scholarly journals Effect of Machining Parameters in Milling Aluminum Alloy 7075-T6 under MQL Condition

2019 ◽  
Vol 9 (2) ◽  
pp. 109-113
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Aluminum Alloy 7075

Minimum quantity lubrication (MQL) is an eco-friendly method, where a small amount of fluid was sprayed to cutting edge in mist form with the aid of the air. The foregoing studies revealed that inappropriate machining parameters without the assistance of the cutting fluid methods became a major challenge in milling aluminum alloy 7075-T6. The paper presents the findings of the experimental work to assess the effect of machining parameters towards cutting tool life and machined surface roughness in milling aluminum alloy 7075-T6 at high cutting speed under MQL condition. An eight-run experiment was designed according to full factorial design based upon two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analyzed employed ANOVA to determine the significant machining parameters. The cutting tool life and machined surface roughness were assigned by the rejection criterion of tool flank wear in the milling operation. The optical microscope and portable surface roughness tester were applied to analyze tool wear and average surface roughness value. Cutting speed and feed rate were significantly contributing to the tool life and surface roughness. The longest tool lifespan of 20.14 minutes and lowest surface roughness value of 0.569 µm were obtained at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter which are 0.12 mm/tooth and 1.40 mm.

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.

Optimization of Surface Roughness by Using Different Cutting Tools for Aluminum Alloy 6063

2020 ◽  
Vol 17 (2) ◽  
pp. 961-966
Author(s):  
Allina Abdullah ◽  
Afiqah Azman ◽  
B. M. Khirulrizwan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Optimum Parameter ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Numerical Control ◽  
Depth Of Cut

This research outlines an experimental study to determine the optimum parameter of cutting tool for the best surface roughness (Ra) of Aluminum Alloy (AA) 6063. For the experiment in this research, cutting parameters such as cutting speed, depth of cut and feed rate are used to identify the effect of both cutting tools which are tungsten carbide and cermet towards the surface roughness (Ra) of material AA6063. The machining operation involved to cut the material is turning process by using Computer Numerical Control (CNC) Lathe machine. The experimental design was designed by Full Factorial. The experiment that had been conducted by the researcher is 33 with 2 replications. The total number of the experiments that had been run is 54 runs for each cutting tool. Thus, the total number of experiments for both cutting tools is 108 runs. ANOVA analysis had been analyzed to identify the significant factor that affect the Ra result. The significant factors that affect the Ra result of AA6063 are feed rate and cutting speed. The researcher used main effect plot to determine the factor that most influenced the surface roughness of AA6063, the optimum condition of surface roughness and the optimum parameter of cutting tool. The factor that most influenced the surface roughness of AA6063 is feed rate. The optimum condition of surface roughness is at the feed rate of 0.05 mm/rev, cutting speed of 600 rpm and depth of cut of 0.10 mm. While the optimum parameter of cutting tool is cermet insert with the lowest value of surface roughness (Ra) result which is 0.650 μm.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Effects of Cutting Speed and Feed Rate on Surface Roughness in Hard Turning of AISI 4140 with Mixed Ceramic Cutting Tool

2018 ◽  
Vol 779 ◽  
pp. 153-158
Author(s):  
Phacharadit Paengchit ◽  
Charnnarong Saikaew
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machined Surface ◽  
Data Set ◽  
Ceramic Cutting Tool ◽  
Aisi 4140 ◽  
Mixed Ceramic

This work investigated the influences of cutting speed and feed rate on surface roughness in hard turning of AISI 4140 chromium molybdenum steel bar using mixed ceramic inserts Al2O3+TiC under dry condition for automotive industry applications. Turning experiments were conducted by varying cutting speed ranging from 150 to 220 m/min and feed rate ranging from 0.06 to 1 mm/rev. General factorial design was used to analyze the data set of surface roughness and determine statistically significant process factors based on analysis of variance results. The results showed that average surface roughness was significantly affected by feed rate and interaction between cutting speed and feed rate at the level of significance of 0.05. An optimal operating condition for hard turning of AISI 4140 with the ceramic cutting tool that produced a minimum machined surface roughness was obtained at cutting speed of 220 m/min and 0.06 mm/rev.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

scholarly journals PENENTUAN KECEPATAN PEMOTONGAN EFEKTIF BERDASARKAN NILAI KEKASARAN PERMUKAAN MATERIAL AA-7075 PADA PROSES FACE MILLING

POROS ◽  
2021 ◽  
Vol 17 (1) ◽  
pp. 51
Author(s):  
Sobron Y. Lubis ◽  
Rosehan Rosehan ◽  
Musa Law
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Tooth Development ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Parameters ◽  
Aa 7075 ◽  
Aluminum Alloy 7075

During face milling machining, several machining parameters such as feed rate and cuttingspeed determine the surface quality of the workpiece produced by the process. The selection of the rightparameters will lead to the surface quality as planned. Therefore, to improve machining effectiveness, amethod is needed to determine the appropriate machining parameters to produce the desired surfacequality. This research was conducted using a milling machine, five variations of cutting speed and fivevariations of feed rate were used to cut the workpiece aluminum alloy 7075. After machining, the surfaceroughness was measured using a surface test. The surface roughness value is then substituted into thefeed rate equation and effective cutting speed. By finding effective cutting parameters, the machiningprocess will be more efficient and effective without using unnecessary resources. From the results of thestudy note that the development equation to determine the feed rate based on the value of surfaceroughness is ???? = 0,6????√???? ????????0.443mm/tooth. Development equation to determine the effective cutting speedbased on Surface roughness value is ???????? = 3.0686????????0.124 mm/min

scholarly journals Optimisation of Cutting Fluid Concentration and Operating Parameters based on RSM for Turning Ti–6Al–4V

2021 ◽  
Author(s):  
Salah Gariani ◽  
Mahmoud Elsayed ◽  
Islam Shyha
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Feed Rate ◽  
Linear Models ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Operating Parameters ◽  
Cutting Condition ◽  
Fluid Concentration

Abstract The paper details experimental and optimisation results for the effect of cutting fluid concentration and operating parameters on the average surface roughness (Ra) and tool flank wear (VB) when flooded turning of Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. Cutting fluid concentration, cutting speed, feed rate and cutting tool were the control variables. Response Surface Methodology (RSM) was employed to develop an experimental design and optimise Ra and VB using linear models. The study revealed that cutting fluid concentration has a little influence on Ra and VB performance while Ra was strongly affected by feed rate and cutting tool type. The developed empirical model also suggested that the best parameters setting to minimise Ra and VB are 5%, 58 m/min, 0.1 mm/rev for cutting fluid concentration, cutting speed and feed rate, respectively, using H13A tool. At this setting, the predicted surface roughness and tool wear were 0.48 and 30 µm, respectively. In the same vein, tool life and micro-hardness tests were performed at the suggested optimum cutting condition with different cutting speeds. A notable decrease in tool life (82.3%) was obtained when a higher cutting speed was used.

scholarly journals Optimization and Analysis of Surface Roughness, Flank Wear and 5 Different Sensorial Data via Tool Condition Monitoring System in Turning of AISI 5140

Sensors ◽  
2020 ◽  
Vol 20 (16) ◽  
pp. 4377 ◽  
Author(s):  
Mustafa Kuntoğlu ◽  
Abdullah Aslan ◽  
Hacı Sağlam ◽  
Danil Yurievich Pimenov ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Feed Rate ◽  
Cutting Speed ◽  
Tool Condition Monitoring ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
Machining Parameters ◽  
Tool Condition ◽  
Condition Monitoring System

Optimization of tool life is required to tune the machining parameters and achieve the desired surface roughness of the machined components in a wide range of engineering applications. There are many machining input variables which can influence surface roughness and tool life during any machining process, such as cutting speed, feed rate and depth of cut. These parameters can be optimized to reduce surface roughness and increase tool life. The present study investigates the optimization of five different sensorial criteria, additional to tool wear (VB) and surface roughness (Ra), via the Tool Condition Monitoring System (TCMS) for the first time in the open literature. Based on the Taguchi L9 orthogonal design principle, the basic machining parameters cutting speed (vc), feed rate (f) and depth of cut (ap) were adopted for the turning of AISI 5140 steel. For this purpose, an optimization approach was used implementing five different sensors, namely dynamometer, vibration, AE (Acoustic Emission), temperature and motor current sensors, to a lathe. In this context, VB, Ra and sensorial data were evaluated to observe the effects of machining parameters. After that, an RSM (Response Surface Methodology)-based optimization approach was applied to the measured variables. Cutting force (97.8%) represented the most reliable sensor data, followed by the AE (95.7%), temperature (92.9%), vibration (81.3%) and current (74.6%) sensors, respectively. RSM provided the optimum cutting conditions (at vc = 150 m/min, f = 0.09 mm/rev, ap = 1 mm) to obtain the best results for VB, Ra and the sensorial data, with a high success rate (82.5%).

scholarly journals Optimisation of cutting fluid concentration and operating parameters based on RSM for turning Ti–6Al–4V

2021 ◽  
Author(s):  
Salah Gariani ◽  
Mahmoud Ahmed El-Sayed ◽  
Islam Shyha
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Feed Rate ◽  
Linear Models ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Operating Parameters ◽  
Cutting Condition ◽  
Fluid Concentration

AbstractThe paper details experimental and optimisation results for the effect of cutting fluid concentration and operating parameters on the average surface roughness (Ra) and tool flank wear (VB) when flooded turning of Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. Cutting fluid concentration, cutting speed, feed rate, and cutting tool were the control variables. Response surface methodology (RSM) was employed to develop an experimental design and optimise Ra and VB using linear models. The study revealed that cutting fluid concentration has a little influence on Ra and VB performance, while Ra was strongly affected by feed rate and cutting tool type. The developed empirical model also suggested that the best parameters setting to minimise Ra and VB are 5%, 58 m/min and 0.1 mm/rev for cutting fluid concentration, cutting speed, and feed rate, respectively, using H13A tool. At this setting, the predicted surface roughness and tool wear were 0.48 and 30 μm, respectively. In the same vein, tool life and micro-hardness tests were performed at the suggested optimum cutting condition with different cutting speeds. A notable decrease in tool life (82.3%) was obtained when a higher cutting speed was used.

Surface Roughness after Machining and Influence of Feed Rate on Process

2013 ◽  
Vol 581 ◽  
pp. 341-347 ◽  
Author(s):  
Róbert Čep ◽  
Adam Janásek ◽  
Jana Petrů ◽  
Marek Sadilek ◽  
Petr Mohyla ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Longitudinal Direction ◽  
Structural Equations ◽  
Steel Grade ◽  
Height Profile ◽  
Machined Surface ◽  
Cut Surface

The aim of the work is find out influence of feed rate on the quality for the machined surface, especially surface roughness. The experiment was carried out by cutting tool HURCO VMXt30 with respect to the following cutting parameter: cutting speed 250; 350; 450; 550 and 850 m.min-1, feed 0,1; 0,5 and 1,0 mm/tooth. For testing was used two most common materials in the steel grade 1.1191 (12 050) and 1.2343 (19 552), and we chose two ordinary parameters of surface roughness; Ra - arithmetical mean roughness deviation and Rz - the largest inequalities height profile in the transverse direction and the longitudinal direction of machining. The structural equations will be the result which can describe the character depending on the cut surface parameters.

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