Evolutionary Computation in Combinatorial of Machining Parameters of Reinforced PEEK Composites Using NSGA-II

2014 ◽  
Vol 875-877 ◽  
pp. 652-656
Author(s):  
Issam Hanafi ◽  
Khamlichi Abdellatif ◽  
Francisco Mata Cabrera
Keyword(s):  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Nsga Ii ◽  
Coated Tools ◽  
Machining Force ◽  
High Feed ◽  
Dry Conditions ◽  
Main Operating

The machining parameters for turning of PEEK CF30 using TiN coated tools under dry conditions have been optimized by using Non dominated Sorting Genetic Algorithm (NSGA-II), a non dominated solution set is obtained. The objectives considered are the minimisation of machining force thereby minimising specific cutting pressure as function of the main operating parameters. The results indicated that the minimal cutting parameters are preferred for reducing the machining force, and the minimal cutting speed, medium depth of cut and high feed rate are recommended for minimal specific cutting machining. As per the requirement, the manufacturing engineer should select the proper cutting parameters.

scholarly journals Influence of Tool Wear on Form Deviations in Dry Machining of UNS A97075 Alloy

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 958
Author(s):  
Francisco Javier Trujillo Vilches ◽  
Sergio Martín Béjar ◽  
Carolina Bermudo Gamboa ◽  
Manuel Herrera Fernández ◽  
Lorenzo Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
General Trend ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Adhesion Wear ◽  
Tool Wear Mechanisms ◽  
Tool Wear Mechanism ◽  
High Feed ◽  
Dry Conditions

Geometrical tolerances play a very important role in the functionality and assembly of parts made of light alloys for aeronautical applications. These parts are frequently machined in dry conditions. Under these conditions, the tool wear becomes one of the most important variables that influence geometrical tolerances. In this work, the influence of tool wear on roundness, straightness and cylindricity of dry-turned UNS A97075 alloy has been analyzed. The tool wear and form deviations evolution as a function of the cutting parameters and the cutting time has been assessed. In addition, the predominant tool wear mechanisms have been checked. The experimental results revealed that the indirect adhesion wear (BUL and BUE) was the main tool-wear mechanism, with the feed being the most influential cutting parameter. The combination of high feed and low cutting speed values resulted in the highest tool wear. The analyzed form deviations showed a general trend to increase with both cutting parameters. The tool wear and the form deviations tend to increase with the cutting time only within the intermediate range of feed tested. As the main novelty, a relationship between the cutting parameters, the cutting time (and, indirectly, the tool wear) and the analyzed form deviations has been found.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

Fuzzy Modeling and Analysis on the Turning Parameters for Machining Force and Specific Cutting Pressure in CFRP Composites

2013 ◽  
Vol 766 ◽  
pp. 77-97
Author(s):  
T. Rajasekaran ◽  
V.N. Gaitonde ◽  
J. Paulo Davim
Keyword(s):  
Fuzzy Logic ◽  
Composite Materials ◽  
Prediction Models ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Sem Images ◽  
Machining Force ◽  
Soft Computing Techniques

Analysis of the cutting force and specific cutting pressure play vital roles in machining of the composite materials. The present experimental work describes the modeling of machining parameters using one of the soft computing techniques i.e. fuzzy logic for machining force and specific cutting pressure. The basic idea is to machine the carbon fiber reinforced plastic (CFRP) composite materials and measuring the cutting forces and then determining the machining force and specific cutting pressure. 27 experiments based on Taguchis L27 orthogonal array were carried out involving three machining parameters, namely, cutting speed, feed and depth of cut, each defined at three levels. Subsequently the prediction models were developed using three different fuzzy logic membership functions, namely, triangular, trapezoidal and bell shape. It is found that the predicted values of proposed responses such as machining force and specific cutting pressure are very close to the experimental values within the chosen ranges of the process parameters. The statistical analysis using ANOVA on machining parameters are also presented and discussed. The machined surface analyzed through SEM images revealed the damages encountered during turning process.

scholarly journals Neural Network Modeling of Cutting Force and Chip Thickness Ratio for Turning Aluminum Alloy 7075-T6

2018 ◽  
Vol 14 (1) ◽  
pp. 67-76
Author(s):  
Mohanned Mohammed H. AL-Khafaji
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Thickness Ratio ◽  
Depth Of Cut ◽  
Feed Force ◽  
Machining Force ◽  
Force Components

The turning process has various factors, which affecting machinability and should be investigated. These are surface roughness, tool life, power consumption, cutting temperature, machining force components, tool wear, and chip thickness ratio. These factors made the process nonlinear and complicated. This work aims to build neural network models to correlate the cutting parameters, namely cutting speed, depth of cut and feed rate, to the machining force and chip thickness ratio. The turning process was performed on high strength aluminum alloy 7075-T6. Three radial basis neural networks are constructed for cutting force, passive force, and feed force. In addition, a radial basis network is constructed to model the chip thickness ratio. The inputs to all networks are cutting speed, depth of cut, and feed rate. All networks performances (outputs) for all machining force components (cutting force, passive force and feed force) showed perfect match with the experimental data and the calculated correlation coefficients were equal to one. The built network for the chip thickness ratio is giving correlation coefficient equal one too, when its output compared with the experimental results. These networks (models) are used to optimize the cutting parameters that produce the lowest machining force and chip thickness ratio. The models showed that the optimum machining force was (240.46 N) which can be produced when the cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.27 mm/rev). The proposed network for the chip thickness ratio showed that the minimum chip thickness is (1.21), which is at cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.17 mm/rev).

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).

scholarly journals Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 927 ◽  
Author(s):  
Irene Del Sol ◽  
Asuncion Rivero ◽  
Antonio J. Gamez
Keyword(s):  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Thin Plates ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Final Thickness ◽  
Machined Parts ◽  
Chemical Milling ◽  
Skin Panels

Nowadays, the industry looks for sustainable processes to ensure a more environmentally friendly production. For that reason, more and more aeronautical companies are replacing chemical milling in the manufacture of skin panels and thin plates components. This is a challenging operation that requires meeting tight dimensional tolerances and differs from a rigid body machining due to the low stiffness of the part. In order to fill the gap of literature research on this field, this work proposes an experimental study of the effect of the depth of cut, the feed rate and the cutting speed on the quality characteristics of the machined parts and on the cutting forces produced during the process. Whereas surface roughness values meet the specifications for all the machining conditions, an appropriate cutting parameters selection is likely to lead to a reduction of the final thickness deviation by up to 40% and the average cutting forces by up to a 20%, which consequently eases the clamping system and reduces machine consumption. Finally, an experimental model to control the process quality based on monitoring the machine power consumption is proposed.

Study on Spindle Vibration and Surface Finish in Turning of Al 7075

2017 ◽  
Vol 261 ◽  
pp. 321-327 ◽  
Author(s):  
Abidin Şahinoğlu ◽  
Şener Karabulut ◽  
Abdulkadir Güllü
Keyword(s):  
Surface Roughness ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting ◽  
Al 7075 ◽  
Spindle Vibration ◽  
Coated Cemented Carbide

In this study, the relationship between the spindle vibration and surface roughness was investigated and the effect of the cutting parameters on surface roughness and spindle vibration during the machining of Aluminum alloy 7075 (Al 7075) were determined. Experimental studies have been carried out on a CNC turning machine using coated cemented carbide cutting tools under dry cutting environment. L64 full factorial design of experiments was used to investigate the optimal machining parameters for spindle vibration and surface roughness. The influences of machining parameters on vibration and surface roughness were evaluated by using analysis of variance (ANOVA) and main effect plots. The results revealed that the feed rate was the most effective cutting parameters on spindle vibration and surface roughness. The machine tool vibration amplitude and surface roughness values were significantly increased with increasing cutting feed. The depth of cut and cutting speed have the least effect on the spindle vibration and indicated an insignificant effect on surface roughness. Mathematical equations were developed to predict the vibration and surface roughness values using the regression analysis.

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

Optimisation of Machining Parameters for High Feed End Milling on Inconel 718 Super Alloy

2014 ◽  
Vol 592-594 ◽  
pp. 584-590 ◽  
Author(s):  
Vinay Varghese ◽  
K. Annamalai ◽  
K. Santhosh Kumar
Keyword(s):  
Inconel 718 ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Operation ◽  
High Feed ◽  
Grey Relational ◽  
Super Alloy

This study investigates about machining practices used worldwide for machining of Inconel 718 super alloy. The effect of machining parameters like cutting speed, feed and depth of cut on machining responses like surface roughness and material removal rate when end milling Inconel 718 is studied using nine trials carried out based on L9 orthogonal array. A Taguchi based grey relational analysis was used for optimisation of machining parameters for high feed end milling operation on Inconel 718. An analysis of variance (ANOVA) was used to find the most significant factor. Validation of results through confirmation tests was performed and experimental results show that surface quality and productivity can be improved efficiently with this approach.

Study of High-Speed Machining Parameters on Nickel-Based Alloy GH2132

2011 ◽  
Vol 189-193 ◽  
pp. 3142-3147 ◽  
Author(s):  
Dong Qiang Gao ◽  
Zhong Yan Li ◽  
Zhi Yun Mao
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Nickel Based Alloy

A model of stress and temperature field is established on nickel-based alloy cutting by finite element modeling and dynamic numerical simulating, and then combining high-speed machining test and orthogonality analysis method, the influence law of cutting parameters on the cutting force and tool wear has been researched, and the tool life and cutting force prediction model based on cutting parameters has been obtained. Finally, by genetic algorithm method cutting parameters are selected reasonably and optimized. The result shows that the bonding wear is main tool wear, and the influence of cutting speed on cutting force is smaller than feed per tooth and axial depth of cut.

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