Influence of Cutting Parameters on Machinable Glass Ceramic Processed by End Milling

2011 ◽  
Vol 264-265 ◽  
pp. 825-830 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Khaled A. Abou-El-Hossein ◽  
Alexander Gorin
Keyword(s):  
Glass Ceramic ◽  
End Milling ◽  
Research Work ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
End Mill ◽  
Roughness Model ◽  
Solid Carbide ◽  
Dry Conditions ◽  
Axial Depth

This experimental research work attempted to use End milling on Machinable Glass Ceramic (MGC) using micro grain solid carbide end mill under dry conditions. The predictive Surface Roughness model has been developed in terms of Spindle speed, Feed rate and axial depth of cut by Response Surface Methodology (RSM). The influence of each milling parameter analyzed and results showed that axial depth of cut was the most dominant variable. The adequacy of the model has been verified by ANOVA.

Surface Roughness Model when Machining Aluminum Nitride Ceramic with Two Flute Square End Micro Grain Solid Carbide End Mill

2013 ◽  
Vol 747 ◽  
pp. 282-286 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Alexander Gorin ◽  
K.A. Abou-El-Hossein ◽  
D. Sujan
Keyword(s):  
Surface Roughness ◽  
Aluminum Nitride ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
End Mill ◽  
Roughness Model ◽  
Solid Carbide

This research presents the performance of Aluminum Nitride ceramic in end milling using two flute square end micro grain solid carbide end mill under dry cutting. Surface finish is one of the important requirements in the machining process. This paper describes mathematically the effect of cutting parameters on surface roughness in end milling process. The quadratic model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using the response surface methodology (RSM). Design of experiments approach was employed in developing the surface roughness model in relation to cutting parameters. The predicted results are in good agreement with the experimental results within the specified range of cutting conditions. Experimental results showed surface roughness increases with increase in the cutting speed, feed rate, and the axial depth of cut.

The Investigation of Prediction Surface Roughness from Machining Forces in End Milling Processes

2011 ◽  
Vol 486 ◽  
pp. 91-94 ◽  
Author(s):  
Jabbar Abbas ◽  
Amin Al-Habaibeh ◽  
Dai Zhong Su
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Irregular Waves ◽  
Depth Of Cut ◽  
End Mill ◽  
Machined Surface ◽  
Machining Forces ◽  
Mill Cutter

Surface roughness is one of the most significant parameters to determine quality of machined parts. Surface roughness is defined as a group of irregular waves in the surface, measured in micrometers (μm). Many investigations have been performed to verify the relationship between surface roughness and cutting parameters such as cutting speed, feed rate and depth of cut. To predict the surface produced by end milling, surface roughness models have been developed in this paper using the machining forces by assuming the end mill cutter as a cantilever beam rigidly or semi- rigidly supported by tool holder. An Aluminium workpiece and solid carbide end mill tools are used in this work. Model to predict surface roughness has been developed. Close relationship between machined surface roughness and roughness predicted using the measured forces signals.

Multi-objective optimisation on end milling of hybrid fibre-reinforced polymer composites using GRA

2017 ◽  
Vol 46 (3) ◽  
pp. 194-202 ◽  
Author(s):  
M.P. Jenarthanan ◽  
Raahul Kumar S ◽  
Vinoth S
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Helix Angle ◽  
Inspection System ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Content Type ◽  
Gfrp Composite ◽  
Solid Carbide

Purpose This study aimed to develop a mathematical model for delamination and surface roughness during end milling by using grey relational analysis (GRA) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre-reinforced plastic (GFRP) (abaca and glass) composite using solid carbide end mill cutter. Design/methodology/approach The Four factors, three levels Taguchi orthogonal array design in GRA is used to conduct the experimental investigation. The Shop Vision inspection system is used to measure the width of maximum damage of the machined hybrid GFRP composite. The Shop Handysurf E-35A surface roughness tester is used to measure the surface roughness of the machined hybrid GFRP composite. “Minitab 14” is used to analyse the data collected graphically. Analysis of variance is conducted to validate the model in determining the most significant parameter. Findings The GRA is used to predict the input factors influencing the delamination and surface roughness on the machined surfaces of the hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination and surface roughness has been conducted using GRA. Originality/value Effect of milling of the hybrid GFRP composite on delamination and surface roughness with various helix angle solid carbide end mill has not been analysed yet using the GRA technique.

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.

Study of Cutting Parameters Effects in MQL-Employed Hard-Milling Process for AISI H13 for Tool Life

2013 ◽  
Vol 393 ◽  
pp. 240-245 ◽  
Author(s):  
Nitin G. Phafat ◽  
Ravindra R. Deshmukh ◽  
Sudhir D. Deshmukh
Keyword(s):  
Tool Life ◽  
Research Work ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Milling Process ◽  
Depth Of Cut ◽  
Aisi H13 ◽  
Coated Carbide ◽  
Notch Wear ◽  
Axial Depth

In this research work, the effects of three parameters, namely, cutting speed, feed and axial depth of cut were studied upon tool life. The milling was performed under environment of minimum quantity of lubrication (MQL), using coated carbide inserts. For tool life, cutting speed was found as the most influential parameter followed by the axial depth of cut and feed rate. High values of cutting speed proved unfavorable for tool life. The major tool damage mechanisms detected were notch wear, diffusion, adhesion, and chipping. The severity of chipping was relatively smaller as compared to that of adhesion and of notch wear because of effective application of MQL employed. The encouraging results include significant increase in tool life by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.

Mathematical modeling of delamination factor on end milling of hybrid GFRP composites through RSM

2016 ◽  
Vol 45 (5) ◽  
pp. 371-379 ◽  
Author(s):  
M.P. Jenarthanan ◽  
A. Lakshman Prakash ◽  
R. Jeyapaul
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Gfrp Composite ◽  
Solid Carbide ◽  
Mill Cutter

Purpose This paper aims to develop a mathematical model for delamination during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut and feed rate) influence the output response (delamination) in machining of hybrid glass fibre reinforced plastic (GFRP; abaca and glass) composite using solid carbide end mill cutter. Design/methodology/approach Three factors, three levels Box–Behnken design in RSM is used to carry out the experimental investigation. Shop microscope Mitutoyo TM-500 is used to measure the width of maximum damage of the machined hybrid GFRP composites. The “Design Expert 8.0” is used to analyse the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter. Findings The RSM is used to predict the input factors influencing the delamination on the machined surfaces of hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination has been carried out using RSM. Originality/value Effect of milling of hybrid GFRP composite on delamination with solid carbide end mill has not been analysed yet using RSM.

scholarly journals Analyzing the Effectiveness of Microlubrication Using a Vegetable Oil-Based Metal Working Fluid during End Milling AISI 1018 Steel

2014 ◽  
Vol 2014 ◽  
pp. 1-13 ◽  
Author(s):  
Vasim Shaikh ◽  
Nourredine Boubekri ◽  
Thomas W. Scharf
Keyword(s):  
Vegetable Oil ◽  
End Milling ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Metal Working ◽  
Solid Carbide ◽  
Scanning Electron Microscope Investigation

Microlubrication minimizes the exposure of metal working fluids to the machining operators leading to an economical, safer, and healthier workplace environment. In this study, a vegetable oil-based lubricant was used to conduct wear analysis and to analyze the effectiveness of microlubrication during end milling AISI 1018 steel. A solid carbide cutting tool with bright oxide finish was used with varying cutting speed and feed rate having a constant depth of cut. Abrasion was the dominant wear mechanism for all the cutting tools under consideration. Other than abrasion, sliding adhesive wear of the workpiece materials was also observed. The scanning electron microscope investigation of the used cutting tools revealed microfatigue cracks, welded microchips, and unusual built-up edges on the cutting tools flank and rake side. A full factorial experiment was conducted and regression models were generated for both the sides of tool flank wear. The study shows that with a proper selection of the cutting parameters it is possible to obtain higher tool life.

scholarly journals Investigating the Possibility to Reduce the Residual Stress Level in 2.5D Cutting Using Titanium Coated Carbide Ball End Mill

2014 ◽  
Vol 2014 ◽  
pp. 1-13 ◽  
Author(s):  
N. Masmiati ◽  
H. S. Chan ◽  
Ahmed A. D. Sarhan ◽  
M. A. Hassan ◽  
M. Hamdi
Keyword(s):  
Residual Stress ◽  
End Milling ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Response Analysis ◽  
End Mill ◽  
Ball End Mill ◽  
Taguchi Optimization ◽  
Machined Surface ◽  
Coated Carbide

End milling is a multipoint cutting process in which material is removed from a workpiece by a rotating tool. It is widely used in cutting 2.5D profiles such as point-to-point, contouring, and pocketing operations. 2.5D machining possesses the capability to translate in all 3 axes but can perform the cutting operation in only 2 of the 3 axes at a time. This study focuses on optimizing the cutting parameters, such as machined surface inclinationangle, axial depth of cut, spindle speed, and feed rate for better surface integrity, namely, microhardness, residual stress, and microstructure in 2.5D cutting utilizing a titanium-coated carbide ball end mill. An optimization method known as Taguchi optimization, which includes planning, conducting, and analyzing results of matrix experiments, was used in order to achieve the best cutting parameter level. Data analysis was conducted using signal-to-noise (S/N) and target performance measurement (TPM) response analysis and analysis of variance (Pareto ANOVA). The optimum condition results obtained through analysis show improvements in microhardness of about 0.7%, residual stress in the feed direction of about 18.6%, and residual stress in the cutting direction of about 15.4%.

Optimization of Cutting Parameters of Multiple Performance Characteristics in End Milling of AlSi/AIN MMC – Taguchi Method and Grey Relational Analysis

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
S. H. Tomadi ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim ◽  
A. R. Daud
Keyword(s):  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Volume Fraction ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Relational Analysis ◽  
Grey Relational

The main objective of this paper is to investigate and optimize the cutting parameters on multiple performance characteristics in end milling of Aluminium Silicon alloy reinforced with Aluminium Nitride (AlSi/AlN MMC) using Taguchi method and Grey relational analysis (GRA). The fabrication of AlSi/AlN MMC was made via stir casting with various volume fraction of particles reinforcement (10%, 15% and 20%). End milling machining was done under dry cutting condition by using two types of cutting tool (uncoated & PVD TiAlN coated carbide). Eighteen experiments (L18) orthogonal array with five factors (type of tool, cutting speed, feed rate, depth of cut, and volume fraction of particles reinforcement) were implemented. The analysis of optimization using GRA concludes that the better results for the combination of lower surface roughness, longer tool life, lower cutting force and higher material removal could be achieved when using uncoated carbide with cutting speed 240m/min, feed 0.4mm/tooth, depth of cut 0.3mm and 15% volume fraction of AlN particles reinforcement. The study confirmed that with a minimum number of experiments, Taguchi method is capable to design the experiments and optimized the cutting parameters for these performance characteristics using GRA for this newly develop material under investigation.

The Effects of Cutting Parameters on Work-Hardening of Milling Invar 36

2015 ◽  
Vol 1089 ◽  
pp. 373-376
Author(s):  
Xing Wei Zheng ◽  
Guo Fu Ying ◽  
Yan Chen ◽  
Yu Can Fu
Keyword(s):  
Work Hardening ◽  
Lattice Distortion ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Metallographic Structure ◽  
Metallographic Observation ◽  
Coated Carbide ◽  
Carbide Insert ◽  
Axial Depth

An experiment of face milling of Invar36 was conducted by using coated carbide insert, the microhardness was tested and the metallographic structure was observed to figure out the principles of work-hardening. The results showed that the depth of work-hardening ranges from 80μm to 160μm among the parameters selected in the experiments. The degree and the depth of work-hardening were significantly affected by the axial depth of cut and feed per tooth. The degree and the depth of work-hardening showed a tendency to increase with the increase of the axial depth of cut and feed per tooth. Compared with the axial depth of cut and feed per tooth, cutting speed had less influence on the degree and depth of work-hardening. The degree and depth of work- hardening decreased slowly with the increase of cutting speed. Metallographic observation showed that work-hardening layer consisted of the thermal force influenced layer and the force influenced layer, while the amorphous metallographic structure was observed in the thermal force influenced layer, and lattice distortion was observed in the force influenced layer.

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