The Effect of Vortex Tube Air Cooling on Surface Roughness and Power Consumption in Dry Turning

2013 ◽  
Vol 310 ◽  
pp. 348-351 ◽  
Author(s):  
Hadi Abdul Salaam ◽  
Phoon Sin Ye ◽  
Zahari Taha ◽  
Tuan Muhammad Yusoff Shah Tuan Ya
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Feed Rate ◽  
Vortex Tube ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Air Cooling ◽  
Coated Carbide

This paper presents a study of the effect of Ranque-Hilsch vortex tube air cooling on surface roughness quality and power consumption when turning mild steel material with coated carbide cutting tool. The cutting parameters involved in this study were cutting speed, feed rate and depth of cut. The cutting speed and feed rate were fixed at 160 m/min and 0.28 mm/rev, while the depth of cut was varied from 1.0 to 4.0 mm. During the turning process, the cutting temperatures were measured using an infrared thermometer and the power consumption was measured using a power and harmonics analyzer. The machined parts surface roughnesses were measured using a surface roughness tester. The results show that cooling using the Ranque-Hilsch vortex tube air cooling reduces the cutting temperature and the power consumption, but the surface roughness results is better when cooling with environment air.

The Effect of Vortex Tube Cooling on Surface Roughness and Carbon Footprint in Dry Turning

2014 ◽  
Vol 903 ◽  
pp. 135-138
Author(s):  
Zahari Taha ◽  
Hadi Abdul Salaam ◽  
Phoon Sin Ye ◽  
Tuan Muhammad Yusoff Shah Tuan Ya
Keyword(s):  
Surface Roughness ◽  
Carbon Footprint ◽  
Feed Rate ◽  
Vortex Tube ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Air Cooling ◽  
Coated Carbide

This paper presents a study on the effect of Ranque-Hilsch vortex tube air cooling on surface roughness quality and carbon footprint when turning mild steel workpiece with coated carbide cutting tool. The cutting parameters involved in this study were cutting speed, feed rate and depth of cut. The cutting speed and feed rate were fixed at 160 m/min and 0.10, 0.18 and 0.28 mm/rev, while the depth of cut was varied from 1.0 to 4.0 mm. During the turning process, the cutting temperatures were measured using infrared thermometer and the power consumption was measured using a power and harmonics analyzer and then converted into carbon footprint. The machined parts surface roughness were measured using a surface roughness tester. The results show that machining with Ranque - Hilsch vortex tube reduces the cutting temperature, but the surface roughness and carbon footprint is better under ambient condition except at a higher feedrate.

scholarly journals Effect of Cutting Insert Type on Surface Roughness of Hardened AISI 420 Stainless Steel

2021 ◽  
Vol 4 (1) ◽  
pp. 171-185
Author(s):  
Anıl Berk Dalkıran ◽  
Furkan Yılmaz ◽  
Samet Emre Bilim
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Feed Rate ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 420 ◽  
Cutting Insert ◽  
Coated Carbide

AISI 420 stainless steel is one of the alloys that can be used in various applications due to its malleability, high strength, and weldability. In this study, the effects of cutting parameters (feed rate, depth of cut, and cutting speed) on the surface roughness were investigated during the turning of AISI 420 under dry test conditions using coated carbide and ceramic cutting inserts. Response surface methodology, analysis of variance, and statistical methods of the main effect plot were applied to investigate the effects of input parameters on response values. The results of this study showed that feed rate followed by the depth of cut had the most significant effect on output parameters. According to the experimental data, as the feed rate and depth of cut increase, the surface roughness increases.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

scholarly journals Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2998 ◽  
Author(s):  
Kubilay Aslantas ◽  
Mohd Danish ◽  
Ahmet Hasçelik ◽  
Mozammel Mia ◽  
Munish Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Cutting Speed ◽  
Small Diameter ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Depth Of Cut ◽  
Turning Process ◽  
Micro Turning

Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

scholarly journals Investigate the Effect of Cutting Parameters on Surface Roughness When Milling X12m Steel

2021 ◽  
pp. 258-263
Author(s):  
Do Thi Kim Lien ◽  
Nguyen Dinh Man ◽  
Phung Tran Dinh
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Negligible Effect ◽  
Depth Of Cut ◽  
The Relationship

In this paper, an experimental study on the effect of cutting parameters on surface roughness was conducted when milling X12M steel. The cutting tool used in this study is a face milling cutter. The material that is used to make the insert is the hard alloy T15K6. The cutting parameters covered in this study include the cutting speed, the feed rate and depth of cut. The experiments are performed in the form of a rotating center composite design. The analysis shows that for both Ra and Rz: (1) the feed rate has the greatest influence on the surface roughness while the depth of cut, the cutting speed has a negligible effect on the surface roughness. (2) only the interaction between the feed rate and the depth of the cut has a significant effect on both Ra and Rz while the interaction between the cutting speed and the feed rate, the interaction between the cutting speed and the depth of cut have a negligible effect on surface roughness. A regression equation showing the relationship between Ra, Rz, and cutting parameters has also been built in this study.

Hard Turning of Hot Work Steel X38CRMOV5-3: Evaluation of Surface Roughness and Current Values Using Cutting Parameters

2020 ◽  
Author(s):  
Ali Kemal Cakir
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Motor Current ◽  
Design Factors

This study evaluates the surface roughness and current values using cutting parameters in the turning of AISI H11 being hot work tool steel under dry machining conditions. The selected design factors are the depth of cut, feed rate, cutting speed. A design of experiments was used to carry out this research. The obtained results were analyzed to determine the effects of input parameters on the resultant surface roughness, current using the analysis of variance (ANOVA) and the Response Surface Methodology (RSM). The experimental results showed that increasing feed rate increased the surface roughness, and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate on the surface roughness. Also, the motor current values were influenced by the 38,48% depth of cut, 23,98% cutting speed, 25,52% feed rate, respectively.

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