Effect of Environmentally Conscious Machining on Machined Surface Quality

2013 ◽  
Vol 309 ◽  
pp. 35-42 ◽  
Author(s):  
Gyula Varga ◽  
János Kundrák
Keyword(s):  
Cutting Tools ◽  
Cutting Parameters ◽  
Helical Milling ◽  
Dry Machining ◽  
Production Environment ◽  
Machining Processes ◽  
Machined Surface ◽  
Environmentally Conscious ◽  
System A ◽  
Cylindricity Error

Modern machining processes continuously face cost pressures and high quality expectations. To remain competitive a company must continually identify cost reduction opportunities in production, exploit economic opportunities, and continuously improve production processes. A key technology that represents cost saving opportunities related to cooling lubrication, and simultaneously improves the overall performance of cutting operations, is dry machining. The elimination of coolants or significant reduction in cooling lubricants affects all components of a production system. A detailed analysis and adaptation of cutting parameters, cutting tools, machine tools and the production environment is mandatory to ensure an efficient process and successfully enable dry machining. Case study is shown for examination of cylindricity error and surface roughness of helical milling machined surfaces by environmentally conscious way.

Effects of Process Parameters on Surface Quality in Turning of Mild Steel with Rotary Cutting Tool

2012 ◽  
Vol 445 ◽  
pp. 137-142 ◽  
Author(s):  
Murat Kiyak ◽  
Erhan Altan
Keyword(s):  
Mild Steel ◽  
Tool Life ◽  
Contact Region ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Negative Effects ◽  
Machining Processes ◽  
Machined Surface ◽  
Inclination Angles ◽  
Rotary Cutting

In machining processes, great amount of the cutting energy transforms to heat energy. Tool life decreases and the quality of the machined surface changes by the effects of heat during machining. Many researches are being done on the reduction of the negative effects of the heat on the tool. In this respect, cutting fluids are used, but usages of them are limited because of their some harmfully effects to the environment. In order to reduce the tool wear and to use the tool longer, during cutting continuously variation of the contact region of the tool and the chip can been realized by using self-propelled rotary tools. The tool life is longer in rotary tools when compared with stationary cutting tools. In machining with these tools lower heat effect at the cutting edge is observed. In this study, the effects of cutting parameters on surface roughness of machined part has been investigated during the turning of mild steel using self-propelled rotary tools. In experiments, cutting tools which inclination angles were 20°, 30° and 45° and rake angles were 0° and-5° were used. Cutting speeds were taken as 60 m/min and 120m/min. RCMX insert with 32mm diameter was used. Feed were chosen as 0.1, 0.2 and 0.4 mm/rev and cutting depth was set at 0.25 mm.

Tool Wear Characters in Micro-Milling of Fully Sintered ZrO2 Ceramics by Diamond Coated End Mills

2012 ◽  
Vol 723 ◽  
pp. 365-370 ◽  
Author(s):  
Rong Bian ◽  
Eleonora Ferraris ◽  
Jun Qian ◽  
Dominiek Reynaerts ◽  
Liang Li ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Tools ◽  
Chemical Vapour ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Machined Surface ◽  
Coated Tools ◽  
Machined Surface Quality ◽  
Coating Delamination ◽  
End Mills

This work presents an experimental investigation on micro-milling of fully sintered Zirconia (ZrO2) by diamond coated tools. The experiments were conducted on a Kern MMP 2522 micro-milling centre and WC micro end mills, diamond coated by chemical vapour deposition (CVD) and of stiff geometry were employed as cutting tools. The effects of cutting parameters and milling time on tool wear were investigated. The results revealed that the tool wear characters included diamond coating delamination and wear of substrate WC. Both cutting forces and machined surface quality were affected by tool wear with the progress of milling.

scholarly journals The Impact Of Surface Shape Of Chip-Breaker On Machined Surface

2015 ◽  
Vol 12 (2) ◽  
pp. 24-27
Author(s):  
Michal Šajgalík ◽  
Andrej Czán ◽  
Juraj Martinček ◽  
Daniel Varga ◽  
Pavel Hemžský ◽  
...  
Keyword(s):  
Automotive Industry ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Surface Shape ◽  
Technological Parameters ◽  
Machined Surface ◽  
Chip Breaker ◽  
Cutting Insert ◽  
Chip Size ◽  
The Impact

Abstract Machined surface is one of the most used indicators of workpiece quality. But machined surface is influenced by several factors such as cutting parameters, cutting material, shape of cutting tool or cutting insert, micro-structure of machined material and other known as technological parameters. By improving of these parameters, we can improve machined surface. In the machining, there is important to identify the characteristics of main product of these processes – workpiece, but also the byproduct - the chip. Size and shape of chip has impact on lifetime of cutting tools and its inappropriate form can influence the machine functionality and lifetime, too. This article deals with elimination of long chip created when machining of shaft in automotive industry and with impact of shape of chip-breaker on shape of chip in various cutting conditions based on production requirements.

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 Machinability of Luxury Vinyl Tiles during Plain Milling Using a Helical Cutter

Materials ◽  
2019 ◽  
Vol 12 (13) ◽  
pp. 2174 ◽  
Author(s):  
Zhaolong Zhu ◽  
Pingxiang Cao ◽  
Xiaolei Guo ◽  
Xiaodong (Alice) Wang ◽  
Fan Zhang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Helix Angle ◽  
Helical Milling ◽  
Tool Geometry ◽  
Cutting Depth ◽  
Diamond Cutting Tools

In order to better provide a theoretical basis for the machining of luxury vinyl tiles, a helical milling experiment was conducted by using diamond cutting tools, and special attention was given to the trends of cutting force and surface roughness in respect to tool geometry and cutting parameters. The results showed that the resultant force was negatively correlated to the helix angle and cutting speed, but positively correlated with the cutting depth. Then, that the surface roughness increased with a decrease of the helix angle and an increase of cutting depth, while as cutting speed raised, the surface roughness first declined and then increased. Thirdly, the cutting depth was shown to have the greatest influence on both cutting force and surface roughness, followed by helix angle and cutting speed. Fourth, the contribution of cutting depth only was significant to cutting force, while both the helix angle and cutting speed had insignificant influence on the cutting force and surface roughness. Finally, the optimal cutting conditions were proposed for industrial production, in which the helix angle, cutting speed and cutting depth were 70°, 2200 m/min and 0.5 mm, respectively.

scholarly journals Study on Technological Effects of a Precise Grooving of AlSi13MgCuNi Alloy with a Novel WCCo/PCD (DDCC) Inserts

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2467 ◽  
Author(s):  
Szymon Wojciechowski ◽  
Rafał Talar ◽  
Paweł Zawadzki ◽  
Stanisław Legutko ◽  
Radosław Maruda ◽  
...  
Keyword(s):  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Fold Increase ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Machined Surface ◽  
Cutting Path

The WCCo/PCD (Diamond Dispersed Cemented Carbide—DDCC) manufactured with the use of PPS (pulse plasma sintering) are modern materials intended for cutting tools with the benefits of tungsten carbides and polycrystalline diamonds. Nevertheless, the cutting performance of DDCC materials are currently not recognized. Thus this study proposes the evaluation of technological effects of a precise groove turning process of hard-to-cut AlSi13MgCuNi alloy with DDCC tools. The conducted studies involved the measurements of machined surface topographies after grooving with different cutting parameters. In addition, the tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. It was also proved that grooving of AlSi13MgCuNi alloy with DDCC inserts enables 5 times longer tool life and almost 3-fold increase of cutting path compared to values obtained during grooving with H3 and H10 cemented carbide inserts. Ultimately, the feed value of f = 0.15 mm/rev and cutting speed in a range of 800 m/min ≤ vc ≤ 1000 m/min during grooving with DDCC inserts can be defined as an optimal machining parameters, enabling the maximization of tool life and improvement in surface quality.

The Effect of Cutting Parameters on Machined Surface Microstructure during High Speed Milling of Titanium Alloy TC17

2012 ◽  
Vol 443-444 ◽  
pp. 133-137 ◽  
Author(s):  
Yu Li ◽  
Wei Jun Tian ◽  
Zhen Chao Yang ◽  
Chang Feng Yao ◽  
Jun Xue Ren
Keyword(s):  
Titanium Alloy ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Surface Microstructure ◽  
Machined Surface ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Experimental Parameters ◽  
Single Factor Experiment

The paper is concerned with the effect of cutting parameters on surface microstructure of titanium alloy TC17 in high speed milling with the carbide cutting tools by single factor experiment. It will be provided experimental evidence for optimization cutting parameters and surface quality control of titanium alloy parts in high-speed cutting process. It is observing microstructure with Germany's Leica DMI 5000M inverted metallurgical microscope. The results show that in the range of experimental parameters, the effect of milling speed, feed per tooth and milling depth on surface microstructure in high-speed milling of titanium alloy TC17 is little. There is no obvious phase change, as indicating that most of the heat generated by chip away, little heat incoming workpiece, under the conditions of high speed milling titanium alloy TC17.

The Influence of Cutting Parameters on Machined Surface Microhardness during High Speed Milling of Titanium Alloy TC17

2012 ◽  
Vol 443-444 ◽  
pp. 127-132
Author(s):  
Wei Jun Tian ◽  
Yu Li ◽  
Zhen Chao Yang ◽  
Chang Feng Yao ◽  
Jun Xue Ren
Keyword(s):  
Titanium Alloy ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Surface Microhardness ◽  
Layer Depth ◽  
Machined Surface ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Single Factor Experiment

The paper is concerned with the effect of cutting parameters on surface microhardness in the high speed milling of titanium alloy TC17 with carbide cutting tools by single factor experiment. To provide experimental evidence for process parameter optimization and surface quality control in high-speed cutting titanium alloy parts. The results show that to aim for lower hardening layer depth, cutting parameters can be optimized as: vc=391.7m/min, fz=0.05mm/z, ap=0.45mm. The effect of cutting parameters on microhardness has experienced surface hardening-softening - re-strengthening - the process of stabilizing，in the experimental range.

An Intelligent Cutting Database for Die and Mold Making Operations

2006 ◽  
Vol 532-533 ◽  
pp. 105-108
Author(s):  
Zhan Qiang Liu ◽  
Ke Jun Xiang ◽  
Xiu Guang Peng
Keyword(s):  
Intelligent System ◽  
Cutting Tools ◽  
Tool Material ◽  
Cutting Parameters ◽  
Case Based Reasoning ◽  
Sculptured Surfaces ◽  
Machining Processes ◽  
Mold Making ◽  
End Mills ◽  
Machining Operations

In the modern manufacturing of sophisticated parts with 3D sculptured surfaces, die/mold making operations are the most widely used machining processes to remove unwanted material. To manufacture a die or a mold, many different cutting tools are involved, from hole-drills to the smallest ball nose end mills. Since the specification of each tool is very different from each other, each die/mold is specific with their complicated shapes and many machining rules exist to consider, a great deal of expertise is needed in selecting cutting tools for the die/mold machining operations. An intelligent system developed by using case-based reasoning (CBR) technology for this purpose is described in the present work. The geometry of the workpiece, workpiece condition, and operation type are considered as input values and various recommendations about the tool material, tool type, tool specifications, and cutting parameters are provided.

scholarly journals Surveying the topography and examining the quality of the machined surface of selected hardened steels in the milling process

2021 ◽  
Vol 9 (3B) ◽  
Author(s):  
Jan Duplak ◽  
◽  
Darina Duplakova ◽  
Michal Hatala ◽  
Svetlana Radchenko ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Simulation Method ◽  
Milling Process ◽  
Machined Surface ◽  
Experimental Procedure ◽  
Hard Materials ◽  
The Individual

The article deals with the surface roughness examination of three selected hard materials, that is, K100, 100CrMnMo7, and 16MnCr5, all with a defined hardness of HRC 60. The individual materials were machined using sintered carbide and cermet cutting materials with TiCN and TiN + TiCN + Al2O3 coatings. The research resided in the realization of three experiments. These experiments were carried out by three alternatives differing in the setting of basic cutting parameters. The experimental procedure was realized by the simulation method and direct contact measurement method of surface roughness. From the overall technical evaluation described in the practical part of the article, for the primarily observed parameter, the surface roughness, the least suitable values were obtained in the evaluation of the material from experiment No. 1-K100 with hardness HRC60. The experiments realized and the results achieved show that the machining of tool steels and other superhard materials requires special cutting tools, machines, and the use of progressive technologies, to ensure the production of a dimensionally and qualitatively shaped functional component.

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