Modeling the Force, Surface Roughness and Cutting Temperature in Ultrasonic Vibration-Assisted Turning of Al7075

2009 ◽  
Vol 83-86 ◽  
pp. 315-325 ◽  
Author(s):  
Mohammad Javad Nategh ◽  
Saeed Amini ◽  
H. Soleimanimehr
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Temperature ◽  
Depth Of Cut ◽  
Ultrasonic Frequency ◽  
Factorial Experiments ◽  
Machining Force ◽  
Cutting Velocity ◽  
Full Factorial

The single point cutting tool in ultrasonic vibration-assisted turning (UAT) is made to vibrate under ultrasonic frequency. In present study, the influence of various parameters such as vibration amplitude, depth of cut, feed rate and cutting velocity on the machining force and workpiece's surface roughness in UAT of Al7075 has been investigated. Full factorial experiments were carried out with an ultrasonic frequency range of 20±0.5 kHz. ANOVA was conducted on the experimental results and regression models were obtained for predicting the machining force, surface roughness and cutting temperature. The proposed models were verified by further experiments. The robustness of the proposed models was then investigated whence the optimal parameters were estimated. Similar full factorial experiments were also carried out with conventional turning (CT) in order to compare the results with those of UAT.

Prediction of Machining Force and Surface Roughness in Ultrasonic Vibration-Assisted Turning Using Neural Networks

2009 ◽  
Vol 83-86 ◽  
pp. 326-334 ◽  
Author(s):  
H. Soleimanimehr ◽  
Mohammad Javad Nategh ◽  
Saeed Amini
Keyword(s):  
Neural Networks ◽  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Back Propagation ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Force ◽  
Nonlinear Relation ◽  
Factorial Design Of Experiments ◽  
Full Factorial

In present study, neural networks have been employed for studying the ultrasonic vibration-assisted turning (UAT) process and for predicting the machining force and workpiece's surface roughness. Extensive experiments were carried out using different values of UAT parameters such as vibration amplitude, depth of cut, feed rate and cutting speed. The tests were implemented on the basis of full factorial design of experiments for three different levels of each UAT parameter. The machining force and workpiece's surface roughness were measured as the responses of the experiments and were subsequently modeled with the aid of back propagation multilayer perceptron neural network for 1.1191 steel. The nonlinear relation existing between the aforementioned UAT parameters and the machining force and workpiec's surface roughness could effectively be modeled by the developed networks and the responses error could be kept less than ten percent. This was verified by further experiments different from those carried out for developing the network.

Finite Element Analysis of Ultrasonic Vibration Assisted Turning of Ferrous Metals

2013 ◽  
Vol 567 ◽  
pp. 33-38 ◽  
Author(s):  
Lai Zou ◽  
Ming Zhou
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Technological Parameters ◽  
Ferrous Metals

Ultrasonic vibration assisted turning has significant improvements in processing of intractable materials compared to conventional turning. This paper presents a theoretical investigation of tool wear in single point diamond turning of ferrous metals based on numerical simulation. Finite element modeling and simulation of ultrasonic vibration turning process were performed, aimed at optimizing a series of technological parameters in the process of machining, reducing tool wear and improving surface quality as much as possible. The results revealed that the cutting speed and depth of cut are two crucial factors for tool wear, unlike the other parameters of vibration frequency, amplitude and flank angle. Moreover, this technological measure has observably decreased the cutting force and cutting temperature, so as to obtain superior surface finish.

Study on Machinability of 35CrMnSiA Steel in Hard Turning Process

2006 ◽  
Vol 532-533 ◽  
pp. 349-352
Author(s):  
Wen Xiang Zhao ◽  
Si Qin Pang ◽  
Zhen Hai Long ◽  
Xi Bin Wang
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
High Strength ◽  
Depth Of Cut ◽  
Turning Process ◽  
High Speed Turning ◽  
Cutting Velocity ◽  
Strength Alloy

35CrMnSiA, is a kind of important engineering materials that used widely in modern manufacturing fields. The machinability of 35CrMnSiA Steel with hardness of HRc40±2 in high speed turning process was studied in this paper. It is concluded that, when high speed turning of this ultra-high strength alloy steel, the chief wear mode of ceramics is the crater on rake faces; the interaction of depth of cut and feed rate is one of statistic significant effects on cutting force; the interaction of cutting velocity of cut and feed rate is one of statistic significant effects on surface roughness Ra; besides, the empirical formula of average cutting temperature, cutting forces, surface roughness Ra, was established.

Deep Hole Machining with a Small Diameter Drill and Ultrasonic Vibration

2017 ◽  
Vol 749 ◽  
pp. 107-110
Author(s):  
Yuta Masu ◽  
Tomohito Fukao ◽  
Taiga Yasuki ◽  
Masahiro Hagino ◽  
Takashi Inoue
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Small Diameter ◽  
Maximum Amplitude ◽  
Depth Of Cut ◽  
Deep Hole ◽  
Work Material ◽  
Finished Surface

The method of imparting ultrasonic vibration to the cutting tool is known to improve the shape accuracy and finished surface roughness. However, a uniform evaluation of this function in drilling has not been achieved, and the cutting process cannot be checked from the outside. The aim of this study is to investigate the cutting characteristics in deep hole drilling when an ultrasonic vibrator on the table of a machining center provides vibration with a frequency of 20 kHz to the work piece. The ultrasonic vibrations in this system reach the maximum amplitude in the center of the work material. We evaluated the change in finished surface roughness between the section where drilling starts to the point of maximum amplitude with ultrasonic vibration. The main cutting conditions are as follows: cutting speed (V) 12.6 (mm/min); feed rate (s) 30, 60 (mm/rev); depth of cut (t) = 32 (mm); work material, tool steel; cutting tool material, HSS; point angle (σ) 118 (°); and drill diameter (φ) 4 (mm). Lubricant powder was also added to clarify the cutting effect, and compared the condition in which there was no ultrasonic vibration. The results showed that surface roughness at the point of maximum amplitude was better than that with no vibration.

Generation mechanism modeling of surface topography in tangential ultrasonic vibration-assisted grinding with green silicon carbide abrasive wheel

2021 ◽  
pp. 095440542110406
Author(s):  
Yutong Qiu ◽  
Jingfei Yin ◽  
Yang Cao ◽  
Wenfeng Ding
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Ultrasonic Vibration ◽  
Generation Mechanism ◽  
Surface Generation ◽  
Depth Of Cut ◽  
Abrasive Wheel ◽  
Grinding Parameters ◽  
Conventional Grinding ◽  
Ultrasonic Vibration Assisted Grinding

Tangential ultrasonic vibration-assisted grinding (TUAG) has a wide prospect in machining difficult-to-machine materials. However, the surface generation mechanism in TUAG is not fully recovered. This study proposes an analytical model of the surface topography produced by TUAG. Based on the model, the surface topography and roughness are predicted and experimentally verified. In addition, the influence of the grinding parameters on the surface topography is analyzed. The predicted surface topography well coincides with experimental measurements, and the prediction error in surface roughness Ra by the proposed model is less than 5%. Compared with conventional grinding, TUAG produces a surface with more uniform scratches and surface roughness Ra was reduced by up to 27% with the proper parameters. However, the improvement of surface roughness in TUAG is weakened when grinding speed or depth of cut increases. Moreover, the influence of the ultrasonic vibration amplitude on the surface roughness is not monotonous. With the grinding parameters selected in this study, TUAG with an ultrasonic amplitude of 7.5 μm produces the minimum surface roughness.

scholarly journals Influence of Ultrasonic Vibration-Assisted Ball-End Milling on the Cutting Performance of AZ31B Magnesium Alloy

2020 ◽  
Vol 9 (4) ◽  
pp. 271-276
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Biomedical Applications ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Machining Process ◽  
Dry Conditions ◽  
Good Biocompatibility

Magnesium alloys have a tremendous possibility for biomedical applications due to their good biocompatibility, integrity and degradability, but their low ignition temperature and easy corrosive property restrict the machining process for potential biomedical applications. In this research, ultrasonic vibration-assisted ball milling (UVABM) for AZ31B is investigated to improve the cutting performance and get specific surface morphology in dry conditions. Cutting force and cutting temperatures are measured during UVABM. Surface roughness is measured with a white light interferometer after UVABM. The experimental results show cutting force and cutting temperature reduce due to ultrasonic vibration, and surface roughness decreases by 34.92%, compared with that got from traditional milling, which indicates UVABM is suitable to process AZ31B for potential biomedical applications.

Surface integrity in laser-assisted machining of Ti6Al4V

2020 ◽  
pp. 095440622097825
Author(s):  
O Kalantari ◽  
MM Fallah ◽  
F Jafarian ◽  
SR Hamzeloo
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Laser Source ◽  
Depth Of Cut ◽  
Thermal Source ◽  
Laser Assisted Machining

In laser-assisted machining (LAM), the laser source is focused on the workpiece as a thermal source and locally increases the workpiece temperature and makes the material soft ahead of the cutting tool so using this method, the machining forces are reduced, which causes improving the surface quality and cutting tool life. Machinability of advanced hard materials is significantly low and conventional methods do not work effectively. Therefore, utilizing an advanced method is inevitable. The product life and performance of complex parts of the leading industry depends on surface integrity. In this work, the surface integrity features including microhardness, grain size and surface roughness (Ra) and also the maximum cutting temperature were investigated experimentally in LAM of Ti-6Al-4V. According to the results, cutting speed has inverse effect on the effectiveness of LAM process because with increasing speed (15 to 63 m/min), temperature decreases (524 °C to 359 °C) and surface roughness increases (0.57 to 0.71 μm). Enhancing depth of cut and feed has direct effect on the process temperature, grain size, microhardness and surface roughness.

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

Cutting Parameters Optimization of Mild Steel via AIS Heuristics Algorithm

2015 ◽  
Vol 761 ◽  
pp. 132-136
Author(s):  
Adnan Jameel Abbas ◽  
Mohammad Minhat ◽  
Md Nizam Abd Rahman
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Optimum Cutting ◽  
Cutting Velocity ◽  
Cutting Zone ◽  
The Ideal

. The minimum cost and high productivity of the recent industrial renaissance are its main challengers. Selecting the optimum cutting parameters play a significant role in achieving these aims. Heat generated in the cutting zone area is an important factor affecting workpiece and cutting tool properties. The surface finish quality specifies product success and integrity. In this paper, the temperature generated in the cutting zone (shear zone and chip-tool interface zone) and workpiece surface roughness is optimized using an artificial immune system (AIS) intelligent algorithm. A mild steel type (S45C) workpiece and a tungsten insert cutting tool type (SPG 422) is subjected to dry CNC turning operation are used in experiments. Optimum cutting parameters (cutting velocity, depth of cut, and feed rate) calculated by the (AIS) algorithm are used to obtain the simulated and ideal cutting temperature and surface roughness. An infrared camera type (Flir E60) is used for temperature measurement, and a portable surface roughness device is used for roughness measurement. Experimental results show that the ideal cutting temperature (110°C) and surface roughness (0.49 μm) occur at (0.3 mm) cut depth, (0.06 mm) feed rate, and (60 m/min) cutting velocity. The AIS accuracy rates in finding the ideal cutting temperature and surface roughness are (91.70 %) and (90.37 %) respectively. Analysis shows that the predicted results are close to the experimental ones, indicating that this intelligent system can be used to estimate cutting temperature and surface roughness during the turning operation of mild steel.

Modelling and Optimization of Tool Chip Interface Temperature and Surface Roughness in CNC Dry Turning of EN 24 Steel

2016 ◽  
Vol 16 ◽  
pp. 7-15 ◽  
Author(s):  
Nirmal Kumar Mandal ◽  
Tanmoy Roy
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Work Piece ◽  
Substantial Impact

Abstract. Kinetic energy of a machining process is converted into heat energy. The generated heat at cutting tool and work piece interface has substantial impact on cutting tool life and quality of the work piece. On the other hand, development of advanced cutting tool materials, coatings and designs, along with a variety of strategies for lubrication, cooling and chip removal, make it possible to achieve the same or better surface quality with dry or Minimum Quantity Lubrication (MQL) machining than traditional wet machining. In addition, dry and MQL machining is more economical and environment friendly. In this work, 20 no. of experiments were carried out under dry machining conditions with different combinations of cutting speed, feed rate and depth of cut and corresponding cutting temperature and surface roughness are measured. The no. of experiments is determined through Design of Experiments (DOE). Nonlinear regression methodology is used to model the process using Response Surface Methodology (RSM). Multi-objective optimization is carried using Genetic Algorithm which ensures high productivity with good product quality.

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