The Quantitative Evaluation on the Lapping Uniformity of Rotated Dual-Plates Lapping Mode

2010 ◽  
Vol 37-38 ◽  
pp. 1534-1539 ◽  
Author(s):  
Ping Zhao ◽  
Wei Yu ◽  
Ke Feng Tang ◽  
Bing Hai Lv ◽  
Ju Long Yuan
Keyword(s):  
Material Removal Rate ◽  
Basic Principle ◽  
Material Removal ◽  
Removal Rate ◽  
Contact Point ◽  
Bearing Steel ◽  
Basic Rule ◽  
Speed Ratio ◽  
Key Factors ◽  
Ball Surface

The lapping trace distribution on ball surface is one of the key factors during the lapping process, which can affect the sphericity of lapping. The Rotated Dual-Plates lapping mode (RDP lapping mode) can achieve better uniformity of lapping trace distribution on precision ball surface, which ensure the results of forming sphere by lapping. Combining with the basic principle of RDP lapping mode, as well as the analysis of the kinematics of the RDP lapping method, this paper puts forward a basic rule about the material removal at the contact point between the ball and the plate with the material removal rate equation of bearing steel, and the improvement of the sphericity which can be simulated, and is defined as the lapping uniformity according to basic rule equation. The influence caused by the lapping pressure and the speed of the plates are considered in the simulation, the surface of ball is triangle grid divided. The uniformity of lapping is evaluated at different speed ratio, and eventually a better curve of the speed ratio can be got, so the lapping uniformity during the RDP lapping mode can finally be accurately evaluated.

Study on Fixed Abrasive Lapping Technology for Ceramic Balls

2006 ◽  
Vol 532-533 ◽  
pp. 460-463 ◽  
Author(s):  
Bing Hai Lv ◽  
Ju Long Yuan ◽  
Ying Xue Yao ◽  
Zhi Wei Wang
Keyword(s):  
Silicon Nitride ◽  
Material Removal Rate ◽  
Wear Mechanism ◽  
Material Removal ◽  
Removal Rate ◽  
Finishing Process ◽  
Photosensitive Resin ◽  
Ball Surface ◽  
Fixed Abrasive ◽  
Free Abrasive

To improve low lapping efficiency of silicon nitride balls in conventional lapping process, fixed abrasive lapping technology for ceramic balls is investigated in this paper. Diamond abrasives and photosensitive resin are used to fabricate the fixed abrasive plate. The lapped ball surface is observed with microscopy to identify the dominant wear mechanism. The results show that the material removal rate of the fixed abrasive lapping is about 20 times of that of conventional free abrasive lapping process, and the roughness is close to the conventional one. The experimental results indicate that the fixed abrasive lapping technology is a promising process to instead of conventional free abrasive lapping process for ceramic balls in rough and semi-finishing process.

Investigation of Orthogonal Turn-Milling for Higher Machining Efficiency and Accuracy: Relationship Between Material Removal Rate and Measured Tool Flank Temperature

2020 ◽  
Author(s):  
Koji Shimanuki ◽  
Akira Hosokawa ◽  
Tomohiro Koyano ◽  
Tatsuaki Furumoto ◽  
Yohei Hashimoto
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Speed Ratio ◽  
3D Cad ◽  
Revolution Speed ◽  
Tool Diameter ◽  
Chip Geometry ◽  
Turn Milling

Abstract Tool flank temperature at various intervals after cutting in dry turn-milling of AISI 1045 steel is measured using a two-color pyrometer with an optical fiber. Complicated undeformed chip geometry, which depends on cutting tool diameter, nose radius, number of tooth, workpiece diameter, tool-work revolution speed ratio, depth of cut, feed per tooth, tool axis offset and cutting distance, is analyzed and visualized by the 3D-CAD system. The effect of cutting parameters associated with material removal rate MRR such as workpiece diameter, workpiece revolution speed and feed rate on tool flank temperature is investigated in this paper. Workpiece diameter affects tool flank temperature, and 10 mm larger diameter causes approximately 40 °C higher temperature in any workpiece revolution speed due to the variation of undeformed chip geometry analyzed by 3D-CAD. Tool flank temperature increases with feed rate and workpiece revolution speed because the cross-sectional cutting area of undeformed chip increases with workpiece revolution speed, and cutting time during the engagement of each flute also increases with feed rate. Almost same values are obtained between the tool flank temperature and the material removal rate MRR when both workpiece revolution speed and feed rate are changed.

Experimental Study on the Surface Roughness with Mill-Grinding SiC Particle Reinforced Aluminum Matrix Composites

2011 ◽  
Vol 188 ◽  
pp. 203-207 ◽  
Author(s):  
Jian Guang Li ◽  
Jin Guang Du ◽  
Hang Zhao
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Aluminum Matrix ◽  
Speed Ratio ◽  
Aluminum Matrix Composites ◽  
Matrix Composites ◽  
Sic Particle

In view of the present machining status of SiC particle reinforced aluminum matrix composites, the electroplated diamond wheel (80# diamond grit) was used for mill-grinding the SiC particle reinforced aluminum matrix composites and the effect of speed ratio (q) and material removal rate (MRR) on surface roughness was studied based on experiments. The experimental results show that surface roughness almost increases with the increase of speed ratio. At the same material removal rate, surface roughness increases when raising material removal rate by raising feed rate singlely or raising depth of mill-grinding singlely; surface roughness has decreasing trend with raising material removal rate by increasing feed rate and depth of mill-grinding at the same time.

Study on Cutting Force of Diamond Cutter in Special-Shaped Stone Processing

2011 ◽  
Vol 291-294 ◽  
pp. 804-809 ◽  
Author(s):  
Bo Huang ◽  
Zeng Wen Liu
Keyword(s):  
Cutting Force ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Key Factors ◽  
Peripheral Speed ◽  
Factors Influencing ◽  
Relationship Of ◽  
The Relationship

The cutting force is the key factors influencing the processing precision and efficiency in special-shaped stone production. In this research, the cutting force is measured and analyzed in the process of special shaped cutter cutting stone. It is found that the relationship of cutting force with peripheral speed of cutter is nearly inverse proportional. The cutting force becomes smaller and smaller as the peripheral speed of cutter increases. The relationship of cutting force with feed rate is nearly proportional. The cutting force becomes larger and larger as the feed rate increases. The relationship between Fx, Fy and Fz is Fz > Fx > Fy. Enhancing the peripheral speed of cutter is a better way to increase the material removal rate.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

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