An Experimental Study of Hard Dry Milling Based on Multi-Sensor Process Monitoring and Analysis

2010 ◽  
Vol 108-111 ◽  
pp. 1086-1091
Author(s):  
Li Bing Liu ◽  
Xi Wang ◽  
Wei Wu Zhong ◽  
Hui Yu ◽  
Dong Ting Liao ◽  
...  
Keyword(s):  
Virtual Instrument ◽  
Wavelet Packet ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Hard Milling ◽  
Vibration Signals ◽  
Ae Signals

This paper aims to collect the acoustic emission (AE), the vibration and the temperature signals produced in the hard dry milling of the die steel by using a signal collecting system based on multi-sensor and virtual instrument. Then the signals are processed by the wavelet transform and the wavelet packet transform. So we could pick up some regular pattern which could reflect the characteristic of the machining process from the results. The cutting parameters are set with single factor method and the experiment primarily focuses on researching the effect of changing the cutting parameters on the three signals mentioned forward. Through the experiment, some conclusions could be drawn as follow. In the process of the die steel’s hard dry milling, the spindle speed has a great effect on the AE signals. The temperature is mainly involved with the spindle speed and the depth of cut. The vibration signals have any clear pattern when the cutting parameter changes, but the energy of the vibration signals concentrate mostly on the first frequency band. Furthermore, the process of the hard milling is more stable.

An Experimental Study on Electric Hot Milling for T10A Tool Steel

2011 ◽  
Vol 117-119 ◽  
pp. 1843-1846
Author(s):  
Yu Cai Chen ◽  
Xi Wang ◽  
Li Bing Liu ◽  
Dong Ting Liao ◽  
Fei Wu
Keyword(s):  
Tool Steel ◽  
Cutting Tool ◽  
Wavelet Packet ◽  
Machining Process ◽  
Signal Acquisition ◽  
Dry Milling ◽  
Vibration Signals ◽  
Milling Tool ◽  
Milling Method ◽  
Tool Durability

This paper introduces a kind of electric hot milling method for T10A tool steel and analyses its feasibility. Collect temperature signals and vibration signals in the machining process by a set of signal acquisition system. Afterwards, process these signals by using wavelet transform and wavelet packet transform, compare and analyze them in different working conditions. The results of the study indicate that through comparison between dry milling and electric hot milling, the latter can be more effectively milling tool steel, and improve the cutting tool durability.

Investigations of Milling Parameters on Hemp Fiber Reinforced Composite Using ANOVA and Regression

2018 ◽  
Vol 877 ◽  
pp. 177-182 ◽  
Author(s):  
Kundan Patel ◽  
Keval Patel ◽  
Piyush Gohil ◽  
Vijaykumar Chaudhary
Keyword(s):  
Composite Structures ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Vital Role ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Fiber Reinforced ◽  
Hemp Fiber ◽  
Delamination Factor

The machinability of fiber reinforced composites is emphatically affected not only by the kind of fiber used in the composite but also by its properties. Milling composite materials is a very usual and plays a vital role for the assembly of composite structures. However, milling of composites is a somewhat complicated errand inferable from the heterogeneity of the material and a plenty of different issues, for instance, delamination factor, which show up amid the machining process and are connected with the qualities of the material and the cutting parameters. Present study looks into the influence of spindle speed, feed rate and depth of cut on thrust force, torque and delamination factor in hemp fiber reinforced polyester composites. The composite specimens were formulated using hand lay-up method. The analysis for attaining the optimality condition is performed using ANOVA and regression model. It was observed that the grouping of the inferior value of feed (0.1 mm/rev), lower spindle speed (1500 rpm) as well as the lower depth of cut (1.5 mm) results in minimum delamination factor and torque. The feed was found to be more significant than the depth of cut for thrust force.

scholarly journals Influence of Cutting Parameters to Surface Area Roughness in Dimple Machining Using Milling Process

2021 ◽  
Vol 18 (3) ◽  
Author(s):  
M.A. Hanafiah ◽  
A.A. Aziz ◽  
A.R. Yusoff
Keyword(s):  
Surface Area ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Ball End Mill

Surface quality is among the predominant criterion in measuring machining process performance, including milling. It is extremely dependent on the process variable, such as cutting parameters and cutting tool conditions. The main intention of this research work is to study the effect of the milling machining parameters, including depth of cut, spindle speed, feed rate as well as machining pattern to the final surface area roughness of the fabricated dimple structure. The concave profile of the dimple is machined at the right angle to a flat Al6061 specimen using a ball end mill attached to a 3-axis CNC milling machine, and the surface area of the concave profile is measured using 3D measuring laser microscope. It is observed that surface area roughness reacts with the spindle speed and feed rate with different tool sizes. Based on the result gained, the work has successfully characterised the influence of studied milling parameters on the dimple surface area roughness, where within the range of the studied parameter, the surface area roughness varies only less than 2.2 μm. The research work will be continued further on the incline milling technique and micro size ball end mill.

scholarly journals Pengaruh Parameter Pemotongan Pada Proses Bubut Ulir (Threading) Terhadap Kepresisian Geometri Ulir Magnesium Paduan AZ31

2019 ◽  
Vol 12 (1) ◽  
pp. 1
Author(s):  
Gusri Akhyar Ibrahim ◽  
Alan Suseno ◽  
Arinal Hamni
Keyword(s):  
Stainless Steel ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Mg Alloy ◽  
Depth Of Cut ◽  
Biomedical Material ◽  
Pitch Error ◽  
Magnesium Az31 ◽  
Stainless Steel Screws

Magnesium telah dikembangkan dalam bidang kedokteran yaitu sebagai material untuk implan dalam tubuh. Hasil penelitian sebelumnya menunjukan bahwa faktor utamanya adalah sifat magnesium sangat mirip dengan sifat tulang manusia. Sekrup AZ31 menunjukkan kekuatan tarik keluar yang serupa dengan sekrup stainless steel saat ditarik dari bahan tulang sintetis, dan tingkat degradasi jenis sekrup Mg-alloy di ruang tulang sumsum dan otot lebih cepat daripada di ruang tulang kortikal. Hal ini menunjukan bahwa pembuatan ulir pada magnesium AZ31 sangat mendukung untuk diaplikasikan pada bidang material biomedic. Kepresisian geometri ulir akan memberikan pengaruh terhadap kwalitas ulir, terutama pada saat ulir bekerja bila sudah digunakan sebagai penyambung tulang. Untuk mengatasi masalah tersebut, dapat dilakukan variasi pada parameter proses pemesinan magnesium, yaitu parameter pemotongan pada saat pembubutan ulir untuk mendapatkan hasil yang paling baik akurasinya. Hasil penelitian menunjukan nilai kesalahan tinggi ulir minimum yaitu 0,018188 mm didapatkan pada parameter kecepatan spindel 424 rpm dan kedalaman potong 0,433015. Nilai kesalahan jarak puncak ulir (pitch) minimum yaitu 0,0205 mm didapatkan pada parameter kecepatan spindel 212 rpm dan kedalaman potong 0,649523 mm. Nilai kesalahan sudut minimum yaitu 0,603 didapatkan pada parameter kecepatan spindel 212 rpm dan kedalaman potong 0,324761 mm. Magnesium has been developed in the field of medic as a material for implants. The results of previous studies show that the main factor is the characteristic of magnesium very similar to the characteristic of human bones. AZ31 screws show outward tensile strength similar to stainless steel screws when pulled from synthetic bone material, and the degradation rate of Mg-alloy screw types in the marrow and muscle bone space is faster than in cortical bone space. This shows that the screw making on magnesium AZ31 is very possible to be applied in the biomedical material field.The precision of the screw geometry will have an effect on the quality of the thread, especially when the screw works when it has been used as a bone joint. To overcome this problem, variations in the machining process parameters are carried out, the cutting parameters at the time of screw turning to get the best accuracy results. The results showed that the minimum screw depth error value is 0.018188 mm, obtained at the spindle speed parameter of 424 rpm and depth of cut 0.433015 mm. The minimum pitch error value is 0.0205 mm obtained on the parameters of the spindle speed of 212 rpm and depth of cut 0.649523 mm. The minimum angle error value is 0.603 ° obtained in the parameters of the spindle speed 212 rpm and the depth of cut 0.324761 mm.

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.

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.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

Analysis of Vibration Signals in Monitoring Titanium End Milling Process Using Triaxial Accelerometer

2021 ◽  
Author(s):  
John Henry Navarro-Devia ◽  
Dzung Viet Dao ◽  
Yun Chen ◽  
Huaizhong Li
Keyword(s):  
Titanium Alloys ◽  
Frequency Domain ◽  
Single Channel ◽  
End Milling ◽  
Cutting Parameters ◽  
Frequency Component ◽  
Spindle Speed ◽  
Triaxial Accelerometer ◽  
Vibration Signals ◽  
Time Frequency

Abstract Vibrations during milling of hard-to-cut materials can cause low productivity, inferior quality and short tool life. It is one of the common issues in the machining of hard-to-cut materials employed in aerospace applications, such as titanium alloys. This paper presents an analysis of the vibration signals in the 3 axes of movement during titanium end milling, under diverse cutting parameters, manipulating spindle speed and feed rate. Signals were obtained using a triaxial accelerometer and processed in MATLAB. The analysis was conducted in the frequency-domain and the time-frequency domain. The results show that high-frequency vibration could occur in any direction with different amplitudes. Response on each axis depends on spindle speed, feed, and type of milling. A frequency component continually appeared in each axis regardless of cutting conditions and is located near the natural frequencies. Finally, the triaxial accelerations were compared for the milling cases with a new and a worn tool. Results highlight the importance and need for continuous monitoring of vibration in the 3 axes, instead of only using a single-channel signal, providing experimental data which could expand knowledge relating to the milling of titanium alloys.

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.

Corrosion Behaviour and Microhardness during Dry and Flood Milling of Ti-6Al-4V Alloy

2019 ◽  
Vol 796 ◽  
pp. 91-96
Author(s):  
Esther Titilayo Akinlabi ◽  
Ipfi Mathoho ◽  
Mukuna Patrick Mubiayi
Keyword(s):  
Corrosion Resistance ◽  
Cutting Tool ◽  
Corrosion Behaviour ◽  
Milling Process ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Milled Surface ◽  
Milling Condition

Milling process is the removal of unwanted materials so as to produce the required shape. The purpose of this study was to investigate the effect of milling process parameters and the cooling technique on corrosion behaviour and microhardness of TI-6AL-4V. Milling of Ti-6Al-4V was carried out using tungsten carbide cutting tool while varying spindle speed (120,150, and 180 rev/min), depth of cut (1, 1.5 and 2 mm) and the feed rate remained unchanged at 4.6 mm/min. Subsequent to milling, characterization of subsurface microhardness and corrosion behaviour was conducted. It was found that varying spindle speed and depth of cut had an impact on microhardness. Furthermore, it was noticed that the type of milling condition (flood and dry milling) affected the subsurface microhardness and the corrosion behavior. The corrosion resistance of the milled surface was generated at 180 rev/min and 150 rev/min for the dry and flood milling respectively. Furthermore, the most corrosion resistance was obtained at 2 mm and 1.5 mm depth of cut during dry and flood milling respectively.

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