Prediction and Investigation of Surface Quality in High Speed End-Milling of Silicon to Eliminate Conventional Finishing Operations

2011 ◽  
Vol 418-420 ◽  
pp. 1237-1241
Author(s):  
A.K.M. Nurul Amin ◽  
Mohd Dali M Ismail ◽  
Muhammad Iqbal Musa ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
High Speed ◽  
End Milling ◽  
High Surface ◽  
Small Diameter ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Machining Process ◽  
Dry Cutting

Surface finish and dimensional accuracy are two of the most important requirements in machining process. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In HSM determination of the optimum combination of cutting parameters for achieving the required level of quality, such as, minimum possible surface roughness and maximum tool life is a very important task. Silicon is conventionally finished using grinding followed by polishing and lapping to achieve required surface finish and surface integrity. 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 ensure high surface roughness values through achievement of ductile mode machining of silicon. Investigations on the effect cutting parameters of high speed end milling on surface finish and integrity of silicon has been conducted to minimizing the amount of finishing requirement in machining of silicon, with the objective of reducing cost and increasing effectiveness of silicon manufacturing process. In this work statistical models were developed using the capabilities of Response Surface Methodology (RSM) to predict the surface roughness in high speed flat end milling of silicon under dry cutting conditions.

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.

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.

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 in Compressed Air Jet Assisted High Speed End Milling of Silicon Using Diamond Coated Tools

2012 ◽  
Vol 576 ◽  
pp. 41-45
Author(s):  
A.K.M. Nurul Amin ◽  
M.A. Mahmud ◽  
M.D. Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Surface Finish ◽  
High Speed ◽  
End Milling ◽  
Silicon Wafers ◽  
Compressed Air ◽  
Machining Parameters ◽  
High Quality ◽  
Ductile Mode

The majority of semiconductor devices are made up of silicon wafers. Manufacturing of high-quality silicon wafers includes numerous machining processes, including end milling. In order to end mill silicon to a nano-meteric surface finish, it is crucial to determine the effect of machining parameters, which influence the machining transition from brittle to ductile mode. Thus, this paper presents a novel experimental technique to study the effects of machining parameters in high speed end milling of silicon. The application of compressed air, in order to blow away the chips formed, is also investigated. The machining parameters’ ranges which facilitate the transition from brittle to ductile mode cutting as well as enable the attainment of high quality surface finish and integrity are identified. Mathematical model of the response parameter, the average surface roughness (Ra) is subsequently developed using RSM in terms of the machining parameters. The model was determined, by Analysis of Variance (ANOVA), to have a confidence level of 95%. The experimental results show that the developed mathematical model can effectively describe the performance indicators within the controlled limits of the factors that are being considered.

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.

Influence of Inclination Angle on Machined Surface Hardness in High Speed Ball End Milling

2012 ◽  
Vol 500 ◽  
pp. 134-139
Author(s):  
Shi Guo Han ◽  
Jun Zhao ◽  
Xiao Xiao Chen ◽  
Yue En Li ◽  
Qing Yuan Cao ◽  
...  
Keyword(s):  
Inclination Angle ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
High Surface ◽  
Surface Hardness ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Abrasive Resistance ◽  
Feed Direction

In this paper, the effects of the variational combinations of cutter inclination angle in feed direction and the feed per tooth on the machined surface hardness were mainly concerned. The cutting forces transformed from the measured cutting forces in OXYZ and the SEM microstructures of the surface layer were analyzed to explore the generation condition of the hardness. Variations of the surface hardness are not apparent with the increment of feed per tooth with the identical other cutting parameters. Inclination angles in feed direction of approximately ranging from 10° to 15° and from 25° to 30°, which correspond to high surface hardness, are suggested to be applied in cutting process when high abrasive resistance is expected. While values of inclination angle approximately equal to 0° and 45° are prior to be chosen when high shock resistance performance is firstly expected. Optimization of the cutting parameters, which could offer guidance to the machining of sculptured surface concerning cutter inclination angle, was presented.

The Effect of Cooling Lubrication Methods on Surface Roughness Measured by the White Light Interferometer

2009 ◽  
Vol 76-78 ◽  
pp. 471-478 ◽  
Author(s):  
Feng Jiang ◽  
Jian Feng Li ◽  
Jie Sun ◽  
Song Zhang
Keyword(s):  
Surface Roughness ◽  
White Light ◽  
End Milling ◽  
Cutting Parameters ◽  
Dry Cutting ◽  
Machined Surface ◽  
White Light Interferometer ◽  
3D Profile ◽  
Optimization Of Cutting Parameters ◽  
Lubrication Conditions

Surface roughness is an important item to evaluate the surface quality. Many researches focused on the optimization of cutting parameters in the specified cooling/lubrication conditions. But the effect of different cooling/lubrication conditions was still less considered. Aimed at this problem, the effect of cutting parameters on the average surface roughness (Ra) in the different cooling/lubrication conditions, including MQL, wet, dry cutting, was analyzed in this study. Orthogonal arrays were applied in the design of the experiments and Ti6Al4V end-milling experiments were performed on the DAEWOO machining center. The white light interferometer was used to obtain the 3D profile of machined surface and calculate the Ra values. The regression analysis and statistical analysis of variance were employed in the process of the experimental data. The relationships between Ra and cutting parameters in the different cooling/lubrication conditions were obtained and the optimum values of the cutting parameters in the range of the experiments were selected.

Surface Quality of High Speed Milling of Silicon Carbide by Using Diamond Coated Tool

2013 ◽  
Vol 446-447 ◽  
pp. 275-278 ◽  
Author(s):  
Mohammad Iqbal ◽  
Mohamed Konneh ◽  
Ahmad Yasir Bin Md Said ◽  
Azri Fadhlan Bin Mohd Zaini
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
High Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Model Interaction ◽  
High Speed Milling ◽  
Coated Tool

The high speed milling of silicon carbide was discussed by using flat end-mill 2 mm in diameter diamond coated tool. Ultra-precision high speed spindle attachment was used to achieve cutting tool rotation speed as high as 50,000 rpm. Special fixture was designed to minimize the chatter on work-piece surface during the machining process. Three cutting parameters were selected as independent variables of the experiments. They were spindle speed, depth of cut and feed rate. The arithmetic mean value of roughness (Ra) was measured on the work-piece surface as the response of the experiment. Result of the experiment shows that the value of surface roughness can be achieved as low as 0.150 μm. Statistical analysis was provided to study the significant of the model, interaction among the cutting parameters and their effects to the surface roughness value.

The Cutting Parameter Affecting to Surface Roughness in Single-Point Diamond Turning

2014 ◽  
Vol 887-888 ◽  
pp. 1236-1239
Author(s):  
Wang Hao ◽  
Yu Zhang ◽  
Qi Ming Xie
Keyword(s):  
Surface Roughness ◽  
Wear Resistance ◽  
Surface Finish ◽  
Diamond Tool ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Process ◽  
Form Accuracy ◽  
Edge Sharpness

Single-point diamond turning (SPDT) is a machining process making use of a monocrystal diamond tool which possesses nanometric edge sharpness, form reproducibility and wear resistance. The process is capable of producing components with micrometre to submicrometre form accuracy and surface roughness in the nanometre range. The cutting parameters that can make an effect on surface finish and form accuracy of SPDT such as spindle speedfeed ratedepth of cut and so on.

Sign in / Sign up

Export Citation Format

Share Document