Hard Turning of AISI D2 Steel In CNC Machining: An Overview

2018 ◽  
Vol 3 (1) ◽  
pp. 17-20
Author(s):  
Navriti Gupta ◽  
◽  
A.K Agrawal, ◽  
R.S Walia ◽  
Ranganath Singari
Keyword(s):  
Metal Removal ◽  
Cnc Machining ◽  
Machining Process ◽  
Tungsten Carbides ◽  
Machining Processes ◽  
Manufacturing Operations ◽  
Aisi D2 ◽  
Removal Processes ◽  
Tough Steel ◽  
D2 Steel

D2 steel is an industrial tool steel. It is widely used in the tool and die industry for making cutting tool inserts, bending inserts, restriking inserts, etc. which can be taken out after their tool life. D2 steel is a very tough steel and difficult to machine also. High generations tool bits like Tungsten carbides and Titanium carbides are required to machine them. The heat treatment follows the machining process. Their machinability is very low. CNC machines are often used to finish them. Often they are machined using programs on UG-NX Uni Graphics(CAM) and DELCAM. And they have to be machined in three steps. Roughing operations, followed by Semi-Finish machining and the last step is finish machining.CNC machining centers are versatile in their applications in metal removal processes. Often they are so modernized that just like many manufacturing operations, metal removal can be automated too. The need for CNC machining arises due to extensive finishing requirements in the aerospace, automotive industries. However, the CNC or Computer and Numerically controlled machining process usage is not limited to these industries only. Tool and Die industry also is heavily dependent on CNC material removal and machining processes as now replaceable inserts are widely used in this industry.

scholarly journals A Novel Technique to Assess the Effect of Machining and Subsurface Microstructure on the Fatigue Performance of Ti-6Al-2Sn-4Zr-6Mo

2020 ◽  
Vol 321 ◽  
pp. 04012
Author(s):  
Daniel Suárez-Fernández ◽  
Bradley P. Wynne ◽  
Pete Crawforth ◽  
Katharine Fox ◽  
Martin Jackson
Keyword(s):  
Structural Integrity ◽  
Metal Removal ◽  
Microstructural Analysis ◽  
Development Stage ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Novel Approach ◽  
And Performance

Aerospace titanium components are manufactured under the strictest standards in order to ensure the highest quality. To develop highly efficient machining processes, extensive research and investment is necessary. For the specific case of rotating titanium critical components, large quantities of forged workpieces are machined to determine the effects of the different machining parameters on tool wear characteristics and component structural integrity and performance. However, testing the different permutations of metal removal parameters and tool combinations is expensive and time consuming at the development stage. The novel approach developed and presented here, enables the machining of smaller titanium parts that can be compared 1-to-1 to parts extracted from industrial machined disc components. This approach not only reduces cost, but ultimately accelerates the research and development process due to more rapid feedback between different iterations of the machining parameters. The proposed technique specifically replicates the face turning operation performed in rotational critical titanium components, such as compressor discs, using small coupons machined in a standard CNC machining centre. The machined coupons can be fatigue tested through a 4-point bending and microstructural analysis can be performed on the tested coupons to directly study the effects of the machining process on the surface and underlying microstructure.

scholarly journals Improvement of Machining Processes: A Case Study

2019 ◽  
Vol 2 (3) ◽  
pp. 634-641
Author(s):  
Hakan Gökçe ◽  
Ramazan Yeşilay ◽  
Necati Uçak ◽  
Ali Teke ◽  
Adem Çiçek
Keyword(s):  
Material Removal ◽  
Current Practice ◽  
Complex Geometry ◽  
Vital Role ◽  
Machining Process ◽  
Machining Processes ◽  
Machining Time ◽  
Machining Strategy ◽  
Removal Processes

In material removal processes, determination of optimal machining strategy is a key factor to increase productivity. This situation is gaining more importance when machining components with complex geometry. The current practice in the determination of machining strategy mostly depends on the experience of the machine operator. However, poorly designed machining processes lead to time-consuming and costly solutions. Therefore, the improvement of machining processes plays a vital role in terms of machining costs. In this study, the machining process of a boom-body connector (GGG40) of a backhoe loader was improved. Improvements of toolpaths and cutting conditions of 22 different material removal processes were checked through a CAM software. According to the simulation results, the process plan was rearranged. Besides, some enhancements in casting model were conducted to decrease in the number of machining operations. When compared to current practice, a reduction of 55% in machining time was achieved.

Boolean Operations for the Simulation of Machining Processes Based on the CSG Modeling Technique

2012 ◽  
Vol 538-541 ◽  
pp. 951-954
Author(s):  
Bai Chun Li ◽  
Xue Wei Zhang ◽  
Lei Geng ◽  
Tian Biao Yu ◽  
Wan Shan Wang
Keyword(s):  
Material Removal ◽  
Cnc Machining ◽  
Machining Process ◽  
Modeling Technique ◽  
Complex Object ◽  
Boolean Operations ◽  
Machining Processes ◽  
Solid Geometry ◽  
Difference Operation ◽  
Swept Volume

The simulation of computer numerically control (CNC) machining process is an important component of CAM, it can check errors and enhance the automation of machining process. In order to realize the material removal simulation of machining process through VC++ and OpenGL, this paper does the research on the Boolean operations based on the Constructive Solid Geometry (CSG) modeling technique. Firstly, this paper introduces the CSG technique, especially the creating complex object from simple primitives by the operations of Boolean algebra and the frame buffer. Then this paper achieves the solid modeling of cutter and stock through VC++ and OpenGL, and does the research on the theory of cutter’s swept volume generation. In terms of the theory, a cutter’s swept volume is created. Finally, the Boolean difference operation of a stock and the cutter’s swept volume is realized, and the code is also given.

Improving Milling Performance with High Pressure Waterjet Assisted Cooling / Lubrication

1995 ◽  
Vol 117 (3) ◽  
pp. 331-339 ◽  
Author(s):  
R. Kovacevic ◽  
C. Cherukuthota ◽  
R. Mohan
Keyword(s):  
High Pressure ◽  
Metal Removal ◽  
Removal Rate ◽  
Water Pressure ◽  
Surface Profile ◽  
Machining Process ◽  
Orifice Diameter ◽  
Machining Processes ◽  
Milling Performance ◽  
Metal Machining

During machining, due to relative motion between tool and workpiece, severe thermal/frictional conditions exist at the tool-chip interface. Metal machining processes can be more efficient in terms of increasing the metal removal rate and lengthening tool life, if the thermal/frictional conditions are controlled effectively. A high pressure waterjet assisted coolant/lubricant system that can be used in conjunction with rotary tools (e.g., face milling) is developed here. The performance of this system is evaluated in terms of cutting force, surface quality, tool wear, and chip shape. The improvement in the effectiveness of the developed system with increase in water pressure and orifice diameter is also investigated. Stochastic modeling of the surface profile is performed to obtain more information about the role of waterjet in the machining process.

Hard Turning of AISI D2 Steel by Polycrystalline Cubic Boron Nitride (PCBN)

2015 ◽  
Vol 766-767 ◽  
pp. 649-654
Author(s):  
A. Srithar ◽  
K. Palanikumar ◽  
B. Durgaprasad
Keyword(s):  
Boron Nitride ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi D2 Steel ◽  
Polycrystalline Cubic Boron Nitride ◽  
Aisi D2 ◽  
D2 Steel

The machining of hard turning is performed on hardened steel in the range of 45 to 68 Rockwell hardness using a variety of tool materials such as Polycrystalline cubic boron nitride (PCBN) , Polycrystalline diamond (PCD) and Cubic boron nitride (CBN). It is an alternative to conventional grinding process is a flexible and effective machining process for hardened metals and hence broadly used in various applications such as dies, moulds, tools, gears, cams, shafts, axles, bearings and forgings. Although the process is performed within small depth of cut and feed rates, estimates to reduce machining time as high as 60 % in hard turning. This paper discusses the importance of hard turning of AISI D2 steel. In this study, Experimental investigations are carried out on conventional lathe using prefixed the cutting conditions. The responses studied in the investigation are cutting forces (Fa, Ft and Fz). The cutting parameters considered for the investigation are cutting speed, feed and depth of cut. The influence of machining parameters on response is studied and presented in detail.

Green Manufacturing - Textured Novel Cutting Tool for Sustainable Machining: A Review

2020 ◽  
Vol 899 ◽  
pp. 135-143
Author(s):  
Awais Farooqi ◽  
Nukman bin Yusoff
Keyword(s):  
Sustainable Manufacturing ◽  
Cutting Tools ◽  
Minimum Quantity Lubrication ◽  
Green Manufacturing ◽  
Machining Process ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Nano Fluid ◽  
Prime Objective ◽  
Removal Processes

Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

scholarly journals Optimization of Process Parameter of Surface Grinding Process of Autenitic Stainless Steel (AISI 304) BY Taguchi Method

2019 ◽  
pp. 72-76
Author(s):  
M. A. Deore ◽  
R. S Shelke
Keyword(s):  
Taguchi Method ◽  
Feed Rate ◽  
Metal Removal ◽  
Removal Rate ◽  
Surface Grinding ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Grinding Process ◽  
Machining Processes

The manufacturing process of surface grinding has been established in the mass production of slim, rotationally symmetrical components. Due to the complex set-up, which results from the large sensitivity of this grinding process to a multiplicity of geometrical, kinematical and dynamical influence parameters, surface grinding is rarely applied within limited-lot production. The substantial characteristics of this grinding process are the simultaneous guidance and machining of the work piece on its periphery. Surface grinding is an essential process for final machining of components requiring smooth surfaces and precise tolerances. As compared with other machining processes, grinding is costly operation that should be utilized under optimal conditions. Although widely used in industry, grinding remains perhaps the least understood of all machining processes. The proposed work takes the following input processes parameters namely Work speed, feed rate and depth of cut. The main objective of this work is to predict the grinding behavior and achieve optimal operating processes parameters. a software package may be utilized which integrates these various models to simulate what happens during surface grinding processes. predictions from this simulation will be further analyzed by calibration with actual data. It involves several variables such as depth of cut, work speed, feed rate, chemical composition of work piece, etc. The main objective in any machining process is to maximize the Metal Removal Rate (MRR) and to minimize the surface roughness (Ra). In order to optimize these values Taguchi method, ANOVA and regression analysis is used.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Modeling of Self-Induced Vibrations that Occur During the Machining Process of Casting Patterns with the Use of The Fuzzy-Neural Networks Method

2013 ◽  
Vol 58 (3) ◽  
pp. 871-875
Author(s):  
A. Herberg
Keyword(s):  
Neural Networks ◽  
Control System ◽  
Network Structure ◽  
Fuzzy Systems ◽  
Fuzzy Neural Networks ◽  
Cnc Machining ◽  
Machining Process ◽  
Modeling Process ◽  
Fuzzy Neural ◽  
Takagi Sugeno

Abstract This article outlines a methodology of modeling self-induced vibrations that occur in the course of machining of metal objects, i.e. when shaping casting patterns on CNC machining centers. The modeling process presented here is based on an algorithm that makes use of local model fuzzy-neural networks. The algorithm falls back on the advantages of fuzzy systems with Takagi-Sugeno-Kanga (TSK) consequences and neural networks with auxiliary modules that help optimize and shorten the time needed to identify the best possible network structure. The modeling of self-induced vibrations allows analyzing how the vibrations come into being. This in turn makes it possible to develop effective ways of eliminating these vibrations and, ultimately, designing a practical control system that would dispose of the vibrations altogether.

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