Modelling and Optimization of Tool Chip Interface Temperature and Surface Roughness in CNC Dry Turning of EN 24 Steel

2016 ◽  
Vol 16 ◽  
pp. 7-15 ◽  
Author(s):  
Nirmal Kumar Mandal ◽  
Tanmoy Roy
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Work Piece ◽  
Substantial Impact

Abstract. Kinetic energy of a machining process is converted into heat energy. The generated heat at cutting tool and work piece interface has substantial impact on cutting tool life and quality of the work piece. On the other hand, development of advanced cutting tool materials, coatings and designs, along with a variety of strategies for lubrication, cooling and chip removal, make it possible to achieve the same or better surface quality with dry or Minimum Quantity Lubrication (MQL) machining than traditional wet machining. In addition, dry and MQL machining is more economical and environment friendly. In this work, 20 no. of experiments were carried out under dry machining conditions with different combinations of cutting speed, feed rate and depth of cut and corresponding cutting temperature and surface roughness are measured. The no. of experiments is determined through Design of Experiments (DOE). Nonlinear regression methodology is used to model the process using Response Surface Methodology (RSM). Multi-objective optimization is carried using Genetic Algorithm which ensures high productivity with good product quality.

scholarly journals Surface Roughness Values of Magnesium Alloy AZ31 When Turning by Using Rotary Cutting Tool

INSIST ◽  
2016 ◽  
Vol 1 (1) ◽  
pp. 54
Author(s):  
Gusri Akhyar ◽  
Suryadiwansa Harun ◽  
Arinal Hamni
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machined Surface ◽  
Rotary Cutting

Abstract - Magnesium and magnesium alloys is one of materials that worldwide used on automotive components due to very good  strength to weight ratio, resistant to corrosion, lighter compare to steel materials. Other than that magnesium has an advantage in easy to form and good machinability.  Nevertheless, magnesium known as metal which is easy to burned because of magnesium has low melting point. To maintain magnesium from burning quickly when proses machining, it needs to use coolant or lubricant to reduce temperature. Using of coolant when machining process can reduce temperature on cutting tool and work piece material, while using of lubricant can reduce friction between the cutting tool and work piece mateial. However, using of coolant and lubricant can harm for the environment and also coolant difficult to destroyed. Therefore, an alternative method to reduce the temperature when machining of magnesium alloy is using  the rotary cutting tool system. In the rotary cutting tool system, the cutting tool has a time to experience cooling in the period time. Other than aspect of temperature, surface roughness values are representative of surface of quality of produced componens. In this research, surface roughness value of magnesium alloy of AZ31 observed in ranges of work piece cutting speed of  (Vw) 25, 50, 120, 160, 200 m/min, rotary cutting speed of (Vt) 25, 50, 75 m/min, feed rate of (f) 0,05  and 0,10 mm/rev, and depth of cut of 0.2 mm. The turning process was done by using two kinds of diameter of rotary cutting tools are 16 and 20 mm, and without applying of coolant. The results of the research showed that the minimum surface roughness value of machined surface was 0,62𝝻m by using insert with diameter of 16 mm, while the maximum surface roughness value of machined surface was 2,86 𝝻m by using insert with diameter of 20 mm. This result stated that the increase in the diameter of rotary cutting tool gives a significant effect on the produced surface roughness value. Factor of feed rate also gives a significant contribution on the surface roughness value of machined magnesium surface.  The increase in feed rate generated significantly surface roughness value as long as the trials experiments. The produced surface roughness values inversely proportional to the cutting speed of rotary cutting tool.Keywords - magnesium, rotary tool, surface roughness, turning. 

Surface integrity in laser-assisted machining of Ti6Al4V

2020 ◽  
pp. 095440622097825
Author(s):  
O Kalantari ◽  
MM Fallah ◽  
F Jafarian ◽  
SR Hamzeloo
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Laser Source ◽  
Depth Of Cut ◽  
Thermal Source ◽  
Laser Assisted Machining

In laser-assisted machining (LAM), the laser source is focused on the workpiece as a thermal source and locally increases the workpiece temperature and makes the material soft ahead of the cutting tool so using this method, the machining forces are reduced, which causes improving the surface quality and cutting tool life. Machinability of advanced hard materials is significantly low and conventional methods do not work effectively. Therefore, utilizing an advanced method is inevitable. The product life and performance of complex parts of the leading industry depends on surface integrity. In this work, the surface integrity features including microhardness, grain size and surface roughness (Ra) and also the maximum cutting temperature were investigated experimentally in LAM of Ti-6Al-4V. According to the results, cutting speed has inverse effect on the effectiveness of LAM process because with increasing speed (15 to 63 m/min), temperature decreases (524 °C to 359 °C) and surface roughness increases (0.57 to 0.71 μm). Enhancing depth of cut and feed has direct effect on the process temperature, grain size, microhardness and surface roughness.

Fuzzy Modeling of Surface Roughness Parameters in Machining Ti-6Al-4V Alloy

2015 ◽  
Vol 766-767 ◽  
pp. 681-686 ◽  
Author(s):  
J. Nithyanandam ◽  
K. Palanikumar ◽  
Sushil Laldas
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Fuzzy Modeling ◽  
Depth Of Cut ◽  
Work Piece ◽  
Nose Radius

Titanium alloys are attractive materials used in different engineering applications, due to its excellent combination of properties such as high strength to weight ratio, good corrosion resistance and high temperature applicability. They are also being used increasingly in chemical process, automotive, biomedical and nuclear plant. When machining of Titanium alloys with traditional tools the tool wear rate high. Because of high chemical reactivity and low modulus of elasticity resulting high cutting temperature and strong adhesion between the tool and work piece materials. The poly crystalline diamond (PCD) cutting tool is used for the turning experiment. The turning parameters for the experimental work are cutting speed, feed, nose radius, and depth of cut. From the results, analysis of the influences of the individual parameters on the surface roughness have been carried out. Fuzzy modeling technique is effectively used to predict the surface roughness in the machining of titanium alloy.

scholarly journals Experimental Investigation of Nano Fluid in Machining Process to Enhance the Performance

2021 ◽  
Vol 9 (VII) ◽  
pp. 1940-1944
Author(s):  
Gaurav Tandekar
Keyword(s):  
Surface Roughness ◽  
Sodium Dodecyl ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Nano Fluid ◽  
Machining Parameter

The surface roughness is paying a very dominant role in manufacturing industries. It is one of the parameters that cannot be avoided in machining process. Investigation was done on turning titanium alloy grade 2 with uncoated carbide insert in a CNC lathe. During machining on titanium, the high cutting temperature found, because of that friction in tool causes, for that purpose we are carry more cutting fluid, cutting tool & actual machining parameter. The present work shows the concentration of multi-walled carbon nanotube (MWCNT) & Graphene nano-particles are in used. The Nano fluid is prepared by using various ratios of nano-particles (MWCNT & Graphene), rice bran oil and blended oil as a base fluid. sodium dodecyl benzene sulfonate (SDBS) Surfactant added in cutting-fluid to provide better lubricant properties. The statistical planning of the experiment is done by using Taguchi method. The process parameters considered in the study are cutting speed, feed rate, depth of cut and surface roughness is considered as a response parameter.

Contribution of Factors such as Machining Parameters, MQL Nozzle Orientation (Angle & Distance) and MQL Nano-Fluid Type on Surface Finish of Turned Steel Work-Pieces Using DOE Approach

2021 ◽  
Vol 1019 ◽  
pp. 181-193
Author(s):  
Miriyala Veerabhadrarao ◽  
Bhushan T. Patil ◽  
Vasim A. Shaikh ◽  
D.S.S. Sudhakar
Keyword(s):  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Orientation Angle ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Nozzle Orientation

Study of input factors play a vital role in controlling of process responses such as surface finish, cutting temperature, energy consumption etc. in machining process. Design of Experiment (DOE) is one such tool used by researchers to identify the key factors and levels and optimize the process.An attempt was made to identify and experiment turning of AISI 4340 steel using 6 factors viz. cutting speed, feed rate, depth of cut, MQL nozzle orientations (distance from the cutting tool-chip interface, nozzle angle) and different cutting fluid (Coolant). The response variable selected for study was surface roughness of the work-piece which needed to fit criteria smaller-the-better. L25 Orthogonal Array-OA design was selected for 6 factors and 5 levels. Comparison of results of average responses of different levels of factors, analysis of variance (ANOVA) of the process is detailed. Experimental results showed that the key contributors in the turning process are due to cutting speed, feed and depth of cut covering from 12% to 40%. The major contributor to the process was the cutting speed. Selection of MQL fluids and nozzle orientation contributed to 10% showing least significance.This experiment helps us to understand the importance of machine cutting conditions as key success factors which can be assisted with MQL fluids and other input factors.

Deep Hole Machining with a Small Diameter Drill and Ultrasonic Vibration

2017 ◽  
Vol 749 ◽  
pp. 107-110
Author(s):  
Yuta Masu ◽  
Tomohito Fukao ◽  
Taiga Yasuki ◽  
Masahiro Hagino ◽  
Takashi Inoue
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Small Diameter ◽  
Maximum Amplitude ◽  
Depth Of Cut ◽  
Deep Hole ◽  
Work Material ◽  
Finished Surface

The method of imparting ultrasonic vibration to the cutting tool is known to improve the shape accuracy and finished surface roughness. However, a uniform evaluation of this function in drilling has not been achieved, and the cutting process cannot be checked from the outside. The aim of this study is to investigate the cutting characteristics in deep hole drilling when an ultrasonic vibrator on the table of a machining center provides vibration with a frequency of 20 kHz to the work piece. The ultrasonic vibrations in this system reach the maximum amplitude in the center of the work material. We evaluated the change in finished surface roughness between the section where drilling starts to the point of maximum amplitude with ultrasonic vibration. The main cutting conditions are as follows: cutting speed (V) 12.6 (mm/min); feed rate (s) 30, 60 (mm/rev); depth of cut (t) = 32 (mm); work material, tool steel; cutting tool material, HSS; point angle (σ) 118 (°); and drill diameter (φ) 4 (mm). Lubricant powder was also added to clarify the cutting effect, and compared the condition in which there was no ultrasonic vibration. The results showed that surface roughness at the point of maximum amplitude was better than that with no vibration.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Experimental Determination of Optimal Speeds for Alloy Steels in Plane Turning

2008 ◽  
Author(s):  
T. Srikanth ◽  
V. Kamala
Keyword(s):  
Surface Roughness ◽  
Force Measurement ◽  
Cutting Speed ◽  
Vital Role ◽  
The Other ◽  
Depth Of Cut ◽  
Work Piece ◽  
Material Interface ◽  
Alloy Steels

In machining, speeds play vital role. The operator should know exactly the speed at which machining should be performed to get the required surface finish. In this paper, an attempt is made to determine the optimal cutting speed for machining of alloy steels. Three work piece materials having different hardness are taken and machined using a round nose tool with a coated tip. The tool dynamometer is attached to the tool post for force measurement. Turning operation on the work piece is performed on lathe at four different speeds, keeping the feed and depth of cut constant. Cutting forces acting on the tool, temperature at the tool and material interface are recorded. Power consumed being determined by a wattmeter and surface roughness values are measured. The same procedure is repeated for the other two work-pieces materials and optimal speeds for machining are determined for the three specimens. The results obtained are compared with the theoretical values and found to be very close.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

Low Cost Vibration Measurement and Optimization during Turning Process

2018 ◽  
Vol 1148 ◽  
pp. 103-108 ◽  
Author(s):  
N.V.S. Shankar ◽  
A. Gopi Chand ◽  
K. Hanumantha Rao ◽  
K. Prem Sai
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Low Cost ◽  
Machining Process ◽  
Vibration Measurement ◽  
Depth Of Cut ◽  
Turning Process ◽  
Taguchi Analysis ◽  
Series Of Experiments

During machining any material, vibrations play a major role in deciding the life of the cutting tool as well as machine tool. The magnitude acceleration of vibrations is directly proportional to the cutting forces. In other words, if we are able to measure the acceleration experienced by the tool during machining, we can get a sense of force. There are many commercially available, pre-calibrated accelerometer sensors available off the shelf. In the current work, an attempt has been made to measure vibrations using ADXL335 accelerometer. This accelerometer is interfaced to computer using Arduino. The measured values are then used to optimize the machining process. Experiments are performed on Brass. During machining, it is better to have lower acceleration values. Thus, the first objective of the work is to minimize the vibrations. Surface roughness is another major factor which criterion “lower is the better” applies. In order to optimize the values, a series of experiments are conducted with three factors, namely, tool type (2 levels), Depth of cut (3 levels) and Feed are considered (3 levels). Mixed level optimization is performed using Taguchi analysis with L18 orthogonal array. Detailed discussion of the parameters shall be given in the article.

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