Experimental Study on Five-Axis Machining Parameter for NAK80 Die Steel

2008 ◽  
Vol 594 ◽  
pp. 226-234
Author(s):  
Cheng Shun Chen ◽  
Chi Hui Huang
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Tool Path ◽  
Spherical Surface ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Optimal Parameters ◽  
Die Steel ◽  
Contact Points ◽  
Five Axis

The surface quality and contouring accuracy of die cavities directly influences the surface roughness of the products. Different types of complex surfaces of products have become popular in product design in recent years and consequently 5-axis machining techniques become a mainstream in the manufacturing of the die and moulds used in products mentioned above, because of their features and flexibility. This research applies Taguchi method to find out a set of optimal machining parameters in five-axis milling process. The table rotating-tilting type five-axis machine is used to perform the experimental cutting. The cavity of die is modeled as convex half spherical surface, and the material of die is NAK 80 die steel. The four parameters studied are cutting speed, feed rate, tool paths, and contact points, and each of these factors has three levels. The target of this study is the feature of smaller-the-better that is minimization of the surface roughness. The experimental results show that the optimal parameters are moderate cutting speed and contact points, higher feed rate, five-axis tool path. ANOVA analysis indicates that the tool path influences the surface roughness most, which accounts for about 86%. Using optimal parameters to machine a roughly machined concave spherical surface can reach its roughness to 0.234μm, and the roundness error about 0.0314mm. It is believed that the results and method presented in the paper give a good reference for industry applied.

Study of The Tool Path Generation Method of an Ultra-Precision Spherical Complex Surface Based on a Five-Axis Machine Tool

2021 ◽  
Author(s):  
Tianji Xing ◽  
Xuesen Zhao ◽  
Zhipeng Cui ◽  
Rongkai Tan ◽  
Tao Sun
Keyword(s):  
Surface Roughness ◽  
Tool Path ◽  
Spherical Surface ◽  
Tool Path Generation ◽  
Path Generation ◽  
Tool Paths ◽  
Spherical Surfaces ◽  
Spherical Complex ◽  
Ultra Precision ◽  
Five Axis

Abstract The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spherical surfaces because of their different applications in various fields. In this research, a method was proposed to generate tool paths for the machining of complex spherical surfaces based on an ultra-precise five-axis turning and milling machine with a C-Y-Z-X-B structure. Through the proposed tool path generation method, ultra-precise complex spherical surface machining was achieved. First, the complex spherical surface model was modeled and calculated, and then it was combined with the designed model to generate the tool path. Then the tool paths were generated with a numerically controlled (NC) program. Based on an ultra-precision three-coordinate measuring instrument and a white light interferometer, the machining accuracy of a workpiece surface was characterized, and t[1]he effectiveness of the provided tool path generation method was verified. The surface roughness of the machined workpiece was less than 90 nm. Furthermore, the surface roughness within the spherical region appeared to be less than 30 nm. The presented tool path generation method in this research produced ultra-precision spherical complex surfaces. The method could be applied to complex spherical surfaces with other characteristics.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Multiresponse optimization of drillability factors and mechanical properties of chitosan-reinforced polypropylene composite

2020 ◽  
pp. 089270572093916
Author(s):  
Nafiz Yaşar ◽  
Mustafa Günay ◽  
Erol Kılık ◽  
Hüseyin Ünal
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Thrust Force ◽  
Flexural Modulus ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Uniaxial Tensile ◽  
Machining Parameters ◽  
Molding Method ◽  
Machining Conditions

In this study, the mechanical and machinability characteristics of chitosan (Cts)-filled polypropylene (PP) composites produced by injection molding method were analyzed. Uniaxial tensile, impact, hardness, and three-point flexural tests were used to observe the influence of Cts filler on the mechanical behavior of PP. For the machinability analysis of these materials, drilling experiments based on Taguchi’s L27 orthogonal array were performed using different drill qualities and machining parameters. Then, machining conditions are optimized through grey relational analysis methodology for machinability characteristics such as thrust force and surface roughness obtained from drilling tests. The results showed that tensile, flexural strength, and percentage elongation decreased while impact strength increased with adding the Cts filler to PP. Moreover, it was determined that the tensile and flexural modulus of elasticity increased significantly and there was a slight increase in hardness. Thrust forces decreased while surface roughness values increased when the Cts filler ratio and feed rate was increased. The optimal machining conditions for minimizing thrust force and surface roughness was obtained as PP/10 wt% Cts material, uncoated tungsten carbide drill, feed rate of 0.05 mm/rev, and cutting speed of 40 m/min. In this regard, PP composite reinforced by 10 wt% Cts is recommended for industrial applications in terms of both the mechanical and machinability characteristics.

scholarly journals Optimization of machining parameters in face milling using multi-objective Taguchi technique

2018 ◽  
Vol 12 (2) ◽  
pp. 104-108 ◽  
Author(s):  
Yusuf Fedai ◽  
Hediye Kirli Akin
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Average Roughness ◽  
Multi Objective ◽  
Control Factors ◽  
Average Maximum

In this research, the effect of machining parameters on the various surface roughness characteristics (arithmetic average roughness (Ra), root mean square average roughness (Rq) and average maximum height of the profile (Rz)) in the milling of AISI 4140 steel were experimentally investigated. Depth of cut, feed rate, cutting speed and the number of insert were considered as control factors; Ra, Rz and Rq were considered as response factors. Experiments were designed considering Taguchi L9 orthogonal array. Multi signal-to-noise ratio was calculated for the response variables simultaneously. Analysis of variance was conducted to detect the significance of control factors on responses. Moreover, the percent contributions of the control factors on the surface roughness were obtained to be the number of insert (71.89 %), feed (19.74 %), cutting speed (5.08%) and depth of cut (3.29 %). Minimum surface roughness values for Ra, Rz and Rq were obtained at 325 m/min cutting speed, 0.08 mm/rev feed rate, 1 number of insert and 1 mm depth of cut by using multi-objective Taguchi technique.

Investigations on Surface Roughness Measurement in Minimum Quantity Lubrication Turning of Titanium Alloys Using Response Surface Methodology and Box–Cox Transformation

2016 ◽  
Vol 16 (2) ◽  
pp. 75-88 ◽  
Author(s):  
Munish Kumar Gupta ◽  
P. K. Sood ◽  
Vishal S. Sharma
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Flow Rate ◽  
Feed Rate ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Machining Parameters ◽  
Minimum Quantity ◽  
Box Cox Transformation

AbstractIn the present work, an attempt has been made to establish the accurate surface roughness (Ra, Rq and Rz) prediction model using response surface methodology with Box–Cox transformation in turning of Titanium (Grade-II) under minimum quantity lubrication (MQL) conditions. This surface roughness model has been developed in terms of machining parameters such as cutting speed, feed rate and approach angle. Firstly, some experiments are designed and conducted to determine the optimal MQL parameters of lubricant flow rate, input pressure and compressed air flow rate. After analyzing the MQL parameter, the final experiments are performed with cubic boron nitride (CBN) tool to optimize the machining parameters for surface roughness values i. e., Ra, Rq and Rz using desirability analysis. The outcomes demonstrate that the feed rate is the most influencing factor in the surface roughness values as compared to cutting speed and approach angle. The predicted results are fairly close to experimental values and hence, the developed models using Box-Cox transformation can be used for prediction satisfactorily.

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.

Influence of Machining Strategies on Surface Roughness in Ball End Milling of Inclined Surfaces

2012 ◽  
Vol 488-489 ◽  
pp. 836-840 ◽  
Author(s):  
S. Shajari ◽  
M.H. Sadeghi ◽  
H. Hassanpour ◽  
B. Jabbaripour
Keyword(s):  
Surface Roughness ◽  
Tool Path ◽  
End Milling ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Scallop Height ◽  
Inclined Surfaces ◽  
Milling Operation ◽  
Variable Surface ◽  
Machining Strategies

Inclined surfaces are commonly used in the aerospace and die/mold industries. For machining this kind of surfaces, many aspects have to be considered as machinability considerations including milling strategies, machining parameters and etc. In machining, achieving better quality is challenging task. Various tool-path strategies during milling operation leads to variable surface roughness on machined samples. The objective of this study is to analyze different machining strategies in 3-axis milling of a typical curved geometry part. The machining parameters used in this study, are cutting speed, feedrate and stepover. This paper also presents an approach to develop a mathematical model for measuring Scallop height size and distribution for different machining strategies to show that Scallop height size has direct relation with Surface roughness measurements in each strategy. Finally the optimized strategy based on the results was determined.

DEVELOPMENT OF SURFACE ROUGHNESS PREDICTION MODEL FOR HARD TURNING ON AISI D2 STEEL USING CUBIC BORON NITRIDE INSERT

2017 ◽  
Vol 80 (1) ◽  
Author(s):  
Amrifan Saladin Mohruni ◽  
Muhammad Yanis ◽  
Edwin Kurniawan
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Feed Rate ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Aisi D2 Steel ◽  
Aisi D2 ◽  
D2 Steel

Hard turning is an alternative to traditional grinding in the manufacturing industry for hardened ferrous alloy material above 45 HRC. Hard turning has advantages such as lower equipment cost, shorter setup time, fewer process steps, greater part geometry flexibility and elimination of cutting fluid. In this study, the effect of cutting speed and feed rate on surface roughness in hard turning was experimentally investigated. AISI D2 steel workpiece (62 HRC) was machined with Cubic Boron Nitride (CBN) insert under dry machining. A 2k-factorial design with 4 centre points as an initial design of experiment (DOE) and a central composite design (CCD) as augmented design were used in developing the empirical mathematical models. They were employed for analysing the significant machining parameters. The results show that the surface roughness value decreased (smoother) with increasing cutting speed. In contrary, surface roughness value increased significantly when the feed rate increased. Optimum cutting speed and feed rate condition in this experiment was 105 m/min and 0.10 mm/rev respectively with surface roughness value was 0.267 µm. Further investigation revealed that the second order model is a valid surface roughness model, while the linear model cannot be used as a predicted model due to its lack of fit significance.

Influence of Machining Parameters on Surface Topography of Cubic Boron Nitride at Rotary Ultrasonic Machining

2016 ◽  
Vol 686 ◽  
pp. 180-185 ◽  
Author(s):  
Marcel Kuruc ◽  
Martin Kusý ◽  
Vladimír Šimna ◽  
Jozef Peterka
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Feed Rate ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Hard And Brittle Materials ◽  
Advanced Machining

Poly-crystalline cubic boron nitride (PCBN) is one of the hardest known material. Therefore only advanced methods are able to treat such material. Advanced machining methods, proper for machining of hard and brittle materials (such as glass and ceramics) include rotary ultrasonic machining (RUM). This method should achieve high precision and low surface roughness (at least during machining of materials such as ceramics). Achievable roughness is affected by machined material and machining parameters. This contribution investigates influence of machining parameters, such as cutting speed and feed rate, on resultant surface roughness during machining of PCBN by rotary ultrasonic machining.

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).

Sign in / Sign up

Export Citation Format

Share Document