Investigation of Machining Parameters for Burr Minimization in CNC Turning of Brass Using RSM and GA

2014 ◽  
Vol 627 ◽  
pp. 54-59 ◽  
Author(s):  
R. Ravikumar ◽  
M. Mohamed Abdul Hafeez
Keyword(s):  
Metal Cutting ◽  
Cutting Parameters ◽  
Optimization Techniques ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Feed Speed ◽  
Machining Parameters ◽  
Cnc Turning ◽  
Control Factors

CNC turning is one among the metal cutting process in which quality of the finished product depends mainly upon the machining parameters such as feed, speed, depth of cut, type of coolant used, types of inserts used etc. Similarly the work piece material plays an important role in metal cutting process. This study involves in indentifying the optimized parameters in CNC turning of Brass. To identify and measure the formation of burrs in the turned samples, are examined under scanning electron microscope (SEM). The optimization techniques used in this study are Response surface methodology, and Genetic algorithm. Several comparisons were made between cutting parameters with surface roughness. These optimization techniques are very helpful in indentifying the optimized control factors with high level of accuracy.

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.

The Process Strategies of Mould High-Speed Machining and their Applications in the Environment of PowerMILL

2011 ◽  
Vol 188 ◽  
pp. 542-548 ◽  
Author(s):  
Jie Liu
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Whole Process ◽  
Machining Strategies ◽  
Selection Of

High-speed machining requires the support of high intelligent CAM software as well as customized machining strategies and properly selected machining parameters. Only by combining the two can the advantage of high-speed machining be made full use of. Compared to ordinary NC cutting, high-speed machining has special requirements for process strategies, CAM system and tool path. A complete tool path includes approaching/retracting tool, moving tool and tool path. Based on the above principles, a mould part is successfully processed using the PowerMILL software at the high-speed machining centre of DMG-DMU40T. The maximum hardness of the mould part is HRC50. There’s a 30 degree corner in the cavity with a transition radius of 3mm. The whole process can be divided into three stages: rough, semi-finish and finish machining and each stage involves the selection of tool path, the selection of tool, the selection of cutting parameters (including spindle speed, feed speed and depth of cut), and the application of PowerMILL specific machining methods (such as Race-line machining, rest roughing, automatic trochoidal machining, 3D offset finishing and etc).

scholarly journals Tool and work piece vibrations measurement - a review

2018 ◽  
Vol 9 (4) ◽  
pp. 1254 ◽  
Author(s):  
Perunalla PBGSN Murthy ◽  
Ch Srinivasa Rao ◽  
K Venkata Rao
Keyword(s):  
Surface Roughness ◽  
Data Acquisition ◽  
Tool Life ◽  
Metal Cutting ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Work Piece ◽  
Feed Speed ◽  
Process Data

Tool condition monitoring is one of the important aspects in machining process to improve tool life. It comprises three important steps namely machining data acquisition, data analysis and decision making. Vibration in metal cutting has direct impact on the tool life as well as surface roughness. The present study focused on measurement of vibration during the machining process. Data acquisition is made by using various types of sensors. A wide variety of technologies like contact and non contact sensors have been used for real time data acquisition of tool or work piece vibrations. Research works carried out by many authors is highlighted in measurement of cutting tool and machine tool vibrations using different sensors. Influence of various input parameters like tool geometry, feed, speed and depth of cut on the magnitude of vibrations is discussed. Influence of vibration on surface roughness, tool life and power consumption is reviewed. Three dimensional vibration measurement with single Laser Doppler Vibrometer is also covered for precise analysis of vibration.

scholarly journals EFFECT OF CUTTING SPEED IN THE TURNING PROCESS OF AISI 1045 STEEL ON CUTTING FORCE AND BUILT-UP EDGE (BUE) CHARACTERISTICS OF CARBIDE CUTTING TOOL

SINERGI ◽  
2020 ◽  
Vol 24 (3) ◽  
pp. 171
Author(s):  
Sobron Yamin Lubis ◽  
Sofyan Djamil ◽  
Yehezkiel Kurniawan Zebua
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Aisi 1045 Steel ◽  
1045 Steel

In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.

scholarly journals MODELLING OF RESPONSES FROM ORTHOGONAL METAL CUTTING OF MILD STEEL USING CARBIDE INSERT TOOL

2016 ◽  
Vol 36 (1) ◽  
pp. 96-109
Author(s):  
MK Onifade ◽  
AC Igboanugo ◽  
JO Osarenmwinda
Keyword(s):  
Mild Steel ◽  
Representative Sample ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Orthogonal Metal Cutting

The purpose of this research was to develop models for the prediction of responses from orthogonal metal cutting process that are responsible for the machinability ratings of this technological system. Mild steel work-piece material that is representative sample for various industrial applications was machined. The various industrial applications of this representative sample range from mechanical shafts to fasteners, screws and hydraulic jack. These machine elements require high degree of surface finish. A fifteen-run based Box-Behnken response surface design was created using widely established machining parameters, namely cutting speed, feed rate and depth of cut. The optimum predicted responses from the orthogonal cutting process for the optimal process parameters are 0.1742 micron, 0.4933 micron, 0.1845 micron, 0.3673 micron, 794.6839 seconds and 19.642 seconds for the Ra, Rz, Rq, Rt, TL and M/C time respectively. The associated desirabilities for these optimum responses are 1.000000, 1.000000, 1.000000, 1.000000, 0.524122, and 0.361858 respectively.   http://dx.doi.org/10.4314/njt.v36i1.13

Tool Wear Analysis in Turning Using Different Inserts and Different Lubrication Systems

2015 ◽  
Vol 813-814 ◽  
pp. 404-409
Author(s):  
R. Panneer ◽  
Kesaraju Venkata Sai Pavan
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Fluids ◽  
Control Factors ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

In metal cutting, increasing cutting spped and feed achieve higher productivity, but it will affect dimensional accuracy and surface integrity of the work surface, wear resistance and life of tool. Cutting fluids when appropriately chosen and applied will minimize these problems. This work deals with the optimization of process parameters in turning of EN24 and SS316L Steels with different cutting fluids with different cutting inserts under different machining conditions using Taguchi’s Robust Design Methodology. The control factors selected are machining environment, cutting speed, feed, depth of cut, work piece material and type of tool. Investigations are carried out on conventional lathe using the prefixed cutting conditions. Tool Wear and Surface Roughness are measured and anlysed using ANOVA and appropriate conclusions are derived.

Unit Machining Operations: An Automated Process Planning and Selection Program

1980 ◽  
Vol 102 (4) ◽  
pp. 297-302 ◽  
Author(s):  
R. A. Wysk ◽  
M. M. Barash ◽  
C. M. Moodie
Keyword(s):  
Process Planning ◽  
Manufacturing Systems ◽  
Metal Cutting ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Machining Parameters ◽  
Automated Manufacturing Systems ◽  
Specific Product ◽  
Automated Process Planning ◽  
Automated Process

In most metal cutting or removing facilities, the task of planning piece part operations and sequences is the responsibility of the process planner. Although this individual holds the key to the profitability of a specific product, little has been done to aid the process planner in the performance of his job. With the cost of machinery skyrocketing as the degree of automation is increasing, much emphasis has been placed on process planning or engineering. This paper outlines the responsibilities and functions carried out by the process planner. The paper is primarily concerned with automated manufacturing systems and, in particular, the planning of parts on machining centers. It demonstrates the decisions required of process planner and the lack of quantifiable data available to make logical decisions at the present time. A review of the two approaches to automated process planning, called variant and generative planning, is presented. The paper also describes some of the shortcomings of classification codes that have been used for automated process planning. The framework for a computer generative process planning scheme is demonstrated. The selection of machining parameters (feed, speed and depth of cut) are also discussed.

Computational of Orthogonal Metal Cutting Process Using Smooth Particle Hydrodynamics

2017 ◽  
Vol 867 ◽  
pp. 119-126
Author(s):  
S. Muthusamy ◽  
A Arulmurugu
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Smooth Particle Hydrodynamics ◽  
Particle Hydrodynamics ◽  
Sph Model

In modern years, simulating metal cutting process used in Finite element method (FEM). The cutting force is used to identify the excessive friction of machining interface and worn out tool. Optimization of machining parameters are used to maintain the precision of the component, power consumption minimized and tool wear reduced. The current project presents the simulated Finite Element SPH Model used for predict the cutting force and associate with experimental confirmation while turning the AA2219-TiB2/ZrB2 metal matrix composites (MMC). Smooth Particle Hydrodynamics (SPH) machining simulation was carried out using a Lagrangian finite element based machining model to predict the cutting force. The turning simulation operation carried out using ANSYS AUTODYN (SPH) software. Machining parameters are cutting speed, feed rate and depth of cut. The results predicted from the SPH analysis virtually close to the results attained from the experimental work. Simulation of machining test using SPH model is preferred over actual cutting test because of it reduce cost and time.

Recent Development of Parameter Optimization for Metal Cutting and Grinding Processes

2013 ◽  
Vol 652-654 ◽  
pp. 2218-2221 ◽  
Author(s):  
Li Bao An ◽  
Chun Guang Lu
Keyword(s):  
Parameter Optimization ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Optimization Of Cutting Parameters

Metal cutting indicates a specific category of processes in which unwanted material is removed from workpeice by single- or multi-point cutting tools for making products meeting prescribed specifications. Parameter optimization in metal cutting plays an important role in satisfying quality requirements of machined parts at low production cost or time. It requires optimal selection of cutting speed, feed rate, depth of cut, and the number of passes. A brief review of recent progress on the optimization of cutting parameters is introduced in the present work. Some new machining practices expending in recent years are involved including hard turning, dry cutting, high speed machining, machining of difficult-to-machine materials and composites. Modeling skills for creating optimization models and optimization techniques for solving optimal or near-optimal solutions are summarized and analyzed.

scholarly journals Experimental Investigation into Influence of Lathe Cutting Parameters on Surface Roughness for Ferrous and Non- Ferrous Alloys

2017 ◽  
Vol 3 (4) ◽  
pp. 11
Author(s):  
Asim M Saddique ◽  
Murali R V ◽  
Salim R.K
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Stainless Steel ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Turning ◽  
Stainless Steel 304 ◽  
Turning Center

Optimization of lathe cutting parameters is very important as they form the best suitable conditions for the machining operations. For the efficient use of a CNC Lathe, a set of optimum cutting parameters (speed, feed and depth of cut) is an essential requirement. Surface Roughness, which heavily depends on these cutting parameters, is one of the most frequently used standards to define the quality of turned components. In this work, a correlative study of cutting parameters and the surface roughness for ferrous (stainless steel 304) and non–ferrous alloy (aluminum) material is carried out and presented. Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) techniques are employed to investigate the influence of cutting parameters on surface roughness values. Results from contour plots are obtained to investigate the patterns of factors and the responses. The combination of optimum experimental parameters can be found by machining these ferrous and non-ferrous materials in CNC turning center and finding the least surface roughness parameters. ANOVA analysis, integrated with Design Expert© software, is used to determine effective ratios of the parameters and subsequently the relationships between input parameters and their responses relationship are established. The minimum surface roughness results in reference to spindle rpm, feed rate, and depth of cut are determined and estimation of the optimal surface roughness values (Ra) for least surface roughness are the results obtained in the study. This study presents the findings of an experimental investigation into the effect of turning parameters like cutting speed. Feed rate and depth of cut by turning ferrous (stainless steel 304) and non-ferrous material (Aluminium) in the CNC turning center and then checked the surface roughness values with Mitutoyo SJ-301 instrument. The effects of parameters and their correlation with the surface roughness and the optimal values have been analysed. These results establish a firm relationship and correlation between cutting parameters and surface roughness and in doing so, results also achieve an optimal set of machining parameters for select ferrous and non-ferrous materials.

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