Studies on the Effect of Approach Angle and Process Parameters in Face Milling

2011 ◽  
Vol 110-116 ◽  
pp. 3147-3155
Author(s):  
Rao T. Sadasiva ◽  
K. Satyanarayana ◽  
Y. Praneeth ◽  
Anne Venu Gopal
Keyword(s):  
Tool Wear ◽  
Process Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Process Time ◽  
Depth Of Cut ◽  
Work Piece ◽  
Approach Angle ◽  
Taguchi Design Of Experiments ◽  
Coated Carbide

Milling is the most widely applied machining process for producing flat surfaces and prismatic shapes. To minimize the process time and maximize the quality of the workpiece, it is essential to monitor the condition of cutting tool in machining operation and to optimize the process parameters. In the present investigations, experiments were performed on EN31 steel with un-coated carbide inserts in face milling with tools having different approach angles in order to determine the performance of the tool. The effects of process parameters namely speed, depth of cut and feed on tool wear of work piece were investigated. The cutting forces and tool wear are measured in order to evaluate the performance of the cutter. Acoustic emission signal was used for the online tool monitoring. A statistical technique, Taguchi design of experiments was used to optimize the machining process parameters such as speed, feed, depth of cut and approach angle.

An investigation on formation of burrs during milling of aluminium alloy under wet condition

2020 ◽  
pp. 095440542097201
Author(s):  
Raj Sekhar Mandal ◽  
Santanu Das ◽  
Partha Pratim Saha
Keyword(s):  
Suitable Condition ◽  
Face Milling ◽  
Machining Process ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Burr Height ◽  
Cutting Velocity ◽  
Wet Condition ◽  
Exit Edge ◽  
Coated Carbide

Undesirable burrs are created out of a machining process. The objective of the present work is to explore the suitable condition to obtain no burr, or negligible burr, around the edge of a machined product at wet condition. Face milling experiments have been carried out on blocks made of aluminum alloy (Alloy-4600M) with a single, coated-carbide inserted cutter for observing the nature of burr formation. Depth of cut has been maintained constant at 3 mm for all sets of experiments. In each experiment set, three cutting velocities (170 m/min, 237 m/min and 339 m/min) and three in-plane exit angles of 30°, 60° and 90° are provided at three different feeds of 0.08 mm/tooth, 0.1 mm/tooth and 0.12 mm/tooth. First set of experiments are done without any exit edge bevel. Similar sets of experiments are carried out with 15° and 30° exit edge bevel angles to find out the condition for minimum burr. The bevel is made of a height of 3 mm. In the present experimental investigation, a minimum burr height of as low as 3 micron is obtained at an in-plane exit angle of 30° and exit edge bevel angle of 15° under the machining condition of 339 m/min cutting velocity and 0.1 mm/tooth feed.

scholarly journals Multi-Objective Process Parameter Optimization for Surface Roughness and Material Removal Rate in Face Milling of Al 6061 T6 Alloy

2019 ◽  
Vol 9 (2) ◽  
pp. 137-142
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Al 6061

This study uses Taguchi methodology and Gray Relational Analysis approach to explore the optimization of face milling process parameters for Al 6061 T6 alloy.Surface Roughness (Ra), Material Removal Rate (MRR) has been identified as the objective of performance and productivity.The tests were performed by selecting cutting speed (mm / min), feed rate (mm / rev) and cutting depth (mm) at three settings on the basis of Taguchi's L9 orthogonal series.The grey relational approach was being used to establish a multiobjective relationship between both the parameters of machining and the characteristics of results. To find the optimum values of parameters in the milling operation, the response list and plots are used and found to be Vc2-f1-d3. To order to justify the optimum results, the confirmation tests are performed.The machining process parameters for milling were thus optimized in this research to achieve the combined goals such as low surface roughness and high material removal rate on Aluminum 6061 t6.It was concluded that depth of cut is the most influencing parameter followed by feed rate and cutting velocity.

scholarly journals Optimization of Turning Process Parameters for Their Effect on En 8 Material Work piece Hardness by Using Taguchi Parametric Optimization Method

2012 ◽  
pp. 230-234
Author(s):  
Ashish Yadav ◽  
Ajay Bangar ◽  
Rajan Sharma ◽  
Deepak Pal
Keyword(s):  
Process Parameters ◽  
Tool Material ◽  
Optimization Method ◽  
Material Surface ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Turning Process ◽  
Cylindrical Parts ◽  
Coated Carbide

A common method to manufacture parts to a specific dimension involves the removal of excess material by machining operation with the help of cutting tool. Turning process is the one of the methods to remove material from cylindrical and non-cylindrical parts. In this work the relation between change in hardness caused on the material surface due the turning operation with respect to different machining parameters like spindle speed, feed and depth of cut have been investigated. Taguchi method has been used to plan the experiments and EN 8 metal selected as a work piece and coated carbide tool as a tool material in this work and hardness after turning has been measured on Rockwell scale. The obtained experimental data has been analyzed using signal to noise and. The main effects have been calculated and percentage contribution of various process parameters affecting hardness also determined.

Optimization of Machining Process Parameters Using Moora Method

2020 ◽  
Vol 402 ◽  
pp. 81-89
Author(s):  
Laxman B. Abhang ◽  
Mohd Iqbal ◽  
M. Hameedullah
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Cutting Force ◽  
Process Parameters ◽  
Machining Process ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Moora Method

A multi-response optimization is a popular tool in many economic, managerial, constructional, manufacturing, process design, product design technologies, machinery and system, devices, process parameters etc. This research paper demonstrates the application of a simple multi-objective optimization on the basis of ratio analysis (MOORA) method to solve the multi-criteria (objective) optimization problem in the machining process. In this paper, the chip-tool interface temperature, main cutting force, and tool wear rate were investigated in various machining conditions in turning operations. Various machining parameters, such as the cutting speed, feed rate, and depth of cut and effective tool inserts nose radius, were considered. Composite factorial design (24+8) was used for experimentation. Multiple response values were obtained using actual experimentation. By using these experiments, two different methods were proposed. Machining parameters were optimized by minimizing chip-tool interface temperatures, tool wear rate, and main cutting force during machining of alloy steel. The results obtained using the MOORA method almost agree with the grey relational analysis method which shows the authenticate applicability, potentiality, and flexibility of MOORA method for solving various complex decision-making problems in present-day manufacturing industries.

Empirical Expression of Tool Wear When Face Milling 416 SS

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Increase Tool Life ◽  
The Cost

During a machining process, cutting parameters must be taken into account, since depending on them the cutting edge starts to wear out to the point that tool can fail and needs to be change, which increases the cost and time of production. Since wear is a negative phenomenon on the cutting tool, due to the fact that tool life is reduced, it is important to optimize the cutting variables to be used during the machining process, in order to increase tool life. This research is focused on the influence of cutting parameters such as cutting speed, feed per tooth and axial depth of cut on tool wear during a face milling operation. The Taguchi method is applied in this study, since it uses a special design of orthogonal array to study the entire parameters space, with only few numbers of experiments. Also a relationship between tool wear and the cutting parameters is presented. For the studies, a martensitic 416 stainless steel was selected, due to the importance of this material in the machining of valve parts and pump shafts.

Evaluation of Forces, Tool Wear and Surface Finish During Orthogonal Machining AISI 1020 Steel in Three Cutting Environments

2013 ◽  
Author(s):  
Vishnu Vardhan Chandrasekaran ◽  
Lewis N. Payton
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
High Speed ◽  
Tool Material ◽  
High Speed Steel ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Average Roughness ◽  
Labview Software

A large statistically designed orthogonal tube turning experiment measuring the forces, tool wear and surface finish involved in machining of AISI 1020 steel under four different cutting environments. The environments studied were nitrogen and cold compressed air against dry machining. Each data run consisted of one minute cutting time at two different feeds of 0.002″/rev. and 0.004″/rev. at a constant depth of cut of 0.125″ width of cut using High speed steel tool material inserts. Post-mortem analysis was carried out under a Keyance microscope to evaluate the wear on the rake face. The cutting force and the thrust force are collected during the machining process with a dynamometer and the data is further processed using Labview software. The surface finish on the work piece after the cutting process is also evaluated based on the average roughness measurement taken from a contact type profilometer. The advantages of using such gaseous cutting fluids are discussed.

Investigation on Performance of a CVD Coated Carbide Tool in Face Milling of Ultra-High Strength Steel 30Cr3SiNiMoVA

2014 ◽  
Vol 800-801 ◽  
pp. 440-445
Author(s):  
Jin Bang Song ◽  
Chang Ying Wang ◽  
Lin Zan ◽  
Ming Chen
Keyword(s):  
Tool Wear ◽  
High Strength Steel ◽  
High Strength ◽  
Face Milling ◽  
Machining Process ◽  
Wear Process ◽  
Coated Tools ◽  
Ultra High Strength Steel ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Ultra-high strength steel 30Cr3SiNiMoVA is a typical difficult-to-cut material. During the machining process of 30Cr3SiNiMoVA, tool wear is an important factor which needs to be investigated seriously. In this work, one kind of CVD coated tools was used to investigate the tool wear mechanism of face milling of Ultra-high Strength Steel 30Cr3SiNiMoVA. Cutting forces during the wear process were measured with a kistler dyna-mometer. Surface roughness and tool wear evolution were determined.

An Enhanced Cutting Force Model for Face Milling With Variable Cutter Feed Motion and Complex Workpiece Geometry

1997 ◽  
Vol 119 (4A) ◽  
pp. 467-475 ◽  
Author(s):  
F. Gu ◽  
S. G. Kapoor ◽  
R. E. DeVor ◽  
P. Bandyopadhyay
Keyword(s):  
Face Milling ◽  
Boundary Representation ◽  
Model Verification ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Force Model ◽  
Two Dimensional ◽  
Radial Depth ◽  
Set Up

An enhanced model for the prediction of static cutting forces in face milling is presented. The key features of the model include the ability to handle complex work-piece geometry, two-dimensional cutter feed paths, multiple pass machining, and effects of machine set-up errors. A two-dimensional boundary representation scheme is used to describe the workpiece geometry which may contain holes, slots, and other complex geometrical features. Variable cutter feed paths are represented by a combination of linear and circular arcs. In view of this and the complex workpiece geometry, a new algorithm for cutter-workpiece engagement determination is developed. Several sources of machine set-up error such as spindle and cutter axis tilt, and cutter center offset runout are modeled and their individual as well as combined effects on key machining process variables such as the axial and the radial depth of cut illustrated. Results of model verification experiments are reported for different workpiece geometry and cutter feed paths. A comparison of the predicted and measured forces shows good agreement.

scholarly journals Pengaruh Kemiringan Benda Kerja dan Kecepatan Pemakanan terhadapGetaran Mesin Frais Universal Knuth UFM 2

MECHANICAL ◽  
2016 ◽  
Vol 7 (2) ◽  
Author(s):  
Romiyadi Romiyadi
Keyword(s):  
Process Parameters ◽  
Positive Impact ◽  
Milling Process ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Milling Machine ◽  
Vertical Milling ◽  
Study Results

In milling process with slope of workpiece, the milling process requires more energy from milling machine. The greater the slope of workpiece estimated to be the greater energyrequired by the milling machine. Therefore, the machining vibration that occurs was estimated to be very big. This study aimed to determine influence theslope of workpiece to machining vibration in milling machine with variations of feeding. This study used Milling Machine Knuth Universal UFM 2 with vertical milling approach. The slope of workpiece used was 300, 450 and 600.The machining process parameters varied was feeding while depth of cut and spindle speed were constant. The study results show that the greater the slope of work piece, the greater the machining vibration on the up milling process and the down milling processes for all slope of work piece. Similarly the influence of feeding to machining vibration in milling process. The study results show that the change of feeding will give a positive impact to machining vibration on the up milling process and the down milling processes. For same the slope of workpiece and feeding the machining vibration on the down milling process is greater than the up milling process.

Correlative Flank Wear Analysis of Single Point Turning Inserts Using Acoustic Emission and Artificial Intelligence Techniques

2008 ◽  
Author(s):  
R. Srinidhi ◽  
Vishal Sharma ◽  
M. Sukumar ◽  
C. S. Venkatesha
Keyword(s):  
Acoustic Emission ◽  
Tool Wear ◽  
Flank Wear ◽  
Machining Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Wear Analysis ◽  
Tools Wear ◽  
Coated Carbide ◽  
Ae Signals

Wear mechanism of a cutting tool is highly complex in that the processes of tool wear results from interacting effect of machining configurations. Various output generated by the study and analysis of each tool is extremely useful in analyzing the tool characteristics in general and to make efforts to obtain the estimated tool life in particular. The gradual process of tool wear has adverse influence on the quality of the surface generated and on the design specifications in the work piece dimensions and geometry, and causes, at the worst case, machine breakdown. Advanced manufacturing demands proper use of the right tool and emphasizes the need to check the wear rate. A scientific method of obtaining conditions for an optimal machining process with proper tools and control of machining parameters is essential in the present day manufacturing processes. Many problems that affect optimization are related to the diminished machine performance caused by worn out tools. One of the indirect methods of tool wear analysis and monitoring is based on the acoustic emission (AE) signals. The generation of the AE signals directly in the cutting zone makes them very sensitive to changes in the cutting process and provides a means of evaluating the wear of cutting tools. Wear parameters obtained in the process are analyzed with the output generated by using Multi Layer Perceptron (MLP) based back propagation technique and Adaptive Neuro Fuzzy Interference System (ANFIS). The results obtained from these methods are correlated for the actual and predicted wear. Experiments have been conducted on EN8 and, EN24 using Uncoated Carbide, Coated carbide and Ceramic inserts (Kennametal, India make) on a high speed lathe for the most appropriate cutting conditions. The AE signal analysis (considering signal parameters such as, ring down count (RDC), rise time (RTT), event duration (ED) and energy (EG). Flank wear in tools and corresponding cutting forces for each of the trials are measured and are correlated for various combinations of tools and materials of work piece.

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