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.

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.

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.

Prediction of Surface Roughness Using Back-Propagation Neural Network in End Milling Ti-6Al-4V Alloy

2011 ◽  
Vol 325 ◽  
pp. 418-423 ◽  
Author(s):  
Song Zhang ◽  
Jian Feng Li
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
End Milling ◽  
Back Propagation ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Back Propagation Neural Network ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Bpnn Model

Surface roughness plays a significant role in machining industry for proper planning of process system and optimizing the cutting conditions. In this paper, a back-propagation neural network (BPNN) model has been developed for the prediction of surface roughness in end milling process. A large number of milling experiments were conducted on Ti-6Al-4V alloy using the uncoated carbide tools. Four cutting parameters including cutting speed, feed per tooth, radial depth of cut, and axial depth of cut are used as the inputs to develop the BPNN model, while surface roughness corresponding to these combinations of different cutting parameters is the output of the neural network model. The performance of the trained BPNN model has been verified with the experimental results, and it is found that the BPNN predicted and the experimental values are very close to each other.

Optimization of tungsten carbide processing parameters for laser heating and ultrasonic vibration composite assisted cutting

2018 ◽  
Vol 233 (12) ◽  
pp. 4140-4153
Author(s):  
Feng Jiao ◽  
Ming-jun Zhang ◽  
Ying Niu
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Ultrasonic Vibration ◽  
Laser Heating ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Properties

Laser heating assisted cutting is a lucrative technique for machining difficult-to-machine materials such as tungsten carbide (YG20), which uses a high power laser to focally heat a workpiece before the material removal with traditional or innovative cutting tool. In the latter case, the application of ultrasonic vibration to the cutting edge was found to replace the continuous cutting mode to the interrupted one, it reduces the adhesion and entanglement of chips, improves the tool wear and surface roughness of the workpiece. The combination of laser heating assisted cutting and two-dimensional ultrasonic vibration cutting methods has been successfully applied by the authors of this paper for cutting of tungsten carbide (YG20). In this follow-up study, the proposed composite method is experimentally and theoretically verified. Through the mathematical model and simulation analysis, its advantages, including small cutting force, softening the effect and improved machining properties of the processed material (YG20) are corroborated. The dependencies between the laser power, cutting speed, depth of cut, and feed rate on the surface roughness are established via the response surface methodology. The genetic algorithm is applied to the optimization of machining parameters by setting the material removal rate as the object variable and surface roughness as a constraint variable. The results obtained strongly suggest that the optimized parameters improve the processing efficiency and furnish the required processing quality.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Possible examinations of stone machining focused on the relationship between technological parameters and surface quality

2013 ◽  
Vol 4 (1) ◽  
pp. 63-68 ◽  
Author(s):  
Zs. Kun ◽  
I. G. Gyurika
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Theoretical Background ◽  
Motion Path ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Technological Parameters ◽  
The Relationship ◽  
Manufacturing Time

Abstract The stone products with different sizes, geometries and materials — like machine tool's bench, measuring machine's board or sculptures, floor tiles — can be produced automatically while the manufacturing engineer uses objective function similar to metal cutting. This function can minimise the manufacturing time or the manufacturing cost, in other cases it can maximise of the tool's life. To use several functions, manufacturing engineers need an overall theoretical background knowledge, which can give useful information about the choosing of technological parameters (e.g. feed rate, depth of cut, or cutting speed), the choosing of applicable tools or especially the choosing of the optimum motion path. A similarly important customer's requirement is the appropriate surface roughness of the machined (cut, sawn or milled) stone product. This paper's first part is about a five-month-long literature review, which summarizes in short the studies (researches and results) considered the most important by the authors. These works are about the investigation of the surface roughness of stone products in stone machining. In the second part of this paper the authors try to determine research possibilities and trends, which can help to specify the relation between the surface roughness and technological parameters. Most of the suggestions of this paper are about stone milling, which is the least investigated machining method in the world.

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.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

scholarly journals An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 460
Author(s):  
Canbin Zhang ◽  
Chifai Cheung ◽  
Benjamin Bulla ◽  
Chenyang Zhao
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
Optical Glass ◽  
Contact Point ◽  
Cutting Speed ◽  
Optical Quality ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cutting Geometry

Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0°, 5°, 10°, and 15°, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.

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