Integrated Monitoring of Surface Roughness and Chip Formation by Utilizing Cutting Force and Cutting Temperature

2012 ◽  
Vol 538-541 ◽  
pp. 1338-1350
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Integrated Monitoring ◽  
Roughness Model ◽  
Spectrum Density ◽  
Roughness Prediction

This research presents the integration of the surface roughness and chip formation monitoring by using the cutting force and the cutting temperature during the in-process turning. The surface roughness prediction model is proposed by utilizing the response surface analysis with the Box-Behnken design. The effects of cutting parameters on the cutting force and the cutting temperature are investigated. The cutting force and the cutting temperature are measured to help analyze the relation between the surface roughness and the cutting conditions. The models of the cutting force ratio and the cutting temperature are also proposed based on the experimental data. The in-process monitoring of chip formation is developed to detect the continuous chip and the broken chip by utilizing the power spectrum density of dynamic cutting force and the variance of the dynamic cutting temperature.The broken chip formation is required for the reliable turning operation. The algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process based on the cutting force and the cutting temperature. It has been proved by series of cutting experiments that the proposed surface roughness model can be effectively used to predict the surface roughness, and the broken chip is well identified by the proposed method.

Development of Surface Roughness Prediction for Steel in CNC Turning by Using Response Surface Method

2011 ◽  
Vol 335-336 ◽  
pp. 921-926
Author(s):  
Siriwan Chanphong ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Response Surface ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Plain Carbon Steel ◽  
Cutting Condition ◽  
Surface Roughness Prediction ◽  
Roughness Prediction ◽  
Coated Carbide

This research presents the development of the surface roughness prediction in the turning process of the plain carbon steel with the coated carbide tool by using the response surface analysis with the Box-Behnken design. The effects of cutting parameters on the cutting force and the cutting temperature are investigated. The cutting force and the cutting temperature are measured to help analyze the relation between the surface roughness and the cutting conditions. The models of cutting force ratio and the cutting temperature are also proposed based on the experimental data. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

Development of In-Process Chip Breaking Detection by Using Cutting Force and Temperature Signals

2011 ◽  
Vol 337 ◽  
pp. 489-493 ◽  
Author(s):  
Kitikun Klungphon ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Low Frequency ◽  
Cutting Conditions ◽  
Frequency Range ◽  
Chip Breaking ◽  
Dynamic Cutting Force ◽  
Spectrum Density ◽  
Continuous Chip

In order to realize the intelligent machines, an in-process monitoring system is developed to detect the continuous chip and the broken chip regardless of the cutting conditions on CNC turning by utilizing the power spectrum density, PSD of dynamic cutting force and the variance of the dynamic cutting temperature, which are measured during the cutting by employing the dynamometer and the infrared pyrometer. The broken chip formation is required for the reliable turning operation. The preliminary experiments suggested that there are basically two patterns of PSDs of chip forms. One is the case of relatively high PSD of the dynamic cutting force at low frequency range, which corresponds to the continuous chip formation. The other is the case of relatively large PSD of the dynamic cutting force observed in a frequency range corresponding to the chip breaking frequency when the broken chip are formed. The variances of the cutting temperature are also significantly different between the broken chip and the continuous chip. Hence, the method has been developed by using the PSD of dynamic cutting force and the variance of cutting temperature to determine the proper threshold values for classification of the broken chip and the continuous chip during the cutting. The new algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process. It has been proved by series of cutting experiments that the broken chip can be well identified by the proposed method even though the cutting conditions are changed.

Cutting Behavior of Self-Lubricating Ceramic Tool in Dry Machining of 40Cr Quenched Steel

2021 ◽  
Vol 871 ◽  
pp. 176-188
Author(s):  
Ben Yuan Wang ◽  
Guang Chun Xiao ◽  
Zhao Qiang Chen ◽  
Ming Dong Yi ◽  
Jing Jie Zhang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Friction Coefficient ◽  
Cutting Force ◽  
Solid Lubricant ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Ceramic Composites ◽  
Ceramic Tool ◽  
Cutting Depth ◽  
Ceramic Tools

In this paper, the dry cutting performance of Al2O3/TiC-based ceramic composites with nanoCaF2 was studied. Compared with the Al2O3/TiC ceramic tool, the Al2O3/TiC/CaF2 ceramic tool has lower cutting force, cutting temperature and surface roughness when milling 40Cr hardened steel. Three cutting parameters of cutting speed, feed per tooth, and cutting depth were used to conduct orthogonal experiments to study its changing trend. Through testing of cutting force, cutting temperature and surface roughness, and by comparison with ceramic tools without nanosolid lubricant added, the order of influence of three cutting parameters on cutting force, cutting temperature and surface roughness was obtained. The experimental results showed that the cutting force, cutting temperature and surface roughness of Al2O3/TiC/CaF2 ceramic tools containing nanoCaF2 werebetter than those of Al2O3/TiC ceramic tools. The cutting force, the cutting temperature, and the surface roughness were respectively reduced by 16.5%, 25.8% and 43% compared to when no solid lubricant was added. In addition, after adding solid lubricant, the effect of cutting depth on cutting force was significantly reduced. The average friction coefficient of the tool rake surface was 31.1% lower than that of ceramic tools without solid lubricant. In order to explain this phenomenon, through scanning electron microscopy (SEM) scanning and energy spectroscopy (EDS) elemental analysis, the wear reduction mechanism of solid lubricants was analyzed, that is, during the cutting process, nanosolid lubricants precipitated and formed lubricating film on the rake surface of the tool to reduce the friction coefficient. This was also the main reason for reducing the cutting temperature.

Effects of Cutting Conditions on the Machinability of Stainless Steel Formed by Laser Cladding

2013 ◽  
Vol 797 ◽  
pp. 166-171
Author(s):  
Bing Wang ◽  
Zhan Qiang Liu ◽  
Lun Chang Su ◽  
Lin Qing Zhang
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Force ◽  
Laser Cladding ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Corner Radius ◽  
1045 Steel

The paper investigates the effects of cutting conditions on the machinability of stainless steel coatings manufactured onto AISI 1045 steel by laser cladding technology. Two kinds of CBN (cubic boron nitride) tools with different corner radius and two different depths of cut were adopted in the experiments. Cutting force during machining, surface roughness and microhardness of machined surface were measured and analyzed. The results show that both the cutting force and surface roughness increase with the increase of depth of cut. When the other cutting parameters are identical, the surface roughness decreases with the increase of tools corner radius while the variations of different cutting force components present different tendencies. The microhardness of the machined surface and its varied gradient in the direction of depth of cut increase with the increase of tools corner radius. The experiment results will provide valuable suggestions for optimization of cutting performance for laser cladding coatings in order to obtain excellent surface quality.

Experimental Study on Spray Cutting Ni-Based Superalloy

2012 ◽  
Vol 723 ◽  
pp. 317-321
Author(s):  
Yu Wang ◽  
Yuan Sheng Zhai ◽  
Fu Gang Yan ◽  
Xian Li Liu
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Production Mode ◽  
Effective Reduction ◽  
Reasonable Choice ◽  
Base Superalloy

In this paper, the effect of cutting parameters on cutting force, cutting temperature and surface roughness on cutting force, cutting temperature and surface roughness are experimentally studied in spray cutting GH4169 Ni-base superalloy used carbide cutting tools. The results showed that reasonable choice of cutting parameters can effective reduction of cutting force and cutting temperature, and improve the machining surface roughness. Thus realizing clean production mode.

Optimization of Cutting Parameters for End Milling AlSi/AlN Metal Matrix Composite Using the Taguchi Method

2013 ◽  
Vol 773-774 ◽  
pp. 429-436 ◽  
Author(s):  
Siti Haryani Tomadi ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron ◽  
Abdul Razak Daud
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Matrix Composite ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Optimum Cutting ◽  
Optimization Of Cutting Parameters

In this paper, the optimization of cutting parameters is investigated to assess surface roughness and cutting force in the end milling of AlSi/AlN metal matrix composite. Eighteen experiments (L18) with five factors (cutting speed, feed rate, depth of cut, volume of particle reinforcement, and type of coated insert) were performed based on Taguchi designs of the experiment method. Two types of coating (TiB2 and TiN/TiCN/TiN) of the carbide cutting tool were employed to machine various volumes of AlN particle (5%, 7% and 10%) reinforced AlSi alloy matrix composite under dry cutting conditions. Signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were applied to investigate the optimum cutting parameters and their significance. The S/N analysis of the obtained results showed that the optimum cutting conditions for the cutting force were; A2 (triple coating of the insert), B2 (cutting speed: 200m/min), C1 (feed rate: 0.6mm/tooth), D1 (axial depth: 0.6mm) and E1 (5% reinforcement). At the mean time, the optimum cutting conditions for surface roughness were; A1 (single coating of insert), B3 (cutting speed: 250m/min), C2 (feed rate: 0.75mm/tooth), D1 (axial depth: 0.6mm) and E1 (5% reinforcement).The study confirmed that, with a minimum number of experiments, the Taguchi method is capable of determining the optimum cutting conditions for the cutting force and surface roughness for this new material under investigation.

scholarly journals Optimizing Multi-Response Parameters in Turning of AISI1040 Steel Using Desirability Approach

2019 ◽  
Vol 4 (4) ◽  
pp. 905-921
Author(s):  
Srinu Gugulothu ◽  
Vamsi Krishna Pasam
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Multi Objective ◽  
Single Objective

In this study, an attempt is made to examine the machining response parameters in turning of AISI 1040 steel under different lubrication environment. Subsequently, design of experiment technique Response surface methodology (RSM) is used for analyzing machining performance by varying cutting conditions with the use of 2wt% of CNT/MoS2(1:2) HNCF. Regression models are developed for multiple machining responses. Optimization is performed for these models by using desirability function, which converts multi-objective into single objective. Then the optimal setting parameters for single objective is found. Significant reduction in main cutting force (Fz), cutting temperature (T), surface roughness(Ra) and tool flank wear (Vb) are found with the use of 2wt% of CNT/MoS2(1:2) HNCF compared to other lubrication environment. Significant factors that affect the main cutting force (Fz), the temperature in the cutting zone are cutting speed, feed rate and depth of cut. Parameter depth of cut has an insignificant effect on tool flank wear and surface roughness (Ra). The optimal cutting conditions for four multi-objective optimization of main cutting force (Fz), cutting temperature, surface roughness (Ra) and tool flank wear are found to be cutting speed 70.25 m/min, feed 0.13 mm/rev and doc 0.5mm at desirability value of 0.907.

Prediction of Surface Roughness on CNC Turning Based on Monitoring of Cutting Force and Cutting Temperature

2013 ◽  
Vol 690-693 ◽  
pp. 2540-2549 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Cnc Turning ◽  
Roughness Model ◽  
Developed Surface ◽  
Coated Carbide

This paper presents the surface roughness model which is proposed and developed to predict the surface roughness in the CNC turning of the carbon steel with the coated carbide tool under various cutting conditions by using the response surface analysis with the Box-Behnken design based on the experimental results. The in-process monitoring of the cutting force and the cutting temperature is utilized to analyze the relation between the surface roughness and the cutting condition. The tool dynamometer and the infrared pyrometer are employed and installed on the turret of CNC turning machine to measure the in-process cutting force and cutting temperature. The models of cutting force ratio and cutting temperature are also developed based on the experimental data. The optimum cutting condition is determined referring to the minimum surface roughness of the surface plot, which is obtained from the developed surface roughness model. The experimental results show that the higher cutting speed gives the better surface roughness due to the higher cutting temperature, however the tool life becomes shorter. The feed rate is the most significant factor which affects the surface roughness, while a small depth of cut helps to improve the surface roughness. The effectiveness of the surface roughness prediction model has been proved by utilizing an analysis of variance (ANOVA) at 95% confident level. Hence, the surface roughness can be predicted and obtained easily referring to the developed surface roughness model.

Research on the Predicted Model of the Surface Roughness in Dry Turning Hardened Steel

2011 ◽  
Vol 337 ◽  
pp. 363-367 ◽  
Author(s):  
Chun Juan Tu ◽  
Xiao Gu
Keyword(s):  
Surface Roughness ◽  
Cubic Boron Nitride ◽  
Cutting Temperature ◽  
Mathematic Model ◽  
Cutting Parameters ◽  
Pso Algorithm ◽  
Hardened Steel ◽  
Dominant Factor ◽  
Dry Turning ◽  
Roughness Prediction

Researching on the mathematic model of surface roughness in machining hardened steel was to provide the reference for the surface roughness prediction. The contrast experiments of dry turning hardened steel were carried out with ceramic tool (CC6050), cubic boron nitride tool (CB7025) and kentanium tool (GC2025), the surface roughness was measured using 2025 surface roughness tester, the predicted models of the surface roughness were built by Particle Swarm Optimization (PSO) algorithm, the reliability analysis was given out, the shape of chips was observed by scanning electron microscope (SEM). Results proved: the reliability of the predicted models built by PSO was to be verified, it could reflect the relation between the surface roughness and cutting parameters exactly. The feed rate was found out to be dominant factor on the surface roughness in turning with three tools. The saw-tooth chips could decrease the cutting temperature and improve the surface quality.

Research Status of Subsequent Machining of Laser Cladding Layers

2020 ◽  
Vol 15 ◽  
Author(s):  
Lei Li ◽  
Yujun Cai ◽  
Guohe Li ◽  
Meng Liu
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Laser Cladding ◽  
Wear Surface ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Cladding Layer ◽  
Cladding Layers

Background: As an important method of remanufacturing, laser cladding can be used to obtain the parts with specific shapes by stacking materials layer by layer. The formation mechanism of laser cladding determines the “Staircase effect”, which makes the surface quality can hardly meet the dimensional accuracy of the parts. Therefore, the subsequent machining must be performed to improve the dimensional accuracy and surface quality of cladding parts. Methods: In this paper, chip formation, cutting force, cutting temperature, tool wear, surface quality, and optimization of cutting parameters in the subsequent cutting of laser cladding layer are analyzed. Scholars have expounded and studied these five aspects but the cutting mechanism of laser cladding need further research. Results: The characteristics of cladding layer are similar to that of difficult to machine materials, and the change of parameters has a significant impact on the cutting performance. Conclusion: The research status of subsequent machining of cladding layers is summarized, mainly from the aspects of chip formation, cutting force, cutting temperature, tool wear, surface quality, and cutting parameters optimization. Besides, the existing problems and further developments of subsequent machining of cladding layers are pointed out. The efforts are helpful to promote the development and application of laser cladding remanufacturing technology.

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