Experimental Investigation of Surface Integrity in Turning of 58SiMn High-Strength Steel

2014 ◽  
Vol 543-547 ◽  
pp. 3759-3763
Author(s):  
Lin Lin Wang ◽  
Li Jiao ◽  
Zhi Wen Luo ◽  
Liang Jun Wei
Keyword(s):  
Surface Integrity ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Dominant Factor ◽  
Residual Tensile Stress ◽  
The Impact

In order to investigate the impact of cutting parameters on surface integrity when high-speed turning 58SiMn without cutting fluid, three-factor three-level orthogonal experiments and single factor experiments based on cutting speed and feed rate are employed, and an empirical model is established. The results of analysis of variance (ANOVA) revealed that feed rate is the dominant factor affecting the surface roughness. With the increase of cutting speed and feed rate, residual tensile stress on the surface becomes larger. Along the depth, micro hardness first decreases and then increases.

scholarly journals Impact of Cutting Forces and Chip Microstructure in High Speed Machining of Carbon Fiber – Epoxy Composite Tube

2017 ◽  
Vol 62 (3) ◽  
pp. 1771-1777 ◽  
Author(s):  
Y. Allwin Roy ◽  
K. Gobivel ◽  
K.S. Vijay Sekar ◽  
S. Suresh Kumar
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Parameters ◽  
High Speed Machining ◽  
The Impact ◽  
Thrust Forces

AbstractCarbon fiber reinforced polymeric (CFRP) composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM) of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure which offer vital inputs to the machinability and deformation characteristics of the material. In this work, the orthogonal machining of CFRP was conducted by varying the cutting parameters such as cutting speed and feed rate at high cutting speed/feed rate ranges up to 346 m/min/ 0.446 mm/rev. The impact of the cutting parameters on cutting forces (principal cutting, feed and thrust forces) and chip microstructure were analyzed. A significant impact on thrust forces and chip segmentation pattern was seen at higher feed rates and low cutting speeds.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

scholarly journals Prediction of Tool Lifetime and Surface Roughness for Nickel-Based Waspaloy

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Shao-Hsien Chen ◽  
Chung-An Yu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Predictive Values ◽  
Actual Surface ◽  
Wide Range

In recent years, most of nickel-based materials have been used in aircraft engines. Nickel-based materials applied in the aerospace industry are used in a wide range of applications because of their strength and rigidity at high temperature. However, the high temperatures and high strength caused by the nickel-based materials during cutting also reduce the tool lifetime. This research aims to investigate the tool wear and the surface roughness of Waspaloy during cutting with various cutting speeds, feed per tooth, cutting depth, and other cutting parameters. Then, it derives the formula for the tool lifetime based on the experimental results and explores the impacts of these cutting parameters on the cutting of Waspaloy. Since the impacts of cutting speed on the cutting of Waspaloy are most significant in accordance with the experimental results, the high-speed cutting is not recommended. In addition, the actual surface roughness of Waspaloy is worse than the theoretical surface roughness in case of more tool wear. Finally, a set of mathematical models can be established based on these results, in order to predict the surface roughness of Waspaloy cut with a worn tool. The errors between the predictive values and the actual values are 5.122%∼8.646%. If the surface roughness is within the tolerance, the model can be used to predict the residual tool lifetime before the tool is damaged completely. The errors between the predictive values and the actual values are 8.014%∼20.479%.

White and Dark Layer Analysis Using Response Surface Methodology

2012 ◽  
Vol 504-506 ◽  
pp. 1335-1340 ◽  
Author(s):  
Giuseppina Ambrogio ◽  
Serena di Renzo ◽  
Francesco Gagliardi ◽  
Domenico Umbrello
Keyword(s):  
Layer Thickness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Bearing Steel ◽  
Cutting Conditions ◽  
Cutting Fluid ◽  
Process Conditions ◽  
Dark Layer ◽  
Layer Analysis

This paper presents a study of the influence of cutting conditions on the finished surface obtained after an hard turning process, in particular a case study is presented where AISI 52100 bearing steel is machined under different cutting conditions. An analysis carried out using Surface Response Methodology has been developed in order to study the influence of the main cutting parameters such as cutting speed, feed rate and workpiece initial hardness on white (WL) and dark layer (DL) thickness. The whole experimental campaign has been performed using a chamfered PCBN tool inserts without any cutting fluid. Results show an evident influence of cutting speed and feed rate on both white and dark layer thickness while less relevant is the contribute given from the workpiece hardness on defining WL and DL depth. Finally, a model to find the optimal process conditions to minimize white and dark layer thickness is developed.

RSM Based Investigations on the Effects of Cutting Parameters on Surface Integrity during Cryogenic Hard Turning of AISI 52100

2015 ◽  
Vol 15 (3) ◽  
pp. 309-318 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Desirability Function ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Aisi 52100 ◽  
Model Equations

AbstractEffect of cryogenic hard turning parameters (cutting speed, feed rate, and depth of cut) on surface roughness (Ra) and micro-hardness (µH) that constitute surface integrity (SI) of the machined surface of alloy steel AISI 52100 is investigated. Multilayer hard surface coated (TiN/TiCN/Al2O3/TiN) insert on CNC lathe is used for turning under different cutting parameters settings. RSM based Central composite design (CCD) of experiment is used to collect data for Ra and µH. Validity of assumptions related to the collected data is checked through several diagnostic tests. The analysis of variance (ANOVA) is used to determine main and interaction effects. Relationship between the variables is established using quadratic regression model. Both Ra and µH are influenced principally by the cutting speed and the feed rate. Model equations are found to predict accurate values of Ra and µH. Finally, desirability function approach for multiple response optimization is used to produce optimum SI.

Experimental Study on Wear-Resistance of Machined Surface in High Speed Milling Aviation Aluminum Alloy

2012 ◽  
Vol 500 ◽  
pp. 117-122
Author(s):  
Xiu Li Fu ◽  
Xiao Qin Wang ◽  
Yong Zhi Pan ◽  
Yang Qiao
Keyword(s):  
Wear Resistance ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Surface Quality ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Resistance Performance

The wear-resistance performance of machined surface is an important factor in the evaluation of surface quality and precision in aerospace manufacturing industry. By using high-speed Ring-Block friction and wear machine (MRH-3), the influence of cutting parameters in milling aluminum alloy 7050-T7451 on wear-resistance of machined surface including friction coefficient and wear quantity are experimentally investigated. The wear-resistance is particularly sensitive to cutting speed and feed rate. The friction coefficient has marked drop trends as cutting speed increases. The influence of cutting speed on wear quantity is more complicated and the tendency of wear quantity was ascend in first and descend at last (v>900/min). The results show that the influence of cutting parameters on wear-resistance was also positively correlated with surface roughness and work-hardening of machined surface. The high work-hardening and surface quality had the promoting effecting on wear-resistance. The experiment and analysis results show that the machined surface by high speed cutting and lower feed rate has more superior in surface quality and wear-resistance performance comparing with conventional cutting speed.

Study on Surface Integrity of an Ultra-High Strength Alloy in HSC Process

2006 ◽  
Vol 532-533 ◽  
pp. 241-244
Author(s):  
Zhen Hai Long ◽  
Xi Bin Wang ◽  
Wen Xiang Zhao
Keyword(s):  
Residual Stress ◽  
Surface Layer ◽  
Surface Integrity ◽  
High Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Tempered Martensite ◽  
Strength Alloy

Aiming to study the surface integrity of an ultra-high strength alloy in high speed milling process, 2K factorial design experiments were conducted to explore the effects of cutting parameters, such as cutting velocity, feed rate and depth of cut, on microstructure, microhardness and residual stress in the sub-surface layer. The following conclusions could be drawn from this paper within the range of cutting conditions: The cutting parameters could significantly influence the microstructure and microhardness in the surface and sub-surface layers, and the original fine martensite of the surface and sub-surface layer might be transformed into the over-tempered martensite, under-tempered martensite, secondary troostite, and tempered sorbite; Compressive residual stress distributions with different maximum stress values in the sub-surface layer of machined surfaces could emerge in high speed cutting process; the properly arranged cutting condition could achieve ideal surface characteristics and surface integrity.

Surface integrity and wear evolution of high strength aluminum alloy after high-speed oblique cutting

2021 ◽  
pp. 135065012110406
Author(s):  
Xiao Yu ◽  
Youqiang Wang ◽  
Ping Zhang ◽  
Yanchun Zhai ◽  
Liying Li
Keyword(s):  
Aluminum Alloy ◽  
Abrasive Wear ◽  
Surface Integrity ◽  
High Speed ◽  
Friction Pair ◽  
High Strength ◽  
Movement Direction ◽  
Residual Tensile Stress ◽  
High Strength Aluminum Alloy ◽  
Friction Testing

In this paper, we present an experimental study on the surface frictional wear mechanism of the high-strength aluminum alloy after high-speed milling. We use a surface profilometer and an X-ray stress tester to characterize the milled surface integrity of the material, and UMT-3 friction testing machine to obtain its surface roughness, oxygen content, hardness, and wear morphology during different wear stages. The results show that milling-induced residual tensile stress makes the cut surface more prone to fatigue cracking and consequently abrasive wear in the initial wear stage. The larger the angle between the friction pair movement direction, the greater the chance of adhesive wear and abrasive wear. A complete friction stage pattern can be obtained at a high load (15 N) and a low sliding speed (0.6 mm/s). The friction pair enters a stable wear stage after 20 sliding cycles. Work hardening constitutes the main driver of stable wear.

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

2014 ◽  
Vol 14 (1) ◽  
pp. 23-30 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Aas Mohammad ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Influential Factor ◽  
Depth Of Cut ◽  
Micro Hardness ◽  
Dry Cutting

AbstractThe cutting parameters such as the cutting speed, the feed rate, the depth of cut, etc. are expected to affect the two constituents of surface integrity (SI), i.e., surface roughness and micro-hardness. An attempt has been made in this paper to investigate the effect of the CNC hard turning parameters on the surface roughness average (Ra) and the micro-hardness (μh) of AISI 52100 hard steel under dry cutting conditions. Nine experimental runs based on an orthogonal array of the Taguchi method were performed and grey relational analysis method was subsequently applied to determine an optimal cutting parameter setting. The feed rate was found to be the most influential factor for both the Ra and the μh. Further, the results of the analysis of variance (ANOVA) revealed that the cutting speed is the most significant controlled factor for affecting the SI in the turning operation according to the weighted sum grade of the surface roughness average and micro-hardness.

Effect of Cutting Parameters on Minimum Quantity Lubrication Machining of High Strength Steel

2009 ◽  
Vol 626-627 ◽  
pp. 387-392 ◽  
Author(s):  
L.T. Yan ◽  
Song Mei Yuan ◽  
Qiang Liu
Keyword(s):  
Chip Formation ◽  
Feed Rate ◽  
High Strength Steel ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
High Strength ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Work Piece ◽  
Minimum Quantity

The cutting performance (tool wear, surface roughness of machined work-piece and chip formation)of wet, dry and Minimum Quantity Lubrication (MQL) machining when milling of high strength steel (PCrNi2Mo) using cemented carbide tools under different (cutting speed, depth of cut, feed rate) was analyzed. The experimental results showed that as the cutting speed, depth of cut and feed rate changed, MQL conditions provided the lowest flank wear and the highest surface quality. Chip formation produced under MQL conditions become more favorable in terms of color and shape. The results obtained prove the potential of using MQL technique in the milling process of high strength steel (PCrNi2Mo) for high cutting speed, feed rate and depth of cut.

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