Research on Optimal Cutting Parameters of High-Speed Machining Based on Taguchi Method

2011 ◽  
Vol 403-408 ◽  
pp. 732-737
Author(s):  
Zhong Lin Tang ◽  
Hong Bin Liu
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
High Speed Machining ◽  
Cutting Depth ◽  
The Mean ◽  
Optimal Cutting Parameters ◽  
Different Levels

In order to find optimal cutting parameters of carbon steel C45, the optimizing experiment of the cutting parameters in High-Speed Machining based on Taguchi method is presented in this paper. High-Speed milling experiments were designed with high-speed machining tool and surface roughness tester as the equipment. The cutting speed, the feed per tooth and the cutting depth were selected as the cutting parameters while the surface roughness was taken as the criterion. The mean surface roughness and SNR of every factor at different levels was obtained. The effects of these parameters on the surface roughness have been researched by means of the analysis of variance, and then the optimal cutting parameters were found.

The Optimization of Cutting Parameters for Surface Roughness in High Speed Milling Based on Taguchi Method

2012 ◽  
Vol 723 ◽  
pp. 196-201 ◽  
Author(s):  
Peng Nan Li ◽  
Ming Chen ◽  
Xiao Jian Kang ◽  
Li Na Zhang ◽  
Ming Zhou
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
High Speed ◽  
Cutting Parameters ◽  
Milling Process ◽  
High Speed Milling ◽  
Aisi 1045 Steel ◽  
Optimization Of Cutting Parameters ◽  
1045 Steel ◽  
Optimal Cutting Parameters

In this study AISI 1045 steel of different hardness are used in high speed milling. According to Taguchi method, cutting parameters (milling speed, milling depth, feed per tooth) and workpiece hardness for the influence of high speed milling of the surface roughness are optimized. Through this study, not only the optimal cutting parameters of the minimum surface roughness is obtained, but also the main cutting parameters that effect performance in high speed milling is analysed. Researching results can be provided to guide establishment of the high speed milling process.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Research on Optimal Cutting Parameters of High-Speed Hard Machining Based on the Principal Component Analysis and Taguchi Method

2012 ◽  
Vol 233 ◽  
pp. 343-346
Author(s):  
Wen Hui Cao ◽  
Hong Bin Liu ◽  
Shen Song Wang ◽  
Ting Yang
Keyword(s):  
Principal Component Analysis ◽  
Taguchi Method ◽  
High Speed ◽  
Cutting Speed ◽  
Principal Component ◽  
Cutting Parameters ◽  
Component Analysis ◽  
Hard Machining ◽  
Optimal Cutting Parameters

The optimization of the parameters in high-speed milling was analyzed based on the principal component analysis and the Taguchi method. The cutting speed, feed per tooth and cutting depth were selected as the cutting parameters while the cutting force, cutting power and surface roughness parameters were selected as quality characteristics. The optimum cutting parameters were obtained and the comprehensive quality of high - speed hard machining has been guaranteed.

Parameters Optimization Research of High-Speed Milling PM60 Mould Steel Based on Taguchi Method

2016 ◽  
Vol 861 ◽  
pp. 75-83
Author(s):  
Ying Xing Xie ◽  
Cheng Yong Wang ◽  
Feng Ding ◽  
Wen Huang
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
High Speed ◽  
High Hardness ◽  
Cutting Parameters ◽  
Parameters Optimization ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Optimal Cutting Parameters

In order to obtain better surface quality after high speed milling high hardness mold steel, and reduce tool wear in cutting process, prolong the service life of cutting tools, obtain superior levels and optimal combination of cutting parameters in the test range. Through the design of orthogonal experiment, the use of Taguchi method, and noise ratio analysis and variance analysis of dry cutting high hardness mould steel PM60 under different cutting parameters; and finally, the optimal cutting parameters of surface roughness and cutting force value were predicted and verified. Research showed that: the worst cutting parameters influenced the surface roughness Ra was radial depth of cut ae, its influence was highly significant, followed by spindle speed n and depth of axial cut ap; the most serious impact cutting parameter of cutting force F was the feed speed vf, followed by the spindle speed n and radial depth of cut ae; verification test showed that the optimal cutting parameters combination were reasonable and the calculation errors of the predicted values and experimental values were very small, indicating that Taguchi method in cutting parameters optimization of cutting mould steel PM60 was valid.

Machinability Improvement by Workpiece Preheating during End Milling AISI H13 Hardened Steel

2011 ◽  
Vol 264-265 ◽  
pp. 888-893
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Experimental Study on Cutting Force and Surface Roughness for 7050-T7451 Aluminum Alloy of High Speed Milling

2013 ◽  
Vol 395-396 ◽  
pp. 1026-1030 ◽  
Author(s):  
Zhao Lin Zhong ◽  
Xing Ai ◽  
Zhan Qiang Liu
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Thermodynamic Relationship

This paper presents the experimental results of cutting force and surface roughness of 7050-T7451 aluminum alloy under the cutting speed of 3000~5000m/min. The cutting forces and surface roughness with different cutting parameters were analyzed. Experimental results suggested that increasing cutting speed would engender thermal softening, which would in return affect the cutting force and surface roughness in high speed milling. The cutting force and surface roughness were affected by cutting depth and feed rate obviously. Surface roughness was also affected by cutting width which changed the cutting force slightly. According to the results, proper parameters could be selected and thermodynamic relationship needed to be discussed for further research.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

Effects of Cutting Parameters on Residual Stresses in High-Speed Milling of Ti-17

2013 ◽  
Vol 834-836 ◽  
pp. 861-865 ◽  
Author(s):  
Yong Shou Liang ◽  
Jun Xue Ren ◽  
Yuan Feng Luo ◽  
Ding Hua Zhang
Keyword(s):  
Experimental Study ◽  
Residual Stresses ◽  
High Speed ◽  
Experimental Parameter ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Single Factor ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Parameter Ranges

An experimental study was conducted to determine cutting parameters of high-speed milling of Ti-17 according to their effects on residual stresses. First, three groups of single factor experiments were carried out to reveal the effects of cutting parameters on residual stresses. Then sensitivity models were established to evaluate the influence degrees of cutting parameters on residual stresses. After that, three criteria were proposed to determine cutting parameters from experimental parameter ranges. In the experiments, the cutting parameter ranges are recommended as [371.8, 406.8] m/min, [0.363, 0.412] mm and [0, 0.018] mm/z for cutting speed, cutting depth and feed per tooth, respectively.

scholarly journals Flank Wear Modelling in High Speed Hard Milling of AISI D2 Steel

2020 ◽  
Vol 5 (2) ◽  
pp. 50-54
Author(s):  
Muataz Al Hazza ◽  
Khadijah Muhammad
Keyword(s):  
Statistical Analysis ◽  
Wear Rate ◽  
Taguchi Method ◽  
Feed Rate ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Aisi D2

High speed machining has many advantages in reducing time to the market by increasing the material removal rate. However, final surface quality is one of the main challenges for manufacturers in high speed machining due to the increasing of flank wear rate. In high speed machining, the cutting zone is under high pressure associated with high temperature that lead to increasing of the flank wear rate in which affect the final quality of the machined surface. Therefore, one of the main concerns to the manufacturer is to predict the flank wear to estimate and predict the surface roughness as one of the main outputs of the machining processes. The aim of this study is to determine experimentally the optimum cutting parameters: depth of cut, cutting speed (Vc) and feed rate (f) that maintaining low flank wear (Vb). Taguchi method has been applied in this experiment. The Taguchi method has been universally used in engineering analysis.  JMP statistical analysis software is used to analyse statically the development of flank wear rate during high speed milling of hardened steel AISI D2 to 60 HRD. The experiment was conducted in the following boundaries: cutting speed 200-400 m/min, feed rate of 0.01-0.05 mm/tooth and depth of cut of 0.1-0.2 mm. Analysis of variance ANOVA was conducted as one of important tool for statistical analysis. The result showed that cutting speed is the most influential input factors with 70.04% contribution on flank wear.

scholarly journals Prediction of Tool Lifetime and Surface Roughness for Nickel-Based Waspaloy

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Shao-Hsien Chen ◽  
Chung-An Yu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Predictive Values ◽  
Actual Surface ◽  
Wide Range

In recent years, most of nickel-based materials have been used in aircraft engines. Nickel-based materials applied in the aerospace industry are used in a wide range of applications because of their strength and rigidity at high temperature. However, the high temperatures and high strength caused by the nickel-based materials during cutting also reduce the tool lifetime. This research aims to investigate the tool wear and the surface roughness of Waspaloy during cutting with various cutting speeds, feed per tooth, cutting depth, and other cutting parameters. Then, it derives the formula for the tool lifetime based on the experimental results and explores the impacts of these cutting parameters on the cutting of Waspaloy. Since the impacts of cutting speed on the cutting of Waspaloy are most significant in accordance with the experimental results, the high-speed cutting is not recommended. In addition, the actual surface roughness of Waspaloy is worse than the theoretical surface roughness in case of more tool wear. Finally, a set of mathematical models can be established based on these results, in order to predict the surface roughness of Waspaloy cut with a worn tool. The errors between the predictive values and the actual values are 5.122%∼8.646%. If the surface roughness is within the tolerance, the model can be used to predict the residual tool lifetime before the tool is damaged completely. The errors between the predictive values and the actual values are 8.014%∼20.479%.

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