Experimental Investigation of Effects of Machining Parameters on Surface Roughness and Chip Formation of Aluminum Alloys by Face Turning

2015 ◽  
Vol 799-800 ◽  
pp. 299-306
Author(s):  
Meshack Olygen Kusimba ◽  
Seong Joo Choi
Keyword(s):  
Surface Roughness ◽  
Chip Formation ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Atomic Force ◽  
Roughness Analysis ◽  
The Face

This paper investigates the effect of process parameters on surface roughness and chips formation in face turning of aluminium A2025 alloy international standard or A3035 alloy Korean standard using conventional lathe. The parameters namely the spindle speed, depth of cut and feed rate are varied to study their effect on surface roughness and chip characteristics. The experiments are conducted with all possible combination of factors in order to get the influence of every factor. The study reveals that the surface roughness is directly influenced by the spindle speed, depth of cut and feed rate. It is observed that the surface roughness increases with increased feed rate and depth of cut and is higher atlower speeds. The surface roughness analysis was done by atomic force microscope (AFM).The chips formed were continuous but varied in size and shape basing on the machining parameters. The depth of cut has no significant influence on the chips formation. The results shown here shows the ability of face turning method to test the surface roughness and chip formation on aluminium alloys. The face turning method used is simple and effective.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

scholarly journals The influence of machining parameters on surface roughness of MDF in milling operation

BioResources ◽  
2019 ◽  
Vol 14 (2) ◽  
pp. 3266-3277
Author(s):  
Ümmü K. İşleyen ◽  
Mehmet Karamanoğlu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Medium Density Fiberboard ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Operation ◽  
Four Levels ◽  
Tool Diameter

This paper examined the effect of machining parameters on surface roughness of medium density fiberboard (MDF) machined using a computer numerical control (CNC) router. The machining parameters such as spindle speed, feed rate, depth of cut, and tool diameter were examined for milling. The experiments were conducted at two levels of spindle speeds, four levels of feed rates, two levels of tool diameters, and two levels of axial depths of cut. The surface roughness values of MDF grooved by CNC were measured with stylus-type equipment. Statistical methods were used to determine the effectiveness of the machining parameters on surface roughness. The influence of each milling parameter affecting surface roughness was analyzed using analysis of variance (ANOVA). The significant machining parameters affecting the surface roughness were the feed rate, spindle speed, and tool diameter (p < 0.05). There was no significant influence of axial depth of cut on the surface roughness. The surface roughness decreased with increasing spindle speed and decreasing feed rate. The value of surface roughness increased with the increase of tool diameter.

Rapid and Versatile Micromold Fabrication Using Micromilling and Nanopolishing for Microfluidic Devices

2019 ◽  
Author(s):  
Thanh-Qua Nguyen ◽  
Jeongmin Mah ◽  
Woo-Tae Park ◽  
Sangyoup Lee
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Surface ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Milling ◽  
Tool Marks ◽  
Mold Fabrication

Abstract In an effort to make microfluidic research more attractive and cost-effective, micromilled polymethyl methacrylate (PMMA) has gained interests as an alternative method to the conventional cleanroom-based micromolds fabrication technologies. The most enabling aspects of micromilling are flexibility on the design changes and the ability to fabricate three-dimensional structures. However, the major drawback of micromilling based micromold fabrication is the presence of burrs and tool marks on the surface after machining. High surface roughness on replicated polymer results in poor bonding strength and optical clarity. The roughness of micromilled surface strongly depends on the machining parameters such as tool size, spindle speed, feed rate, width of cut, and depth of cut. Thus, it is crucial to optimize the machining parameters to obtain a good surface finish. Although the optimal fabrication parameters are used to machine the micromold, the surface roughness of micromilled mold is still relative high compared to the surface of unprocessed PMMA. In this paper, we first optimize the micromilling parameters of Computer Numerical Control (CNC) milling machine to achieve the best possible of surface roughness. We have optimized the machining parameters for a flat endmill with 100 μm, 200 μm, and 400 μm in diameter of spindle speed, feed rate, width of cut, and the depth of cut respectively at 18000 rpm, 20 mm/min, 30 μm, and 20 μm. Then, a method to polish the structured surface of the micromilled mold was developed using the rotary magnetic field. By modifying the CNC program language G-code, we were able to control the polishing path, polishing force and time precisely. Consequently, the burrs and tool marks are completely removed, such that the roughness of the surface is decreased from 350 nm Ra to 30 nm Ra, and 1200 nm Rz to 300 nm Rz while the profile of microstructures is not deteriorated. Finally, we demonstrate our mold fabrication scheme by building a microfluidic immunoassay device with four Quake’s valves and showed the sequential assay process successfully.

Study on Surface Roughness in Minimum Quantity Lubrication Turning of Al-6082/SiC Metal Matrix Composites

2019 ◽  
Vol 895 ◽  
pp. 127-133 ◽  
Author(s):  
C.J. Vishwas ◽  
M. Naik Gajanan ◽  
B. Sachin ◽  
Roy Abhinaba ◽  
N.P. Puneet ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composites ◽  
Feed Rate ◽  
Metal Matrix ◽  
Minimum Quantity Lubrication ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Minimum Quantity

Aluminum-based metal matrix composites (MMCs) have been suggested due to intense interest from automobile, marine, aerospace and other structural applications owing to their balanced mechanical, physical and chemical properties. MMCs are manufactured in order to meet present demand such as low material density, high mechanical strength and higher wear resistance of the component. Generally,MMCs tend to form rougher surface during machining because of the abrasive nature of hard ceramic particles present in them. Stir casting technique was used for fabrication of this composite which ensures better homogeneity.Furthermore, an attempt has been made in this paper to examine the results on the surface roughness of Al-6082/SiC metal matrix composites (containing 0%, 5% and 10% SiC particles).Focus was spent on parametric optimization of these composites in order to achieve cost-effective machining limits. The machining parameter studies have been carried out through the design of experiments (DoE) under minimum quantity lubrication (MQL) condition and effect of machining parameters such as spindle speed, feed rate and depth of cut on surface roughness was investigated to analyze the influence of reinforcement on surface roughness. In addition, analysis of variance was studied to obtain percentage contribution of machining parameters involved. Also, the surface morphology of the machined surface was studied through a scanning electron microscope (SEM). Distribution of SiC in aluminum alloy is fairly uniform with few clusters. Results of the experiments revealed that most significant turning parameter for surface roughness was spindle speed followed by feed rate and depth of cut. Furthermore, an optimal setting parameter for getting lower surface roughness was presented in confirmation table.

Evaluation of Face Milling Operation Parameters on Surface Roughness of Crankcase Housing by Two Level Factorial Design with Center Points

2018 ◽  
Vol 780 ◽  
pp. 105-110
Author(s):  
Ukrit Thanasuptawee ◽  
Chamrat Thakhamwang ◽  
Somsak Siwadamrongpong
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Milling Process ◽  
Face Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Significance Level ◽  
Machining Center ◽  
Semi Solid

In this study, there are three machining parameters consist of spindle speed, feed rate and depth of cut which were conducted through full factorial with four center points to determine the effect of machining parameters on the surface roughness and verify whether there is curvature in the model for CNC face milling process in an automotive components manufacturer in Thailand. The workpieces used semi-solid die casted ADC12 aluminum alloy crankcase housing which they were performed by the ARES SEIKI model R5630 3-axis CNC vertical machining center and face milling cutter with diameter of 63 millimeters. The surface roughness of face-milled was measured by the surface roughness tester. It was found that the greatest main effect influence to surface roughness was spindle speed, followed by feed rate and depth of cut at significance level of 0.05.

scholarly journals Investigation the Optimization of Machining Parameters to Surface Roughness in Free Form Surface of Composite Material

2019 ◽  
Vol 15 (2) ◽  
pp. 60-69
Author(s):  
Reem S. Kazaal ◽  
Wisam K. Hamdan
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Feed Rate ◽  
Spindle Speed ◽  
Free Form ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Side Milling ◽  
Vertical Milling Machine ◽  
Free Form Surface

The aim of this research is to investigation the optimization of the machining parameters (spindle speed, feed rate, depth of cut, diameter of cutter and number of flutes of cutter) of surface roughness for free-form surface of composite material (Aluminum 6061 reinforced boron carbide) by using HSS uncoated flat end mill cutters which are rare use of the free-form surface. Side milling (profile) is the method used in this study by CNC vertical milling machine. The purpose of using ANFIS to obtain the better prediction of surface roughness values and decreased of the error prediction value and get optimum machining parameters by using Taguchi method for the best surface roughness at spindle speed 4500 r.p.m, 920mm/rev feed rate, 0.6mm depth of cut, 10mm diameter, 2 flute.

Analysis of Machining Parameters in Turning Operation on Duplex 2205 by using RSM for Vehicle Structure

2019 ◽  
Vol 11 (1) ◽  
Author(s):  
V. Vijayan ◽  
B. Sureshkumar ◽  
G. Sathishkumar ◽  
R. Yokeshwaran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Operation ◽  
Feed Force ◽  
Cylindrical Parts

Turning is the machining process carried out to make cylindrical parts. Since the process is economical and the flexibility of turning operation is high, the process has become highly versatile among the industrial scenario. The design of experiments concept along with response surface methodology is used to analyze the machining parameters such as spindle seed, feed rate and depth of cut, of the turning operation. Three levels of spindle speed, feed rate and depth of cut are used as input parameters and their corresponding responses such as material removal rate (M.R.R), surface roughness, feed force, thrust force and cutting force are considered as the output parameters. The main aim of this experimentation process is to identify the optimal process parameters to get high M R R and low surface roughness. During high spindle speed, the M R R is high and vice versa. Surface roughness is high when its corresponding spindle speed and depth of cut is high. A high spindle speed, the chip formation is continuous whereas in medium speed, discontinuous chip is formed. M.R.R is high when spindle speed, depth of cut and feed rate are high.

scholarly journals Optimizing Cutting Conditions for Minimum Surface Roughness in Face Milling of High Strength Steel Using Carbide Inserts

2016 ◽  
Vol 2016 ◽  
pp. 1-14 ◽  
Author(s):  
Adel Taha Abbas ◽  
Adham Ezzat Ragab ◽  
Essam Ali Al Bahkali ◽  
Ehab Adel El Danaf
Keyword(s):  
Surface Roughness ◽  
Factorial Design ◽  
Feed Rate ◽  
High Strength Steel ◽  
High Strength ◽  
Face Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Quadratic Term ◽  
Machining Parameters

A full factorial design technique is used to investigate the effect of machining parameters, namely, spindle speed(N), depth of cut(ap),and table feed rate(Vf),on the obtained surface roughness (RaandRt) during face milling operation of high strength steel. A second-order regression model was built using least squares method depending on the factorial design results to approximate a mathematical relationship between the surface roughness and the studied process parameters. Analysis of variance was conducted to estimate the significance of each factor and interaction with respect to the surface roughness. ForRa, the results show that spindle speed, depth of cut, and table feed rate have a significant effect on the surface roughness in both linear and quadratic terms. There is also an interaction between depth of cut and feed rate. It also appears that feed rate has the greatest effect on the data variation followed by depth of cut. ForRt, the results show that the table feed rate is the most effective factor followed by the depth of cut, while the spindle speed had a significant small effect only in its quadratic term. The conditions of minimumRaandRtare identified through least square optimization. Moreover, multiobjective optimization for minimizingRaand maximizing metal removal rateQis conducted and the results are presented.

Optimization of Milling Parameter for Untreated and Heat Treated Polyetheretherketones (PEEK) Biomaterials

2015 ◽  
Vol 761 ◽  
pp. 293-297
Author(s):  
Raja Izamshah ◽  
A. Yu Lung ◽  
Effendi Mohamad ◽  
Mohd Asyadi Azam ◽  
Mohd Amri ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Heat Treated ◽  
Machining Parameter

Polyetheretherketones (PEEK) have been widely used as biomaterials for trauma, orthopedics and spinal implants. However, machining of this material poses several challenges such as rough machined surface which can affect the implant functional application. This research attempts to optimize the machining parameter (cutting speed, feed rate and depth of cut) for effectively machining Polyetheretherketones (PEEK) implant material using carbide cutting tools. Apart from optimizing machining parameters, effects of annealing condition on PEEK towards surface qualities are discuss. Response Surface Methodology (RSM) technique was used to evaluate the effects of the parameters and their interaction towards the ability of the optimum conditions. Based on the analysis results, the optimal machining parameter to obtain the smallest surface roughness values were by using spindle speed of 5754 rpm, feed rate of 0.026 mm/tooth and 5.11 mm depth of cut for un-annealed PEEK. As for the annealed PEEK to get the smallest surface roughness values were by using spindle speed of 5865 rpm, feed rate of 0.025 mm/tooth and 2 mm depth of cut.

Prediction of Surface Roughness and Optimization of Cutting Parameters in CNC Turning of Rotational Features

2020 ◽  
Vol 38 (8A) ◽  
pp. 1143-1153
Author(s):  
Yousif K. Shounia ◽  
Tahseen F. Abbas ◽  
Raed R. Shwaish
Keyword(s):  
Surface Roughness ◽  
Linear Regression ◽  
Regression Model ◽  
Linear Regression Model ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Non Linear ◽  
Optimization Of Cutting Parameters

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

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