Surface Roughness Characteristics of Polyamide APA after the Turning by Unconventional Cutting Tool

2013 ◽  
Vol 702 ◽  
pp. 263-268 ◽  
Author(s):  
Katarina Monkova
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Statistical Data ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Automotive Applications ◽  
Machined Surface ◽  
Total Cost ◽  
Lower Volume ◽  
Structural Parts

The article deals with surface roughness characteristics of polyamide APA after the turning by tool with linear cutting edge. The experiment was centred on the obtaining of Ra and Rz dependences on both cutting speed and feed per revolution concurrently. Polyamide APA allows the production of very large structural and semi-structural parts for automotive and non-automotive applications including interior, exterior and under-the-hood applications. It also allows reducing the total cost of production, especially for lower volume parts. Therefore, the authors deals with the possibility to work this material. The special cutting tool was selected in regard to the author´s previous experiments. The surfaces of investigated metal samples, which were machined by the tool with linear cutting edge, achieved very good properties, so it was the reason for the using of this tool at the experiments presented in the article. Obtained values of surface roughness characteristics were worked up by means of regression analysis and according to the rules for statistical data processing. The results are arranged into the table and consequently into the graphical presentations. The shapes of chips at the machining within various working conditions are shown at the end of the article. Next experiments will be focused on the machining of other types materials with the same unconventional cutting tool and for the obtaining new data that characterize the machined surface.

Machined Surface Roughness Geometry Model Development on Ultrasonic Vibration Assisted Micromilling with End Mill

2020 ◽  
Vol 846 ◽  
pp. 122-127
Author(s):  
Gandjar Kiswanto ◽  
Yolanda Rudy Johan ◽  
Poly ◽  
Tae Jo Ko
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Model Development ◽  
Cutting Edge ◽  
End Mill ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Geometry Model ◽  
Machined Surface Roughness

Micro products or micro components are commonly used in today’s world. Research around micromanufacture technologies to produce a better product quality has been going on extensively. Ultrasonic vibration assisted micromilling (UVAM) is one of the technologies that can give a better machining qualities over the conventional ones. One of the benefits UVAM can give is reducing the machined surface roughness. The purpose of this paper is to give an idea how vibration assisted micromilling can give a better surface roughness quality. The theoritical surface roughness geometry model is made using MATLAB software. The cutting tool used in the simulation is end mill. There is a feature of the cutting tool called bottom cutting edge angle. This feature will be considered on this paper. The effects of the bottom cutting edge on workpiece machined surface can be looked visually from the simulation. Thus, the effects of cutting process using UVAM on the workpiece surface can be looked as well through the simulation.

The Comparison of Surface Roughness Characteristics Achieved by the Machining with Conventional and Unconventional Geometry of Tools

2012 ◽  
Vol 622-623 ◽  
pp. 352-356 ◽  
Author(s):  
Peter Monka
Keyword(s):  
Surface Roughness ◽  
Regression Analysis ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Surface Profile ◽  
Operation Time ◽  
Cutting Edge ◽  
Technological Operation ◽  
Profile Characteristics ◽  
Machining Productivity

The paper deals with the experiments realized by means of cutting tool with linear cutting edge not parallel with the axis of the workpiece in order to be observed the suitable values of surface roughness characteristics in dependency on the feed and cutting speed. During experiments were machined three types of steels. Acquired data were statistical processed by regression analysis. The results of the measurements show that the investigated cutting tool enables to secure the same values of surface profile characteristics of steels as a classical cutting tool at finishing with the significant increase of the feed per revolution. It directly influences length of the technological operation time which is several times shortened and so the machining productivity can increase.

Theoretical Value of Total Height of Profile in Rotational Turning

2013 ◽  
Vol 309 ◽  
pp. 154-161 ◽  
Author(s):  
István Sztankovics ◽  
János Kundrák
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Edge ◽  
Technological Parameters ◽  
Machined Surface ◽  
Total Height ◽  
Roughness Profile ◽  
Rotational Turning ◽  
Longitudinal Turning ◽  
Chip Removal

The roughness of the machined surface is determined by the kinematics of chip removal, the shaping and the geometry of the cutting edge. The change of the surface roughness in cutting done under different conditions is easy to follow examining the theoretical value of roughness characteristics. This paper examines how the extent of the theoretical value of total height of profile depends on the different technological parameters in rotational turning. Furthermore the surface roughness and roughness profile is compared achievable by rotational turning and traditional longitudinal turning (in case of radius and pointed cutting tool).

Experimental Research of Effective Cutting Speed Influence on Surface Roughness in Ball End Milling of C45 Material with Hardness 34 HRC

2014 ◽  
Vol 657 ◽  
pp. 53-57 ◽  
Author(s):  
Sándor Ravai Nagy ◽  
Ioan Paşca ◽  
Mircea Lobonțiu ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Experimental Research ◽  
Inclination Angle ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Speed ◽  
Cnc Machine Tools ◽  
Machined Surface ◽  
Ball End Milling

Machining of Complex Concave or Convex Surfaces Requires the Use of Ball End Milling Cutters. Obtaining the Expected Surface Quality Compete Various Technological Factors which should be Taken into Account. Following the Machining of the Surface with Different Inclination Angles between the Cutting Tool Axes and the Machined Surface, Significant Changes of the Surface Roughness have been Observed. Based on the Tests Performed, we can Determine the Range of the Tool Inclination Angle, which is the Best for the Surface Quality. we have also Made a Correlation between the Cutting Speeds, Inclination Angle of the Cutting Tool Toward the Machined Surface for an Obtained Surface Quality. the Presented Results are Based on Experimental Research in Industrial Conditions by Using CNC Machine Tools with 5 Axes. the Tests have been Performed on the C45 Material, Heat Treated to 34HRC.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Effects of Cutting Speed and Feed Rate on Surface Roughness in Hard Turning of AISI 4140 with Mixed Ceramic Cutting Tool

2018 ◽  
Vol 779 ◽  
pp. 153-158
Author(s):  
Phacharadit Paengchit ◽  
Charnnarong Saikaew
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machined Surface ◽  
Data Set ◽  
Ceramic Cutting Tool ◽  
Aisi 4140 ◽  
Mixed Ceramic

This work investigated the influences of cutting speed and feed rate on surface roughness in hard turning of AISI 4140 chromium molybdenum steel bar using mixed ceramic inserts Al2O3+TiC under dry condition for automotive industry applications. Turning experiments were conducted by varying cutting speed ranging from 150 to 220 m/min and feed rate ranging from 0.06 to 1 mm/rev. General factorial design was used to analyze the data set of surface roughness and determine statistically significant process factors based on analysis of variance results. The results showed that average surface roughness was significantly affected by feed rate and interaction between cutting speed and feed rate at the level of significance of 0.05. An optimal operating condition for hard turning of AISI 4140 with the ceramic cutting tool that produced a minimum machined surface roughness was obtained at cutting speed of 220 m/min and 0.06 mm/rev.

Evaluation of PVD-Inserts Performance and Surface Integrity when Turning Ti-6Al-4V ELI under Dry Machining

2011 ◽  
Vol 264-265 ◽  
pp. 1050-1055 ◽  
Author(s):  
Gusri Akhyar Ibrahim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd. Ghani
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Base Material ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Softening Effect ◽  
Surface Segmentation ◽  
Initial Stage ◽  
Deformed Layer

The great advancement in the development of carbide cutting tool with super-hard coating layers taken place in recent few decades, can improve the performance of cutting tool and machinability of titanium alloy. The turning parameters evaluated are cutting speed (55, 75, 95 m/min), feed rate (0.15, 0.25, 0.35 mm/rev), depth of cut (0.10, 0.15, 0.20 mm) and tool grade of PVD carbide tool. The results that tool life shows patterns of rapidly increase at the initial stage and gradually increased at the second stage and extremely increased at the final stage. The trend lines of surface roughness have are the surface roughness value is high at first machining after that regularly decreases. Work hardening of the deformed layer beneath machined surface caused higher hardness than the average hardness of the base material. However, the softening effect also occurred below the machined surface. Segmentation or serration at the chip edge was caused by high strain and pressure during machining.

Evaluation of Surface Integrity during Machining with Different Tool Grades of Sicp/Al-Si Composites Produced by Powder Metallurgy

2011 ◽  
Vol 672 ◽  
pp. 319-322 ◽  
Author(s):  
Mustafa Günay ◽  
Ulvi Şeker
Keyword(s):  
Surface Roughness ◽  
Powder Metallurgy ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Process ◽  
Machined Surface ◽  
Alloy Matrix ◽  
Surface Finishes

MMCs components are mostly produced using near net shape manufacturing methods and are subsequently machined to the final dimensions and surface finishes. The MMCs consist of extremely hard reinforcing particles and pose considerable challenges due to the poor machinability and severe wear of the cutting tool. In this study, cutting performance of WC, CBN and PCD cutting tools were investigated with respect to surface roughness during machining of 10 wt % SiCp reinforced Al-Si alloy matrix composites produced by powder metallurgy (PM) method. Average surface roughness (Ra) corresponding to each machining condition was measured. After the machining process the worn insert tips were examined under the scanning electron microscope (SEM). Chip geometry and machined surface photographs have been taken by optical microscopy. The experimental results showed that surface roughness decreased with increasing cutting speed for all of cutting tool materials. The best surface integrity was occurred after the machining with PCD insert at the highest cutting speed employed.

Effect of Cutting Conditions on Dimensional Accuracy and Surface Roughness in Traditional Milling of Steel

2016 ◽  
Author(s):  
Brian Stringer ◽  
Rui Liu ◽  
Alfonso Fuentes Aznar ◽  
Patricia Iglesias
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Gear Tooth ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Cutting Conditions ◽  
Variable Speed ◽  
Machined Surface ◽  
Gear Manufacturing

Gear milling is one of the common gear manufacturing processes. In gear milling, the cutting edge of the cutting tool has an identical profile with the profile between gear teeth, and the cutting tool travels along the axial direction of the gear blank to produce the gear tooth by tooth. Due to the high requirements about the dimensional accuracy and the surface roughness during the gear manufacturing process, it is very crucial to understand the influences of cutting conditions on those requirements to improve the quality of the product and increase the production rate. In this study, a machined gear blank made from 1018 cold-rolled steel was subjected to variable speed and feed-rates in a traditional milling operation using a standard gear-milling cutter. The effect of the variable speed and feed-rates were analyzed by measuring the total lead (helix) error, total profile (involute) error, and surface finish of each gear tooth subjected to the variable cutting conditions. The objective is to experimentally investigate the correlation between the cutting conditions, i.e. cutting speed and feed, with the accuracy and quality of the machined surface during the gear milling process.

Surface Roughness after Machining and Influence of Feed Rate on Process

2013 ◽  
Vol 581 ◽  
pp. 341-347 ◽  
Author(s):  
Róbert Čep ◽  
Adam Janásek ◽  
Jana Petrů ◽  
Marek Sadilek ◽  
Petr Mohyla ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Longitudinal Direction ◽  
Structural Equations ◽  
Steel Grade ◽  
Height Profile ◽  
Machined Surface ◽  
Cut Surface

The aim of the work is find out influence of feed rate on the quality for the machined surface, especially surface roughness. The experiment was carried out by cutting tool HURCO VMXt30 with respect to the following cutting parameter: cutting speed 250; 350; 450; 550 and 850 m.min-1, feed 0,1; 0,5 and 1,0 mm/tooth. For testing was used two most common materials in the steel grade 1.1191 (12 050) and 1.2343 (19 552), and we chose two ordinary parameters of surface roughness; Ra - arithmetical mean roughness deviation and Rz - the largest inequalities height profile in the transverse direction and the longitudinal direction of machining. The structural equations will be the result which can describe the character depending on the cut surface parameters.

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