Study on Factors which Make CBN Insert can Turn S45C Steel Have Surface Roughness Less than Ra 0.4

2019 ◽  
Vol 805 ◽  
pp. 3-7
Author(s):  
Manus Sriswat ◽  
Kittipong Kimapong ◽  
Atthakorn Chanchana
Keyword(s):  
Surface Roughness ◽  
Contact Area ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Standard Type ◽  
Good Surface ◽  
Cylindrical Parts

Grinding process is necessary final process of making cylindrical parts with less than Ra 0.4 surface roughness. Generally we cannot obtain good surface quality without grinding process. As the experience of the authors, using CBN (Cubic Boron Nitride) insert to turning cylindrical parts could be obtained Ra 0.438 surface roughness. The surface roughness result is similar to ground parts. This result becomes the main focus of the study. Authors study to find out factors affecting CBN performance in turning with CBN to obtain less than Ra 0.4 surface roughness. According to the study, it was found that tool contact area allied to surface roughness. The experiment is turning S45C medium carbon steel under the following condition: Cutting speed is 300 m./min, Feed is 0.05 mm./rev and depth of cut is 0.1 mm. Experiment under the same condition in different contact area. Modify contact area of CBN insert to be 5,10,15,20 and 25 mm. and testing in order. CBN insert standard type contact area is 0 mm. Compare test results of modified CBN inserts with standard type result. The results of experiments were as follows: 1) Turning steel with CBN contact area 10 mm. was obtained Ra 0.456 surface roughness, 2) Turning steel with CBN contact area 15 mm. was obtained Ra 0.293 surface roughness, Thus less than Ra 0.4 surface roughness.

PREDICTION AND INVESTIGATION OF SURFACE ROUGHNESS WHILE TURNING SG IRON WITH CUBIC BORON NITRIDE (CBN) AND TUNGSTEN CARBIDE INSERTS

2017 ◽  
Vol 41 (1) ◽  
pp. 129-141 ◽  
Author(s):  
K.M. Kumar ◽  
P. Hariharan
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Tungsten Carbide ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Spheroidal Graphite ◽  
Surface Model ◽  
Sg Iron ◽  
The Impact

This work compares the effect of cubic boron nitride (CBN) and multilayer (TiCN+Al2O3+TiN) coated tungsten carbide (WC) tools during the turning of spheroidal graphite (SG) nodular iron. Nodular irons have more ductility which is required in mechanical components that demand high fatigue resistance like crankshafts, cam shafts, bearing caps and clutch housings. The impact of various process parameters like the depth of cut, cutting speed and feed on the surface roughness (Ra) of SG iron is studied and optimized using the response surface model. The chip morphology is also discussed for evaluation of the quality of the turned surface. The experimental outcomes reveal that the WC tool offers a high surface finish at the optimal combination of the cutting speed at 102 meter/minute, feed at 0.051 millimeter/revolution and depth of cut at 0.5 millimeter and that, for the CBN insert, at 245 meter/minute of cutting speed, 0.051 millimeter/revolution of feed and 0.75 millimeter of depth of cut.

scholarly journals Analysis and Optimization of Ceramic Cutting Tool In Hard Turning of EN-31 Using Factorial Design

2012 ◽  
pp. 53-58
Author(s):  
Chetan Darshan ◽  
Lakhvir Singh ◽  
APS Sethi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
Feed Rate ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Good Surface ◽  
En 31

Manufacturers around the globe persistently looking for the cheapest and quality manufactured machined components to compete in the market. Good surface quality is desired for the proper functioning of the produced parts. The surface quality is influenced by cutting speed, feed rate and depth of cut and many other parameters. In the present study attempt has been made to evaluate the performance of ceramic inserts during hard turning of EN-31 steel. The analysis of variance is applied to study the effect of cutting speed, feed rate and depth of cut on Flank wear and surface roughness. Model is found to be statically significant using regression model, while feed and depth of cut are the factor affecting Flank wear and feed is dominating factors for surface roughness. The analysis of variance was used to analyze the input parameters and there interactions during machining. The developed model predicted response factor at 95% confidence level.

Optimisation of Machining Parameters for Milling Polyetheretherketones (PEEK) Biomaterial

2014 ◽  
Vol 699 ◽  
pp. 198-203 ◽  
Author(s):  
Raja Izamshah Raja Abdullah ◽  
Aaron Yu Long ◽  
Md Ali Mohd Amran ◽  
Mohd Shahir Kasim ◽  
Abu Bakar Mohd Hadzley ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Processing Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dimensional Precision ◽  
Good Surface

Polyetheretherketones (PEEK) has been widely used as biomaterial for trauma, orthopaedic and spinal implants. Component made from Polyetheretherketones generally required additional machining process for finishing which can be a problem especially to attain a good surface roughness and dimensional precision. This research attempts to optimize the machining and processing parameters (cutting speed, feed rate and depth of cut) for effectively machining Polyetheretherketones (PEEK) implant material using carbide cutting tools. Response Surface Methodology (RSM) technique was used to assess the effects of the parameters and their relations towards the surface roughness values. Based on the analysis results, the optimal machining parameters for the minimum surface roughness values were by using cutting speed of 5754 rpm, feed rate of 0.026 mm/tooth and 5.11 mm depth of cut (DOC).

Research on the Surface Roughness of Dry Cutting Different Levels of Austempering Ductile Iron (ADI)

2011 ◽  
Vol 464 ◽  
pp. 496-500
Author(s):  
Xiao Hong Xue ◽  
Xu Hong Guo ◽  
Ting Ting Chen ◽  
Dong Dong Wan ◽  
Qiao Wang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Isothermal Quenching ◽  
Dry Cutting ◽  
Quenching Temperature

Three cutting tools of different materials (ceramics CC6050, cubic boron nitride CB7025, carbide GC2025) are used for dry turning of 9 groups of ADI which heat-treated under different quenching time and quenching temperature. The surface roughness of ADI workpieces were tested after the finish turning at changed cutting parameters, and the influencing factors of surface quality were analysed. Results showed that the surface roughness values of all 9 groups of ADI workpieces obtained by CC6050 were the lowest and the surface quality was better at lower depth of cut ap and feed rate f with higher cutting speed vc . Meanwhile, the surface roughness was influenced by the isothermal quenching parameters of ADI workpieces significantly.

Optimization of Surface Roughness in End Milling of Medium Carbon Steel under the Influence of Magnets Attached to the Machine Spindle

2012 ◽  
Vol 576 ◽  
pp. 115-118
Author(s):  
A.K.M. Nurul Amin ◽  
Syidatul Akma ◽  
Maizatul Akma ◽  
M.D. Arif
Keyword(s):  
Surface Roughness ◽  
Carbon Steel ◽  
Metal Cutting ◽  
Permanent Magnets ◽  
End Milling ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Medium Carbon

One of the major technological parameters in metal cutting is surface roughness. It is an unavoidable, and often, unwanted by-product of all machining operations, especially end milling. Surface roughness is directly related to product quality and performance, operation cost, machining accuracy, and chatter. Today’s stringent customer requirements demand machined parts with minimum (mirror finished) products. Hence, the prediction, modeling, and optimization of surface roughness is a quintessential concern in machining research and industrial endeavor. This research was undertaken in order to determine whether end milling of medium carbon steel performed using chosen ranges of cutting parameter and under magnetic field generated by permanent magnets could effectively improve surface roughness. A small central composite design with five levels and an alpha value of 1.4142, in Response Surface Methodology, was used in developing the relationship between cutting speed, feed, and depth of cut, with surface roughness. Design-Expert 6.0 software was utilized to develop the quadratic empirical mathematical model for surface roughness. The experiments were performed under two different conditions. The first condition was cutting under normal conditions, while the other one was cutting under the application of magnetic fields from two permanent magnets. Medium carbon steel was used as the work material. The resultant average surface roughness was found to be reduced by a maximum of 59% due to magnet application.

Evaluation of the Performance of CBN Tools When Turning Austempered Ductile Iron Material

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
K. Aslantas ◽  
İ. Ucun ◽  
K. Gök
Keyword(s):  
Surface Roughness ◽  
Ductile Iron ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Salt Bath ◽  
Austempered Ductile Iron ◽  
Depth Of Cut ◽  
Tool Performance ◽  
Austempering Temperature

The study deals with the machinability properties of austempered ductile iron using cubic boron nitride cutting tools. To emphasize the role of the austempering process, ductile iron specimens were first austenitized in salt bath at 900°C for 60min, after which they were quenched in a salt bath at 250°C and 325°C for 60min. Machining tests were carried out at various cutting speeds under the constant depth of cut and the feed rate. Tool performance was evaluated based on the workpiece surface roughness and flank wear. The influence of the austempering temperature and cutting speed on the chip form was also studied. The results point out that the lower austempering temperature results in the increase in the cutting forces, while better surface roughness is attained.

Performance of Turning Steels by Using Polycrystalline Cubic Boron Nitride Cutting Tool

2013 ◽  
Vol 315 ◽  
pp. 146-150
Author(s):  
Mohd Zulhasyree Mohd Zulkifli Cheng ◽  
Yusri Yusof
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Aisi 4140 ◽  
Roughness Analysis ◽  
Cutting Length ◽  
Aisi D2 ◽  
Steel Aisi

PCBN cutting tool is widely used in turning process and known as second best cutting tool after Diamond. This study investigates the suitability of PCBN cutting tool to cut variety types of steel. Experimental results for three major parameters which are cutting speed 150, 175 and 200 m/min, depth of cut 0.1, 0.2 and 0.3 mm, and feed 0.1, 0.2, and 0.3 mm/rev were converted into surface roughness analysis to look on the performance of PCBN to cut three different types of steels. The selected work materials of carbon steel AISI 1040, alloy steel AISI 4140 and tool steed AISI D2 were machined in dry tuning process with constant cutting length 50 mm and initial workpiece diameter 40 mm. At the end of this study, it is shown that higher cutting speed produced better surface roughness for AISI 1040 and AISI D2 but worsen the surface of AISI 4140. Low feed value is the most practical parameter to be used to produce fine surface finish using PCBN cutting tool. Fluctuate roughness value produced by increasing depth of cut use in turning parameters and no specific relationship can be concluded between depth of cut and surface roughness value.

Evaluation and investigation of grinding process of biomedical polymer (PEEK)

2021 ◽  
pp. 095440892110225
Author(s):  
Mohammad Khoran ◽  
Bahman Azarhoushang ◽  
Hossein Amirabadi
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Speed Ratio ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cutting Condition ◽  
Grinding Process ◽  
Wheel Topography ◽  
Overlap Ratio

Polyether ether ketone (PEEK) has been widely used in the medical engineering due to its high strength to weight ratio, creep and wear-resistance, and anti-allergically properties. Grinding is generally used to produce PEEK parts with high accuracy and surface quality requirements. In this research, the tool loading and the effect of cryogenic cooling in the grinding of PEEK are studied for the first time. It is shown that the generated heat in the grinding process, which is mainly influenced by the tool micro-topography, process parameter, and coolant lubricant has an important role in the surface integrity of PEEK. Additionally, the influence of specific material removal rate and the dressing speed ratio on the specific grinding energy of PEEK was studied. The input parameters of the grinding process that are investigated in this study include cutting speed (vs), depth of cut (ae), and feed rate (vft). To investigate the grinding wheel topography, the effects of dressing overlap ratio (Ud) and the dressing speed ratio (qd) were also investigated. Grinding force, surface roughness, and loading of the grinding wheel were considered as output parameters. The experiments were designed based on response surface methodology and the optimum cutting condition was obtained based on this method. The depth of cut and the dressing overlap ratio had respectively the maximum and minimum impact on the surface roughness and cutting forces. Additionally, the tool loading was mainly influenced by the cutting speed.

Multivariate Optimization of the Cutting Parameters when Turning Slender Components

2012 ◽  
Vol 2 (4) ◽  
pp. 12-31 ◽  
Author(s):  
A.R. Silva Filho ◽  
A.M. Abrão ◽  
A.P. Paiva ◽  
J.R. Ferreira
Keyword(s):  
Surface Roughness ◽  
Slenderness Ratio ◽  
Cutting Speed ◽  
Principal Component ◽  
Cutting Parameters ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Work Piece ◽  
Multivariate Optimization

The geometric features of the work piece and the cutting parameters considerably affect the quality of a finished part subjected to any machining operation owing to the imposed elastic and plastic deformations, especially when slender components are produced. This work is focused on the influence of the work piece slenderness ratio and cutting parameters on the quality of the machined part, assessed in terms of surface roughness and both geometric (run-out) and dimensional (diameter) deviations. Turning tests with coated tungsten carbide tools were performed using AISI 1045 medium carbon steel as work material. Differently from the published literature, a statistical analysis based on the multivariate one-way analysis of variance (MANOVA) was applied to the data obtained using a Box-Behnken experimental design. In order to identify the combination of parameters (slenderness ratio, cutting speed, feed rate and depth of cut) levels which simultaneously optimize the responses of interest (surface roughness, run-out and diameter deviation), a multivariate optimization method based on principal component analysis (PCA) and generalized reduced gradient (GRG) was employed.

Optimization of Ti-6Al-4V Flank Milling Parameters Using Taguchi Method

2009 ◽  
Vol 69-70 ◽  
pp. 364-368
Author(s):  
Chang Yi Liu ◽  
Jun Jie Yi ◽  
Wen Hui Zhou ◽  
Cheng Long Chu
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Milling Parameters ◽  
Good Surface ◽  
Operation Parameters

This paper presents a study of the Taguchi design methodology, which is applied to optimize flank milling operation parameters when machining titanium alloy Ti-6Al-4V in conventional and high speed regimes. This study includes cutting speed, feed rate and depth of cut. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of surface roughness. ANOVA analyses are carried out to analyze the effect of these operation parameters, and the optimal parameters combination is determined by seeking the best surface roughness. The analysis of result shows that the optimal combination for good surface roughness is high cutting speed, low feed rate. Finally, confirmation run verifies the results, which indicated that Taguchi method is both efficient and effective in determining the Ti-6Al-4V flank milling parameters for the optimization with minimum number of trials.

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