather
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Energy Consumption ◽  
Power Factor ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Dry Milling ◽  
Stainless Steel 304

Dry machining represents an eco-friendly method that reduces the environmental impacts, saves energy costs, and protects operator health. This article presents a multi-response optimization which aims to enhance the power factor and decrease the energy consumption as well as the surface roughness for the dry machining of a stainless steel 304. The cutting speed ( V), depth of cut ( a), feed rate ( f), and nose radius ( r) were the processing conditions. The outputs of the optimization are the power factor, energy consumption, and surface roughness. The relationships between inputs and outputs were established using the radial basis function models. The experimental data were normalized, with the use of the Grey relational analysis. The principal component analysis is applied to calculate the weight values of technical responses. The desirability approach is used to observe the optimal values. The results showed that the technical outputs are primarily influenced by the feed rate and cutting speed. The reductions of energy consumption and surface roughness are approximately 34.85% and 57.65%, respectively, and the power factor improves around 28.83%, compared to the initial process parameter settings. The outcomes and findings of the investigated work can be used for further research in sustainable design and manufacturing as well as directly used in the knowledge-based and expert systems for dry milling applications in industrial practices.

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.

Cutting Forces and Tool Wear in Dry Milling of Ti6Al4V

2012 ◽  
Vol 565 ◽  
pp. 454-459 ◽  
Author(s):  
Yun Chen ◽  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Workpiece Material ◽  
Tool Wear Mechanism ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Cutting Speeds

Titanium alloys are difficult-to-cut materials. This paper presents an experimental study of the effects of different cutting conditions and tool wear on cutting forces in dry milling Ti6Al4V with coated carbide inserts. The experimental results show that the peak forces increase with the increase in the feed rate and depth of cut. With the cutting speed increment in the range from 50 m/min to 150 m/min the peak forces decrease, while at further higher cutting speeds investigated peak forces increase. The decrease of the peak forces is due to thermal softening of the workpiece material and the increase is because of the strain hardening rate of Ti6Al4V. The tool wear experiment reveals that the major tool wear mechanism is the flank wear. The variations of the peak forces are caused by both the tool wear propagation and the thermal effects.

Optimization of Cutting Parameters in Turning of AISI 1018 Steel With Constant Material Removal Rate Using Robust Design for Minimizing Cutting Power

2013 ◽  
Author(s):  
C. Camposeco-Negrete ◽  
J. Calderón-Nájera ◽  
J. C. Miranda-Valenzuela
Keyword(s):  
Energy Consumption ◽  
Power Consumption ◽  
Robust Design ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimization Of Cutting Parameters

Environmental and energy efficiency awareness of manufacturers and customers along with high electricity costs have promoted the development of strategies to reduce energy consumption in manufacturing processes. Machine tools are one of the main contributors to energy consumption in the industrial sector. Several studies have been undertaken to optimize the cutting parameters in order to minimize the power consumed in the removal of material. However, these studies do not consider the influence that different combinations of cutting parameters can have on power consumption at a constant material removal rate, quantity that has a direct influence in production rates. This paper describes an experimental study of AISI 1018 steel turning under roughing conditions and constant material removal rate, in order to obtain the cutting parameters that minimize power consumption. Robust design is used to analyze the effects of the depth of cut, feed rate and cutting speed on electric power consumed.

scholarly journals Multiple Regression Prediction Model for Cutting Forces in Turning Carbon-Reinforced PEEK CF30

2010 ◽  
Vol 2010 ◽  
pp. 1-7 ◽  
Author(s):  
Francisco Mata ◽  
Elena Beamud ◽  
Issam Hanafi ◽  
Abdellatif Khamlichi ◽  
Abdallah Jabbouri ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Quadratic Regression ◽  
Turning Operations ◽  
Dry Conditions ◽  
Full Factorial

Among the thermoplastic polymers available, the reinforced polyetheretherketone with 30% of carbon fibres (PEEK CF 30) demonstrates a particularly good combination of strength, rigidity, and hardness, which prove ideal for industrial applications. Considering these properties and potential areas of application, it is necessary to investigate the machining of PEEK CF30. In this study, response surface methodology was applied to predict the cutting forces in turning operations using TiN-coated cutting tools under dry conditions where the machining parameters are cutting speed ranges, feed rate, and depth of cut. For this study, the experiments have been conducted using full factorial design in the design of experiments (DOEs) on CNC turning machine. Based on statistical analysis, multiple quadratic regression model for cutting forces was derived with satisfactory -squared correlation. This model proved to be highly preferment for predicting cutting forces.

scholarly journals An investigation of cutting parameters effect on sound level, surface roughness, and power consumption during machining of hardened AISI 4140

2020 ◽  
Vol 21 (5) ◽  
pp. 523
Author(s):  
Abidin Şahinoğlu ◽  
Efehan Ulas
Keyword(s):  
Surface Roughness ◽  
Energy Consumption ◽  
Power Consumption ◽  
Feed Rate ◽  
Cutting Speed ◽  
Total Power ◽  
Depth Of Cut ◽  
Machining Time ◽  
Total Power Consumption ◽  
Aisi 4140

In recent years, the necessity for energy in the manufacturing industry has become an important problem because fossil fuel reserves are decreasing in order to produce energy. Therefore, the efficient use of energy has become an important research topic. In this study, energy efficiency is investigated in detail for sustainable life and manufacturing. AISI 4140 material with high hardness of 50 HRC hardness has been applied cryogenic process to improve mechanical and machinability properties. In this experiment study, the effects of feed rate (0.04, 0.08, 0.12 mm/rev), cutting speed (140, 160, 180 m/min), depth of cut (0.05, 0.10, 0.15 mm) and tool radius (0.4, 0.8) on energy consumption, surface roughness and sound intensity were investigated. Then, a new mathematical model with high accuracy was developed. Total power consumption was calculated by considering the instantaneous current value and machining time. As a result, it is found that good surface quality obtained when the feed rate is low, and the tool radius is high and the machining time is shortened, the energy consumption is reduced due to the increase in cutting speed, depth of cut and feed rate. Also, it is found that the tool radius has a limited effect on energy consumption, but low feed value increases energy consumption.

Experimental and Numerical Investigation into Residual Stress During Turning Operation for Stainless Steel AISI 316

2020 ◽  
Vol 38 (12A) ◽  
pp. 1862-1870
Author(s):  
Safa M. Lafta ◽  
Maan A. Tawfiq
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Main Role ◽  
Turning Operation ◽  
Aisi 316

RS (residual stresses) represent the main role in the performance of structures and machined parts. The main objective of this paper is to investigate the effect of feed rate with constant cutting speed and depth of cut on residual stresses in orthogonal cutting, using Tungsten carbide cutting tools when machining AISI 316 in turning operation. AISI 316 stainless steel was selected in experiments since it is used in many important industries such as chemical, petrochemical industries, power generation, electrical engineering, food and beverage industry. Four feed rates were selected (0.228, 0.16, 0.08 and 0.065) mm/rev when cutting speed is constant 71 mm/min and depth of cutting 2 mm. The experimental results of residual stresses were (-15.75, 12.84, 64.9, 37.74) MPa and the numerical results of residual stresses were (-15, 12, 59, and 37) MPa. The best value of residual stresses is (-15.75 and -15) MPa when it is in a compressive way. The results showed that the percentage error between numerical by using (ABAQUS/ CAE ver. 2017) and experimental work measured by X-ray diffraction is range (2-15) %.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

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