Analysis of Main Optimization Techniques in Predicting Surface Roughness in Metal Cutting Processes

2012 ◽  
Vol 217-219 ◽  
pp. 2171-2182 ◽  
Author(s):  
Eva M. Rubio ◽  
María Villeta ◽  
Adolfo J. Saá ◽  
Diego Carou
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Industrial Sector ◽  
Optimization Techniques ◽  
Machining Parameters ◽  
Future Trends ◽  
Advantages And Disadvantages ◽  
Adequate Information ◽  
Cutting Processes

This paper collects the main methodologies and tools employed for predicting the surface roughness. The goal of this work is to provide compact and adequate information that could be useful in metal cutting industries to select the techniques and optimization tools that best suit to their needs and particular requirements. Each approach, with its advantages and disadvantages, is outlined and the present and future trends are discussed. As result, a quick guide for using practitioners of mentioned industrial sector is provided in form of tables that relate: machining parameters, cutting tool properties, workpiece properties and cutting phenomena with the different techniques and optimization tools usually employed to analyze the different parameters and phenomena involved in the process of surface roughness generation.

scholarly journals Optimization of Grinding Parameters for Minimum Surface Roughness by Taguchi Parametric Optimization Technique

2012 ◽  
pp. 265-269
Author(s):  
Deepak Pal ◽  
Ajay Bangar ◽  
Rajan Sharma ◽  
Ashish Yadav
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Optimization Technique ◽  
Grinding Wheel ◽  
Machining Parameters ◽  
Cylindrical Grinding ◽  
Optimal Surface ◽  
Optimal Values ◽  
Grinding Machine ◽  
Cutting Processes

Cylindrical grinding is one of the important metal cutting processes used extensively in the finishing operations. Surface finish is the important output responses in the production with respect to quantity and quality respectively. The Experiments are conducted on universal tool and cutter grinding machine with L9 Orthogonal array with input machining variables as work speed, grinding wheel grades and hardness of material. The developed model can be used by the different manufacturing firms to select right combination of machining parameters to achieve an optimal surface roughness (Ra).The results reveals surface roughness (Ra).The predicted optimal values for Ra for Cylindrical grinding process is 1.07 Ra respectively. The results are further confirmed by conducting confirmation experiments.

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.

Parametric Optimization in Drilling Operation Using Response Surface Approach

2016 ◽  
Vol 1137 ◽  
pp. 117-131
Author(s):  
Kamaljit Singh Boparai ◽  
Sandeep Singh ◽  
Amritpal Singh
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Metal Cutting ◽  
Parametric Optimization ◽  
Machining Parameters ◽  
Surface Approach ◽  
Contour Plots ◽  
Cutting Processes

Modeling and optimization of machining parameters are the indispensable elements in modern metal cutting processes. The present study realize the interaction of drilling input process parameters such as spindle speed, feed rate and number of holes and their influence on the surface roughness, diameter and position of hole obtained in drilling of mild steel. The contour plots were generated to highlights the interaction of process parameters as well as their effect on responses. An empirical model of surface roughness, diameter and position of hole was developed using response surface methodology (RSM). The model fitted and measured values were quite close, which indicates that the developed models can be effectively used to predict the respective response. The process parameters are optimized using desirability-based approach response surface methodology.

Comparative Analysis between Conventional and Dry Turning

2017 ◽  
Vol 261 ◽  
pp. 267-274
Author(s):  
Pantelis N. Botsaris ◽  
Chaido Kyritsi ◽  
Dimitris Iliadis
Keyword(s):  
Experimental Data ◽  
Surface Roughness ◽  
Cutting Tool ◽  
Spindle Motor ◽  
Air Cooling ◽  
Machining Parameters ◽  
Turning Process ◽  
Dry Cutting ◽  
Cold Air ◽  
Cooling And Lubrication

In this paper, there is an attempt to monitor and evaluate machining parameters when turning 34CrNiMo6 material under different cooling and lubrication conditions. The machining parameters concerned are temperature of the cutting tool and the workpiece, level of vibrations of the cutting tool, surface roughness of the workpiece, noise levels of the turning process and current drawn by the main spindle motor. Four different experimental machining scenarios were completed, specifically: conventional wet turning process, dry cutting and two additional modes employing cooling by cold air. Experimental data were acquired and recorded by an optimally designed network of sensors. Experimental data were statistically analyzed in order to reach conclusions. According to the research that has been done, although, overall, minimum cutting tool and workpiece temperatures were observed under wet machining, cold air cooling is capable of achieving comparable cooling results to wet machining. The lowest values of surface roughness were achieved by wet machining, whereas the lowest level of cutting tool vibrations were observed under cold air cooling.

Grey-Based Taguchi Analysis Approach for Optimization of Multi-Objective Problem

2014 ◽  
pp. 219-239
Author(s):  
Nirmal S Kalsi ◽  
Rakesh Sehgal ◽  
Vishal S. Sharma
Keyword(s):  
Feed Rate ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Removal Rate ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Multi Objective ◽  
Analysis Technique ◽  
Grey Relation

Due to the increase in complexity and expectations of more reliable solutions for a problem, the importance of multi-objective problem solutions is increasing day by day. It can play a significant role in making a decision. In the present approach, many combinations of the optimization techniques are proposed by the researchers. These hybrid evolutionary methods integrate positive characteristics of different methods and show the advantage to reach global optimization. In this chapter, Taguchi method and the GRA (Grey Relation Analysis) technique are pronounced and used to optimize a multi-objective metal cutting process to yield maximum performance of tungsten carbide-cobalt cutting tool inserts in turning. L18 orthogonal array is selected to analyze the effect of cutting speed, feed rate, and depth of cut using cryogenically treated and untreated inserts. The performance is evaluated in terms of main cutting force, power consumption, tool wear, and material removal rate using main effect plots of S/N (Signal to Noise) ratios. This chapter indicates that the grey-based Taguchi technique is not only a novel, efficient, and reliable method of optimization, but also contributes to satisfactory solution for multi-machining objectives in the turning process. It is concluded that cryogenically treated cutting tool inserts perform better. However, the feed rate affects the process performance most significantly.

scholarly journals Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 9 ◽  
Author(s):  
Andrzej Matras
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Laser Scanning ◽  
Cutting Tool ◽  
Scanning Speed ◽  
Milling Process ◽  
Face Milling ◽  
Machining Parameters ◽  
The Face ◽  
Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

scholarly journals Prediction of Surface Roughness When End MillingTi6Al4VAlloy Using Adaptive Neurofuzzy Inference System

2013 ◽  
Vol 2013 ◽  
pp. 1-12
Author(s):  
Salah Al-Zubaidi ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
End Milling ◽  
Cutting Tools ◽  
Computing Methods ◽  
Milling Process ◽  
Dry Cutting ◽  
Inference System ◽  
Cutting Processes ◽  
Adaptive Neurofuzzy Inference System

Surface roughness is considered as the quality index of the machine parts. Many diverse techniques have been applied in modelling metal cutting processes. Previous studies have revealed that artificial intelligence techniques are novel soft computing methods which fit the solution of nonlinear and complex problems like metal cutting processes. The present study used adaptive neurofuzzy inference system for the purpose of predicting the surface roughness when end millingTi6Al4Valloy with coated (PVD) and uncoated cutting tools under dry cutting conditions. Real experimental results have been used for training and testing ofANFISmodels, and the best model was selected based on minimum root mean square error. A generalized bell-shaped function has been adopted as a membership function for the modelling process, and its numbers were changed from 2 to 5. The findings provided evidence of the capability ofANFISin modelling surface roughness in end milling process and obtainment of good matching between experimental and predicted results.

scholarly journals Machine tool vibration on dimensional accuracy and surface roughness during milling operation of Al6082 with indexable carbide inserts

2020 ◽  
Vol 18 (2) ◽  
Author(s):  
Paramesh Chamble ◽  
M. R. Bharath ◽  
K. Lokeshaa ◽  
S. Christopher Ezhil Singh
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Dimensional Accuracy ◽  
Eutectic Phase ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Tool Vibration ◽  
Milling Operation ◽  
Carbide Inserts

In this research paper, machining tool vibration occurs because of relative motion between the work piece and the cutting tool, which influences the surface finish of the machined part and the lifespan of the cutting tool. Some of the parameters that influence machining tool vibration include feed rate, depth of cut and spindle speed. In this study, experimentation is carried out on a conventional vertical milling machine to investigate the influence of machining tool vibration on surface roughness during face milling operation of Al6082 alloy with indexable carbide inserts. The eutectic phase for joint of Al6082 is β-Al5FeSi eutectic phase. The machining is done in dry condition under the different combinations of Machining parameters designed through Taguchi L9 orthogonal array. The machining tool vibrations are captured with the help of tri-axial accelerometer. Analysis of variance (ANOVA) technique used to formulate the experimental data to analyze the effect of each parameter and machining tool vibration on surface roughness.

scholarly journals Tool Wear Rate Prediction by using Optimization Techniques

2019 ◽  
Vol 9 (2) ◽  
pp. 1271-1277
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

Study of Cutting Force and Surface Roughness on Drilling Stainless Steel 316L under Various Coolant Condition

2018 ◽  
Vol 791 ◽  
pp. 116-122
Author(s):  
K. Kamdani ◽  
A.A. Hamsah ◽  
N.H. Rafai ◽  
M.Z. Rahim ◽  
C.K. Wong ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Force ◽  
Metal Cutting ◽  
Thrust Force ◽  
Helix Angle ◽  
Industrial Sector ◽  
Stainless Steel 316L ◽  
High Tendency ◽  
Drilling Condition

Drilling is the metal cutting process that are widely used in industrial sector such as in aerospace, automotive and manufacturing to produce a various of durable parts. Stainless steels in general are regarded as difficult to machine materials due to their high tendency to work harden; their toughness and relatively low thermal conductivity. In this research, the experimental setup for the effect of various parameters on drill performance in term of cutting force and surface roughness. Stainless steel 316L used as workpiece and uncoated tungsten carbide drill bit as the tool. From the experimental investigation, the results show that internal coolant with helix angle of 40 and feed rate of 0.1 mm/rev condition is the best drilling condition in term of thrust force and surface roughness. By observation on experiment, MQL coolant condition give highest thrust force while internal coolant is best condition to have most minimum force. For internal coolant, MQL and external supply, the optimum helix angle to obtain low surface roughness is 15° and 40°.

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