Surface Quality of High Speed Milling of Silicon Carbide by Using Diamond Coated Tool

2013 ◽  
Vol 446-447 ◽  
pp. 275-278 ◽  
Author(s):  
Mohammad Iqbal ◽  
Mohamed Konneh ◽  
Ahmad Yasir Bin Md Said ◽  
Azri Fadhlan Bin Mohd Zaini
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
High Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Model Interaction ◽  
High Speed Milling ◽  
Coated Tool

The high speed milling of silicon carbide was discussed by using flat end-mill 2 mm in diameter diamond coated tool. Ultra-precision high speed spindle attachment was used to achieve cutting tool rotation speed as high as 50,000 rpm. Special fixture was designed to minimize the chatter on work-piece surface during the machining process. Three cutting parameters were selected as independent variables of the experiments. They were spindle speed, depth of cut and feed rate. The arithmetic mean value of roughness (Ra) was measured on the work-piece surface as the response of the experiment. Result of the experiment shows that the value of surface roughness can be achieved as low as 0.150 μm. Statistical analysis was provided to study the significant of the model, interaction among the cutting parameters and their effects to the surface roughness value.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Effect of Various Cooling Strategies on Surface Roughness of High Speed Milling Ti-6Al-4V

2011 ◽  
Vol 697-698 ◽  
pp. 49-52 ◽  
Author(s):  
Xiao Yong Yang ◽  
Cheng Zu Ren ◽  
Guang Chen ◽  
Bing Han ◽  
Y. Wang
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Side Milling ◽  
High Speed Milling ◽  
Cooling Strategies ◽  
Radial Depth

This study focused on the side milling surface roughness of titanium alloy under various cooling strategies and cutting parameters. The experimental results show that the cooling strategies significantly affect the surface roughness in milling Ti-6Al-4V. Surface roughness (Ra) alterations are investigated. Cutting fluid strategy made nearly all the smallest and most stable roughness values. The surface roughness values produced by all cooling strategies are obviously affected by feed, radial depth-of-cut and cutting speed. However, axial depth-of-cut has little influence.

Experimental Investigation of Surface Roughness in High Speed Turning of Hardened AISI P20 Steel

2011 ◽  
Vol 418-420 ◽  
pp. 1228-1231 ◽  
Author(s):  
Bo Di Cui
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
High Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Turning ◽  
Aisi P20 ◽  
Optimal Cutting Parameters ◽  
Aisi P20 Steel

Surface roughness is one of the most important product quality characteristics. In this paper, experimental investigation of surface roughness was performed in high speed turning of hardened AISI P20 steel with CBN tool based on design of experiment. The influence of cutting speed, feed rate, depth of cut and nose radius on surface roughness were assessed using analysis of variance (ANOVA). Optimal cutting parameters were found to improve the machining performance. Due to the complexity of machining process, artificial neural network (ANN) was employed to develop the predictive model of surface roughness. Simulations were done to study the relationship between surface roughness and cutting parameters based on the proposed model.

Design Optimization of Cutting Parameters Using Taguchi Method and ANOVA during High-Speed Machining Hardened H13 Steel

2009 ◽  
Vol 626-627 ◽  
pp. 129-134
Author(s):  
Song Zhang ◽  
Y.B. Guo
Keyword(s):  
Surface Roughness ◽  
Design Optimization ◽  
High Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
H13 Steel ◽  
High Speed Milling ◽  
Optimization Of Cutting Parameters ◽  
Coated Carbide

High-speed machining thoroughly hardened tool steels has emerged as a competitive finishing technology for making dies and molds. The objective of this paper is to develop an optimization method for the better (i. e., lower value) surface roughness in terms of cutting parameters when high-speed milling hardened H13 steel. The cutting parameters to be considered were cutting speed, feed per tooth, radial depth of cut, and axial depth of cut, respectively. A series of high-speed milling experiments of hardened H13 steel using PVD coated carbide inserts without any cutting fluids were performed to measure the surface roughness data. Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) were used to evaluate the effects of cutting parameters on surface roughness and to find the optimal factor/level combination for the better surface roughness. The investigations of this study would be used for design optimization of cutting parameters to obtain the better surface roughness.

Parameters Optimization Research of High-Speed Milling PM60 Mould Steel Based on Taguchi Method

2016 ◽  
Vol 861 ◽  
pp. 75-83
Author(s):  
Ying Xing Xie ◽  
Cheng Yong Wang ◽  
Feng Ding ◽  
Wen Huang
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
High Speed ◽  
High Hardness ◽  
Cutting Parameters ◽  
Parameters Optimization ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Optimal Cutting Parameters

In order to obtain better surface quality after high speed milling high hardness mold steel, and reduce tool wear in cutting process, prolong the service life of cutting tools, obtain superior levels and optimal combination of cutting parameters in the test range. Through the design of orthogonal experiment, the use of Taguchi method, and noise ratio analysis and variance analysis of dry cutting high hardness mould steel PM60 under different cutting parameters; and finally, the optimal cutting parameters of surface roughness and cutting force value were predicted and verified. Research showed that: the worst cutting parameters influenced the surface roughness Ra was radial depth of cut ae, its influence was highly significant, followed by spindle speed n and depth of axial cut ap; the most serious impact cutting parameter of cutting force F was the feed speed vf, followed by the spindle speed n and radial depth of cut ae; verification test showed that the optimal cutting parameters combination were reasonable and the calculation errors of the predicted values and experimental values were very small, indicating that Taguchi method in cutting parameters optimization of cutting mould steel PM60 was valid.

Machinability Improvement by Workpiece Preheating during End Milling AISI H13 Hardened Steel

2011 ◽  
Vol 264-265 ◽  
pp. 888-893
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

SURFACE ROUGHNESS OF MAGNESIUM ALLOY AZ91D IN HIGH SPEED MILLING

2016 ◽  
Vol 78 (6-9) ◽  
Author(s):  
Mohd Shahfizal Ruslan ◽  
Kamal Othman ◽  
Jaharah A.Ghani ◽  
Mohd Shahir Kassim ◽  
Che Hassan Che Haron
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Parameters ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Polishing Process ◽  
High Speed Cutting ◽  
Radial Depth

Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 µm, which is less than the 0.5µm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061µm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

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