Influence of Turning by Burnishing on Surface Integrity to Analyze Feasibility of Hybrid Process

2008 ◽  
Vol 375-376 ◽  
pp. 411-415
Author(s):  
Feng Lei Li ◽  
Wei Xia ◽  
Zhao Yao Zhou ◽  
Tian Zhang
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Speed ◽  
Hybrid Process ◽  
Surface Microhardness ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Taguchi’S Design Of Experiments ◽  
Dominant Influence

Burnishing, an ultra-precision superficial plastic deformation process, is used increasingly as a surface enhancement finishing treatment after machining operations not only to give a mirror-like and work-hardened surface but also to impose favorable compressive residual stress in it. To analyze the feasibility of turning-burnishing hybrid process, the Taguchi’s L27(313) orthogonal array method with the analysis of variance (ANOVA) were used to analyze the influence of the initial turning process on surface integrity of roller burnished AISI 1045 steel such as surface roughness, surface microhardness. three turning parameters, namely the cutting feed, cutting depth and cutting speed, three burnishing parameters, namely the burnishing feed, burnishing depth and burnishing speed were selected as the experimental factors in Taguchi’s design of experiments to determine which one has the dominant influence and how it works on burnishing effects, namely the surface roughness and surface microhardness, the interactions between cutting feed, burnishing feed and burnishing depth were considered. The experimental results agreed well with the theoretical analysis and the conclusion is cutting feed has dominant influence on burnished surface integrity.

scholarly journals Pengaruh Kecepatan Pemotongan dan Ketebalan Bahan Terhadap Kekerasan dan Kekasaran Permukaan Baja AISI 1045 Menggunakan CNC Plasma Arc Cutting

2019 ◽  
Vol 4 (2) ◽  
pp. 93-98
Author(s):  
Ami Rima Rahmawati ◽  
Samsudin Anis ◽  
Rusiyanto Rusiyanto
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Surface Hardness ◽  
Hardness Test ◽  
Plasma Arc ◽  
Plasma Arc Cutting ◽  
Material Thickness ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This experimental study aims to determine the effect of cutting speed and material thickness on the surface hardness and roughness resulting from the cutting of AISI-1045 steel using CNC Plasma Arc Cutting. The data analysis technique being used was descriptive statistics. The variables of cutting the AISI-1045 steel for the cutting speeds are 75 mm/min, 100 mm/min, and 125 mm/min. The variables for material thickness are 5 mm, 9 mm, and 13 mm. The experiment carried out were the hardness test using Micro-hardness Tester M800 and roughness test using Surfcorder SE-1700. The results show that the lower the cutting speed, the higher the surface hardness and roughness value, and vice versa. The great thickness of the material, the hardness produced and the roughness value is higher. When the cutting speed and thickness of the material value are high, the workpiece cannot be cut off. The lowest hardness and surface roughness values were 261.33 HV and 10.3 µm, respectively, using a cutting speed of 125 mm/min and the material thickness of 5 mm. The highest hardness value is 319.66 HV, using a cutting speed of 75 mm/min and a material thickness of 13 mm. The highest surface roughness value is 26.8 µm, which were obtained using a cutting speed of 75 mm/min and material thickness of 9 mm.Penelitian ini bertujuan untuk mengetahui pengaruh kecepatan pemotongan dan ketebalan bahan terhadap kekerasan dan kekasaran permukaan hasil pemotongan baja AISI-1045 menggunakan CNC Plasma Arc Cutting. Penelitian ini menggunakan metode eksperimen dan teknik analisis data yang digunakan adalah statistika deskriptif pada pemotongan baja AISI-1045 dengan kecepatan pemotongan 75 mm/min, 100 mm/min, 125 mm/min dan tebal bahan 5 mm, 9 mm, dan 13 mm. Pengujian kekerasan dilakukan menggunakan microhardness terster M800 dan pengujian kekasaran dilakukan menggunakan Surfcorder SE-1700. Hasil penelitian menunjukkan bahwa semakin rendah kecepatan pemotongan maka nilai kekerasan semakin tinggi dan nilai kekasaran permukaan semakin tinggi atau sebaliknya. Semakin besar ketebalan bahan yang digunakan maka nilai kekerasan yang dihasilkan semakin tinggi dan nilai kekasaran semakin tinggi atau sebaliknya. Semakin tinggi kecepatan pemotongan dan ketebalan bahan, benda kerja tidak dapat terpotong. Nilai kekerasan dan kekasaran permukaan paling rendah yaitu 261,33 HV dan 10,3 µm dengan kecepatan pemotongan 125 mm/min dan ketebalan bahan 5 mm. Nilai kekerasan yang paling tinggi yaitu 319,66 HV dengan menggunakan kecepatan pemotongan 75 mm/min dan ketebalan bahan 13 mm dan nilai kekasaran permukaan paling tinggi yaitu 26,8 µm dengan kecepatan pemotongan 75 mm/min dan ketebalan bahan 9 mm.

Fuzzy Modeling to Simulate Surface Roughness in CNC Turning of AISI 1045 Steel

2011 ◽  
Vol 486 ◽  
pp. 262-265
Author(s):  
Amit Kohli ◽  
Mudit Sood ◽  
Anhad Singh Chawla
Keyword(s):  
Experimental Data ◽  
Surface Roughness ◽  
Process Parameters ◽  
Fuzzy Model ◽  
Fuzzy Modeling ◽  
Cnc Machine ◽  
Model Based ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

The objective of the present work is to simulate surface roughness in Computer Numerical Controlled (CNC) machine by Fuzzy Modeling of AISI 1045 Steel. To develop the fuzzy model; cutting depth, feed rate and speed are taken as input process parameters. The predicted results are compared with reliable set of experimental data for the validation of fuzzy model. Based upon reliable set of experimental data by Response Surface Methodology twenty fuzzy controlled rules using triangular membership function are constructed. By intelligent model based design and control of CNC process parameters, we can enhance the product quality, decrease the product cost and maintain the competitive position of steel.

scholarly journals PENGARUH PENGHILANGAN KEKASARAN PERMUKAAN TERHADAP KEKUATAN FATIK = EFFECT OF SURFACE ROUGHNESS REMOVAL TO FATIGUE STRENGTH

2015 ◽  
Vol 9 (3) ◽  
pp. 115-130
Author(s):  
H. Agus Suhartono
Keyword(s):  
Surface Roughness ◽  
Fatigue Life ◽  
Fatigue Strength ◽  
Fatigue Loading ◽  
Bending Fatigue ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Test Result ◽  
Effect Of Surface

The aim of the study is to investigate and to prove that the fatigue failure of steel is initiated from the surface. Hence the preventif action of smoothening the surface that has been loaded by fatigue loading is very important. The specimen of AISI 1045 Steel is loaded by means of rotary bending fatigue. The fatigue loading will be interupted as the fatigue life reaching 50% of fatigue life and 75% of fatigue life. During the interuption the specimen will be grinded and polished, before tested completely until fatigue fracture occured. The fatigue life of each group of scpecimen based on the art of loading will be compared to the specimen tested by fatigue loading without interuption.The Miner rule is used to evaluated the test result. The influence of interuption and surface treatment is evaluated and analyzed. ABSTRAKTujuan penelitian ini adalah untuk menyelidiki dan membuktikan bahwa kegagalan kelelahan baja dimulai dari permukaan. Oleh karena itu tindakan pencegahan dengan memperhalus permukaan sangat penting untuk mencegah beban kelelahan baja. Spesimen dari AISI 1045 Steel dimuat dengan cara uji kelelahan lentur putar. Kelelahan pemuatan akan disela sebagai umur kelelahan mencapai 50% dari umur kelelahan dan 75% dari umur kelelahan. Selama gangguan lainnya yang spesimen akan digiling dan dipoles, sebelum diuji benar-benar sampai patah akibat kelelahan yang terjadi. Umur kelelahan dari setiap kelompok specimen diuji berdasarkan beban akan dibandingkan dengan spesimen oleh kelelahan bongkar tanpa aturan. The Miner rule digunakan untuk mengevaluasi hasil tes. Pengaruh gangguan lainnya dan perlakuan permukaan dievaluasi dan dianalisis. 

Constrained Optimization of Surface Roughness in Longitudinal Turning via Novel Modified Harmony Search

2011 ◽  
Author(s):  
Reza Farshbaf Zinati ◽  
Mohammad Reza Razfar
Keyword(s):  
Surface Roughness ◽  
Search Algorithm ◽  
Harmony Search ◽  
Harmony Search Algorithm ◽  
Cutting Condition ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Artificial Neural ◽  
Longitudinal Turning ◽  
1045 Steel

The present research deals with a modified optimization algorithm of harmony search coupled with artificial neural networks (ANNs) to predict the optimal cutting condition. To this end, several experiments were carried out on AISI 1045 steel to attain required data for training of ANNs. Feed forward artificial neural network was utilized to create predictive models of surface roughness and cutting forces exploiting experimental data, and Modified Harmony Search algorithm (MHS) was used to find the constrained optimum of the surface roughness. Furthermore, Simple Harmony Search algorithm (SHS) and Genetic Algorithm (GA) were used for solving the same optimization problem to illustrate the capabilities of MHS algorithm. The obtained results demonstrate that MHS algorithm is more effective and authoritative in approaching the global solution than the SHS algorithm and GA.

Selection of Optimal Tool Geometry and Cutting Conditions in End Milling With Graphite as a Solid Lubricant

2004 ◽  
Author(s):  
N. Suresh Kumar Reddy ◽  
P. Venkateswara Rao
Keyword(s):  
Solid Lubricant ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

Coolants dissipate the heat generated during machining and hence improve productivity, machinability, etc. However, the use of cutting fluids in machining operations may seriously degrade the quality of environment. So, in recent years researchers have started machining with the use of solid lubricants with the aim of improving machining performance and overcome some of the limitations that arise with the use of cutting fluids or while machining dry. This paper deals with an investigation on using graphite as a solid lubricant to reduce the heat generated at the milling zone for improving the surface roughness of the machined AISI 1045 steel. An experimental setup has been developed to maintain constant flow rate of graphite powder continuously on to the workpiece and tool interface zone. The experimental studies have been conducted to see the effect of tool geometry (radial rake angle and nose radius) and cutting conditions (cutting speed and feed rate) on the machining response such as surface finish in solid lubricant assisted machining using four fluted solid TiAlN coated carbide cutters. Results indicate that there is a considerable improvement in the performance of milling AISI 1045 steel using graphite as a solid lubricant when compared with machining with cutting fluids. An attempt has also been made to select optimum tool geometry and cutting conditions in end milling with graphite as a solid lubricant by using the prediction model obtained from these experimental results.

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