Finite Element Simulation of Precision Cutting Monocrystalline Silicon

2013 ◽  
Vol 662 ◽  
pp. 99-102 ◽  
Author(s):  
Li Qiu Shi ◽  
Xiao Wen Li ◽  
Feng Yu
Keyword(s):  
High Surface ◽  
Cutting Speed ◽  
Monocrystalline Silicon ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Tool Edge Radius ◽  
Transition Mechanism ◽  
Edge Radius ◽  
Tool Edge ◽  
Optimization Of Cutting Parameters

Monocrystalline silicon is typical of hard brittle materials, a high surface quality can be obtained in ductile-regime cutting. The success of the turning process depends on optimizing the machining parameters such as the tool edge radius, tool rake angles, depth of cut and cutting speed, etc. In this study, based on the ductile–brittle transition mechanism, the optimization of cutting parameters were determined with the commercial, general purpose FEA software Msc.Marc. The result demonstrates that the value of temperature is minimum when the tool rake angle is in the range of -15º～-30º. Smaller tool edge radius was selected while maintaining quality of tool edge radius and tool life. As long as beyond the range of cutting speed 6 ~ 8 mm/s, smaller residual stress can be obtain.

scholarly journals Modeling and Optimization of Cutting Parameters during Machining of Austenitic Stainless Steel AISI304 Using RSM and Desirability Approach

2020 ◽  
Vol 65 (1) ◽  
pp. 10-26
Author(s):  
Septi Boucherit ◽  
Sofiane Berkani ◽  
Mohamed Athmane Yallese ◽  
Riad Khettabi ◽  
Tarek Mabrouki
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Cutting Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Desirability Approach ◽  
Optimization Of Cutting Parameters ◽  
Coated Carbide

In the current paper, cutting parameters during turning of AISI 304 Austenitic Stainless Steel are studied and optimized using Response Surface Methodology (RSM) and the desirability approach. The cutting tool inserts used in this work were the CVD coated carbide. The cutting speed (vc), the feed rate (f) and the depth of cut (ap) were the main machining parameters considered in this study. The effects of these parameters on the surface roughness (Ra), cutting force (Fc), the specific cutting force (Kc), cutting power (Pc) and the Material Removal Rate (MRR) were analyzed by ANOVA analysis.The results showed that f is the most important parameter that influences Ra with a contribution of 89.69 %, while ap was identified as the most significant parameter (46.46%) influence the Fc followed by f (39.04%). Kc is more influenced by f (38.47%) followed by ap (16.43%) and Vc (7.89%). However, Pc is more influenced by Vc (39.32%) followed by ap (27.50%) and f (23.18%).The Quadratic mathematical models, obtained by the RSM, presenting the evolution of Ra, Fc, Kc and Pc based on (vc, f, and ap) were presented. A comparison between experimental and predicted values presents good agreements with the models found.Optimization of the machining parameters to achieve the maximum MRR and better Ra was carried out by a desirability function. The results showed that the optimal parameters for maximal MRR and best Ra were found as (vc = 350 m/min, f = 0.088 mm/rev, and ap = 0.9 mm).

A Study of Exit-Burr Formation Mechanism Using the Finite Element Method in Micro-Cutting of Aluminum Alloy

2008 ◽  
Vol 375-376 ◽  
pp. 470-473 ◽  
Author(s):  
Dong Lu ◽  
Jian Feng Li ◽  
Yi Ming Rong ◽  
Jie Sun ◽  
Jun Zhou ◽  
...  
Keyword(s):  
Cutting Speed ◽  
Chip Thickness ◽  
Burr Formation ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Speed Effect ◽  
Exit Burr

A burr formation process in micro-cutting of Al7075-T7451 was analyzed. Three stages of burr formation including steady-state cutting stage, pivoting stage, and burr formation stage are investigated. And the effects of uncut chip thickness, cutting speed and tool edge radius on the burr formation are studied. The simulation results show that the generation of negative shear zone is one of the prime reasons for burr formation. Uncut chip thickness has a significant effect on burr height; however, the cutting speed effect is minor. Unlike in conventional cutting, in micro-cutting the effect of tool edge radius on the burr geometry can no longer be neglected.

Minimized Wear and Debris Generation Through Optimized Machining of Co-Cr-Mo Alloys for Use in Metal-on-Metal Hip Implants

2012 ◽  
Author(s):  
Ashish Deshpande ◽  
Shu Yang ◽  
Dave Puleo ◽  
David Pienkowski ◽  
Oscar Dillon ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Wear Debris ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Conditions ◽  
Metal On Metal ◽  
Tool Edge

More than 380,000 hips are replaced with total joint prostheses each year in the U.S. Wear debris generated by metal-on-metal implant designs is of concern due to potential adverse biological effects arising from chronic exposure of human tissue to the wear debris. This paper presents a new methodology for optimizing the wear performance of prosthesis made of Co-Cr-Mo alloys by varying tool edge geometry and machining conditions to alter the wear behavior of this alloy, while also controlling the residual stresses induced during the machining process. The machining process causes inhomogeneous inelastic deformations near the surface layer of machined parts which create residual stresses in the surface of machined components. Residual stresses in the machined surface and the subsurface are affected by cutting tool material, tool geometry, workpiece, tool-work interface conditions, and the cutting parameters such as feed rate, depth of cut and cutting speed. In the current work, residual stresses were measured using X-ray diffraction technique (XRD). The surface residual stresses in two directions (radial and hoop) were measured on the machined pins after machining with different machining conditions, but prior to the wear test. Wear behavior of Co-Cr-Mo alloy pin specimens, produced from machining with varying tool edge geometry and machining conditions, was studied using a custom-made biaxial motion pin-on-disc tribological testing system in which the pin specimen is immersed in a simulated bio-fluid environment. Wear-induced weight loss (± 10 μg) and changes in surface roughness (± 0.001 μm) were obtained at 100,000 cycle intervals upto 500,000 cycles. Metallographic analysis was performed on the machined pin specimens to analyze the microstructure and microhardness before and after testing. The rate of wear for the specimens was lowest for those pins where the change of the subsurface microhardness was small due to prevention of additional steady state wear after the initial run-in wear in the wear tester. A combination or response surface methodology and genetic algorithm (GA) was used in to optimize the various machining parameters for minimized wear generation. The optimal combination of the four machining parameters (feed 0.18mm/rev, nose radius 0.6 mm, cutting speed 27.6 m/min and depth of cut 0.38) produced the largest compressive residual stresses on the surface and subsurface of the implants thereby reducing the wear/debris generation by about fifty percent.

scholarly journals Effect of Machining Parameters on Tool Wear and Surface Roughness In Dry and Wet Machining of Aisi 316 Austenitic Stainless Steel by Taguchi Method

2019 ◽  
Vol 8 (9) ◽  
pp. 3292-3298
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Taguchi Method ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Response Factors ◽  
Aisi 316 ◽  
Optimization Of Cutting Parameters

Stainless steels are widely used to manufacture mechanical components due to excellent mechanical properties. Machining is considered as one of the most critical manufacturing processes in mechanical industry to produce desired shapes and dimensional accuracy of the components. It also affects the performance of the components in its functional requirement. This paper deals with the optimization of cutting parameters in machining operation for AISI 316 austenitic steel with dry and wet environment conditions. The chosen machining parameters in this research are cutting speed, feed rate, and depth of cut as input variables, whereas the response factors are surface roughness and wear rate. Taguchi method with the L9 orthogonal array was used to analyze the process parameters based in dry and wet machining conditions. The Taguchi approach provides the best setting with lower values of surface roughness and wear rate. The regression analysis is performed to obtain a mathematical model of responses in terms of the process parameter. The composite regression optimization gives best setting for dry condition (cutting speed 173 rpm, feed 0.25 mm/rev, and 0.87 mm of the depth of cut) and for wet condition (cutting speed 173 rpm, feed 0.3 mm/rev, and 0.57 mm of the depth of cut). The results show that surface roughness and wear rate are lower in the wet environment than the dry environment.

Optimization of Cutting Parameters using Cryogenically Treated High Speed Steel Tool by Taguchi Application

2013 ◽  
Vol 3 (1) ◽  
pp. 26-38 ◽  
Author(s):  
Lakhwinder Pal Singh ◽  
Jagtar Singh
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Small Scale ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimization Of Cutting Parameters

In the field of mechanical engineering, engineers are always looking for ways to improve the properties of materials. Cryogenic treatment of tooling steels is a proven technology to increase wear resistance and extend intervals between component replacements. The main idea of this paper is to apply Taguchi method to optimize cutting parameters in turning operation using cryogenic treated (CT) and untreated (UT) high speed steel (HSS) tools, so that the scope of cryogenic treatment on HSS tool material may be presented for the benefit of medium and small scale industry using HSS tools for cutting operation. Taguchi L25 orthogonal array is employed to study the performance characteristics in turning operations of AISI 1020 steel bars using CT and UT HSS tools. The microstructure has been found more refined and uniformly distributed after cryogenic treatment of HSS tool. It has been observed that optimum machining parameters in both the cases (CT HSS and UT HSS tools) are higher cutting speed (49.9 to 75.7 m/min.), lower feed rate (0.15 mm/rev.), medium depth of cut (0.40 mm). Analysis of variance (ANOVA) indicates that the cutting speed is most significant parameter followed by feed rate in case of CT HSS tool and depth of cut in case of UT HSS tool.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

Multiresponse Optimization of Al Alloy-SiC Composite Machining Parameters for Minimum Tool Wear and Maximum Metal Removal Rate

2013 ◽  
Vol 135 (2) ◽  
Author(s):  
Rajesh Kumar Bhushan
Keyword(s):  
Tool Wear ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Machining Parameters ◽  
Metal Removal Rate ◽  
Nose Radius ◽  
Multiresponse Optimization

Optimization in turning means determination of the optimal set of the machining parameters to satisfy the objectives within the operational constraints. These objectives may be the minimum tool wear, the maximum metal removal rate (MRR), or any weighted combination of both. The main machining parameters which are considered as variables of the optimization are the cutting speed, feed rate, depth of cut, and nose radius. The optimum set of these four input parameters is determined for a particular job-tool combination of 7075Al alloy-15 wt. % SiC (20–40 μm) composite and tungsten carbide tool during a single-pass turning which minimizes the tool wear and maximizes the metal removal rate. The regression models, developed for the minimum tool wear and the maximum MRR were used for finding the multiresponse optimization solutions. To obtain a trade-off between the tool wear and MRR the, a method for simultaneous optimization of the multiple responses based on an overall desirability function was used. The research deals with the optimization of multiple surface roughness parameters along with MRR in search of an optimal parametric combination (favorable process environment) capable of producing desired surface quality of the turned product in a relatively lesser time (enhancement in productivity). The multi-objective optimization resulted in a cutting speed of 210 m/min, a feed of 0.16 mm/rev, a depth of cut of 0.42 mm, and a nose radius of 0.40 mm. These machining conditions are expected to respond with the minimum tool wear and maximum the MRR, which correspond to a satisfactory overall desirability.

Simulation of Meso-Scale Machining of AISI1045 Based on Multiphase Model

2016 ◽  
Vol 836-837 ◽  
pp. 374-380
Author(s):  
Teng Yi Shang ◽  
Li Jing Xie ◽  
Xiao Lei Chen ◽  
Yu Qin ◽  
Tie Fu
Keyword(s):  
Cutting Force ◽  
Cutting Process ◽  
Multiphase Model ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Cutting Insert ◽  
Multiphase Models ◽  
Hot Rolled ◽  
Meso Scale

In the meso-scale machining, feed rate, grain size and tool edge radius are in the same order of magnitude, and cutting process is often carried out in the grain interior and grain boundary. In this paper the meso-cutting process of hot-rolled AISI1045 steel is studied and its metallographic microstructure is analyzed for the establishment of multiphase models which incorporate the effect of ferrite and pearlite grains. In order to discover the applicability of multiphase models to the simulation of meso-cutting, three contrast simulation models including multiphase model with rounded-edge cutting insert (model I), multiphase model with sharp edge cutting insert (model II) and equivalent homogeneous material model with rounded-edge cutting insert (model III) are built up for the meso-orthogonal cutting processes of hot-rolled AISI1045. By comparison with the experiments in terms of chip morphology, cutting force and specific cutting force, the most suitable model is identified. Then the stress distiribution is analyzed. And it is found that multiphase model with tool edge radius can give a more accurate prediction of the global variables and reveal more about these important local variables distribution.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

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