Experimental Optimization of Process Parameters for Turning TC11 Titanium Alloy Using Taguchi Methodology Design

2016 ◽  
Vol 693 ◽  
pp. 1009-1014 ◽  
Author(s):  
Su Lin Chen ◽  
Bin Shen ◽  
Fang Hong Sun
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cvd Diamond ◽  
Depth Of Cut ◽  
Taguchi Methodology ◽  
Turning Process

This paper presents a study of the influence of cutting conditions (cutting velocity, feed, cutting depth and lubrication) on turning TC11 (Ti-6.5Al-3.5Mo-1.5Zr-0.3Si) titanium alloy. Taguchi methodology design was adopt for carrying out experiments. Turning process parameters such as cutting speed, feed rate and depth of cut were varied to study their effect on process responses such as cutting force (Ft), surface roughness (Ra) and temperature on cutting zones (T). Minimum quantity lubrication (MQL) technology was adopt to increase the lubricating and cooling effect. Meanwhile, CVD diamond coating was deposited on the cemented carbide insert to reduce its friction with workpiece and increase its wear resistance. From the analysis of orthogonal tests, depth of cut contributes the most for the main cutting force and cutting temperature, while feed rate had the most significant effect on surface roughness on the workpiece. MQL can reduce the cutting temperature at the cutting zones, especially for the uncoated cutting inserts whose temperature decreases by an average of 60~80°C. The cutting force, surface roughness and cutting temperature of CVD diamond coated inserts were all higher than those of uncoated tools, especially with MQL lubrication. Considering the cutting efficiency and cost, the optimal parameters in the turning process of TC11 for minimizing the cutting force, surface roughness and cutting temperature are obtained as Vc=115m/min, f=0.08mm, ap=0.5mm under MQL lubricating with uncoated cemented carbide as the cutting tool.

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.

Effect of Silicon Content of Aluminum Alloy 6351 in Turning Process

2012 ◽  
Author(s):  
Daniel Fernandes da Cunha ◽  
Marcio Bacci da Silva
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Silicon Content ◽  
The Other ◽  
Depth Of Cut ◽  
Edge Region ◽  
Turning Process ◽  
Free Region

The machinability of three commercial samples of the 6351 aluminum alloy with different silicon content was investigated in this work. Several parameters were used to evaluate the machinability in turning process, including the quality of the machined surface and cutting force. A design of experiments with three levels was used focusing on low values of feed rate (0.10, 0.15 and 0.2 mm/rev). The other parameters involved were: depth of cut (1.0, 1.5 and 2.0 mm), the silicon content (1.1, 1.2 and 1.3%) and two sets of cutting speed, one in the build up edge region (80, 100 and 120 m/min) and the other in a built up edge free region (200, 600 and 1000 m/min). The surface roughness parameter evaluated was Rq. A second design of experiment with three levels using higher values of feed rate (0.2, 0.35 and 0.5 mm/rev) and depth of cut of 2.0 mm was used to evaluate the influence of the silicon content in the cutting force. The effect of cutting fluid (dry machining, minimum quantity of fluid and over head cooling) was also analyzed. The results show that the silicon content has influence on the surface roughness. The statistical model in the build up edge region explains 79.95% of the total variation of roughness and 99% for cutting forces, for the other region this value is 81.99% for surface roughness and 98.96% for cutting force. The diameter of the workpiece has an influence on the results because the variation of hardness.

Monitoring of Surface Roughness Based on Cutting Force and Cutting Temperature in Ball-End Milling Process by Utilizing Response Surface Analysis

2015 ◽  
Vol 799-800 ◽  
pp. 324-328
Author(s):  
Panrawee Yaisuk ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Process ◽  
Depth Of Cut ◽  
Tool Diameter ◽  
End Milling Process

The surface roughness is monitored using the cutting force and the cutting temperature in the ball-end milling process by utilizing the response surface analysis with the Box-Behnken design. The optimum cutting condition is obtained referring to the minimum surface roughness, which is the spindle speed, the feed rate, the depth of cut, and the tool diameter. The models of cutting force ratio and the cutting temperature are proposed and developed based on the experimental results. It is understood that the surface roughness is improved with an increase in spindle speed, feed rate and depth of cut. The cutting temperature decreases with an increase in tool diameter. The model verification has showed that the experimentally obtained surface roughness model is reliable and accurate to estimate the surface roughness.

scholarly journals Prediction of surface roughness and cutting force under MQL turning of AISI 4340 with nano fluid by using response surface methodology

2018 ◽  
Vol 5 ◽  
pp. 5 ◽  
Author(s):  
Pralhad B. Patole ◽  
Vivek V. Kulkarni
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Nano Fluid ◽  
Aisi 4340

This paper presents an investigation into the minimum quantity lubrication mode with nano fluid during turning of alloy steel AISI 4340 work piece material with the objective of experimental model in order to predict surface roughness and cutting force and analyze effect of process parameters on machinability. Full factorial design matrix was used for experimental plan. According to design of experiment surface roughness and cutting force were measured. The relationship between the response variables and the process parameters is determined through the response surface methodology, using a quadratic regression model. Results show how much surface roughness is mainly influenced by feed rate and cutting speed. The depth of cut exhibits maximum influence on cutting force components as compared to the feed rate and cutting speed. The values predicted from the model and experimental values are very close to each other.

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.

The Cutting Behavior of Diamond Coated Tool in Machining Al-20wt%Si Alloy

2010 ◽  
Vol 431-432 ◽  
pp. 365-368
Author(s):  
Wen Zhuang Lu ◽  
Dun Wen Zuo ◽  
B. Yang ◽  
Feng Xu ◽  
M. Wang
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cvd Diamond ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Coated Tool ◽  
Coated Cemented Carbide

The performance of CVD diamond coated cemented carbide cutting tool in comparison with K10 uncoated cemented carbide tool in the dry turning of Al-20wt%Si aluminum-silicon hypereutectic alloy was investigated. The obtained results showed a better cutting performance for CVD diamond coated tool in machining Al-20wt%Si, particularly in terms of cutting force, tool wear, surface roughness, when compared with K10. The cutting forces are lower with CVD diamond coated tool and the depth of cut promotes a great increment of the cutting force. The tool wear processes taking place in the tool tips in all cutting conditions. The tool life of CVD diamond coated tool is longer than that of the uncoated K10. The surface roughness Ra increases obviously with the increase of feed rate using a CVD diamond coated cutting tool. A higher feed rate produces surface rougher. The chip morphology in machining of Al-20wt%Si alloy by CVD diamond coated tool is continuous. The tests showed that the CVD diamond coated tool can be applied on the K10 tool at low feed rate to produce high quality surfaces.

Nature instigated Grey wolf algorithm for parametric optimization during machining (Milling) of polymer nanocomposites

2021 ◽  
pp. 089270572199320
Author(s):  
Prakhar Kumar Kharwar ◽  
Rajesh Kumar Verma
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Polymer Nanocomposites ◽  
Feed Rate ◽  
Fitness Function ◽  
Depth Of Cut ◽  
Multiwall Carbon Nanotube ◽  
Grey Wolf ◽  
Milling Characteristics ◽  
The Impact

The new era of engineering society focuses on the utilization of the potential advantage of carbon nanomaterials. The machinability facets of nanocarbon materials are passing through an initial stage. This article emphasizes the machinability evaluation and optimization of Milling performances, namely Surface roughness (Ra), Cutting force (Fc), and Material removal rate (MRR) using a recently developed Grey wolf optimization algorithm (GWOA). The Taguchi theory-based L27 orthogonal array (OA) was employed for the Machining (Milling) of polymer nanocomposites reinforced by Multiwall carbon nanotube (MWCNT). The second-order polynomial equation was intended for the analysis of the model. These mathematical models were used as a fitness function in the GWOA to predict machining performances. The ANOVA outcomes efficiently explore the impact of machine parameters on Milling characteristics. The optimal combination for lower surface roughness value is 1.5 MWCNT wt.%, 1500 rpm of spindle speed, 50 mm/min of feed rate, and 3 mm depth of cut. For lower cutting force, 1.0 wt.%, 1500 rpm, 90 mm/min feed rate and 1 mm depth of cut and the maximize MRR was acquired at 0.5 wt.%, 500 rpm, 150 mm/min feed rate and 3 mm depth of cut. The deviation of the predicted value from the experimental value of Ra, Fc, and MRR are found as 2.5, 6.5 and 5.9%, respectively. The convergence plot of all Milling characteristics suggests the application potential of the GWO algorithm for quality improvement in a manufacturing environment.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

scholarly journals Optimization of Boring Process Parameters in Manufacturing of Polyacetal Bushing using High Speed Steel

2019 ◽  
Vol 130 ◽  
pp. 01031 ◽  
Author(s):  
The Jaya Suteja ◽  
Yon Haryono ◽  
Andri Harianto ◽  
Esti Rinawiyanti
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Optimum Result ◽  
Edge Angle

Polyacetal is commonly used as bushing material because of its low coefficient of friction and self lubricant characteristics. The polyacetal is machined by using boring process to produce bushing in certain surface roughness. The objectives of this research are to optimize three independent parameters (depth of cut, feed rate and principal cutting edge angle) of boring process of polyacetal using high speed steel tool to achieve the highest material removal rate and the required surface roughness. Response Surface Methodology is used to investigate the influence of the parameters and optimize the boring process. The research shows that the influence of the boring process parameters on polyacetal is similar compared to on metal. The result reveals that the optimum result is achieved by applying the value of depth of cut, feed rate, and principal cutting edge angle is 2.9 × 10–3 m, 0.229 mm rev–1, and 99.1° respectively. By applying these values, the maximum material rate removal achieved in this research is 1263.4 mm3 s–1 and the surface roughness achieved is 1.57 × 10–6 m.

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