An Experimental Study on the Cutting Forces, Surface Roughness and the Hardness of Al 6061 in 1D and 2D Ultrasonic Assisted Turning

2014 ◽  
Vol 680 ◽  
pp. 224-227 ◽  
Author(s):  
Reza Nosouhi ◽  
Saeed Behbahani ◽  
Saeed Amini ◽  
Mohammad Reza Khosrojerdi
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Detectable Effect ◽  
Work Piece ◽  
Micro Hardness ◽  
Al 6061 ◽  
Hardness Tests ◽  
Ultrasonic Assisted ◽  
Conventional Machining

The machinability of Al 6061 in 1D and 2D ultrasonic assisted turning (UAT) in terms of machining forces, surface roughness and hardness is investigated in this research. In order to perform the machining experiments, a 1D vibration tool and a 2D vibration tool are designed and manufactured. The cutting forces and surface roughness of the work-pieces in 1D UAT and 2D UAT are measured in different cutting speeds and feed rates and compared with that in conventional machining. To investigate the effect of the ultrasonic vibration on the material properties, hardness tests are performed on the work-piece material and micro-hardness tests are carried out on the chip specimens. The results showed that reduction in the cutting forces occurred in UAT. The results also showed that the surface roughness is exceled in UAT in comparison with the conventional machining. While no detectable effect of the ultrasonic vibration on the work-piece material could be observed, the chip micro-hardness experiments showed that the softening phenomenon occurred in UAT, which can be the cause of the force reduction in UAT.

Analytical Modeling of Machining Forces and Friction Characteristics in Ultrasonic Assisted Turning Process

2021 ◽  
pp. 1-13
Author(s):  
Jay Airao ◽  
Chandrakant Kumar Nirala
Keyword(s):  
Analytical Model ◽  
Work Piece ◽  
Contact Ratio ◽  
Friction Characteristics ◽  
Machining Forces ◽  
Ultrasonic Assisted ◽  
Predicted Model ◽  
Ss 304 ◽  
Intermittent Cutting ◽  
Conventional Machining

Abstract Intermittent cutting characteristics of Ultrasonic assisted turning (UAT), Compared to conventional turning (CT), has shown a significant enhancement in the machinability of hard-to-cut materials. The enhancement in machinability is associated with machining forces and friction characteristics of the process. The present article covers an analytical approach to predict the output responses such as machining forces and friction characteristics in UAT and CT processes. Specific cutting energy (SCE) for a particular work-piece material was considered to predict the output responses. The predictions were made by considering the conventional machining theories. Experiments for the UAT and the CT of SS 304 were carried out to validate the predicted model. The results from the analytical model showed that the shear angle increases and the tool-workpiece contact ratio (TWCR) decrease with an increase in amplitude and frequency of vibration. The results obtained from the analytical model were found to be in close agreement with the experimental ones, with an approximate error of 2-20%.

Assessment of Plasma Enhanced Machining for Improved Machinability of Inconel 718

1997 ◽  
Vol 119 (1) ◽  
pp. 125-129 ◽  
Author(s):  
J. W. Novak ◽  
Y. C. Shin ◽  
F. P. Incropera
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Tool Life ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Experimental Results ◽  
Hybrid Machining ◽  
Machining System ◽  
Conventional Machining

An experimental study has been performed to assess the feasibility of using a hybrid machining system to improve the machinability of Inconel 718. An assembled plasma enhanced machining (PEM) system is described, and experimental results obtained from both conventional and plasma enhanced machining of Inconel 718 are compared. Several advantages of PEM over conventional machining are demonstrated, including improvement of surface roughness, lower cutting forces and extended tool life.

scholarly journals Machinability, Modelling and Statistical Analysis of In-Situ Al–Si–TiB2 Composites

2019 ◽  
Vol 3 (1) ◽  
pp. 28 ◽  
Author(s):  
Jimmy Karloopia ◽  
Shaik Mozammil ◽  
Pradeep Jha
Keyword(s):  
Surface Roughness ◽  
Statistical Analysis ◽  
Tool Wear ◽  
Cutting Forces ◽  
Elevated Temperatures ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Conventional Machining

Aluminum and its alloys have numerous applications in manufacturing, aerospace, and automotive industries. At elevated temperatures, they start to fail in fulfilling their roles and functions. Aluminum-based metal matrix composites (MMCs) are good alternatives for metal and alloys due to their excellent properties. However, the conventional machining of several composites shows complications for a number of reasons, such as high tool wear, poor surface roughness, high machining cost, cutting forces, etc. Numerous studies have already been conducted on the machinability of various MMCs, but the machinability of Al–Si–TiB2 composite is still not well studied. It is of utmost importance that several process parameters of conventional machining are precisely controlled as well as optimized. In this study an effort was made to optimize input parameters such as cutting speed, depth of cut, and feed to obtain well-finished final components with the minimum cutting force and tool wear. These progressions are involved with multiple response characteristics, therefore the exploration of an appropriate multi-objective optimization technique was indeed essential. The performance characteristics of cutting forces and surface roughness were considered for optimization of the machining parameters. Analysis of variance (ANOVA) was employed for the optimization and statistical analysis.

Study on Effect of Ultrasonic Vibration in Machining of Alumina Ceramic

2012 ◽  
Vol 516 ◽  
pp. 311-316 ◽  
Author(s):  
Kyung Hee Park ◽  
Kyeong Tae Kim ◽  
Yun Hyuck Hong ◽  
Hon Jong Choi ◽  
Young Jae Choi
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Ultrasonic Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Combination Technique

Ultrasonic machining can be applied for the machining of difficult-to-cut materials using ultrasonical oscillation in an axial direction on top of tool rotation, which can cause reduction of cutting temperature and tool wear. In this study, the experiments were performed on a DMG ULTRASONIC 20 linear machine tool using diamond tools in both conventional and ultrasonic vibration assisted machining. The machining performance was evaluated and compared for both cases in terms of cutting forces, machined surface roughness and tool wear. And the combination technique of 3D surface topography measurement and image processing was applied for the tool wear progress. Overall, the experimental results showed that ultrasonic machining had less tool wear and lower cutting forces at low cutting speed compared to conventional machining. Also surface roughness was slightly lower in ultrasonic machining than that without ultrasonic vibration.

Analysis of Machinability of Ti- and Ni-Based Alloys

2012 ◽  
Vol 188 ◽  
pp. 330-338 ◽  
Author(s):  
Agostino Maurotto ◽  
Anish Roy ◽  
Vladimir I. Babitsky ◽  
Vadim V. Silberschmidt
Keyword(s):  
Surface Quality ◽  
Cutting Forces ◽  
Material Removal ◽  
Process Zone ◽  
Machining Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Rates ◽  
Conventional Machining

Efficient machining of advanced Ti- and Ni-based alloys, which are typically difficult-to-machine, is a challenge that needs to be addressed by the industry. During a typical machining operation of such alloys, high cutting forces imposed by a tool on the work-piece material lead to severe deformations in the process zone, along with high stresses, strains and temperatures in the material, eventually affecting the quality of finished work-piece. Conventional machining (CT) of Ti- and Ni-based alloys is typically characterized by low depths of cuts and relatively low feed rates, thus adversely affecting the material removal rates (MRR) in the machining process. In the present work, a novel machining technique, known as Ultrasonically Assisted Turning (UAT) is shown to dramatically improve machining of these intractable alloys. The developed machining process is capable of high MRR with an improved surface quality of the turned work-piece. Average cutting forces are significantly lower in UAT when compared to those in traditional turning techniques at the same machining parameters, demonstrating the capability of vibration-assisted machining as a viable machining method for the future.

Cutting force prediction in ultrasonic-assisted milling of Ti–6Al–4V with different machining conditions using artificial neural network

2020 ◽  
pp. 1-12
Author(s):  
Ramazan Hakkı Namlu ◽  
Cihan Turhan ◽  
Bahram Lotfi Sadigh ◽  
S. Engin Kılıç
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Cutting Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Weight Ratio ◽  
Machining Process ◽  
Ultrasonic Assisted ◽  
Artificial Neural ◽  
Conventional Machining

Abstract Ti–6Al–4V alloy has superior material properties such as high strength-to-weight ratio, good corrosion resistance, and excellent fracture toughness. Therefore, it is widely used in aerospace, medical, and automotive industries where machining is an essential process for these industries. However, machining of Ti–6Al–4V is a material with extremely low machinability characteristics; thus, conventional machining methods are not appropriate to machine such materials. Ultrasonic-assisted machining (UAM) is a novel hybrid machining method which has numerous advantages over conventional machining processes. In addition, minimum quantity lubrication (MQL) is an alternative type of metal cutting fluid application that is being used instead of conventional lubrication in machining. One of the parameters which could be used to measure the performance of the machining process is the amount of cutting force. Nevertheless, there is a number of limited studies to compare the changes in cutting forces by using UAM and MQL together which are time-consuming and not cost-effective. Artificial neural network (ANN) is an alternative method that may eliminate the limitations mentioned above by estimating the outputs with the limited number of data. In this study, a model was developed and coded in Python programming environment in order to predict cutting forces using ANN. The results showed that experimental cutting forces were estimated with a successful prediction rate of 0.99 with mean absolute percentage error and mean squared error of 1.85% and 13.1, respectively. Moreover, considering too limited experimental data, ANN provided acceptable results in a cost- and time-effective way.

A Study on Micro-Milling of Aluminium 6061 and Copper With Respect to Cutting Forces, Surface Roughness and Burr Formation

2018 ◽  
Author(s):  
A. Sravan Kumar ◽  
Sankha Deb ◽  
S. Paul
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
End Milling ◽  
Micro Milling ◽  
Bottom Surface ◽  
Micro Channel ◽  
Al 6061 ◽  
Feed Force ◽  
Micro Channels ◽  
Burr Width

In the present study, micro-milling of aluminium 6061 alloy and copper was undertaken. TiAlN coated two-flute flat end milling cutters of 0.5 mm diameter were used for conducting micro-channel milling experiments with minimum quantity lubrication (MQL) as the cutting environment. The effect of process parameters namely cutting velocity (vc) and feed per flute (fz) on the cutting forces, surface roughness and burr width are reported. RMS values of longitudinal feed force (FX), transverse cutting force (FY) and vertical thrust force (FZ) were measured and the maximum values for Al 6061 are 0.33 N, 0.16 N and 0.21 N respectively, and the same for copper are measured to be 0.11 N, 0.17 N and 0.22 N respectively. Average surface roughness along the milling direction (Ra) at the bottom surface of the micro-channel was measured. Smoother surfaces were generated at lower feed per flute in both the materials. Ra is found to be varying from 28.2 nm to 86.9 nm for Al 6061, and for copper, the range is from 4.9 nm to 32.7 nm. SEM images of the micro-channels were analysed and top burr width was measured in both up-milling and down-milling directions. Higher feed per flute produced smaller burrs in both up-milling and down-milling directions. Maximum burr width for Al 6061 is measured to be 12.86 μm and 15.28 μm in up-milling and down-milling direction respectively, and for copper, the same are measured to be 12.84 μm and 20.46 μm respectively.

Research on Surface Roughness of Slender Shaft in Ultrasonic Vibration Turning

2014 ◽  
Vol 800-801 ◽  
pp. 580-584
Author(s):  
Liang Yang ◽  
Lei Sun ◽  
Li Xu
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Parameters ◽  
Orthogonal Test ◽  
Second Step ◽  
Work Piece ◽  
Test Design ◽  
Extreme Position ◽  
Experimental Parameters ◽  
Orthogonal Test Design

According to the principle of ultrasonic vibration turning, the first step is to study different position changes of surface roughness with cutting parameters under ultrasonic vibration turning of slender shaft by the test of single factor, and determining the extreme position of surface roughness with the slender shaft changes in different cutting conditions. The second step is to study the influence of cutting parameters on the overall average surface roughness of work piece under ultrasonic vibration turning of slender shaft by orthogonal test design, and compared with the conventional turning. The experimental results show that ultrasonic vibration turning slender shaft processing can significantly improve the surface roughness. At the same time, the influence laws of cutting parameters on the surface roughness are investigated, and finding out the optimal cutting experimental parameters. Key words: slender shaft; ultrasonic vibration turning; surface roughness; orthogonal test design.

Studies on Ceramic Cutting Tool Wear for the High Speed Milling Nickel-Based Superalloy

2014 ◽  
Vol 800-801 ◽  
pp. 501-505
Author(s):  
Can Zhao ◽  
Yang Yang Shi ◽  
Min Qi ◽  
Zi Biao Wang ◽  
Wang Xi
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Parameters ◽  
Second Step ◽  
Work Piece ◽  
Nickel Based Superalloy ◽  
Experimental Parameters ◽  
Orthogonal Test Design

According to the principle of ultrasonic vibration turning, the first step is to study different position changes of surface roughness with cutting parameters under ultrasonic vibration turning of slender shaft by the test of single factor, and determining the extreme position of surface roughness with the slender shaft changes in different cutting conditions. The second step is to study the influence of cutting parameters on the overall average surface roughness of work piece under ultrasonic vibration turning of slender shaft by orthogonal test design, and compared with the conventional turning. The experimental results show that ultrasonic vibration turning slender shaft processing can significantly improve the surface roughness. At the same time, the influence laws of cutting parameters on the surface roughness are investigated, and finding out the optimal cutting experimental parameters.

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